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NCSX Coil Winding Development Program
Application of Epoxy/Fiberglass Modular Coil Molds
-Ventilation/Exhaust Issues
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NCSX Cross-section
Modular coils
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ModularModular Coil Fabrication
The modular coils will be wound in the TFTR Test Cell
Two winding stations
“VPI” Vacuum-Pressure
Impregnation station using
autoclave
VPI Exhaust ventilation
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FabricationFabrication Steps- part 2 VPI
Waffle Boards and fill ports (sprues) will be added to the modular coil bundle.
Tedlar insulation (non-stick) will then be over-wrapped.
The mold will then be installed around the turns (R&D program will define the VPI methodology) Mold shall be epoxy/glass fiber sprayed over Tedlar
insulation The shell is non-conductive and could remain
around coil The modular coil will then be vacuum
impregnated with the resin system approved by the NCSX Project based upon the R&D program
Once cured, the coil will be electrically tested and transferred to Field Period Assembly station
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NCSX Modular Coil
Typical Cross-section
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Two Phases of Work• Prototyping Development
– Components will be “table-top” sized, ~ 4 foot in length.
– Six to eight prototypes samples will be encased.
– We plan to do the work in a portable tent enclosure set up in the TFTR Test Cell.
– Modest amounts of material use.
• Modular coil molds.– Much larger enclosure needed.
– Each coil has +20 feet of coil.
– 19 coils to encase.
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Typical Application
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Materials- Spray Application• Materials being proposed
– Hetron 980/35 Resin System (Low Styrene Content Epoxy Vinyl Ester Resin)
• Promoter-Nuodex DMR Cobalt 6% Naphthenate
• Co-promoter-N, N-Dimethylaniline
• Catalysts- Cadox L-50a
– Acetone (for cleaning)
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Safety Concerns• Ventilation- good air flow• Personnel protective equipment
– Respirators
– Eye/face protection
– Gloves, coveralls, etc.
• Exhaust- via the elephant trunk system– HP concerns
– Environmental
– Flammability concerns
– Mixed waste