Company Structure Company Overview Founded 1973. Producer of - - PowerPoint PPT Presentation

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Company Structure Company Overview Founded 1973. Producer of - - PowerPoint PPT Presentation

Apr 06, 2024 177 likes •612 views

Company Structure Company Overview Founded 1973. Producer of precision electromagnets. 200 employees (still growing). Sales ~ 30 million. Mostly export. Mixture of project based & medium volume work. All key

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Company Structure

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Company Overview

  • Founded 1973. Producer of precision electromagnets.
  • 200 employees (still growing).
  • Sales ~ € 30 million. Mostly export.
  • Mixture of project based & medium volume work.
  • All key processes in-house. Vertical integration.
  • MRI, Accelerators, Proton Therapy, Fusion, Semi-con.
  • Highly customer focussed.
  • Exports to Europe, U.S.A., Canada & Asia.
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Sustained Growth

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 5 10 15 20 25 30 £M Actual sales Plan sales 12% trend line 15% trend line

Tesla Group Sales

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Tesla Engineering Ltd. Organisational Chart.

Managing Director

  • Dr. M.Begg

Production Director Steve Bates Q.A. Manager Paul Smithers Engineering Director

  • Dr. Ben Leigh

Finance Director David Cracknell Accounts & Administration Design Office 10 CAD seats Engineering Dept. 8 Project Mgrs. 1 Scientist Production Managers (7 Factories) Personnel Manager Nanci Wan Materials Control & Purchasing Stores Unit 1 - ITER Unit 2 - PMS Unit 3 – Magnet Coils Unit 6 – Prototypes Unit 7 – PH, 7T Unit 8 – LHC Magnets Unit 4 – Machining & Welding Manager – Tony Brown

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Manufacturing Facilities, UK

Unit Details Size (ft2) Size (m2) Crane (tonnes) 1

ITER & Clean Assy

6,400 9,600 19,300 24,000 2,000 14,000 576 17,600 2

MRI Coil Assembly

874 2 2 & 2 10 & 10 5 & 15 1 2 & 16 3

Magnet Coil Factory

1,758 4

Machine Shop & Magnet Fabrication

2,184 6

Special Projects

188 7

MRI & Magnet Assembly

1,265 8

CERN LHC s/c Magnets

8 1,600

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SLIDE 7

Design Capabilities

Opera 3-D finite element s/w.

Solid Edge 3-D CAD s/w.

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Magnetic Design + Gradient optimiser, thermal design.

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MRI Cylindrical Gradient Coils ~ 650 per annum, various types

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Panorama 1T Open

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Heat Exchanger

~ 3000 shipped

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Accelerator Magnets

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Proton Therapy Magnets

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Ion Implanter Magnets

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Superconducting Magnets for CERN LHC Currently making ~ 3000

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Superconducting Coils for Fusion (W7X)

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W7X Stellerator (Fusion) 20 Planar Coils being made by Tesla

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Superconducting Coils for Fusion (ITER)

Computer Aided Design model of the Poloidal Field Conductor Insert coil (right) & PFCI coil (left) during manufacture at Tesla Engineering Ltd.

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SLIDE 19

ITER

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Solid Edge 3-D CAD.

  • Feature based Part modelling.
  • Sheetmetal Part modelling.
  • Large Assembly creation.
  • Weldment environment.
  • 2D drafting to world standards, with direct linked updates from 3D parts /

assemblies.

  • Fully integrated document management.
  • Foreign data input, including DWG, DGN, STEP, IGS, ProE, & I-DEAS data files.
  • Full parametric modelling capabilities.
  • Xpress Route piping module.
  • Photo rendering.
  • Surfacing environment.
  • Web based Part & Assembly publishing.
  • Standard part libraries.
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SLIDE 22

Released drgs & docs on central database.

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Coil Factory Equipment

  • 5 Magnet Coil Winding Lines with In-line Tape Wrapping

& Sand Blasting (optional).

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  • Autoclave 4m dia x 6m long.

Pressure to 6 bar, tempre to 200oC.

  • 7 Vacuum Impregnation Chambers

up to 4m dia x 8m long. High current power supplies for ohmic heating.

Coil Factory Equipment

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Yoke Lamination Punching

200 tonne sheet feed press. 200 tonne coil feed press.

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Yoke Lamination Stacking

Location & compression fixture for bonding Stabolit 70 steel laminations (2 curing ovens in background.)

