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?

• Is the fixture cost and procurement schedule consistent with the program schedule and budgets?

Structural weight is 3,909 lbs

The Stage 2 tooling fixture is a built-up structural weldment with pin connections for MC position adjustment.

Crane connection point.

Frame fastened to floor

Crane connection point.

Local framing added to increase stiffness.

Center element is removable for Type-C

to C fit-up check.

Flange of MC’s mount to local gussets.

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

4’

Type-C

Type-B

9’ 2”

6’ 5”

Stage 2

Modular Coil Half Period Assembly Fixture

Type-C

Type-B

Type-A

Crane lift line

Bolt connection points

Type-C to Type-C

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

Stage 2 Tooling Fixture Analysis

FEA Model for the A-B-C sub-assembly @40 degrees 18,271 lbs

Assembly modeled as Rigid elements from the C.G. to frame mounting

B.C.s:

The bottom frame surfaces are vertically restrained by the floor & in all directions at the anchor points

Frame:

Model consists of CQUAD4 & CTRIA3 plates with bending & membrane stiffness.

The A-B-C sub-assembly @40 degrees - Tresca stress contours

Peak Tresca Stress 14.1 ksi

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)

Peak Tresca Stress 18.2 ksi @ upper gusset mtg. hole

Tresca stress contours for A-B-C @ 20 degree position

Displacement contours (SRSS) for the A-B-C sub-assembly @ 40 degrees

Peak displacement on the frame is 0.028”

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

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.

The estimated cost of the Stage 2 fixture is ~ $16,000, assuming $4 per lb.

Stage 2 Tooling Fixture Cost

8,000 lbs estimated weight, assumes 2” thick plate and a 20° wedge.

MTM Type-C Support Fixture is available. Can it be used for this or some other assembly application?

My recommendation is to use the MTM Type-C fixture for checking the Type-C to C fit-up

Type-C

Type-B

Type-A

Type-C

Type-B

Application of MTM Type-C Fixture

Structure would be needed to orient fixture for full MCHP assembly.

Type-C

Type-C

Updated Plan

Current Baseline (ECP-50)

Stage 2 assembly is carried out in series, requiring only one fixture.

Ron’s latest schedule that provides adequate FY-07 & 08 budget contingency

D-Site Assembly Layout

It has been proposed to move Stage 5 to the NCSX test cell which would free up space for the earlier assembly stages.

MTM Type-C fixture

NCSX test cell activity

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?

0.0021

0.0033

0.0040

Figure shows the Lateral deflection with 100 lbs applied at the frame corner with different support methods.

No added lateral support.

Lateral support as originally drawn

Diagonal bracing added

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