1 Assembly Tooling PU Workshop on NCSX Cost & Schedule Princeton Plasma Physics Laboratory Princeton, NJ Mar 1-4, 2007 T. Brown Princeton Plasma Physics Laboratory Oak Ridge National Laboratory 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 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 4 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: 5 The design intent for Stage 3 is pass two modular coil half period assemblies over the VV and accurately position mating flangeswithout hitting the VV. Vacuum Vessel 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. An assembly path has been established that maximizes the VV/MCHP distance. Assume a 1 stand-off to vessel surface components 7 A 0.45 minimum clearance exists between wing region of Type As as the two half period MC shells comes together. MC to MC Clearance 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 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 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. The block was manipulated to follow the sequential points with an occasional maximum deviation of about to 1, all within our allowed assembly tolerances. Improvements will be made using motor driven mechanical screws with in-line encoder. 12 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 Violas FPA cost estimate 13 The Stage 3 fixtures will support the MCs 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. 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. 16 17 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: 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 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 20 Stage 5 assembly design details are preliminary FPA lowered onto support standVV ports installed TF temporarily positioned TF final fit-up 21 22 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: 23 Stage 6 Spool piece assembly motion 24 Stage 6 Machine assembly motion lbs Spool piece support and motion control 26 Each FPA will properly oriented in their final position using the same technique that has been developed in assembling the MCHPs and then pulled back to a pre-fit position. Stage 6 incorporates MCHP positioning techniques 27 FPA support and motion control 28 29 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