QALI DCMA Inspection Criteria.pdf

Encl (2) Part (2)

COIL MANUFACTURE PROCEDURE

NEW DESIGN

The coils shall be manufactured in accordance with the following instructions. Vendor to manufacture the coils to match the dimensions of the sample coils, using Figure I as a guide. All materials shall be as specified.

Equivalent materials may be used only if approved by Portsmouth Naval Shipyard (PNS) in writing or via email.

The coil manufacturer is responsible to provide a Final Certification Package, which is comprised of:

1. A copy of the "Coil Manufacture Procedure" including certification signatures at the required signature blocks.

2. A copy of all specification or data sheets for all material used in the manufacture of the coils.

3. A Certification of Compliance letter stating that the coils were manufactured in accordance with the requirements of the contract.

This Final Certification Package shall be shipped with each set of coils manufactured. Subsequent sets of coils shall be certified on photocopied sheets of this instruction. Failure to meet any requirements shall be cause for rejection of coils.

DATA FOR MANUFACTURE OF COILS

Armature conductor: 4ea.(0.080" X 0.300") Weight of armature coils: 300 lbs.

(approx.)

Conductor Insulation for Magnet Wire Conductor Insulation for Magnet Wire

Magnet wire consists of copper conductor insulated with a heavy build of polyesterimide enamel plus a single wrap of polyester glass fiber covering bonded with non silicone insulating varnish thermal class 180 per ANSI/NEMA MW-1000/MW 53-C.

NEMA P/N MW053CHd080300N.

Encl (2) Part (2)

INSTRUCTIONS:

1. NO SILICONE OR SILICONE CONTAINING PRODUCTS SHALL BE USED IN THE

MANUFACTURE OF THE COILS INCLUDING BINDER TAPE.

2. Cut and shape magnet wire for the coils per PNS provided Drawing. A 3D printed sample along with 3D .step files will also be provided. Use provided plastic fixture to verify coil has been formed in accordance with drawing.

Magnet wire formed per PNS Drawing.

Signature/Date:

3. Strip the insulation from both ends of the coil per PNS Provided drawing. Do not tin the stripped areas. The connections will be welded by GTAW method at PNS.

Magnet wire stripped per PNS Drawing.

Signature/Date:

4. Assemble the coil bundles and insulate as follows.

Note: Do not use adhesive film tape to hold the insulation tape near the ends of the conductors, as this will burn when the conductors are welded to the commutator. Adhesive tape use shall be kept to a minimum on the entire coil.

4.1 Apply two layers half lapped (+0, -.12”) .005"TK x 3/4"W mica mat tape (VonRoll Mica Mat 77944 or equivalent) to the entire coil stopping ¼-½” from the stripped portion on each end.

Start with tuck under method and terminate with a small amount of adhesive (Sterling T-723 or equivalent).

4.2 Apply one layer .004"TK x 3/4"W caramelized glass tape (Breyden Products Inc. GT475MW or equivalent) to the same portion of coil as listed in 4.1. Extend slightly beyond the mica mat tape to seal over end of mica mat tape. The glass tape is to be butt lapped (+0, -.12”) in the slot portion and 1/2 lapped (+0, -.12”) on the end-turns. The max taped size in the slot is .224 x .664”. The slot is the straight section that is 17.75” long. Start with tuck under method and terminate with a small amount of adhesive (Sterling T-723 or equivalent).

4.3 Use provided plastic fixture to verify coil has been formed in accordance with drawing.

Coils formed and taped per PNS drawing and paragraph 4.

Signature/Date:

5. The required number of armature coils in each set will be 160 coils; (152 actual and 8 spares)

DCMA Post-Manufacture Inspection Criteria- New Design Coils

1. Randomly select a single coil.

2. Coil must meet the dimensions per the build drawing. Use the PNS provided fixture to assist.

3. Visually check coil for proper taping. Coil shall be taped in a manner that will not have adhesives or tapes applied on, or any closer than the bend nearest, the stripped ends of the conductors. Mica shall be adhered with adhesive tape just past the first bend, and glass tape shall be adhered using Sterling T-723 or equivalent.

4. The glass tape should be butt-lapped in the slot portion and half-lapped on the end-turns. Tape shall be tightly wrapped. Tape edges shall not be frayed, folded, puffed, or non-uniform. Tape shall not deform or fray when lightly tugged or abraded.

5. Coil ends that will be installed in the commutator shall have all insulation removed down to bare copper and shall not have been tinned.

6. Witness the removal of insulation from the coil ensuring the following criteria are met:

6.1. The outer layer of caramelized glass tape is a single layer, 0.004” TK x ¾” wide (Breyden Products Inc.

GT475MW or equivalent) that is butt-lapped in the slot and half lapped on the end turns.

6.2. The glass tape is started at the lead end so that it covers the mica mat tape beneath.

6.3. The following two layers are 0.005” TK x ¾” wide mica mat tape (VonRoll Mica Mat 77944 or equivalent) at a minimum-third lapped and maximum half-lapped. The mica will start ½”- ¾” from the stripped portion of the coil leads and ¼”- ½” from the bend nearest the stripped ends of the coil.

6.4. Visually inspect the magnet wire. Ensure there are no nicks, burrs or other defects noted.

6.5. No varnish shall have been applied to the coil prior to or after taping to allow for penetration of resin during the

VPI process.

7. The required number of coils will be 160, including sample coils (152 actual and 8 spares)

Administrative Inspection

1. New Design Coils, in accordance with the Manufacture Procedure and Statement of Work, shall include a final certification package comprised of the following:

1.1. A copy of the “Coil Manufacture Procedure” including certification signatures at the required signature blocks.

1.2. A copy of all specification or data sheets for all materials used during the manufacture of the coils.

1.3. A Certification of Compliance memo stating that the coils were manufactured in accordance with the requirements of the contract.

2. The Final Certification Package is to be included in the shipping box with each set of coils.

3. DCMA Inspector, verify below the additional layers of insulation are as described above and the Final Certification

Package is complete and included in the shipping box.

Additional layers of insulation are satisfactory. Final Certification Package is complete and included in shipping box.

Signature/Date