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NCSX Modular coil winding pack To shim or not to shim?

NCSX Modular coil winding pack To shim or not to shim?. What is requirement? What is baseline winding pack design? What are alternate winding pack designs? How will we figure out what to do? What do we need to do now?. NCSX WBS 1 Engineering Meeting July 7, 2004.

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NCSX Modular coil winding pack To shim or not to shim?

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  1. NCSX Modular coil winding packTo shim or not to shim? • What is requirement? • What is baseline winding pack design? • What are alternate winding pack designs? • How will we figure out what to do? • What do we need to do now? NCSX WBS 1 Engineering Meeting July 7, 2004

  2. What is winding requirement? • Winding current center must be within .06 inches of theoretical winding • If current center is more than 30 cm from plasma, some relaxation may be possible.

  3. Tolerance budget apportioned in thirds 1/3 for winding 1/3 for field period assembly 1/3 for final machine assembly

  4. Baseline design: accuracy achieved by shimming • Winding position continuously adjusted to AVOID TOLERANCE STACKUP • Form machined to high accuracy (Flanges to +/- 0.01 in, Contours to +/- 0.01 in) • Windings placed to high accuracy relative to each other and the form • Final position of coil form in assembly adjusted for optimum fit Custom lateral shim 1.5 mm radius tolerance on winding center Custom shim layer to layer Each conductor layer can be custom shimmed Custom shims adjust flanged joints between adjacent coil winding forms

  5. Baseline design: What are issues? • Measurement of each layer could be time consuming • What fraction of winding needs custom shimming? • What fraction can use standard shim? • Measurement tools may not work properly on insulation layer • Other issues Custom lateral shim 1.5 mm radius tolerance on winding center Custom shim layer to layer Each conductor layer can be custom shimmed

  6. What are alternate winding pack concepts? • Lumped shim concept • Estimate total keystoning at each position along winding pack • Shim between tee and ground wrap • Mid-course correction, if necessary • Variation: perform trial winding to quantify shim thickness • Pros • Less work measuring and shimming • Cons • Must be able to predict keystoning a priori • Hard to gage compressibility of winding pack and shims – are turns evenly distributed? No keystoning, max shims Max keystoning, no shims

  7. What are alternate winding pack concepts? (2) Current center, desired • No-shim – use winding form as is • Take what we get, no shims • Pros • Less work measuring and shimming • Cons • Art says this won’t work – islands too big Current center, actual current center shifts, but stellarator symmetry preserved

  8. What are alternate winding pack concepts? (3) • No-shim – variable section winding form • Predict keystoning • machine winding form with variable section to put winding center in correct place without shims • Pros • Less work measuring and shimming • Cons • Must be able to predict keystoning a priori • Winding pack size varies, so clamps, cladding, chill plates must vary No shims, winding form maintains current center

  9. What are alternate winding pack concepts? (4) • Other ideas • Pros • Cons

  10. How do we make decision? • Need experience winding prototypical coil to select shimming technique • Twisted racetrack will arrive this week • Conductor has been ordered and is in house • Ground wrap, insulation finalized • Cladding, chill plate ideas are firming up • Clamps are on order • Lead block design nearly complete • Try two shimming approaches: • Baseline on one side of coil • Alternate approach on other side of coil (lumped shim) • Trial winding first to determine lumped shim size

  11. What do we do next? • Order more conductor, if needed: Chrzanowski • Figure out correspondence between layers of glass and apparent thickness of shim: Chrzanowski et al • Get drawings of new lead block design to PPPL: Fogarty • Get drawings of new cladding to PPPL: Hargrove • Test Romer arm scanner on insulated conductor: Raftopolous • Order studs for stud welder: ? • Make fixture for locating studs: ? • Review TRT test objectives: Chrzanowski, Reiersen, Gettelfinger • Finish test plan: Nelson

  12. Summary • We need to finalize winding pack shimming scheme • Trials on twisted racetrack will provide input • Recommend both the baseline concept and alternate concepts be included in winding / shimming trials on twisted racetrack

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