1 Modular Coil Assembly Fixture (MCAF) Information Meeting February 23, 2005

2 Agenda Define the basic design requirements of the Modular Coil Assembly Fixture (MCAF), Define VV / MC clearances during MC assembly Describe the Reference Design that was used to generate the MCAF design specifications, Review the MCAF performance requirements as they currently stand, and Answer questions

3 The design intent of the MCAF is pass two modular coil assemblies over the VV and accurately position mating flanges.

4 The Modular Coil Assembly Fixture Reference Design

5 MC Design and VV Clearance Module Coil Half Period 1.76” actual minimum for nominal sizes

6 A 1.76" (metal-to-metal) min clearance between MC’s and VV. MC to VV Clearance MC is at its final position

7 A 0.45” minimum clearance exists between wing region of Type A’s as the two half period MC shells comes together. MC to MC Clearance Wing region

8 How can assembly tolerances effect clearances? 0.96” 1.0” VV insulation ” VV tolerance 0.060” MC tolerance 1.25 ” Minimum Space MC is at its final position

9 MCAF Reference Design The Reference Design was develop to qualify technical feasibility and help in establishing a design specification. Gantry Crane Module Coil Half Period Turning Fixture Base Guide Rail Type “A” Type “B” Type “C” Turning Fixture / MC Interface Components VV Support

” 60 Deg The relation between the Reference Design and Machine Coordinate System X Z Y Machine Coordinate System Reference Design Coordinate System 6.125” Y

11 Rx Rz X Y Z X Ry X. Z For the Reference Design the X-axis was shifted up 6.125”

12 tdydxdzrxryrz The Reference Design MCAF motion is based on a 248 step servo table to drive six motors MC is at its final position

13 MCHP / Turning Fixture interface Module Coil Half Period Pivot and rotation gimbal component Cradle component Vertical guide component Linear turntable structure Linear motion structure (25000 lbs max) (3200 lbs) (6300 lbs) (3500 lbs) (2700 lbs) (3000 lbs) 18,700 lbs MCAF Component Details

14 Exploded isometric view MCHP / Turning Fixture interface Gimbal structure supports the MCHP and drives the pivot motion (“X rot”) A cradle structure support stabilizes and drives “Y rot” of a gimbal structure. The vertical guide component stabilizes four screw jacks (“Z” dir) which are driven by a single motor A linear turntable provides “X” motion with a pivot point (“Z rot”) and a bearing surface Base structure provides “Y” motion

15 Extent of motion of turning fixture components. DZ = 16” DX = 12” RZ = 15° Y X Z RX = 5° RY = 13° DY = 140”

16 MC Interface Structure A Local beam that interfaces with the gantry crane picks up existing MC holes The MC CG location stays within the attachment points Shaft attached to mid-section of Type “B” MC

17 Gantry crane designed with intermediate support system to provide final fit-up

18 In the 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.

19 What seismic design criteria do you apply during an assembly process? We have set a static seismic criteria of.108 as the design requirement following the NCSX Seismic Specification NCSX-CRIT-SEIS-00

20 Starting Position - CG Locations 18,300 MCHP 38,000 MCAF (Base End and Front Views)

” Final Position - CG Locations 18,300 MCHP 38,000 MCAF (Front and Top Views from Base Structure)

lbs (assumes a.108 seismic factor) 38,000 lbs 104” 34” A Side view show worst seismic position The existing base should work with captured rollers and a.108 static seismic factor but a broader base may be necessary if the CG moves up or a dynamic stop condition governs the design. Capture roller

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

’ 21.25’ Test cell assembly space requirements.

25 System Requirements  Performance Requirements  Fit-up and Assembly Space Allocation  Motion Controllers Requirements