Assembly Sequence Plan T. Brown Princeton Plasma Physics Laboratory Oak Ridge National Laboratory NCSX Lehman Review Princeton Plasma Physics Laboratory Princeton, NJ August 15-17, 2007
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
FPA is accomplished in five Stages VVPrep Stage 1 MC Half Period Assembly Stage 2 MCHP installation over VV Period Stage 3 Stage 4 TFHP assembly combined with Stage 5 Stage 5 Final FPAssembly Stage 6 Final Machine Assembly
MCHP assembly – Stage 2 MCHP is assembled in a horizontal position. MC Half Period Type-A Type-C Type-B
MCHP installation over VV period – Stage 3 BASIC REQUIREMENTS: • 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”.
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
The MCHP must follow a prescribed path The 24,000 lb MCHP must move over the VV field period within a prescribed assembly path. Assume a 1” stand-off to vessel surface components An assembly path has been established that maximizes the VV/MCHP distance.
MC to MC Clearance A 0.45” minimum clearance exists between wing region of Type A’s as the two half period MC shells comes together. Wing region
Type B distance to shell off-normal points is 1.53” at the 60% step 1.528”
The Stage 3 fixtures will support the MC’s and allow movement for different fit-up conditions. Pre-fit flange shim installation at Type-A interface. The right MCHP is positioned using the crane/mechanized screw system Metrology measurements taken to establish left MCHP position
The Stage 3 fixture supports the VV. Vacuum Vessel supported and is in position to receive left MCHP • Take metrology measurements • Define VV position
The Stage 3 fixture includes local structure for laser supports, laser path screen surfaces and structure to interface with crane drive system.
Complete FPA – Stage 5 BASIC REQUIREMENTS: • Provide a stable FP support system for installation of VV ports. • Provide a support method for rotating individual TF coils over each half period.
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.
The Stage 5 fixture details are preliminary The design have been developed in sufficient detail to define cost and schedule estimates. FPA base support Type-C side support Stage 5 weldment cost items
Stage 5 assembly design details are preliminary FPA lowered onto support stand VV ports installed TF temporarily positioned TF final fit-up
Final Machine Assembly Fixtures –Stage 6 BASIC REQUIREMENTS: • 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”.
Stage 6 incorporates MCHP positioning techniques 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.
N N Period 2 Period 2 Period 1 Stage 6 installation will allow Station 5 operations that are planned within the test cell.
Summary • 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