SEPT 20, 2006 T. Brown, M. Cole, P. Fogarty, P. Goranson, K. Freudenberg, D. Williamson NCSX STAGE 2 COIL TO COIL ASSY

20 September 2006Stage 2 Coil to Coil Assy2 AGENDA 3 POINT POSITIONING SUPPORT – Mike Cole BOLT REAMING – Paul Goranson SHEAR PLATE – Kevin Freudenberg WING SUPPORTS – Dave Williamson

20 September 2006Stage 2 Coil to Coil Assy3 3 Point Positioning Support Requirements Position Winding Center within a TP of.020 inch. Maintain electrical isolation between coils.

20 September 2006Stage 2 Coil to Coil Assy4 Type-A Type-B on A Stand repositioned to receive Type-C Type-C added along with supports MCHP Assembly Sequence where flanges and spherical seats must come together…accurately.

20 September 2006Stage 2 Coil to Coil Assy5 3 Point Positioning Support

20 September 2006Stage 2 Coil to Coil Assy6 Shim geometry is formed from MC developed surfaces rather from individual curves. Separate curves would be better. The flange interface involves the need to accurately mate spherical seats and inclined flange surfaces that are separated by shim material. Can shims be accurately machined and located? Can glass epoxy be used to take up misalignment? Mold release on flange surface

20 September 2006Stage 2 Coil to Coil Assy7 Thin layer of glass epoxy insulation. How thin, 15 – 30 mil ? Individually machined SS wedges. Can uncured glass epoxy (placed or pumped in) be used to take out the shim alignment imperfections? Will it meet the flange load capacity? Where tapped holes do not exist on flanges can spring pins be used to hold metal shim in place? Will we be cutting and machining individual SS shim pieces?

20 September 2006Stage 2 Coil to Coil Assy8 Sphere Flat “V” Proposed new alignment method. 1.5” Ø Switch from aligning three spheres to aligning a sphere, flat and “V”.

20 September 2006Stage 2 Coil to Coil Assy9 An alignment hole is need in the flat and “V” spherical seats to locate an alignment sphere, used for locating the mating sphere.

20 September 2006Stage 2 Coil to Coil Assy10 PROBLEM: How do you align the spherical seats when the shim surfaces are making contact at the same time?

20 September 2006Stage 2 Coil to Coil Assy11 Initial Alignment Position Fixed Adjustable Position for Final Shim Compression Uses spring loaded seats! Keyed interface prevents rotation. Option 1 We’ve added a pop up system to aid alignment.

20 September 2006Stage 2 Coil to Coil Assy12 Three or four captured precision compression springs provides an additional 3/8” extension above flange shims to aid alignment. Alternate approach for establishing a spring loaded interface Keyed interface prevents rotation. Option 2

20 September 2006Stage 2 Coil to Coil Assy13 How does the A-to-A interface set-up effect the flange assembly? Left side Right side The left side is rotated over the VV and placed ¾” from its final position and supported from the roller system below. The right side is rotated to within ¾” of its final position and held by the crane. The left side is then moved to its final position via rollers and the right side mates with the spherical seats via the crane system.

20 September 2006Stage 2 Coil to Coil Assy14 With no shims in place the MC position is verified with metrology measurements. Left side Right side

20 September 2006Stage 2 Coil to Coil Assy15 13”gap Left side fixed at -0.75” to alignment plane Right side backed to Step 32 Once metrology is verified the right side is backed off 13” via crane and secured from below. The flange shim system is installed and then the device is reassembled and metrology rechecked. This sounds okay, will it work? Backing off 13” involves an inclined moment with little rotation.

20 September 2006Stage 2 Coil to Coil Assy16 3 Point Positioning Support Issues Selection of 3 point support mechanism Ball and Socket only vs Flat, “V”, & Socket Variations include Spring loaded vs static. Determining Shim thickness & size One piece vs more than one piece

20 September 2006Stage 2 Coil to Coil Assy17 Extra slides follow

20 September 2006Stage 2 Coil to Coil Assy18 Early coil design with spherical seat machined into flange of winding form