AA-22908-DOC002

VT HOKIESAT RECTANGULAR TORQUE COIL ASSEMBLY PROCEDUREDATE ______

Part number: ADCS-RTC1

Note: To ensure part cleanliness and reduce the risk of contamination, rubber gloves should be worn at all times when working with the flight hardware. At least three people, preferably four, are required for the initial steps of the torque coil assembly. The person holding the wire spool should wear protective gloves to avoid cuts or other injuries from the wire. One person controls the speed of the lathe, and one person holds the wire spool and guide the wire onto the winding mount. A third person uses a hand counter to count the number of turns. A fourth person, if available, also uses a hand counter. If there are only three people, the lathe controller is the second counter. This procedure should be done in the clean room.

Step-by-Step Torque Coil Assembly Procedure;12 steps, 1 page

  1. Secure the winding mount in a lathe and adjust the lathe to the appropriate turning direction. The lathe should turn away from the wire spool.
  2. Using Kapton tape, attach approximately 12” of wire to the side of the winding mount.
  3. Use a metal rod to support the wire spool and begin guiding the wire into the gaps of the winding mount.
  4. Begin winding of the torque coil. During this procedure, two assistants should be counting the number of turns. This can be done by marking one of the spokes of the winding mount with color to be used as a reference. The wire should be held under tension to reduce slack in the coils.
  5. After 25 turns, stop the lathe and wrap the coil with Kapton tape in at least four, preferably eight places.
  6. Use Kapton tape again after the next 25 turns and continue until wrapping every 25 turns until the desired number of turns (133) is reached.
  7. The two counters should differ no more than 2%, i.e. by two turn counts.
  8. Using Kapton tape, attach approximately 12” of coil to the side of the winding mount before the wire is cut.
  9. Carefully remove the wound wire from the winding mount. It is very important that the insulation of the coil wire not be damaged.
  10. Hang the coil on one side with Kapton tape above a surface covered with brown paper.
  11. Apply the Scotchweld 2216 Gray stiffening epoxy generously according to manufacturer’s specifications to the suspended side of the coil.
  12. Wrap the coil twice completely with Kapton tape to insure proper electrical insulation.

Assembly Verification Record
Assembled by: ______/ Signature: ______/ Date: ______
Witnessed by: ______/ Signature: ______/ Date: ______

Required Tools:Required Materials:

Winding Mount Wire

LatheKapton tape

CountersScotchweld 2216 Gray Epoxy

Hardening support Metal Rod

Brown Paper Gloves

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