the operators to make the necessary corrections to the relative positions of the turns, based on the deviations detected with an accuracy of a few hundredths of a millimeter.”


“Our process is closely dependent in every phase on dimensional and form inspection.”


The subsequent assembly stages include the


This ghosted view of the completed winding assembly shows details of its components.


the subsequent assembly stages. We use a second Leica Absolute Tracker AT901 along with a Leica T-Probe contact sensor for this task. A guided inspection procedure allows


fi tting of the windings into a special housing, insula- tion and sealing of the turns with special covers that will be welded with a roboticized system. A third Leica Absolute Tracker AT901 laser tracker is used for calibration of the fi xture to support the individual pancakes inside the welding station. Once the cov- ers have been welded and after accurate dimension- al inspections in a vacuum chamber and electrical inspections, every pancake is carefully wrapped in an insulating coating. Subsequently, it is fi lled with a resin using a vacuum impregnation process. The last step before delivery is the stacking of the seven components and the fi nal insulation of the assembly. After the second impregnation and the fi nal tests, at last the huge D-shaped winding is ready to leave for its fi nal destination. “Our process,” Barutti said, “is closely dependent in every phase on dimensional and form inspections that we perform with equipment and procedures supplied by Hexagon Manufacturing Intelligence, and set up in close cooperation with their techni- cians. Some years ago, the measurement equipment from Leica Geosystems had allowed us to improve and certify the process for making large-sized mag- nets for the LHC. So when we acquired the order for the ITER project, we had no doubt about how to address the problems of analysis, checks and corrections of the production cycle. In addition to that, the technology of measurement systems has


signifi cantly evolved in the last few years, allowing us to set up procedures that are faster and more accurate than in the past, thus optimizing the whole process.”


33 — Energy Manufacturing 2016


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