NCSX Metrology

Goals –Need to accurately make measure measurements for several NCSX systems Modular coil –As-built measurements of coil form –Conductor, before/during/after winding –Install monuments on outer surface for assy phase Vacuum Vessel –As-cast measurements –Port nozzle locations and axes –Flange locations/alignments –Install monuments for assy phase and for future installation of first wall and diagnostics components. Field Period Assembly –Alignment of the field periods First Wall components Diagnostics Conventional Coils

Path Lets figure out what we need to measure and to what accuracy. –Need to understand overall scope before we dive into details, but… Need to get into details ASAP, especially for the components that are in bid phase now (modular coil forms, VV) This leads us to determine what tools are required for the job –Do we have the right tools on hand now? –What do we need to acquire?? How much $$ - not cheap. Based on the tools we decide on, we determine what type and how many monuments we require and how we’re going to make the measurements. –For assembly & positioning of field periods –For installation & alignment of diagnostics, neutral beams –For installation & alignment of PFCs

Existing measurement systems –Leica Laser Tracker Requires continuous, unbroken line of site. Need to establish reference monuments in order to move the tracker. Will have to move frequently – decreases accuracy and increases probability of error. Good range Extremely precise Requires extremely stable base –FARO 7-axis measurement arm Short reach Will have to remount frequently – decreases accuracy and increases probability of error. –Numerous hand held, mechanical instruments Accurate Good for making local measurements

Existing Software –Leica AXYZ package Only works with laser tracker Rudimentary graphing capability Poor post processing features –CAM2 Good post processing features Cannot take laser tracker input –AutoCAD Poor post processing features Takes FARO data directly (old software could) –ProEngineer ?? Have not input metrology data into ProE yet

What We’ve Done to Date Formed a metrology task force: –S. Raftopoulos, J. Chrzanowski, E. Perry, D. Loesser, R. Feder, B. Nelson, P. Goranson, D. Williamson –Having weekly 3:00pm on Mondays –Working on a measurement matrix that will identify measurement need throughout all phases of NCSX Looking into hardware/software –Arcsecond is holding an on-site (PPPL) demo of the Indoor GPS on 5/28. –Updating FARO arm software to CAM2. Price includes training for 2.

Proposed Plan Assign Responsibilities –Individual areas should determine what measurements (tolerances) and monuments they require. This will lead us to determine what hardware/software we need. Metrology Purchases (suggestions) –ModelMaker surface scanner (FARO arm attachment). – Non-contact measurement system that allows complex surface measurements to be accomplished readily. –Arcsecond GPS system – Laser-based system that can track multiple targets. Will enable the installation/positioning of the modular coils and field periods to the required accuracy. –Spectral Analyzer metrology software. Takes input from wide range of measurement systems. Can perform post processing and CAD-compare. Training –Get more (advanced) training for the users of the measurement systems. We are NOT proficient enough yet.

Arcsecond Internal GPS ModelMaker is a revolutionary portable laser scanning which is capable of capturing 3D geometry. The scanner is attached to a mechanical arm which moves about the object, freeing the user to capture data rapidly and with a high degree of resolution. An optional tripod provides complete portability in the field. Intuitive software allows full model editing, polygon reduction, and data output to all standard 3D packages. Flexible: From consumer goods to full size cars, the applications are unlimited. Ease of Use: Quick and easy to set-up and use (30 mins). Minimal operator training is required. The system gives the user instant feedback by rendering the collected data in real time. Portable: Ability to take the scanner to the object. Ideal for both styling studio and factory floor. Adjustable Laser Power: For use on nearly any material, or color, and in any lighting condition. Fast: Cuts down the time taken to measure complex shapes from weeks to hours Non-Contact: Suitable for measuring soft or delicate materials such as foam, rubber or clay. CAD Compatible: Interfaces to all major software packages for reverse engineering and inspection. ModelMaker Measurement System $70-$100K ~$50K