Transcript Willard_Flex Strap Design and Development_01-06-10.ppt

• Same vendor as used in current design
• For compact design, Hydratight
recommends changing bolt pattern to 4x
5/8” bolts
• Can reuse existing pneumatic-driven
hydraulic pump (most expensive
component of tensioning system; should
consider factory inspecting/ refurbishing
unit for 21,500 psi use)
Rout = 5.688”
31 Laminations:
- 12X .090” thk (outer)
- 19X .060” thk (inner)
- .005” gap between laminations
- Mat’l: Full-Hard C15100 H04 Cu-Zr
5”
7.5”
Rin = 3.255”
Flexible Strap Lamination Current Distribution: Outer Strap 12X .09" Thick Laminations, 19x .06" Thick Laminations
Lamination
Number
n
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Outside
Radius
Ro
in
5.688
5.593
5.498
5.403
5.308
5.213
5.118
5.023
4.928
4.833
4.738
4.643
4.485
4.42
4.355
4.29
4.225
4.16
4.095
4.03
3.965
3.9
3.835
3.77
3.705
3.64
3.575
3.51
3.445
3.38
3.315
Radius of
Width
Thickness
Curvature
h
d
R
in
in
in
5.643
2
0.09
5.548
2
0.09
5.453
2
0.09
5.358
2
0.09
5.263
2
0.09
5.168
2
0.09
5.073
2
0.09
4.978
2
0.09
4.883
2
0.09
4.788
2
0.09
4.693
2
0.09
4.598
2
0.09
4.455
2
0.06
4.39
2
0.06
4.325
2
0.06
4.26
2
0.06
4.195
2
0.06
4.13
2
0.06
4.065
2
0.06
4
2
0.06
3.935
2
0.06
3.87
2
0.06
3.805
2
0.06
3.74
2
0.06
3.675
2
0.06
3.61
2
0.06
3.545
2
0.06
3.48
2
0.06
3.415
2
0.06
3.35
2
0.06
3.285
2
0.06
Arch
Arch+Legs 72 straps (ft)
.09 Length
193.04
343.04
2058.23
.06 Length
231.00
468.50
2811.01
Total Length 811.53961
Length
L
in
Area
A
in2
1.773E+01
1.743E+01
1.713E+01
1.683E+01
1.653E+01
1.624E+01
1.594E+01
1.564E+01
1.534E+01
1.504E+01
1.474E+01
1.445E+01
1.400E+01
1.379E+01
1.359E+01
1.338E+01
1.318E+01
1.297E+01
1.277E+01
1.257E+01
1.236E+01
1.216E+01
1.195E+01
1.175E+01
1.155E+01
1.134E+01
1.114E+01
1.093E+01
1.073E+01
1.052E+01
1.032E+01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.800E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1.200E-01
1462.66
1331.74
2794.40
Total Wt (lbm)
Electrical
Resistivity
r
W*in
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
R
1/R
I
6.685E-05
6.573E-05
6.460E-05
6.348E-05
6.235E-05
6.123E-05
6.010E-05
5.898E-05
5.785E-05
5.672E-05
5.560E-05
5.447E-05
7.917E-05
7.801E-05
7.686E-05
7.570E-05
7.455E-05
7.339E-05
7.224E-05
7.108E-05
6.993E-05
6.877E-05
6.762E-05
6.646E-05
6.531E-05
6.415E-05
6.300E-05
6.184E-05
6.069E-05
5.953E-05
5.838E-05
Total
Rtot
V
1.496E+04
1.521E+04
1.548E+04
1.575E+04
1.604E+04
1.633E+04
1.664E+04
1.696E+04
1.729E+04
1.763E+04
1.799E+04
1.836E+04
1.263E+04
1.282E+04
1.301E+04
1.321E+04
1.341E+04
1.363E+04
1.384E+04
1.407E+04
1.430E+04
1.454E+04
1.479E+04
1.505E+04
1.531E+04
1.559E+04
1.587E+04
1.617E+04
1.648E+04
1.680E+04
1.713E+04
4.773E+05
2.095E-06
2.724E-01
4.074E+03
4.144E+03
4.216E+03
4.291E+03
4.368E+03
4.449E+03
4.532E+03
4.619E+03
4.708E+03
4.802E+03
4.899E+03
5.000E+03
3.440E+03
3.491E+03
3.544E+03
3.598E+03
3.654E+03
3.711E+03
3.771E+03
3.832E+03
3.895E+03
3.961E+03
4.028E+03
4.098E+03
4.171E+03
4.246E+03
4.324E+03
4.404E+03
4.488E+03
4.575E+03
4.666E+03
1.300E+05
Fop Total/2
• Non-stock Sizes
•Minimum Mil Run Buy = 2000 kg each
thickness = 4000 kg (2675 kg more than
required for 72 assemblies)
• Total Price = $49,450 (excluding
shipping), based on TTB = 90.04 JPY/$,
LME Copper = $7025/ tonne (metric ton
= 1000 kg), and LME Japan Premium =
$.0065/ kg
• Avg. Price/ lb = $5.61/ lb (versus
$3.19/ lb for Grade A copper)
• Cu Price/ assy = $686.81 (including
excess cu)
Flexible Strap Lamination Current Distribution: Outer Strap 31X .078" Thick Laminations
Lamination
Number
n
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Outside
Radius
Ro
in
5.688
5.603
5.518
5.433
5.348
5.263
5.178
5.093
5.008
4.923
4.838
4.753
4.668
4.583
4.498
4.413
4.328
4.243
4.158
4.073
3.988
3.903
3.818
3.733
3.648
3.563
3.478
3.393
3.308
3.223
3.138
.078" Thick
Radius of
Curvature
R
in
5.649
5.564
5.479
5.394
5.309
5.224
5.139
5.054
4.969
4.884
4.799
4.714
4.629
4.544
4.459
4.374
4.289
4.204
4.119
4.034
3.949
3.864
3.779
3.694
3.609
3.524
3.439
3.354
3.269
3.184
3.099
Arch (in)
425.98
Width
h
in
Thickness
d
in
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
2
0.078
Arch+Legs (in) 72 straps (ft)
890.98
5345.89
45.73
Arch
Length
L
in
1.775E+01
1.748E+01
1.721E+01
1.695E+01
1.668E+01
1.641E+01
1.614E+01
1.588E+01
1.561E+01
1.534E+01
1.508E+01
1.481E+01
1.454E+01
1.428E+01
1.401E+01
1.374E+01
1.347E+01
1.321E+01
1.294E+01
1.267E+01
1.241E+01
1.214E+01
1.187E+01
1.161E+01
1.134E+01
1.107E+01
1.080E+01
