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Please cite this article in press as: K. Nam, et al., Development of the ITER IOIS assembly tool and mock-up, Fusion Eng. Des. (2014), http://dx.doi.org/10.1016/j.fusengdes.2014.04.002 ARTICLE IN PRESS G Model FUSION-7434; No. of Pages 4 Fusion Engineering and Design xxx (2014) xxx–xxx Contents lists available at ScienceDirect Fusion Engineering and Design jo ur nal home p age: www.elsevier.com/locate/fusengdes Development of the ITER IOIS assembly tool and mock-up Kyoungo Nam a,, Dongjin Kim a , Hyunki Park a , Heejae Ahn a , Kyoungkyu Kim b , Yongsoo Yoo c , Emma Watson d , Robert Shaw d a National Fusion Research Institute, Daejeon, Republic of Korea b Mecha T&S, Jinju, Republic of Korea c SFA Engineering Corp., Asan, Republic of Korea d ITER Organization, 13115 Saint Raul Lez Durance, France a r t i c l e i n f o Article history: Received 12 September 2013 Received in revised form 19 March 2014 Accepted 1 April 2014 Available online xxx Keywords: ITER Tokamak Assembly tools TFC IOIS Mock-up a b s t r a c t The ITER toroidal field coils (TFCs) are connected by 3 different connecting structures as follows; Outer Intercoil Structure (OIS), Inner Intercoil Structure (IIS), Intermediate Outer Intercoil Structure (IOIS). In assessing the assembly, requirements and environmental conditions of each Intercoil structure, the IOIS and IIS assembly were thought to be the most challenging compared to the OIS assembly due to the very limited assembly space available and the strict requirements requested by IO, especially the IOIS assembly, which has particularly difficult installation requirements including complicated shear pin assemblies. A conceptual and preliminary design has been developed by the Korean domestic agency (KODA) for the sub assembly and final assembly phase; the tool includes the ability to control both IOIS plates simultaneously. For design verification of the IOIS assembly tool mentioned above, structural analysis has been carried out considering seismic event. Also, a half sized mock-up has been fabricated and tested according to assembly procedures. In this paper, a description of tool design and the results of analysis and mock-test will be introduced. © 2014 Elsevier B.V. All rights reserved. 1. Introduction The ITER Tokamak machine is composed of nine 40 sectors. Each 40 sector is made up of one 40 vacuum vessel (VV), two 20 toroidal filed coils and associated vacuum vessel thermal shield (VVTS) segments which consist of one inboard and two outboard vacuum vessel thermal shields. Based on the design description document and final report prepared by the ITER organization (IO) [1,2] and tooling requirements, Korea has carried out the concep- tual and preliminary design of these assembly tools [3–9]. In the sector sub-assembly at the assembly building and sec- tor assembly at the in-pit, the TFC assembly is very important and controlled carefully because the TFC assembly accuracy is directly related to Tokamak machine performance. TFC is assem- bled at both the assembly building for sector sub-assembly and Tokamak in-pit for sector assembly. The ITER TFCs are connected by three different connecting structures; OIS, IIS and IOIS. One of them, the IOIS is composed of a front and rear plates and 6 customized pin connections located at the upper and lower Corresponding author. Tel.: +82 42 879 5662. E-mail address: [email protected] (K. Nam). areas of the TFC. The IOIS are assembled in the assembly building between two TFCs of one sector during sector sub-assembly phase and in in-pit between neighboring sectors during sector assembly procedure. According to the IO’s modified IOIS assembly procedure, the IOIS front and rear plate should be handled and installed simultaneously by the dedicated assembly tool considering very limited man access and crane accessibility conditions. When the rear plate of the IOIS is inserted there is a very limited space between VVTS and the TFC wings. Also, the front and rear plates of the IOIS should be controlled and assembled simultaneously. The two plates of the IOIS should be positioned and supported temporarily at their install locations before arbor operation and pin connections. The design of the dedicated assembly tool for the IOIS assem- bly has been developed to use both during sub-assembly and final assembly phase by KODA. The adjustment system of this assem- bly tool having electrical handling system for control of the TFC front and rear plates has been also designed to meet the func- tional requirements requested by IO. For design verification of the IOIS assembly tool mentioned above, structural analysis consider- ing seismic event has been carried out and a half sized mock-up has been fabricated and tested according to the IOIS assembly proce- dure. http://dx.doi.org/10.1016/j.fusengdes.2014.04.002 0920-3796/© 2014 Elsevier B.V. All rights reserved.

