Modular coil assembly fixture mcaf
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Modular Coil Assembly Fixture (MCAF). Peer Review February 16, 2005. T. Brown. Agenda. Define the basic design intent Describe the Reference Design used to generate design specifications. Review design Issues: kinematics, bolt access, CG location, seismic, safety. . .

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Modular Coil Assembly Fixture (MCAF)

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Modular coil assembly fixture mcaf

Modular Coil Assembly Fixture(MCAF)

Peer Review

February 16, 2005

T. Brown


Agenda

Agenda

  • Define the basic design intent

  • Describe the Reference Design used to generate design specifications.

  • Review design Issues:

    • kinematics, bolt access, CG location, seismic, safety. . .

  • Discuss upcoming information meeting


Modular coil assembly fixture mcaf

  • Design Intent:

  • Rotate module coil half period over the vacuum vessel

  • Join two MC half periods at their precise “winding” position


Modular coil assembly fixture mcaf

A 1.76" (metal-to-metal) min clearance between MC’s and VV. VV insulation is 1.0” and VV/MC nominal tolerances are 0.06”.


Modular coil assembly fixture mcaf

A .45” minimum clearance exists between the Type A’s as the two half period MC shells comes together.


Modular coil assembly fixture mcaf

.

Y

X

Z

The motion of the MC over the VV was controlled by six axis following Art’s data transformed with a 6.125” X-axis vertical shift.

Z

Rz

Rx

X

X

Ry


Modular coil assembly fixture mcaf

MCAF motion is based on a 248 step servo table to drive the six motors.


Modular coil assembly fixture mcaf

In their final position two modular coil half periods will be separated by 0.50” (nominally) with three spherical seats engaged within an accuracy of 0.009”. . . If all goes well.

Leica laser system used for assembly measurement.


Modular coil assembly fixture mcaf

C5

B5

A5

C4

A6

B4

B6

A4

C6

A3

C1

B3

B1

C3

A1

C2

B2

A2

Half Period Assembly Sequence – perform all alignment and hole placement at this stage.


Modular coil assembly fixture mcaf

Gantry Crane

Module Coil Half Period

Module Coil Half Period

Turning Fixture

Base Guide Rail

MCAF Reference Design

The Reference Design was develop to qualify technical feasibility and help in establishing a design specification.


Modular coil assembly fixture mcaf

MCAF Component Details

Module Coil Half Period

(25000 lbs max)

MCHP / Turning Fixture interface

Pivot and rotation component

(3200 lbs)

Cradle component

(6300 lbs)

Vertical guide component

(3500 lbs)

18,700 lbs

(2700 lbs)

Linear turntable structure

Linear motion structure

(3000 lbs)


Modular coil assembly fixture mcaf

RY = 13°

RX = 5°

DZ = 16”

RZ = 15°

DX = 12”

Z

Y

X

Defined extent of motion of turning fixture subcomponents.

DY = 140”


Modular coil assembly fixture mcaf

0.54”

74”

82”

Typically ½ HP Motors with 200 : 1 reducers drive mechanical screws, screw jacks and gears

For movement in “Y” direction:

Assume 1750 rpm motor with 200:1 reducer & 0.25 screw lead

1

3

2

@ 1750 rpm – 2.2”/min

1

Travel time – 33.3 min

@ 1200 rpm – 1.5”/min

2

Travel time – 54.7 min

@ 500 rpm – .625”/min

3

Travel time – .86 min


Modular coil assembly fixture mcaf

Sideways clearances between MC shell and secondary support structure shall be greater that 60”


Modular coil assembly fixture mcaf

Half Period Bolt Access – accessible on top and outside

– more restrictive in reaching the lower, inside bolts.

A 40” local platform required


Modular coil assembly fixture mcaf

34.8’

21.25’

Test cell assembly space requirements.


Modular coil assembly fixture mcaf

With rotational extraction of the completed Period the required test cell assembly space can be reduced.

63” potential space savings.


What seismic design criteria do you apply during an assembly process

What seismic design criteria do you apply during an assembly process?

  • 30 days is the schedule time to complete the half period assembly operation.

  • 5 days are allocated to secure one HP by the gantry crane, and as noted earlier one successful run takes a minimum of 1.5 hrs.

    If a seismic design criteria is needed does a dynamic magnification factor of 0.12 apply?


Modular coil assembly fixture mcaf

The red curve defines the path of the MCHP CG as the assembly fixture moves from a starting position just outside the VV to it final position.

final position

starting position


Modular coil assembly fixture mcaf

Starting Position - CG Locations

(Base End and Front Views)

18,300 MCFP

38,000 MCAF


Modular coil assembly fixture mcaf

89.1”

Starting Position - CG Locations

(End and Top Views from Vertical Guide Structure)

18,300 MCHP

38,000 MCAF


Modular coil assembly fixture mcaf

Final Position - CG Locations

(Front and Top Views from Base Structure)

18,300 MCHP

38,000 MCAF

100.0”


Modular coil assembly fixture mcaf

Side view shows worst seismic position

  • The existing base will work with captured rollers and a .12 DMF.

  • Values above .16 will require an expanded base.

4560 lbs (assumes a .12 DMF)

38,000 lbs

104”

34”


Modular coil assembly fixture mcaf

Very preliminary stress analysis of the gantry crane and assembly fixture have been generated at this time.

Load = 23,000 lbs


Modular coil assembly fixture mcaf

Max stress = 11 ksi

Max Disp = .09 in

Load = 23,000 lbs

Total Unit weight = 36,410 lbs


Vendor list

Vendor List

Five vendors have expressed interest in the MCAF fabrication at this time.

- Hilman Rollers

- Sissco Control

- three others?

A vendor information meeting is scheduled for 9 AM Wednesday, February 23.


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