NCSX A. Brooks, P. Fogarty, G. Lovett, D. Williamson June 3, 2005 Modular Coil Type-C Final Design Review – Part II

NCSX 2 Charge Questions Does the lead block design meet requirements (EM, elec, therm, struct, fab)? Are the lower lead blocks and terminals ready for fabrication (C1)? What is the procurement plan for C2-C6, A, B? What issues remain for Type-C? How to solve? What is status/schedule for comprehensive FDR documentation?

NCSX 3 FDR Part I Results – Cladding (4/27) To be addressed by this review

NCSX 4 Lead block and terminal requirements RequirementTRC Design SolutionType-C Changes Provide an accurate means of positioning the conductor. Eighteen block G10 asm with slots and finger guides, line-to-line contact everywhere. G-11CR material, reduce no. of blocks, increase slot widths, mount to complex tee shape. Provide a practical geometry for assembly. Multiple parts, compact bends.Increase min bend radius, fewer parts ok. Isolate the conductors electrically. Compact design but with discrete conductor slots, allowance for varying insulation thickness. Spacing increased, esp between jumpers. Provide thermal continuity with winding pack. Chill plate between upper/lower blocks and side plate extends through MCWF. Same design as TRC. Minimize field errors to island size < 1% total flux Mod coil set with TRC-style leads is ok if leads oriented a certain way. Errors cancel within each coil. Same orientation of new leads gives similar results, but more interaction between coils. Meet clearance requirements for machine assembly. Jumpers base block height increased for ease of fabrication, design would interfere with TF. Height minimized through use of angled terminal jumpers assembly.

NCSX 5 Modifying the TRC geometry Minimize large gaps by conforming to winding pack Change conductor path to ramp up, exit WP at 45-deg angle Minimum radius increased, but MCWF opening slightly larger Lead block envelope after “subtraction” of winding pack TRC conductor path Type-C

NCSX 6 Lead blocks assembly Seven G-11CR blocks, max dimensions are 6.5 x 11 x 3.25-in thick Side-A Side-B Lower block Upper block Side plate Top plate

NCSX 7 Lead blocks assembly Oversize holes for alignment Tee mount bushing Layer #1-2 ramp Positioning tab Upper lead block

NCSX 8 Upper / lower blocks combine features Split blocks used in TRC good for manual machining, but require additional fasteners, glass cloth between interfaces Combined block suitable for NC machining, minimal drawing details SE142C-122 Side-A Lower Block Finger Slots SE142C-134 Side-A Lower Block Straight Slots SE142C-135 Side-B Lower Block Combined

NCSX 9 Lower block drawing

NCSX 10 Side plates w/ cooling Chill plate between lead blocks and side plate cools conductor external to winding pack, same design as TRC Side Plate

NCSX 11 Field errors with TRC style leads Analysis by A. Brooks (11/04) indicates need to reverse coax for Type-A and –B from that shown Type-B is the largest contributor; it can be reversed alone if necessary A B C

NCSX 12 New leads filament model Coax Original Revised Coax A. Brooks 6/2/05

NCSX 13 Goal: ds < 1% Total Flux Results shown for worse 3/5 mode with plasma equilibrium at 179 KA, full beta Other Modular Coil current distributions may produce larger islands Revised Design Reduces Total Resonant Field Error Individual Contributions from A & C Increased A. Brooks 6/2/05 Field error analysis

NCSX 14 Leads terminal assembly

NCSX 15 Clearance check with TRC geometry Analysis by M. Cole (2/05) gives ~.25-in interference between leads and TF structure when increased height of base block is considered Type-A needs to be reversed for coax attachment, consistent with error field analysis A

NCSX 16 Clearance with new design is improved Flange Boundary TF Clearance Envelope 0.75”

NCSX 17 Plan to complete lead blocks, terminal Order long lead G11-CR blank material –Revised blank dimensions issued 5/18 Develop models/drawings of lower lead blocks –Drawings of Side-B combined block are ready to promote, complete by 6/8 –Drawings of Side-A combined block in progress, complete by 6/8 Develop models/drawings of remaining lead blocks –Models complete, drawings in progress, complete by 6/10 Create STL model of lead block asm, incl MCWF –Ready for quote, order by 6/10, est receive all parts by 6/24 Evaluate current filaments for field errors, all coils –Update geometry for actual Type-A, -B filaments, by 6/8 Develop models/drawings of lead terminal parts and asm –Drawings ready to promote except SE142C-050 (asm) –Template plate model/drawing in progress, complete by 6/10 –Evaluate material selection for cable connector, SE142C-059 Revise MCWF machining in leads area –Drawing revision complete except for ECN, complete by 6/8

NCSX 18 Conclusion Does the lead block design meet requirements (EM, elec, therm, struct, fab)? –Revised design improves conductor bend radius and ability to wind coil, leading to a more accurate and repeatable assembly Are the lower lead blocks and terminals ready for fabrication (C1)? –Lower lead block drawings to be promoted by 6/7 –Terminal parts and assembly (w/ minor corrections) ready for sign-off What is the procurement plan for C2-C6, A, B? –NC machining will require all lead blocks to be outside procurement –Terminal parts could be made in-house What issues remain for Type-C? How to solve? –Chill plate and cladding assembly drawings What is status/schedule for comprehensive FDR documentation? –Review is scheduled for Jun-29