Arc-shaped skeleton based on DCT coil configuration and manufacturing method thereof

Abstract

The present invention discloses a curved skeleton based on a DCT coil configuration and its manufacturing method. The skeleton comprises multiple skeleton units, which are spliced ​​end to end. The axial surfaces of the multiple skeleton units are coplanar. The curved skeleton is formed by assembling skeleton units with trapezoidal or fan-shaped axial surfaces from a straight cylindrical DCT coil. This reduces manufacturing difficulty and solves the problems of large machining workload, high cost, and long cycle time associated with the one-piece molding process.

Description

Technical Field

[0001] The present invention relates to the technical field of superconducting magnets, and in particular to an arc-shaped skeleton based on a DCT coil configuration and a manufacturing method thereof. Background Art

[0002] The curved DCT coil structure is a novel magnet structure characterized by high magnetic field quality, compact size, low cold mass, and ease of optimization. It is increasingly being used in particle accelerator and medical accelerator magnet designs. This coil consists of a Walstrom end and lateral arc structure with a specific periodic distribution. By optimizing the conductor arrangement, an ideal dipole, quadrupole, sextupole, or combination of functional magnetic fields can be generated within the coil aperture. Furthermore, the DCT superconducting coils are secured using grooves on the surface of the curved skeleton, effectively blocking the accumulation of Lorentz forces between the coil turns and resulting in outstanding mechanical properties.

[0003] Currently, there are two most common methods for manufacturing curved DCT coil bobbins: one uses cold or hot bending techniques to bend straight metal tubes into curved tubes with a defined curvature; the other uses a non-metallic curved tube formed by a multi-layer pre-impregnated glass fiber cloth molding and curing process. DCT coil slots are machined into the curved bobbin surface using CNC machine tools. This one-piece bending process has significant disadvantages. It requires mold production and complex tooling, and the use of large CNC machines with more than five axes to produce the slots. This leads to high mold and processing costs and low molding efficiency. Furthermore, the inner diameter accuracy of the bent tube cannot be guaranteed, hindering the assembly of the multi-layer bobbin. Summary of the Invention

[0004] The present invention provides an arc-shaped skeleton based on a DCT coil configuration, which solves the problems of great difficulty, high cost and long cycle in manufacturing the arc-shaped skeleton.

[0005] In order to solve the above technical problems, the technical solution of the present invention is: an arc-shaped skeleton based on the DCT coil configuration, including multiple skeleton units, and the multiple skeleton units are spliced ​​end to end.

[0006] Optionally, the skeleton unit includes a fan-shaped skeleton unit and / or a trapezoidal skeleton unit.

[0007] Optionally, the side surfaces of the fan-shaped skeleton unit and the trapezoidal skeleton unit are the same in size and shape.

[0008] Optionally, the side surface of the skeleton unit is circular, elliptical or rectangular.

[0009] Optionally, a wire groove is provided on one side of the skeleton unit, and the wire grooves on multiple skeleton units correspond to each other.

[0010] Optionally, the skeleton unit is provided with a positioning groove and / or a positioning hole, and a plurality of the skeleton units are assembled through the positioning groove and / or the positioning hole.

[0011] The present invention also provides a method for preparing an arc-shaped skeleton based on a DCT coil configuration. The method is used to prepare the above-mentioned arc-shaped skeleton based on a DCT coil configuration, comprising the following steps:

[0012] S1. Based on the superconducting magnet electromagnetic design, determine parameters such as the inner and outer radii, deflection radius and angle, side azimuth distribution, and wire slot dimensions for each layer of the arc-shaped DCT coil to be formed;

[0013] S2. Based on the above parameters, a three-dimensional mechanical model of the arc DCT coil skeleton is established;

[0014] S3 using an arc-shaped skeleton, intercepting a certain azimuth range of the arc-shaped skeleton unit in its middle region or using a straight cylindrical skeleton, intercepting a certain straight segment of the skeleton length range of the trapezoidal skeleton unit in its middle region;

[0015] S4. Batch production of arc-shaped skeleton units or trapezoidal skeleton units;

[0016] S5. Assemble the arc-shaped skeleton units or trapezoidal skeleton units according to the alignment of the wire troughs, and assemble them with the skeleton ends to form a complete arc-shaped DCT coil skeleton.

[0017] Optionally, in step S1 , the current density on the side of the arc-shaped DCT coil bobbin satisfies the Cos(nθ) distribution, and the wire slot distribution of the middle arc segment structure has a certain periodicity along the arc length direction.

[0018] Optionally, the skeleton unit is an integrated structure or a spliced ​​structure.

[0019] Optionally, the skeleton unit can be manufactured by CNC machine processing, 3D printing or injection molding.

