Critical issues for the manufacture of the ITER TF coil winding pack

Research and trials by the Japan Atomic Energy Agency (JAEA) focus on the remaining technical issues in the ITER TF coil winding pack (WP) manufacturing process. Specific issues include the feasibility of automatically measuring conductor length during automatic winding with a high degree of accuracy (±0.02%) and a fabrication process to comply with the demanding tolerances (up to 1 mm distortion in flatness and 1.5 mm in-plane shrinkage) of the radial plate (RP) due to cover plate (CP) welding. The authors developed a new technique to measure conductor length very accurately by combining an ordinary encoder and a newly developed optical system. A simulation based on test results of CP welding using a RP mock-up indicates that a flatness of 1 mm is achievable, but the in-plane shrinkage of the RP is approximately 5 mm. One possible solution is to fabricate the RP larger than required to allow for in-plane shrinkage. Another solution is to reduce the thickness or length of the welding. The feasibility of these solutions to most of the major technical issues suggests that it is time for full qualification testing of the fabrication process in a dummy double-pancake trial.