Development of the ITER IOIS assembly tool and mock-up

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Page 1: Development of the ITER IOIS assembly tool and mock-up

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ARTICLE IN PRESSG ModelUSION-7434; No. of Pages 4

Fusion Engineering and Design xxx (2014) xxx–xxx

Contents lists available at ScienceDirect

Fusion Engineering and Design

jo ur nal home p age: www.elsev ier .com/ locate / fusengdes

evelopment of the ITER IOIS assembly tool and mock-up

youngo Nama,∗, Dongjin Kima, Hyunki Parka, Heejae Ahna, Kyoungkyu Kimb,ongsoo Yooc, Emma Watsond, Robert Shawd

National Fusion Research Institute, Daejeon, Republic of KoreaMecha T&S, Jinju, Republic of KoreaSFA Engineering Corp., Asan, Republic of KoreaITER Organization, 13115 Saint Raul Lez Durance, France

r t i c l e i n f o

rticle history:eceived 12 September 2013eceived in revised form 19 March 2014ccepted 1 April 2014vailable online xxx

eywords:TER

a b s t r a c t

The ITER toroidal field coils (TFCs) are connected by 3 different connecting structures as follows; OuterIntercoil Structure (OIS), Inner Intercoil Structure (IIS), Intermediate Outer Intercoil Structure (IOIS).In assessing the assembly, requirements and environmental conditions of each Intercoil structure, theIOIS and IIS assembly were thought to be the most challenging compared to the OIS assembly due tothe very limited assembly space available and the strict requirements requested by IO, especially theIOIS assembly, which has particularly difficult installation requirements including complicated shear pinassemblies. A conceptual and preliminary design has been developed by the Korean domestic agency

okamakssembly toolsFCOIS

ock-up

(KODA) for the sub assembly and final assembly phase; the tool includes the ability to control bothIOIS plates simultaneously. For design verification of the IOIS assembly tool mentioned above, structuralanalysis has been carried out considering seismic event. Also, a half sized mock-up has been fabricatedand tested according to assembly procedures. In this paper, a description of tool design and the resultsof analysis and mock-test will be introduced.

© 2014 Elsevier B.V. All rights reserved.

. Introduction

The ITER Tokamak machine is composed of nine 40◦ sectors.ach 40◦ sector is made up of one 40◦ vacuum vessel (VV), two 20◦

oroidal filed coils and associated vacuum vessel thermal shieldVVTS) segments which consist of one inboard and two outboardacuum vessel thermal shields. Based on the design descriptionocument and final report prepared by the ITER organization (IO)1,2] and tooling requirements, Korea has carried out the concep-ual and preliminary design of these assembly tools [3–9].

In the sector sub-assembly at the assembly building and sec-or assembly at the in-pit, the TFC assembly is very importantnd controlled carefully because the TFC assembly accuracy isirectly related to Tokamak machine performance. TFC is assem-led at both the assembly building for sector sub-assembly andokamak in-pit for sector assembly. The ITER TFCs are connected

Please cite this article in press as: K. Nam, et al., Development of thehttp://dx.doi.org/10.1016/j.fusengdes.2014.04.002

y three different connecting structures; OIS, IIS and IOIS. Onef them, the IOIS is composed of a front and rear plates and

customized pin connections located at the upper and lower

∗ Corresponding author. Tel.: +82 42 879 5662.E-mail address: [email protected] (K. Nam).

ttp://dx.doi.org/10.1016/j.fusengdes.2014.04.002920-3796/© 2014 Elsevier B.V. All rights reserved.

areas of the TFC. The IOIS are assembled in the assembly buildingbetween two TFCs of one sector during sector sub-assembly phaseand in in-pit between neighboring sectors during sector assemblyprocedure.

According to the IO’s modified IOIS assembly procedure, the IOISfront and rear plate should be handled and installed simultaneouslyby the dedicated assembly tool considering very limited man accessand crane accessibility conditions. When the rear plate of the IOISis inserted there is a very limited space between VVTS and the TFCwings. Also, the front and rear plates of the IOIS should be controlledand assembled simultaneously. The two plates of the IOIS shouldbe positioned and supported temporarily at their install locationsbefore arbor operation and pin connections.