[0020] The beneficial effects of the present invention are as follows: (1) The arc-shaped skeleton based on the DCT coil configuration is assembled in sections, which reduces the manufacturing difficulty and solves the problems of large machining volume, high cost and long cycle in the one-piece molding process; (2) The arc-shaped skeleton of the present invention is suitable for arc-shaped DCT coil skeletons of different sizes and shapes, takes into account dimensional accuracy, and can meet the design requirements of superconducting magnets; (3) The skeleton material selection and manufacturing method are more flexible and diversified; (4) It can be manufactured using 3D printing or injection molding technology, and the wire groove does not need to be processed. The production is convenient and fast, and the consistency is high, which effectively improves the skeleton manufacturing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a flowchart of the manufacturing process of the arc-shaped DCT coil skeleton of the present invention;

[0022] Figure 2 Schematic diagram of side parameters of the arc-shaped DCT coil skeleton of the present invention;

[0023] Figure 3 This is a schematic diagram of the structure of the arc-shaped DCT coil skeleton of the present invention;

[0024] Figure 4 This is a schematic diagram of the arc-shaped skeleton unit assembly scheme of the present invention;

[0025] Figure 5 This is a schematic diagram of the assembly scheme of the trapezoidal skeleton unit according to the present invention;

[0026] Figure 6 This is a schematic diagram of an arc-shaped skeleton unit intercepted within a certain azimuth range according to the present invention;

[0027] Figure 7 This is a schematic diagram of a trapezoidal skeleton unit cut according to a certain straight segment skeleton length range of the present invention.

[0028] In the figure, 1 represents the inner diameter of the DCT coil bobbin, 2 represents the outer diameter of the DCT coil bobbin, 3 represents the side azimuth angle of the DCT coil bobbin in the embodiment, 4 represents the outer shape of the wire slot, 5 represents the arc-shaped DCT coil bobbin model, 6 represents the arc segment structure, 7 represents the end structure, 8 represents the arc-shaped bobbin, 9 represents the arc-shaped bobbin unit within a certain azimuth angle range, 10 represents the assembly of the arc-shaped bobbin unit, 11 represents the straight column bobbin, 12 represents the trapezoidal bobbin unit within a certain straight segment length range, and 13 represents the assembly of the trapezoidal bobbin unit.

[0029] The accompanying drawings are for illustrative purposes only and should not be construed as limitations on this patent. To better illustrate this embodiment, some components of the accompanying drawings may be omitted, enlarged, or reduced in size and do not represent the actual dimensions of the product. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted from the accompanying drawings. The same or similar reference numerals correspond to the same or similar components. The terms describing positional relationships in the accompanying drawings are for illustrative purposes only and should not be construed as limitations on this patent. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0031] The curved DCT coil structure is a novel magnet structure characterized by high magnetic field quality, compact size, low cold mass, and ease of optimization. It is increasingly being used in particle accelerator and medical accelerator magnet designs. This coil consists of a Walstrom end and lateral arc structure with a specific periodic distribution. By optimizing the conductor arrangement, an ideal dipole, quadrupole, sextupole, or combination of functional magnetic fields can be generated within the coil aperture. Furthermore, the DCT superconducting coils are secured using grooves on the surface of the curved skeleton, effectively blocking the accumulation of Lorentz forces between the coil turns and resulting in outstanding mechanical properties.

[0032] Currently, there are two most common methods for manufacturing curved DCT coil bobbins: one uses cold or hot bending techniques to bend straight metal tubes into curved tubes with a defined curvature; the other uses a non-metallic curved tube formed by a multi-layer pre-impregnated glass fiber cloth molding and curing process. DCT coil slots are machined into the curved bobbin surface using CNC machine tools. This one-piece bending process has significant disadvantages. It requires mold production and complex tooling, and the use of large CNC machines with more than five axes to produce the slots. This leads to high mold and processing costs and low molding efficiency. Furthermore, the inner diameter accuracy of the bent tube cannot be guaranteed, hindering the assembly of the multi-layer bobbin.

[0033] Due to the particularity of the arc-shaped skeleton structure and the limitations of inner diameter processing, the existing manufacturing methods are not suitable for mass production of arc-shaped DCT magnet skeletons. It is necessary to combine the characteristics of the DCT coil structure and start from the perspective of economy and timeliness to solve the problems of difficult large-size skeleton forming, low precision and high cost, and promote the application of arc-shaped DCT superconducting magnet technology in the field of large accelerator magnets and compact medical treatment devices.

[0034] Example 1:

[0035] To solve the problems existing in the background technology, this embodiment provides an arc-shaped skeleton based on a DCT coil configuration, including multiple skeleton units, which are spliced ​​end to end; the skeleton units include fan-shaped skeleton units and trapezoidal skeleton units.

[0036] In this embodiment, the axial surfaces of the multiple skeleton units are in the same plane. Figure 4 Shown and Figure 5 shown.

