1. Assembly Tooling T. Brown Princeton Plasma Physics Laboratory Oak Ridge National Laboratory PU Workshop on NCSX Cost & Schedule Princeton Plasma Physics Laboratory Princeton, NJ Mar 1-4, 2007

2. 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.

3. FPA is accomplished in five Stages VV Prep 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 FP Assembly Stage 6 Final Machine Assembly

4. 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”.

5. 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

6. 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.

7. 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

8. Type B distance to shell off-normal points is 1.53” at the 60% step 1.528”

9. R&D activities were used to help developed the Stage 3 assembly approach. Crane Supported – hand assisted assembly

10. MC InstallationDevelopmentActivity 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. 25,000 lb concrete block 120” long, 40” wide and 60” high

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

12. Crane system updated with mechanized screws To improve the accuracy of moving the MCHP we will be replacing the chain falls with mechanized screw systems with inline encoders. The screw mechanism cost is part of Viola’s FPA cost estimate

13. 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

14. The Stage 3 fixture supports the VV. Vacuum Vessel supported and is in position to receive left MCHP • Take metrology measurements • Define VV position

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

17. 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.

18. 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.

19. 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

20. Stage 5 assembly design details are preliminary FPA lowered onto support stand VV ports installed TF temporarily positioned TF final fit-up

22. 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”.

23. Stage 6 – Spool piece assembly motion

24. Stage 6 – Machine assembly motion

25. Spool piece support and motion control 183 lbs

26. 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.

27. FPA support and motion control

29. 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