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Station 2 Tooling PDR/FDR

Station 2 Tooling PDR/FDR. T. Brown F. Dahlgren L. Morris. Charges. Does the tooling fixture provide adequate support and adjustability to perform the MCHP assembly? Are the drawings complete and ready for sign-off? Has the analysis been documented and checked?

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Station 2 Tooling PDR/FDR

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  1. Station 2 Tooling PDR/FDR T. Brown F. Dahlgren L. Morris

  2. Charges • Does the tooling fixture provide adequate support and adjustability to perform the MCHP assembly? • Are the drawings complete and ready for sign-off? • Has the analysis been documented and checked? • Is the fixture cost and procurement schedule consistent with the program schedule and budgets?

  3. The Stage 2 tooling fixture is a built-up structural weldment with pin connections for MC position adjustment. Crane connection point. Structural weight is 3,909 lbs Frame fastened to floor

  4. Flange of MC’s mount to local gussets. Crane connection point. Center element is removable for Type-C to C fit-up check. Local framing added to increase stiffness.

  5. Type-B Type-C 4’ The Stage 2 tooling fixture configured for assembly of Type-B to Type-C module coil.

  6. Type-C Crane lift line Type-B Type-A Stage 2 Modular Coil Half Period Assembly Fixture 9’ 2” Bolt connection points 6’ 5”

  7. Removing the center element allows a fit-up check of the Type-C MC’s. Type-C to Type-C

  8. Assembly modeled as Rigid elements from the C.G. to frame mounting Stage 2 Tooling Fixture Analysis Frame: Model consists of CQUAD4 & CTRIA3 plates with bending & membrane stiffness. B.C.s: The bottom frame surfaces are vertically restrained by the floor & in all directions at the anchor points FEA Model for the A-B-C sub-assembly @40 degrees 18,271 lbs

  9. Peak Tresca Stress 14.1 ksi The A-B-C sub-assembly @40 degrees - Tresca stress contours

  10. Peak Tresca Stresses @ the stanchion pin mounting hole perimeters is 14.1 ksi Allowable stress for A36 steel is 24 ksi (2/3rd yield criteria)

  11. Peak Tresca Stress 18.2 ksi @ upper gusset mtg. hole Tresca stress contours for A-B-C @ 20 degree position

  12. Peak displacement on the frame is 0.028” Displacement contours (SRSS) for the A-B-C sub-assembly @ 40 degrees

  13. Stage 2 tooling fixture drawings are complete and ready for release.

  14. Stage 2 Tooling Fixture Cost The estimated cost of the Stage 2 fixture is ~ $16,000, assuming $4 per lb. Ron’s allocated M&S budget for Stage 2 is $54,000. This number contains magnetic alignment tooling components which we now do not have. It also includes money for match drilling of flange holes to an intermediary plate which we may or may not do.

  15. MTM Type-C Support Fixture is available. Can it be used for this or some other assembly application? 8,000 lbs estimated weight, assumes 2” thick plate and a 20° wedge.

  16. Application of MTM Type-C Fixture Structure would be needed to orient fixture for full MCHP assembly. Type-B Type-A Type-B Type-C Type-C Type-C My recommendation is to use the MTM Type-C fixture for checking the Type-C to C fit-up Type-C

  17. Stage 2 assembly is carried out in series, requiring only one fixture. Updated Plan Current Baseline (ECP-50) Ron’s latest schedule that provides adequate FY-07 & 08 budget contingency

  18. It has been proposed to move Stage 5 to the NCSX test cell which would free up space for the earlier assembly stages. NCSX test cell activity MTM Type-C fixture D-Site Assembly Layout

  19. Charges • Does the tooling fixture provide adequate support and adjustability to perform the MCHP assembly? • Are the drawings complete and ready for sign-off? • Has the analysis been documented and checked? • Is the fixture cost and procurement schedule consistent with the program schedule and budgets?

  20. 0.0021 Figure shows the Lateral deflection with 100 lbs applied at the frame corner with different support methods. Diagonal bracing added No added lateral support. 0.0033 0.0040 Lateral support as originally drawn

  21. Note that the pivot frame itself only deflects ~0.0017" a small distance away from the corner load application point.

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