The design of the dedicated assembly tool for the IOIS assem-bly has been developed to use both during sub-assembly and finalassembly phase by KODA. The adjustment system of this assem-bly tool having electrical handling system for control of the TFCfront and rear plates has been also designed to meet the func-tional requirements requested by IO. For design verification of the

ITER IOIS assembly tool and mock-up, Fusion Eng. Des. (2014),

IOIS assembly tool mentioned above, structural analysis consider-ing seismic event has been carried out and a half sized mock-up hasbeen fabricated and tested according to the IOIS assembly proce-dure.

Page 2: Development of the ITER IOIS assembly tool and mock-up

ARTICLE IN PRESSG ModelFUSION-7434; No. of Pages 4

2 K. Nam et al. / Fusion Engineering and Design xxx (2014) xxx–xxx

2

2

esOtaiabmsa

Fig. 1. Configuration of the TF coils and linkage system including IIS, OIS and IOIS.

. IOIS and its installation tools

.1. IOIS of TFC

As shown in Fig. 1, the ITER TFCs are connected by three differ-nt types of connecting structures; OIS, IIS and IOIS. Each intercoiltructure is positioned at both upper and lower area respectively.ne of them, IOIS is composed of front and rear plate and 6 cus-

omized shear pin connections located at the upper and lowerreas of the TFC as shown Fig. 2. IOIS assembly is assembled dur-ng sector sub-assembly and sector assembly phase. In originalssembly procedure, IOIS’s plates are handled and controlled one

Please cite this article in press as: K. Nam, et al., Development of thehttp://dx.doi.org/10.1016/j.fusengdes.2014.04.002

y one. But, according to IO’s new IOIS assembly procedure, the twoajor front and rear plates of IOIS should be handled and installed

imultaneously for reduction of assembly time, risk and increasingssembly effectiveness.

Fig. 2. Configuration of IOIS components.

Fig. 3. Overall configuration of the IOIS assembly tool having alignment system forfive motions including one rotation to handle and control two plates.

IOIS assembly between adjacent TF coils is required at the in-pit and assembly hall. And IOIS assembly operation starts afterthe adjacent TF coils are positioned relatively within assembly tol-erance. Access to the backside of the TFC wings is very limitedtherefore the rear plate has to be slid behind the TFC wings fromequatorial port level.

2.2. IOIS installation tool

IOIS installation tool should have adequate strength to support;two IOIS plates of 2.3 ton and five degrees of freedom alignmentsystem to manipulate plates to their desired position. Also, thistool should be designed to be used at both upper and lower IOISassembly locations commonly. Tool size and main structure shouldbe controlled carefully due to TFC interface and environmental con-dition of in-pit assembly phase.

As shown in Fig. 3, IOIS assembly tool was designed to meetassembly procedure and requirements. The tool is composed of;a main supporting structure with TFC interface, plate holder andalignment system operated servo-motors. The main supportingstructure is attached to TFC and has two lifting lugs. The plate holderwas designed to hold two plates simultaneously and to support andhang 2.3 tons of the two IOIS plates. For adjustment of IOIS plates,alignment system operated by servo-motors, reducers, ball screwsand linear motion guides was designed to meet motion require-ments for positioning of plates. The plate holder should be rotatedup to a maximum of 62◦ considering upper and lower inclinedwings of TFC. Also, this holder was designed to be detached andtwo TFC plates are pre-assembled into this holder in the assem-bly building and transferred and installed to the alignment systemagain.

The IOIS installation tool is attached to TFC with four connectingbrackets as shown in Fig. 4. Alignment system and moving rangewere designed to avoid the clash between plate holder and envi-ronmental condition in its assembly trajectories during upper andlower assembly works.

ITER IOIS assembly tool and mock-up, Fusion Eng. Des. (2014),

2.3. Structural analysis

The structural analysis of the IOIS installation tool was carriedout considering its dead weight and external load which is the front

Page 3: Development of the ITER IOIS assembly tool and mock-up

ARTICLE IN PRESSG ModelFUSION-7434; No. of Pages 4

K. Nam et al. / Fusion Engineering and Design xxx (2014) xxx–xxx 3

Fig. 4. Configuration of the IOIS assembly tool attached to TFC and upper/lower IOIS.

