Our Capabilities

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Project and Program Management

Everson Tesla has developed an effective management philosophy which incorporates processing a project using a Program/Project Engineer heading each key program. A dedicated Team is established which includes design and quality engineering, manufacturing, cost accounting, and product control.

  • Technology and project feasibility analysis
  • Cost estimating & risk assessments
  • Design reviews
  • Configuration management
  • Scheduling, program tracking
  • MPO's (manufacturing process outline is a set of detailed work instructions)
  • Inventory management
  • Prototype to production transition management

Design

Everson Tesla has a strong base in engineering that covers many of the engineering disciplines including electrical, mechanical, material science and physics. Our core technology is in the design and manufacture of components, coils, magnets and complete systems from motors and generators to cryo-free superconducting magnet systems. Everson Tesla provides complete services in designing and manufacturing from prototype to production quantities of components and products. Below is a list of some of the key elements in the design process.

  • Functional/Performance requirements
  • Interface requirements
  • Design conceptualization and layout
  • Materials selection
  • Feasibility analysis
  • Electrical and mechanical design
    • Magnetic, thermal, mechanical FEA
    • Thermal requirements/analysis
    • Technical documentation and CAD design
  • Material selection, analysis and testing
    • Conductor
      • Hollow, solid, silver bearing
      • Superconducting, braided NbTi, Nb3Sn
      • Conduited superconductor
      • Foil wound
      • Litz wire
      • Magnet wire
      • High temperature superconductor
    • Active motor core and magnet core materials and magnetically inert materials
      • Oriented and non-Oriented grain electrical steels
      • Pure iron to 1018 steel for magnet cores
      • 304 to 316LN stainless steels
      • Specialty Inconel steels
    • Insulation
      • Up to 30 kV HV insulation systems
      • NEMA Class F,H,N insulation systems
      • Radiation resistant cyanate ester systems
  • Cryogenic requirements
  • Ultra-high vacuum
  • Harsh environment designs
  • Cost optimization analysis
  • CAD drawing packages
  • FMECA/MTTF/MTTR, risk assessments
  • Tooling design and build
  • Regulatory and safety requirements

Prototype Development

Everson Tesla prides itself in building single units in any of our product areas. We have the ability to document the development in order to improve the processes used in manufacturing the product. Every product that Everson Tesla produces is fully tested and documented. The key elements of the prototype development process are:

  • Procure, fabricate and commission tooling
  • Build and test prototypes
  • Process improvement studies
  • Test plans (acceptance and qualification)
  • Final design and drawing package
  • Systems integration and test

Manufacturing

Everson Tesla uses a variety of tools, including software systems, to prepare for production. Hard tooling and equipment is also specified as part of the production preparation process, including automated tooling, winding applications and insulating equipment. Our expertise includes integration of multi-component system. Our capabilities include:

  • CNC machining, bending
  • Coil spreading, forming, winding
  • Application of insulation systems
    • Tapes, resins
    • RTM, VPI, B-stage
    • Multilayer insulation
  • Brazing, welding, soldering, bonding technologies, vacuum vessel welding
  • SPC
  • Material source planning (MRP)
  • Just-in-time inventory control

Quality Control

The management and employees of Everson Tesla Incorporated are committed to quality and excellence in all endeavors. Our number 1 priority is customer satisfaction in a safe, healthy work environment. We believe that quality is the responsibility of every employee.

Testing

Everson Tesla conducts inspection and testing of all the products produced including motors, coils, and magnets to meet project requirements from 100% inspection to statistical sampling. We have developed detailed testing procedures and travelers to address traceability and certification of our products.

  • Specialized test facilities
    • Motor test shop
    • Motor load testing
  • Electrical
    • Impulse testing
    • Hi-potential
    • Dielectric testing (dielectric and polarization index)
    • Tip-up test
  • Mechanical
    • Surface plate measurements
    • Dimensional tolerances (standard)
    • Tooling fixtures and gauges
    • Strain gauge systems
  • Magnetic
    • Magnetic testing using a hall probe configured on a CMM
    • Hall probes
    • NMR probes
    • Inductive coils
    • 3D and 2D mapping
  • Cryogenic
    • Helium mass spectrometer leak detection
    • Temperature measurements
    • Pressure measurements
    • Flow-rate measurements
    • Determination of cryogenic efficiencies
    • Materials thermal quench cycling

Services

Everson Tesla Incorporated provides engineering and field service for magnets, motors, rotor coils, and other electro-mechanical components, products and equipment. Our staff of technicians and engineers has experience with a wide-range of OEM equipment. Everson Tesla's dedicated staff of customer service specialists provide communications, assistance with contractual matters and coordination of field service activities. Areas of specialized capabilities include:

  • Diagnostic and failure evaluation studies
  • Magnetic field mapping
  • Synchronous motor excitation and controls
  • Vacuum and cryogenic systems and components
  • Field inspection of high-voltage windings
  • AC motor repair