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Assembly Tooling

PU Workshop on NCSX Cost & SchedulePrinceton Plasma Physics Laboratory

Princeton, NJMar 1-4, 2007

T. Brown

Princeton Plasma Physics Laboratory Oak Ridge National Laboratory

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Assembly Tooling (WBS 186)

Summarize the tooling requirements for each assembly stage

Provide the tooling design status.

Review the tooling cost estimate for each assembly stage.

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Stage 1

Stage 3

Stage 5

VV Prep

MCHP installation over VV Period

Final FP Assembly

Stage 2

MC Half Period Assembly

Stage 4

TFHP assembly combined with Stage 5

FPA is accomplished in

five Stages

Stage 6 Final Machine Assembly

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MCHP installation over VV period – Stage 3

Provide a stable VV support system.

Provide a method for rotating a MCHP over the VV without interferences.

Provide for temporary support for each MCHP to set Type-A flange interfacing components.

The final tolerance for the completed assembled MC period is ± 0.020”.

BASIC REQUIREMENTS:

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The design intent for Stage 3 is pass two modular coil half period assemblies over the VV and accurately position mating flanges…without hitting the VV.

Vacuum Vessel Period

Module Coil Half Period

Module Coil Half Period

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The MCHP must follow a prescribed path

The 24,000 lb MCHP must move over the VV field period within a prescribed assembly path.

An assembly path has been established that maximizes the VV/MCHP distance.

Assume a 1” stand-off to vessel surface components

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0.5

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1.5

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2.5

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0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Time Step

Dis

tan

ce (

in)

Modular Coil Assembly Path Over VVRevised Servo Data - R1

(Local Region)

A 1.76" minimum clearance occurred when BOTH MC sets were allowed to move

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A 0.45” minimum clearance exists between wing region of Type A’s as the two half period MC shells comes together.

MC to MC Clearance

Wing region

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Type B distance to shell off-normal points is 1.53” at the 60% step

1.528”

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R&D activities were used to help developed the Stage 3 assembly approach.

Crane Supported – hand assisted assembly

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25,000 lb concrete block

120” long, 40” wide and 60” high

MC crane assisted assembly simulation was set up using a concrete block with three lasers mounted to it.

The concrete block motion was controlled by using a combination of the D-site test cell crane and three chain-fall supports mounted to the crane hook.

MC Installation Development Activity

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The path traveled by each laser was plotted on sheets of velum and mounted to the screens, aligning pre-marked crosshairs located on the screen with marks on the printed paper

One-quarter inch circles were used to define the required laser positions along the curve path.

The block was manipulated to follow the sequential points with an occasional maximum deviation of about ¾” to 1”, all within our allowed assembly tolerances.

Improvements will be made using motor driven mechanical screws with in-line encoder.

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To improve the accuracy of moving the MCHP we will be replacing the chain falls with mechanized screw systems with inline encoders.

Crane system updated with mechanized screws

The screw mechanism cost is part of Viola’s FPA cost estimate

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The Stage 3 fixtures will support the MC’s and allow movement for different fit-up conditions.

Metrology measurements taken to establish left MCHP position

The right MCHP is positioned using the crane/mechanized screw system

Pre-fit flange shim installation at Type-A interface.

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The Stage 3 fixture supports the VV.

Vacuum Vessel supported and is in position to receive left MCHP

• Take metrology measurements

• Define VV position

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The Stage 3 fixture includes local structure for laser supports, laser path screen surfaces and structure to interface with crane drive system.

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Complete FPA – Stage 5

Provide a stable FP support system for installation of VV ports.

Provide a support method for rotating individual TF coils over each half period.

BASIC REQUIREMENTS:

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Final FP Assembly– Stage 5

Stage 5 completes the FPA assembly process bringing together the VV/MCHP

assembly, VV ports, TF coils, trim coils and FPA services.

Two large diagnostic ports tack welded in Stage 5.

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The design have been developed in sufficient detail to define cost and schedule estimates.

The Stage 5 fixture details are preliminary

Stage 5 weldment cost items

FPA base support

Type-C side support

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Stage 5 assembly design details are preliminary

FPA lowered onto support stand VV ports installed

TF temporarily positionedTF final fit-up

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Final Machine Assembly Fixtures – Stage 6

Provide a stable support system that provides the radial movement of each FPA to their final assembled position.

Provide a stable VV spool support that provides radial and angular movement to their final assembled position.

The final tolerance for the completed machine is ± 0.020”.

BASIC REQUIREMENTS:

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Stage 6 – Spool piece assembly motion

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Stage 6 – Machine assembly motion

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183 lbs

Spool piece support and motion control

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Each FPA will properly oriented in their final position using the same technique that has been developed in assembling the MCHP’s and then pulled back to a pre-fit position.

Stage 6 incorporates MCHP positioning techniques

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FPA support and motion control

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• The FPA tooling design is still in progress– The Stage 3 fixture design is complete and a final design

review scheduled– Stage 4(TF assembly) has been combined with Stage 5– 5 and 6 fixture designs are in progress

• Additional small scale tooling and handling fixtures will be developed as they are identified.

• The assembly design and fixture details will continue to be updated through design review and the prototyping process

Summary