When assembling the massive vacuum vessel of the ITER fusion research project, the requirements for precision are some of the toughest in the industry. The weld-on parts on the reactor chamber, which measures approximately 1,400 cubic meters, may deviate by no more than 2 millimeters. To ensure this, ITER project relies on EXTEND3D – Part of Atlas Copco Group IPG Mobile laser templating system.
Challenge
Manual and high-tech processes and tools are required in vehicle manufacturing
The ITER fusion reactor project required extremely high precision for assembly, particularly for the placement of 150,000 welded studs on the vacuum vessel, allowing for deviations of no more than ±2 millimeters. Traditional methods could not achieve this level of accuracy, necessitating an innovative solution. Additionally, the project faced challenges due to its unprecedented nature, requiring precise data for implementation and efficient, adaptable processes.
Solution
The IPG Mobile uses stereophotogrammetry cameras for precise and flexible positioning.
EXTEND3D’s IPG Mobile dynamic laser projection system was used in several applications. The IPG Mobile projected laser markings onto the vacuum vessel, guiding welders and technicians with precision. It also allows flexible positioning without the need for metrology teams to be permanently on site, enhancing efficiency. The system was further used to project cable routing, tack weld points, and instructional markings directly onto the vessel.
Key features included:
- High-precision laser projection of weld points and component locations
- Flexible positioning thanks to built-in stereophotogrammetry cameras
- Integrated instructions projected directly onto the surface to eliminate paper-based referencing
- Support for cable routing and progress tracking, enhancing installation speed and accuracy
Result
With two IPG Mobile units in use for over a year, ITER has significantly increased production precision—surpassing conventional industrial standards. As the project enters its next construction phase, additional units are planned to support the growing workload. The system has proven to be an indispensable tool in building the future of fusion energy.
- Faster alignment of components
- Reduced training time (only 3 days)
- Seamless integration with existing measurement workflows
Interested to know more? Download the full customer success story.
- IPG Success Story ITER 2.5 MB