1.054E+01
1.027E+01
1.000E+01
9.736E+00
Total Length
Wt/ assy (lbm)
XSection
Area
A
in2
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
1.560E-01
Electrical
Resistivity
r
W*in
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
6.788E-07
R
(W)
1/R
(1/W)
7.722E-05
7.606E-05
7.490E-05
7.374E-05
7.257E-05
7.141E-05
7.025E-05
6.909E-05
6.793E-05
6.676E-05
6.560E-05
6.444E-05
6.328E-05
6.212E-05
6.095E-05
5.979E-05
5.863E-05
5.747E-05
5.631E-05
5.514E-05
5.398E-05
5.282E-05
5.166E-05
5.050E-05
4.933E-05
4.817E-05
4.701E-05
4.585E-05
4.469E-05
4.353E-05
4.236E-05
Total (1/W)
Rtot (W)
V (volt)
1.295E+04
1.315E+04
1.335E+04
1.356E+04
1.378E+04
1.400E+04
1.423E+04
1.447E+04
1.472E+04
1.498E+04
1.524E+04
1.552E+04
1.580E+04
1.610E+04
1.641E+04
1.672E+04
1.706E+04
1.740E+04
1.776E+04
1.813E+04
1.852E+04
1.893E+04
1.936E+04
1.980E+04
2.027E+04
2.076E+04
2.127E+04
2.181E+04
2.238E+04
2.298E+04
2.361E+04
5.350E+05
1.869E-06
2.430E-01
I
(A)
3.146E+03
3.195E+03
3.244E+03
3.295E+03
3.348E+03
3.402E+03
3.459E+03
3.517E+03
3.577E+03
3.639E+03
3.704E+03
3.771E+03
3.840E+03
3.912E+03
3.986E+03
4.064E+03
4.144E+03
4.228E+03
4.315E+03
4.406E+03
4.501E+03
4.600E+03
4.703E+03
4.812E+03
4.925E+03
5.044E+03
5.168E+03
5.299E+03
5.437E+03
5.582E+03
5.736E+03
1.300E+05
Date: 11/23/2009
Phone
Fax
(630) 260-1040
(630) 260-1102
A. J. Oster Company
Quotation Form
To:
Co.:
Tom Willard
Quote Submitted By: Sean Rozanski
Princeton Plasma Physics
Laboratory
Metal Value Based On: $ 3.700
Cu
$ 1.850
$
$
$
Zn
Sn
Ni
609-243-2481
[email protected]
Item Description:
Alloy: 151
• Stock-size, 100 lb minimum-buy on
Temper: 4#
Coil:
S/L
STW
ID
OD:
max
Gauge:
Tin
Specifications:
.078 +/-.0015
HTD
ET
Width:
100%
2.000 +/-.005
60/40
Matte
Reel Size:
Bright
Other:
Lead Time:
Release Qty’s 100#
3000#
Comments:
• Price/ lb = $6.15/ lb (versus $3.19/
lb for Grade A copper)
Minimum Buy: 9000 lbs min mill buy
9-10 weeks upon reciept of an order
for 100 lbs order. 12 week lead time
for min mill buy.
Fab $
$
$
$
$
$
5.3113
2.3113
Freight Terms:
M/V $
$
$
$
$
$
3.7963
3.7963
•Minimum Mil Run Buy = 9000 lb
(5708 lb more than required for 72
assemblies); parent company, Olin
Brass, may reduce minimum mil run
buy to 4000 lb. Possible to avoid mil
run if PPPL order coincides with
stock order
• Total Price/ 4000 lb = $24,612
(excluding shipping)
Thickness
Flash
Estimated Annual Usage:
shelf, enough to fabricate two
prototype assemblies. Price/ 100 lb =
$915.
• Cu Price/ assy = $341.83 (including
excess cu)
Total Price $
$
$
$
$
$
9.1076
6.1076
Fuel Surcharge $.0043/lb, Energy Surcharge $.0075/lb, and Copper Surcharge $.0340/lb
added at time of invoicing.
• Non-stock Size
•Minimum Mil Run Buy = 2000 kg
(505 kg more than required for 72
assemblies)
• Total Price = $24,503 (excluding
shipping), based on TTB = 90.04
JPY/$, LME Copper = $7025/ tonne
(metric ton = 1000 kg), and LME
Japan Premium = $.0065/ kg
• Price/ lb = $5.56/ lb (versus $3.19/
lb for Grade A copper)
• Cu Price/ assy = $340.32 (including
excess cu)
Pressurex® is a unique, affordable and easy to use tool that reveals the distribution and
magnitude of pressure between any two contacting, mating or impacting surfaces.
pressure indicating sensor film is extremely thin (4 to 8 mils) which enables it to conform
to curved surfaces. It is ideal for invasive intolerant environments and tight spaces not
accessible to conventional electronic transducers.
How It Works
Pressurex® is a mylar based film that contains a layer of tiny microcapsules. The
application of force upon the film causes the microcapsules to rupture, producing an
instantaneous and permanent high resolution "topographical" image of pressure variation
across the contact area.
Simply place Pressurex® between any two surfaces that touch, mate or impact. Apply
pressure, remove it and immediately the film reveals the pressure distribution profile that
occurred between the two surfaces. Like Litmus paper, the color intensity of the film is
directly related to the amount of pressure applied to it. The greater the pressure, the more
intense the color.
Pressurex® has a wide array of uses. For example, Pressurex® can be used in a bolted
joint interface, composite layup, heat sealing and lamination or press. Our pressure
indicating film acts as a force sensing resistor. It can measure surface pressure
distribution whether it is used as an impact force sensor, seat pressure sensor, as a strain
gauge or even as nip impression paper.
• Static, one-time measurement