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Table 2The stress and displacement results of two analysis conditions considering dynamicamplification factor 1.6.

Case Von-Mises stress(MPa)

Allowable stress(MPa)

Displacement(mm)

swing caused the overload condition to servo-motor. In final design,this problem should be reflected in the design of IOIS installationtool.

ig. 5. Configuration of (a) design of tool (b) FE model including two IOIS plate model

or analysis.

nd rear plates about 2.3 tons. In this analysis, two analysis casesere considered due to its assembly condition and procedure; one

s the case of the horizontal position which is initial configurationf two IOIS plates just before assembly begins and the other is thease of an inclined position, 62◦ for introduction of plates. Dynamicmplification factor 1.6 [10] in vertical load condition was appliedo all analysis considering seismic event.

Fig. 5 shows simplified configuration and full finite element (FE)esh model for structural analysis of the IOIS installation tool. Theaterials applied to structure are SM490YB and SS400. The prop-

rties of materials are given in Table 1. Each allowable stress iserived from safety factor 1.177 of the yield stress.

The stress results have been evaluated according to their allow-

Please cite this article in press as: K. Nam, et al., Development of thehttp://dx.doi.org/10.1016/j.fusengdes.2014.04.002

ble stress and Von-Mises stress as the equivalent stress. The stressnd displacement results of both analyses are given respectively inable 2.

able 1he material properties used tool design and analysis.

Material Elastic modulus(GPa)

Yield stress(MPa)

Allowablestress (MPa)

SM490YB 206 365 310SS400 206 245 208

Inclined 91.8 208 2.68Horizontal 165 208 8.59

The Fig. 6(a) and (b) indicates the maximum Von-Mises stressof 91.8 MPa and displacement of 2.7 mm at the end of the IOIS platein condition of 62◦ inclined. Fig. 6(c) and (d) shows the maximumVon-Mises stress of 165 MPa and displacement of 8.6 mm at theend of the IOIS plate in horizontal condition. In both analyses, themaximum stress is seen at the plate holder and these maximumstress values are below the allowable stress 208 MPa.

3. Mock-up

For verification of design and feasibility of the assembly; thetool should be qualified using appropriate methods i.e. mock-uptest. The mock-up of IOIS assembly tool was fabricated in half sizeas shown in Fig. 7. Also TFC wings and IOIS plate dummies weremade for the mock-up test. Mock-up of IOIS assembly tool includingalignment system, as shown in Fig. 7, was designed to be operatedby servo-motors, reducers, ball screws and motion guides.

This mock-up test was prepared to check the feasibility ofassembly and motion. Assembly sequence and procedure also wereverified through this mock-up test. The upper and lower IOISassembly tests as shown in Fig. 8(a) and (b) were implementedaccording to their assembly sequence. In this mock-up test, thereare no problems in the movement of alignment system during IOIShandling sequence and clashes with environmental components.However, one problem was found at the rotation of the plate holder.The low servo-motor capacity caused emergency stop of the plateholder during the rotation due to a little swing of plate holder. This

ITER IOIS assembly tool and mock-up, Fusion Eng. Des. (2014),

Fig. 6. Stress and displacement results; (a) 91.8 MPa and (b) 2.7 mm in condition of62 degree inclined condition and (c) 165 MPa and (d) 8.6 mm in horizontal condition.

Page 4: Development of the ITER IOIS assembly tool and mock-up

ARTICLE ING ModelFUSION-7434; No. of Pages 4

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Fig. 7. Configuration of mock-up including TFC wings and plates dummies for theverification of the IOIS assembly feasibility and tool design.

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ig. 8. Configuration of mock-up test; (a) upper IOIS assembly and (b) lower IOISssembly.

KODA now is preparing to update the mock-up of IOIS assemblyool considering a high capacity servo-motor and developed plateolder design. For rotation motion, high capacity servo-motors wille applied at both side of plate holder to avoid emergency stop dueo swing of plate holder.

