NCSX Web Pages  

Project | Management | Physics | Procurement | Manufacturing

NCSX FTP Sites  

Project FTP Server | Supplier FTP Server

Navigation Trail  

Engineering > Field Period Assembly


Vendor Files Stored in Ops Center


Modular Coil Half Period Assembly Over Vacuum Vessel (Done 8/25/2008)


Field Period Assembly - Photo Album

  • Current Coil Status - The spreadsheet provides the current coil status and which fit-ups the pre-measurements that remain.

  • Station 1 - contains photographs of the diagnostic loop terminations, and photographs of the respective VVSA coils

  • Station 2 - contains information on the A1/B1 fit and the respective drawings and various spreadsheets and presentations on the C-C joint, assembly comparisons, coil to coil test methodology, coil to coil interfaces, etc. FPA Pictures

  • Coil to Coil Assembly - contains various folders on the coil to coil assembly (e.g., A1/A2 alignment, gross  and final fit of coils, A1 bolt kit fit, A1 clearance issues, videos, SuperNut clearances,  etc.

  • Metrology - files can be found at:

  • Welded Interfaces - contains several photographs of the welded interfaces/

  • Job Manager FPA Files - contains informal files maintained by the Job manager (e.g., coil lifts, iterations of the Field Period Assembly Plan, iterations of the FPA-001 procedure, FPA sequence plans, MIT/QA plans, etc.

  • CERN/W7-X Visit - contains copies of the presentations made both by NCSX and CERN/W-7-X personnel, photographs, trip report, etc.

  • Mail Communications - Mail and communications has been saved under a .pst file for the VVSA 

    and FPA. Also included are the records of the daily 3:15 pm meeting.
  • Back Office Dimensional Control Support of FPA

    • Shim Sizing - contains data and code/methods used to size the shims for thee MCWF Joints. 
      Metrology Data used for shim sizing to date:


      The Realignment Matrices (RM.A1 - RM.C6) are applied to the metrology data of the coils to determining shim sizes within the sizeshims3.f code.  A check of this process is provided by Matlab routines under Mark Smith's archival directory.  The Realignment Matrices were generated and documented under directory : "Job8205 - Dimensional Control\Modular_Coil_Windings\Coil_Realignment"

    • Station 2 Half Period Assembly - contains the spreadsheet calculators deveoped to support the HP assembly operation. Each calculator is fundamentally the same, howere improvements were made with each use. Also there is data to be changed in each that is specific to the joint being made up (ie A1-B1, B1-C1, ...)

    • Station 3 Assembly of Half Period Over the Vacuum Vessel Segment - This directory contains data and methods used to create the traces to be mounted on the screens which the three lasers will follow during station 3 - HP assembly over the VV.

      Prior to assembly of th HP over the VV, the installed screen locations (3 points per screen) are provided as well as the installed laser lines (2 points per line). These coordinates are processed offline using the scripts and codes defined below. The intersection of the lasers on the screens is returned in the form of ProE ibl files of curves that are then further processed by the CAD group (Tom Brown) and printed for mounting on the screens.  This was an iterative process as indicated by the typical iteration for an email correspondence:


      I've updated the assembly traces using your new coordinates for the lasers and your revised screen locations.

      Attached are some files in an zip file (renamed giving the traces of the lasers for assembly from the right (+Y) and the left (-Y). The files ending in 11r are for the right side, those ending in 11l are for the left side. The spreadsheets give the xyz data of the laser traces and plots of them. They also give plots of the "Strap Lengths" on the second worksheet for a fixed hook height. I used a height of 275 for the left side, but reduced it to 255 for the right side to minimize the total variation in length required. The required motion to has dropped slightly to 25.85" inches with this scenario. Unfortunately, you cannot live with one size fits all for the straps. To do that, the stroke would have to increase to >31.1" (ie 36") . This assumes the hook height is fixed during assembly at it's initial height and all vertical adjustment is done with the actuators.

      There are a bunch of ibl files as well. Files labeled trace01 thru trace03 are the laser traces, trace04 is the CG and trace05 thru trace07 are the swivel points. I've looked at these in ProE and the Lasers do track the lines.

      I've done a check on the tension of the straps to make sure we are not going into compression. The right side has one sling which drops to only 4% of the load and the left side has one that goes as high as 65%. I've added some columns at the end of the second worksheet that calculates how close to the edges of the triangle formed by the three support points the hook/cg comes (in plan view) which is also an indication of the opposite sling going limp. The right side gets to within 2". If we don't know the CG that accurately, it could force us to move the support points further apart.


      Scripts and Codes:

      The following scripts and codes are run on the UNIX platform using the screen and laser coordinate data provide with the previously calculated matrix transformation defining the assembly process over a number of steps (248)

      doall.path5tom3r15_right - script for doing assembly from right side
      doall.path5tom3r18_left - script for doing assembly from left side

      invkinematic2a.f - code to do inverse kinimatic calculations but can also be used as it is here to just do the matrix transformations during assembly.

      invkinematic2a.inp.path5tom3r15r - input to invkinematic2a.f for right
      invkinematic2a.inp.path5tom3r18l - input to invkinematic2a.f for left

      NOTE: The invkinematic2a.f code assumes assembly from right. For assembly from left, the script assumes the user has imaged the screen and laser point data to the right side and then images the results back for the left side.

      genleftscreen.f, genrightscreen.f - utility codes to help set up script data using data supplied by CAD (Tom Brown)

      lasertrace2.f90 - code called by doall script to do intersection calculation of transformed laser line points with screens.

      genpts_iblrev.f, genpts_ibl.f - utility codes run by doall script to create ibl files from tables of points.

      tension.f90 - code for calculating tension in each sling
      at each step of assembly to verify stability of HP.


Privacy and Security Notice

Please forward comments and questions to the