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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
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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 telecons @ 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) • ModelMakersurface 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.
ModelMaker Measurement System Arcsecond Internal GPS ~$50K $70-$100K • 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.