Permanent record of maximum instantaneous pressure
• Captures bolt pretension-only contact pressure distribution
• Does not capture contact pressure distribution with applied loads (lift-off)
• Dynamic pressure distibution
Optimize torque
sequencing

Contact pressure
distribution with applied
load

• System Cost = $25K
Includes software,
signal-conditoning
hardware, tactile sensor

3 month rental
available for $10K; full
rental cost applied to
purchase

Prior to rental/
purchase, vendor will
test for free a PPPLsupplied bolted joint
mock-up assembly

Vertical Field Magnetic Flux Density Bz at TF Coil Flex Strap Center vs
PF and OH Coil Operational Current Scenario: Plasma Current ~ 2 MA
(1)
Vertical Field Magnetic Flux Density - Bz (Tesla)
0.2
0.1
-24kA OH
0kA OH
+24kA OH
0
-0.1
-0.2
(1)
(2)
No Plasma
-0.3
1
2
3
4
5
6
A B C D E F G H
I
J
K L M N O P Q R S T U V W X Y Z
PF Coil Operational Current Scenario
(1) "NSTX CSU Poloidal Field Flux - 5 cm Plots" spreadsheet, R. Woolley, June 2009.
(2) R. Hatcher, December 2009.
(#82)
Radial Field Magnetic Flux Density B r at TF Coil Flex Strap Center vs
PF and OH Coil Operational Current Scenario: Plasma Current ~2 MA (1)
Radial Field Magnetic Flux Density - Br (Tesla)
0.2
0.15
-24kA OH
0kA OH
0.1
+24kA OH
0.05
0
-0.05
-0.1
-0.15
1
2
3
4
5
6
A B C D E F G H
I
J
K
L M N O P Q R S
PF Coil Operational Current Scenarios
(1) "NSTX CSU Poloidal Field Flux - 5 cm Plots" spreadsheet, R. Woolley, June 2009.
T
U V W X Y
Z