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Assembly Sequence Plan

NCSX Lehman ReviewPrinceton Plasma Physics Laboratory

Princeton, NJAugust 15-17, 2007

T. Brown

Princeton Plasma Physics Laboratory Oak Ridge National Laboratory

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Assembly Sequence Plan

Summarize the overall machine assembly steps

Provide a summary background of the key assembly requirements and issues.

Briefly review the assembly sequence plan

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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 assembly – Stage 2

Type-A

MC Half Period MCHP is assembled in a horizontal position.

Type-B

Type-C

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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 2 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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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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N

Period 1

Period 2

Period 2

N

Stage 6 installation will allow Station 5 operations that are planned within the test cell.

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FPA support and motion control

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Brief review of the assembly sequence plan

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Assembly sequence plan break down

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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