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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 - PowerPoint PPT Presentation
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1
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
5
6
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
0
0.5
1
1.5
2
2.5
3
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