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Rope & Cable management
A vertical electro-optical backbone cable for KM3NeT
Gertjan Mul ([email protected])
On behalf of the km3net collaborationNikhef Mechanical departmentNikhef Electronic department
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KM3Net Rope & Cable managementVLVnT11
2) Backbone (VEOC)
1) Mechanical Rope (rope layout)
3) PenetratorIntroduction
Break out box
Optical module
Detector unit
Detector unit pallet
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Mechanical Rope specifications
Load /part 250 kg
Mechanical Rope -Dyneema(R) SK78 -4 mm diameter -breaking load of 1250kg.-1% stretch
Creep of Dyneema(R) at 15 deg And 20% static load is 0.9% / 10 yrs
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Rope layout Detector Unit (DU)
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Before unfurling the VEOC and Dyneema® must be stored.
During unfurling and mission time of the DU the VEOC must be supported to the mechanical cable.
Cable reel with friction
Backbone (VEOC)
Dyneema® rope
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Rope layout Detector Unit (DU)
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Belleville washers frictionDyneema®
100 mm
KM3Net Rope & Cable managementVLVnT11
Rope layout Detector Unit (DU)
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A
B250
kg
Increasing Stability
with A triangle
Connection of the DOM Bar
Constraining a degree of free dom
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Test Rope management July 2011
4 m
Dyneema® Reel
VEOC
Roll Stabilility
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Rope Summary
- No floating ropes which can tangle during deployment. (Cable reel with a friction system)
- Compact storage for deployment.
- Avoid tension on the VEOC . (spiral around the rope)
- Stability and smooth unfolding by A triangle
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KM3NeT VEOC (Vertical Electrical Cable)
KM3Net Rope & Cable managementVLVnT11
-Layout
-Goal
-Design
-History
-Production of Prototype Nikhef
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Layout
860
Met
er
Veoc
1Ve
oc 2
DWDM
Conn
ectin
g 11
DO
M’s
Conn
ectin
g 9
DOM
’sCross section of the pressure balanced cable1) Outer shell ¼ LDPE Tube2) 11 optical fibers3) 2 Electrical wire4) Oil Filling
1
2
3
4
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-Cable with a low drag For DU Mechanical stable
-A Flexible Cable for deployment and logistics
-An Easy cable to manufacture for the lowest Cost
For this Nikhef looked at an oil filled cable design.Pressure Balanced Oil Filled (PBOF)
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Goals
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History100 meter Cable by Nikhef and Seacon.22 fibers 1” tube 4 electrical wiresTest at NIOZ under pressure 600 bar Performance; OK
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210 meter Cable by Nikhef, Baas and Seacon.13 fibers in a bundle 2 electrical wires. (fibers are gradient-index bend bright 10 mm bend radius)Test at NIOZ and Southampton under pressure 600 bar.¼ “ LDPE tube Performance; OK
History
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New machine to Spiralthe cable
Oil Filler
Cable Tray
Production of Prototype Nikhef
45 m Cable trail
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Spiral Storage 45 m
Break Out Box
Production of Prototype Nikhef
13 lose Fiber standard SMF 282 electrical wires¼” LDPE tube
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Production Scheme
Production of Prototype Nikhef
Feeding direction
Cable Lengte
1
425
6
1 Data cable reel2 Optical Fiber bundle3 Electrical wire4 Outer cable shell5 Cable guide6 Pull Cord7 Glue
3
362 7
Cable guide
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Production Scheme
Production of Prototype Nikhef
Feeding direction
Cable Lengte
1
425
6
1 Data cable reel2 Optical Fiber bundels3 Electrical wire4 Outer cable shell5 Cable guide6 Pull Cord7 Glue
3
362 7
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Cable guide
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Production Scheme
Production of Prototype Nikhef
Feeding direction
Cable Lengte
1
425
6
1 Data cable reel2 Optical Fibers3 Electrical wire4 Outer cable shell5 Cable guide6 Pull Cord7 Glue
3
362 7
KM3Net Rope & Cable managementVLVnT11
Cable guide
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Coiling Tempering
Steam Boiler-100 °C -5 min-.1 MPa
Production of Prototype Nikhef
d1 d3d2
D1 =167 mm 110 °C during 1 hourD2 =190 mm 90 °C during 1 hourD3 =320 mm no heat treatment
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Production of Prototype Nikhef Production of the proto type
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Break Out Box
Connector Box
VEOC Spiral
Test of the proto type
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40 m
Production of Prototype Nikhef Test of the proto type
Attenuation 2.731 dB Not stretched
Attenuation 3.21 dB Stretched
Stretched over a length
Green laser 125 mW
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Production of Prototype Nikhef
Sharp bend < 30 mm Attenuation
Problems loose fibers
-Because of length differences in tube optical fiber twist at some points in the tube resulting in a small bend < 30
-Standard fibers have a min. bend radius of 30 mm
Test of the proto type
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40 m
Production of Prototype Nikhef Test of the proto type
New 40 meter Cable, Optical 0,227 dB 5 fibers standard smf28
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SummarizedProduction of Prototype Nikhef
2 pressure balanced cables tested proof the system works.
1 spiral cable with the 13 smf28 standard fibers.-Due to length differences many twists with small bending radius occured.
2 new spiraling test tubes to build. To test if losses can be reduced by improving the production method. -Instead of loose fibers a bundle is used for pulling into the tube. -Use of bend bright fiber.
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Penetrator
A reliable high pressure penetrator.By reducing the stress in the glass
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Design principle
Penetrator
Penetrator
Load60 MPa pressure
Stress in glass near hole 1000 MPa
Stress in glass near hole 500 MPa Ti grade 39
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1) 16 Optical Fibers2) Silicon Seal3) Glass Epoxy Plate4) Conical Plug5) Test flange for Hera Pressure Vessel
Penetrator Feedthrough Test
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600 bar 0 Bar
Pressure difference 600 Bar for 3 weeks
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Mechanical Test -5 conical plugs distributed over 1 hemisphere80% of the sphere is filled with water for safety
The sphere is submerged in the NIOZ pressure tank.Test Pressure 600 Bar for 1 hour.
After removing the sphere from the tank the conical plugs and holes were inspected: OK
Penetrator Test
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Proto design
6 Electrical pins
Fiber protection tube
Connector
Connector jacket
Epoxy bulkhead
Silicon seal
Silicon fiber protection Conical penetrator
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Summarized
The design reduced stress at the hole edge.
Test of the penetrators at 600 bar show no problems.
Test of the penetrators feedthrough at 600 bar shows no problems.
Optimized design will be implemented in the BEOC.
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To summarize
Rope & Cable management
-Keep the ropes under tension with a cable reel and break system.-Locking the VEOC around the Dyneema ® rope in a spiral.-Connection of the DOM bar with an A triangle.
-VEOC performs well with gradient-index fiber (bend bright). -The spiraled VEOC must be optimized with gradient-index fiber.
-Conical plug reduces stress on the edge of the hole.-Optimization for production.
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