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A. Brooks, P. Fogarty, G. Lovett, D. Williamson

June 3, 2005

Modular Coil Type-CFinal Design Review – Part II

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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?

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FDR Part I Results – Cladding (4/27)

To be addressed by this review

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Lead block and terminal requirements

Requirement TRC Design Solution Type-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.

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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

TRCconductor path

Type-C

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Lead blocks assembly

• Seven G-11CR blocks, max dimensions are 6.5 x 11 x 3.25-in thick

Side-A

Side-B

Lowerblock

Upperblock

Sideplate

Topplate

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Lead blocks assembly

Oversize holes for alignment

Tee mountbushing

Layer #1-2 ramp

Positioningtab

Upper leadblock

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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-122Side-A Lower Block Finger Slots

SE142C-134Side-A Lower Block Straight Slots

SE142C-135Side-B Lower Block Combined

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Lower block drawing

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Side plates w/ cooling

• Chill plate between lead blocks and side plate cools conductor external to winding pack, same design as TRC

Side Plate

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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

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New leads filament model

Coax

Original Revised

Coax

A. Brooks 6/2/05

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Goal: ds < 1% Total FluxResults shown for worse 3/5 mode with plasma equilibrium at 179 KA, full beta

Other Modular Coil current distributionsmay produce larger islands

• Revised Design Reduces Total Resonant Field Error Individual Contributions from A & C Increased

A. Brooks 6/2/05

Field error analysis

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Leads terminal assembly

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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

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Clearance with new design is improved

Flange BoundaryTF Clearance Envelope

0.75”

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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

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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