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 processes in-house. Vertical integration. • MRI, Accelerators, Proton Therapy, Fusion, Semi-con. • Exports to Europe, U.S.A., Canada & Asia. • Highly customer focussed.
Sustained Growth Tesla Group Sales £M 30 25 Actual sales 12% trend line 20 Plan sales 15% trend line 15 10 5 1996 1998 2000 2002 2004 1997 1999 2001 2003 2005
Tesla Engineering Ltd. Organisational Chart. Managing Director Dr. M.Begg Personnel Manager Nanci Wan Production Director Q.A. Manager Engineering Director Finance Director Steve Bates Paul Smithers Dr. Ben Leigh David Cracknell Materials Production Managers Control & (7 Factories) Purchasing Stores Engineering Dept. Accounts & Design Office Unit 1 - ITER Administration 10 CAD seats 8 Project Mgrs. 1 Scientist Unit 2 - PMS Unit 4 – Machining & Welding Unit 3 – Magnet Coils Manager – Tony Brown Unit 7 – PH, 7T Unit 8 – LHC Magnets Unit 6 – Prototypes
Manufacturing Facilities, UK Size (ft 2 ) Size (m 2 ) Unit Details Crane (tonnes) ITER & Clean Assy 1 6,400 576 2 MRI Coil Assembly 2 9,600 874 2 & 2 Magnet Coil Factory 3 19,300 1,758 10 & 10 Machine Shop & Magnet 4 24,000 2,184 5 & 15 Fabrication Special Projects 6 2,000 188 1 MRI & Magnet Assembly 7 14,000 1,265 2 & 16 CERN LHC s/c Magnets 8 17,600 1,600 8
Solid Edge 3-D CAD s/w. Design Capabilities Opera 3-D finite element s/w.
+ Gradient optimiser, thermal design. Magnetic Design
MRI Cylindrical Gradient Coils ~ 650 per annum, various types
Panorama 1T Open
Heat Exchanger ~ 3000 shipped
Accelerator Magnets
Proton Therapy Magnets
Ion Implanter Magnets
Superconducting Magnets for CERN LHC Currently making ~ 3000
Superconducting Coils for Fusion (W7X)
W7X Stellerator (Fusion) 20 Planar Coils being made by Tesla
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.
ITER
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.
Released drgs & docs on central database.
Coil Factory Equipment • 5 Magnet Coil Winding Lines with In-line Tape Wrapping & Sand Blasting (optional).
Coil Factory Equipment • 7 Vacuum Impregnation Chambers up to 4m dia x 8m long. High current power supplies for ohmic heating. • Autoclave 4m dia x 6m long. Pressure to 6 bar, temp re to 200 o C.
200 tonne coil feed press. Yoke Lamination Punching 200 tonne sheet feed press.
Yoke Lamination Stacking Location & compression fixture for bonding Stabolit 70 steel laminations (2 curing ovens in background.)
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
Machining 5 Axis CNC Mill. Table length 8m. X = 6m, Y = 1m, Z = 1.5m Accuracy better than 10 μ m for all axes. (Certificates available on request)
Measurement 3 AXIS CMM X = 3200mm Y = 1300mm Z = 1000mm Resolution 1 μ m Accuracy 40 μ m
• TRAVELLERS USED TO INSTRUCT OPERATORS. PROCESS CONTROL
PROCESS CONTROL PH Coil Z Average 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -0.1 -0.2 C oi l N umbe r Asymmet ry Z average - Pre Pot Asymmet ry Z average - Post Pot
Typical Electromagnets made by Tesla . CERN LEP Sextupole Magnets – 550 off Brookhaven National Lab SNS Quadrupole Magnets 59 off Mitsubishi Heavy Electric Proton Therapy Quadrupole Magnets 139 off
QUADRUPOLE COIL WORKFLOW DIAGRAM EPOXY RESIN :- VANTICO Parts by Weight MY740 100 HY906 80 GLASS TAPE DY073 2 GLASS TAPE BRAZE & WIND OVERWRAP VACUUM INSULATE MOULD MAIN COIL COIL IMPREGNATE COIL TAILS HOLLOW FILLER PIECES COPPER UNIT 7 – ASSEMBLY
QUADRUPOLE YOKE WORKFLOW DIAGRAM Shuffle Laminations (Around 640 tonnes steel) HALF YOKE PUNCH YOKE QUADRANT ASSEMBLY Tool for :- LAMINATIONS STACKING MILLING WITH • Compression END PLATES • Location 300 N/cm 2 200 o C. DRILL & PIN YOKE HALVES Compression Stacking CNC PROBE 1200-100A STABOLIT 70 Fixture STEEL COIL Alignment Mandrel INSPECTION DRILL & FULL YOKE PAINTING PROBE ON PIN YOKE + ASSEMBLY CNC M/C FINAL M/C Granite Table UNIT 7 ASSEMBLY Note – All magnet yokes assembled prior to fitting coils.
QUADRUPOLE MAGNET WORKFLOW DIAGRAM COILS from Unit 3 Factory PIECE PARTS FINAL ASS’Y FIT COILS FIXINGS PACK, TEST INTO YOKE HOSES DESPATCH YOKES from Unit 4 Factory
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.
Main EFACS Menu
Sample BOM
Purchase Order Report
Goods Received
Sales Order
Labour Time Logging
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