FEA-Aided Design for a Working Model of a Split Florida-Helix

The NHMFL is developing a high-field split resistive magnet for use in far-infrared photon scattering experiments. The magnet will include four large scattering ports of elliptical shape at the midplane. Such a magnet configuration results in unique design challenges being especially severe for the windings in the midplane region of the innermost coils. Consequently, the NHMFL developed a new technology called split Florida-helix. To test and demonstrate those new concepts, the NHMFL recently completed the design and fabrication of a working model of a split Florida- helix. Advanced 3-D finite element analysis (FEA) served as the essential tool guiding the design optimization. This paper provides a systematic discussion of the critical features and techniques utilized in the complex model-based analysis including orthotropic material properties, actual non-symmetric current and load distributions as well as turn-to-turn frictional contact and sliding. Furthermore, the authors present a variety of detailed FEA results that prove to be fundamental for a successful application and integration of the split Florida-helix. Critical design decisions are discussed.