status of modular coil design d. williamson, 4/9/03 prototype winding form - interim model based on...
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Status of Modular Coil DesignD. Williamson, 4/9/03
Prototype Winding Form- Interim model based on m50_e03- PF/TF supports, poloidal break added- To be superseded by Production Type-C
Production Coils and Forms- WC, XV updated to m50_256.z01- Tweak of shell surface, coil twist in progress- Pattern of clamps being optimized for space- Additional features are being added - Type-C model will become prototype
View at V=0 (NB Port)
Inboard View at V=0 (NB Port)Current, kA 653Width, in 4.100Height, in 4.671
Tee Width, in 0.750HT Layer, in 0.040Groundwrap, in 0.030Turn Insulation, in 0.054Clamp Width, in 0.000
Cond Width, in 0.660Cond Height, in 0.395
Current Density, kA/cm2 13.8
A A B
C
Inboard View at V=1/2 (FP Joint)
C CBA B
Interface A-A
Interface A-B
Interface B-C
# ITEM REQUIREMENT RESP SUCCESS STATUS 4/9/2003
1 General requirementsSpecify general requirements for NCSX facility. Emphasis on performance characteristics of sub- systems during typical operating scenarios and off- normal conditions.
Reiersen Issue for commentIssued
8/12/02 Complete
2 Conduct peer review of GRD ReiersenResolve comments,
sign and place under change control
Peer review scheduled for
4/3/03Complete
3Modular coil design
requirements
Specify functional requirements, characteristics, and constraints for modular coil systems. Requirements flow from GRD.
Williamson Issue for commentTo be issued
4/16/03 50% needs formatting
4 Conduct peer review of MC Design Requirements Doc WilliamsonResolve comments,
sign and place under change control
5 Basic geometry
Develop ProE models that define basic coil configuration, including electrical, thermal, and structural features: - Winding center and x- vector - Winding pack dimensions
Williamson Post in IntralinkUpdating e03 to
z01, to be posted 4/9/03
70%
shell shape and winding twist are still the biggest issues
6Develop overview drawing of each coil assembly. Include weight calculation for ICD: Support Structures. Review drawings as part of Task #37.
Williamson Post in IntralinkTo be posted
4/11/03 30%falls out quickly once models are done
7 STL models Create STL models of vessel and coils. WilliamsonPost .zip file in
Intralink
Waiting on vessel, coil
models
8 Procure models through quickparts.com WilliamsonSend to QuickParts,
receive modelsNeed to send
by 5/1/03
9Interface scope
sheetsPrepare list of functional and physical interfaces between modular coils and other primary systems.
SimmonsIssue for comment, resolve comments,
post on web
Posted 12/19/02 Complete
10ICD: Support Structures
Develop a drawing that defines the physical interface between MC assembly and PF/TF structure. Write ICD.
WilliamsonPost in Intralink,
review with Feder, issue ICD
To be posted 4/23/03
11Calculate net EM loads from MC to support structure. Output of Task #30. Write ICD.
FanIssue EM loads memo,
issue ICDTo be issued
5/9/03
ICD: Vacuum VesselDevelop a drawing that describes the physical interface between MC assembly and vacuum vessel. Write ICD.
WilliamsonPost in Intralink,
review with Goranson, issue ICD
To be posted 4/23/03
12 ICD: Coil ServicesDevelop a drawing that defines the position of electrical leads on the MC assembly.
WilliamsonPost in Intralink,
review with self, issue ICD
To be posted 4/23/03
13Develop a drawing that defines location of LN2 connection between MC assembly and cryostat manifold.
WilliamsonPost in Intralink,
review with self, issue ICD
To be posted 4/23/03
14 ICD: CryostatCalculate mod coil parameters that affect cool- down, heat load to cryostat. Document on MC assembly drawings.
Williamson
Post in Intralink, review with
Gettlefinger, issue ICD
To be issued 4/25/03
15 ICD: AssemblyDefine asm related attachments, lifting points, clearance requirements for field period and final assembly. Document on MC assembly drawings.
Williamson
Post in Intralink, review with
Chrzanowski, issue ICD
To be posted 4/23/03
16 ICD: RF SystemDevelop a drawing that defines access for RF system coax feeds.
WilliamsonPost in Intralink,
review with Majeski, issue ICD
To be posted 4/23/03
17 ICD: DiagnosticsDefine co- wound magnetic sensor loops for mod coils. Document on MC assembly drawings.
StrattonSketch and ICD from
Stratton, Post in Intralink
ICD issued 3/23/03,
drawings to be posted 4/23/03
70%
REQUIREMENTS
CONFIGURATION AND INTERFACES
PDR Tasks
PDR Tasks
18Develop detailed ProE models and drawings of production winding forms. Include comments on ICDs and feedback from Manuf Dev tasks.
Williamson Post in IntralinkTo be posted
5/9/03 20%will go quickly once type C is figured out
19Develop detailed ProE models and drawings of winding packs, including leads.