. Conclusion

Please cite this article in press as: K. Nam, et al., Development of thehttp://dx.doi.org/10.1016/j.fusengdes.2014.04.002

Based on the conceptual design suggested by the IO, the pre-iminary design of the IOIS installation tool has been developedo satisfy modified assembly procedure, technical and functional

[

PRESSd Design xxx (2014) xxx–xxx

requirements by KODA. And conclusions are summarized as fol-lowing.

• The design of the IOIS installation tool has been developed byKODA to meet design requirements and new assembly procedure.For common use in both the upper and lower IOIS assembly, arotation alignment system has been designed and the plate holderwas modified for handling two plates simultaneously accordingto new assembly procedure.

• The structural stability of IOIS installation tool has been stud-ied using FE analysis for verifying structural strength of this tool.In the results of the analysis for assessing structural stability ofthe IOIS installation tool considering its dead weight, 2.3 ton oftwo IOIS plates and dynamic amplification factor 1.6, all stress ofthe IOIS installation tool are less than the allowable stress. Con-sequently, strength of the tool was verified to handle the IOISplates.

• For feasibility of the IOIS assembly, the mock-up in half size hasbeen fabricated and tested according to new assembly procedure.The feasibility of assembly procedure has been confirmed in thismock-up test and the findings of mock-up test will be reflectedto final design of tool.

• For the next step, KODA will find the alternative kinematic designto share load of the servo motor and confirm the similitudebetween full size and half-scale mock-up in terms of the joint,capacity of the servo motors including reducer.

Preliminary design of the IOIS installation tool has been com-pleted and KODA will finish the final design by the end of 2014.

Acknowledgments

This research was supported by National R&D Program throughthe National Research Foundation of Korea (NRF) funded by theMinistry of Science, ICT and Future Planning. The views and opin-ions expressed herein do not necessarily reflect those of the ITERorganization.

References

[1] I.T.E.R. Organization, Final Report of the ITER Engineering Design Activities,2001.

[2] I.T.E.R. Organization, Design Description Document; Assembly Tooling (DDD22) (2004).

[3] K.H. Im, D.H. Kim, J.H. Lee, K.S. Lim, M.S. Ban, G.T. Lee, et al., The StructuralDesign of ITER Tokamak In-pit Assembly Tools, in: APFA 2005, Jeju-city, Korea,29–31 August, 2005.

[4] H.K. Park, J.S. Lee, T.H. Kim, Y.J. Song, K.H. Im, B.C. Kim, et al., Design of the ITERTokamak Assembly Tools, in: ISFNT-8, Heidelberg, Germany, 30 September–5October 5, 2007.

[5] H.K. Park, J.S. Lee, T.H. Kim, Y.J. Song, K.H. Im, B.C. Kim, et al., Design of the ITERTokamak Assembly Tools, Fusion Eng. Des. 83 (2008) 1583–1587.

[6] H.K. Park, K.O. Nam, H.J. Ahn, K.J. Jung, G.S. Lee, J.H. Lee, et al., Progress onthe Design of the ITER Tokamak Assembly Tools, in: 22nd IAEA Fusion EnergyConference, Geneva, Switzerland, 13–18 October, 2008.

[7] K.O. Nam, H.K. Park, H.J. Ahn, J.H. Lee, K.K. Kim, K.H. Im, et al., The Concep-tual Design of Assembly Tools for the 40◦ Sector Assembly and Sub-assemblyProcess, in: SOFE 2009, San Diego, USA, 31 May–5 June, 2009.

[8] K.O. Nam, H.K. Park, D.J. Kim, H.J. Ahn, K.K. Kim, K.H. Im, et al., ConceptualDesign and Structural Stabilities of In-pit Assembly Tools for the Completionof Final Sector Assembly at Tokamak Hall, Fusion Eng. Des. 10–12 (85) (2010)1716–1719.

ITER IOIS assembly tool and mock-up, Fusion Eng. Des. (2014),

[9] K.H. Im, R. Shaw, J.H. Lee, K.K. Kim, K.O. Nam, S.H. Jung, et al., The Design ofthe Assembly Tools for the ITER Tokamak, in: SOFT 2010, Porto, Portugal, 27September–1 October, 2010.

10] ITER Organization, ITER Machine Assembly Attachment Point Loads – DynamicAmplification Factor, 2012.