Bolted coil support at the W7-X module interface

The paper presents an overview of the design, finite element (FE) analysis results, tests, and assembly strategy of the bolted connection between the coils of neighboring W7-X modules. The design is based on an accurately machined bridge and allows the accommodation of expected misalignments of the coil positions up to ±23 mm and 1°. The joint is capable to cope with forces up to 1.3 MN and moments up to 0.2 MNm. Loads are transmitted by a combination of form lock provided by tapered coil block shoulders, and by friction on the bottom of the blocks. Special friction-enhancing foils are inserted between the bridge bottom surfaces and coil blocks to ensure a friction factor above 0.5. Non-linear FE analyses with elastic–plastic material models show that local plastification and even slippage in spite of the initial high friction are unavoidable but stay within an acceptable margin. In parallel, machining and assembly tests have been carried out to check and simplify the design further, and to develop the manufacturing strategy.