Williamson Post in IntralinkTo be posted
5/9/03 20%will go quickly once type C is figured out
20Develop detailed ProE models and drawings of clamps and cooling system.
Williamson Post in IntralinkTo be posted
5/9/03 20%will go quickly once type C is figured out
21Develop assembly models and drawings, including bolts, insulation, assembly features.
Williamson Post in IntralinkTo be posted
5/9/03 20%will go quickly once type C is figured out
22 Develop draft specification for production winding forms. Williamson Issue specificationTo be issued
5/16/03 20%will go quickly once type C is figured out
23Conduct peer review of draft spec and drawings before releasing to Manuf Dev teams.
WilliamsonResolve comments, promote models and
drawings
to be scheduled before 5/1/03
24 ElectricalCalculate current waveforms and electrical parameters. Document as technical data on web.
Reiersen Post on webTo be posted
4/4/03 30% needs conductor size
25Calculate eddy current time constants for MC structure. Document in memo.
Brooks
Issue eddy current memo, resolve
comments, post on web
To be issued 4/4/03 90% Need memo
26 ThermalCalculate heat transfer and temperature distribution in winding pack due to current pulse. Document in memo.
Fan
Issue thermal analysis memo, resolve
comments, post on web
To be issued 4/4/03 90% Need memo
27Calculate thermal stress in winding pack and clamps due to current pulse.
Freudenberg
Issue thermal stress memo, resolve
comments, post on web
To be issued 5/9/03 30%
reasonable progress with modeling technique, clamp spacing
28Calculate cool- down of MC assembly from room temperature to 80- K. Document in memo.
Fan
Issue cool- down memo, resolve
comments, post on web
To be issued 5/9/03
UT is doing similar analysis and this may help us
29 EM / StructuralDevelop finite element models for integrated EM and structural analysis.
Fan 30% Progress being made
30Calculate electromagnetic loads and identify critical load cases. Document in memo.
FanIssue EM loads memo,
resolve comments, post on web
To be issued 5/9/03
re- do 7 cases for new currents
31Incorporate winding pack material properties based on R&D test results.
Fanproperty data will be late
32Perform stress analysis for critical EM load cases and compare to allowables. Document in memo.
Fan
Issue stress analysis memo, resolve
comments, post on web
To be issued 5/30/03
MODELS AND DRAWINGS
ANALYSIS
PDR Tasks
33 Conductor PropertiesProduce samples of vacuum- pressure impregnated conductor for use in mechanical and thermal tests.
Zatz Samples ready
34Perform mechanical and thermal tests to determine properties of single and bundled conductor. Document through vendor reports.
Zatz Report from CTD Due in Aprilsamples to CTD next week
35Establish design allowables and document through structural design criteria.
ZatzIssue for comment, resolve comments,
post on web
Posted 5/13/02, awaits revision
36 Winding Form R&D Develop detailed drawings of Type C winding form. Williamson Post in Intralink Post by 4/11/03 50%drawings go relatively fast after models are done
37 Conduct peer review of Type C models and drawings. Williamson
Resolve chits, sign spec and drawings,
authorize vendors to proceed
38Describe manufacturing methods for all three forms and recommended casting alloy.
Heitzenroeder Report from EIO/ J PP Due 4/28/03
39Describe mold fabrication and analysis. Describe plan for heat treatment, repair, and inspection.
Heitzenroeder Report from EIO/ J PP Due 5/13/03
40Describe preliminary MIT plan and budgetary cost estimate for production coils.
Heitzenroeder Report from EIO/ J PP Due 5/25/03
41 PPPL Winding R&DConduct VPI trials on straight tee section. Develop VPI procedure, recommendation on needed design features. Document VPI procedure, current center analysis.
ChrzanowskiIssue for comment, resolve comments,
post on webIssued 3/21/03 Complete
42Perform keystone trials on coil fixture using single and bundled conductor. Document recommendations.
ChrzanowskiIssue for comment, resolve comments,
post on web
To be completed in
Aprilstarts next week
43Wind and VPI a racetrack demonstration coil with spliced crossover joint and leads. Document fabrication, test plan.
ChrzanowskiIssue for comment, resolve comments,
post on web
Winding, VPI done late April
winding form delivered for PPPL coil, UT coil to be
44Prepare FMECA identifying potential failure modes and recovery provisions.
WilliamsonIssue FMECA, resolve comments, post on
web
To be issued 5/23/03
45Document design approach, analysis results, and comparison with performance requirements. Write design basis document.
Williamson
Issue design basis document, resolve comments, post on
web
To be issued 5/23/03
46Develop cost and schedule estimates for MC Winding and Assy (WBS 142)
Chrzanowski
47Provide integrated cost and schedule inputs to Strykowsky for WBS 14
Williamson
48 Prepare Preliminary Design Report Williamson
49 Prepare presentations for PDR Williamson
MANUFACTURING DEVELOPMENT
DESIGN EVALUATION
COST AND SCHEDULE
PDR PREPARATION
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