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MACHINE SHOP PLANT LIST

MACHINE TOOL Axes in mm X Y Z A B COLCHESTER CENTRE LATHE AND TOOLING Manual 850 n/a 1600 HARDINDGE TOOL ROOM CENTRE LATHE AND TOOLING 15YRS Manual 200 n/a 600 4/10 PROTURN CNC CENTRE LATHE Programable 350 n/a 1250 CUT OFF CIRCULAR SAW Manual 1250 n/a 300 UNIVERSAL MILL 3 AXIS Manual 750 250 350 UNIVERSAL MILL 3 AXIS Manual 750 250 350 UNIVERSAL MILL 3 AXIS Programable 750 250 250 MACHINING CENTRE YANG 4 AXIS

  • CNC. Probing

1000 450 400 Int' Axis HITACHI VA40 VERTICAL MACHINING CENTRE 4 AXIS CNC 800 400 300 HITACHI VA50 VERTICAL MACHINING CENTRE 4 AXIS CNC. 1000 500 400 Int' Axis HITACHI VA65 + TOOLING 4 AXIS CNC. 1200 650 550 Int' Axis TOS KURIM UNIVERSAL MILL 5 AXIS

  • CNC. Probing

6000 1250 1500 Full Axis Full Axis BUTLER ELGA MILL UNIVERSAL M/C CENTRE 5 AXIS CNC. 6000 1250 1950 Full Axis Manual

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Machining

5 Axis CNC Mill. Table length 8m. X = 6m, Y = 1m, Z = 1.5m Accuracy better than 10 μm for all axes. (Certificates available on request)

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Measurement

3 AXIS CMM X = 3200mm Y = 1300mm Z = 1000mm Resolution 1 μm Accuracy 40 μm

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  • TRAVELLERS USED TO INSTRUCT OPERATORS.

PROCESS CONTROL

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PROCESS CONTROL

PH Coil Z Average

  • 0.2
  • 0.1

0.1 0.2 0.3 0.4 0.5 0.6 0.7 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 C oi l N umbe r Asymmet ry Z average

  • Pre

Pot Asymmet ry Z average

  • Post

Pot

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Typical Electromagnets made by Tesla.

Brookhaven National Lab SNS Quadrupole Magnets 59 off CERN LEP Sextupole Magnets – 550 off Mitsubishi Heavy Electric Proton Therapy Quadrupole Magnets 139 off

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OVERWRAP COIL WIND MAIN COIL

QUADRUPOLE COIL WORKFLOW DIAGRAM

GLASS TAPE HOLLOW COPPER

EPOXY RESIN :- VANTICO Parts by Weight MY740 100 HY906 80 DY073 2

GLASS TAPE

VACUUM IMPREGNATE BRAZE & INSULATE COIL TAILS

UNIT 7 – ASSEMBLY

MOULD

FILLER PIECES

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FULL YOKE ASSEMBLY QUADRANT MILLING YOKE STACKING PUNCH LAMINATIONS

QUADRUPOLE YOKE WORKFLOW DIAGRAM

1200-100A STABOLIT 70 STEEL COIL DRILL & PIN YOKE + FINAL M/C DRILL & PIN YOKE HALVES CNC PROBE HALF YOKE ASSEMBLY WITH END PLATES

Tool for :-

  • Compression
  • Location

Granite Table

UNIT 7 ASSEMBLY

Compression Stacking Fixture

Note – All magnet yokes assembled prior to fitting coils.

(Around 640 tonnes steel)

Shuffle Laminations

300 N/cm2 200 oC.

Alignment Mandrel

INSPECTION PROBE ON CNC M/C PAINTING

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PIECE PARTS FIXINGS HOSES FINAL ASS’Y PACK, TEST DESPATCH

QUADRUPOLE MAGNET WORKFLOW DIAGRAM

FIT COILS INTO YOKE

COILS from Unit 3 Factory YOKES from Unit 4 Factory

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Production Control System

  • ERP system called “efacs” used by Tesla.
  • Bills of Material.
  • Purchasing database.
  • Stock control.
  • Accounts. Invoicing.
  • Sales orders.
  • Cost control.
  • Can use customer part numbers.
  • Fully networked.
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Main EFACS Menu

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Sample BOM

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Purchase Order Report

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Goods Received

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Sales Order

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Labour Time Logging