[0037] The skeleton unit in this embodiment can be formed by splicing multiple trapezoidal skeleton units end to end, or by splicing multiple fan-shaped skeleton units end to end, or by splicing multiple trapezoidal skeleton units and multiple fan-shaped skeleton units together.

[0038] It should be noted that the trapezoidal skeleton unit in this embodiment should be understood as a skeleton unit whose axial surface is trapezoidal, and the fan-shaped skeleton unit in this embodiment should be understood as a skeleton unit whose axial surface is fan-shaped.

[0039] The fan-shaped skeleton unit in this embodiment can be cut from the arc-shaped skeleton within a certain azimuth angle range, and the trapezoidal skeleton unit can be cut from the straight column-shaped skeleton within a straight section length range.

[0040] like Figure 2 As shown, the DCT coil in this embodiment has an inner diameter of 1 and an outer diameter of 2 of the DCT coil bobbin. Serial number 3 represents the side azimuth angle of the DCT coil bobbin. Serial number 4 represents the shape of the DCT coil bobbin slot, which can be a circular bottom or a rectangular bottom. The specific shape can be designed according to actual application requirements and is not limited here.

[0041] The arc-shaped skeleton based on the DCT coil configuration in this embodiment is formed by segmented assembly, which reduces the manufacturing difficulty and solves the problems of large machining volume, high cost and long cycle in the one-piece molding process.

[0042] Example 2:

[0043] The second embodiment provides an arc-shaped skeleton based on a DCT coil configuration. The arc-shaped skeleton based on a DCT coil configuration in the second embodiment is optimized based on the first embodiment to achieve a better effect.

[0044] In the description of this embodiment, the axial surfaces of the plurality of skeleton units are in the same plane.

[0045] In this embodiment, the side surfaces of the sector-shaped and trapezoidal frame units are identical in size and shape, and adjacent frame units are assembled using their two opposing faces. The side surfaces of the trapezoidal or sector-shaped frame units can be circular, elliptical, rectangular, or other shapes, depending on actual application requirements, and are not limited to specific shapes herein.

[0046] The "side" described in this embodiment should be understood as follows: for example, the side of a trapezoidal skeleton should be understood as a skeleton unit with a trapezoidal axial surface, and the surface where the waists on both sides of the trapezoidal axial surface are located; for example, the side of a fan-shaped skeleton should be understood as a skeleton unit with a fan-shaped axial surface, and the surface where the straight edges on both sides of the fan-shaped axial surface are located.

[0047] In the description of this embodiment, a wire groove is provided on one side of the skeleton unit, and the wire grooves on multiple skeleton units correspond to each other. Depending on the actual assembly needs, a positioning groove can also be provided on one side of the skeleton unit for assembling the skeleton units, or a positioning hole can be provided on one side of the skeleton unit for assembling the skeleton units; or both positioning grooves and positioning holes can be provided for assembling the skeleton units. The design of the positioning grooves or positioning holes here is intended to achieve assembly of the skeleton units through the positioning structure. All methods of assembly through the positioning mechanism are covered by the protection scope of the present invention and are not specifically limited here.

[0048] The arc-shaped skeleton in this embodiment includes an end structure and an arc segment structure, such as Figure 6 As shown, serial number 14 represents an arc-shaped skeleton unit, such as Figure 7 As shown, serial number 15 represents a trapezoidal skeleton unit, and the arc segment structure is an arc-shaped DCT coil. Depending on the actual application needs, the trapezoidal skeleton units can be placed at both ends of the arc segment structure; the arc-shaped skeleton units can also be placed at both ends of the arc segment structure; and the arc-shaped skeleton units and the trapezoidal skeleton units can also be combined and spliced ​​in any combination according to the application requirements; this is not limited here.

[0049] Since the trapezoidal skeleton units are straight columnar, the upper bases and lower bases of each skeleton unit along the axial direction thereof alternate and have the same shape.

[0050] In this embodiment, the straight column shape cannot be narrowly understood as a cylindrical shape, and its two side surfaces can be of any shape.

[0051] In this embodiment 2, by setting the positioning structure and the assembling structure used in the assembly process, the arc-shaped skeleton in this embodiment can take into account the dimensional accuracy, thereby meeting the requirements of different superconducting magnet design solutions.

[0052] Example 3:

[0053] This embodiment 3 provides a method for preparing an arc-shaped skeleton based on a DCT coil configuration, characterized in that the method is used to prepare the arc-shaped skeleton based on the DCT coil configuration described in embodiment 1 and embodiment 2, comprising the following steps:

[0054] S1. Based on the superconducting magnet electromagnetic design, determine parameters such as the inner and outer radii, deflection radius and angle, side azimuth distribution, and wire slot dimensions for each layer of the arc-shaped DCT coil to be formed;

[0055] S2. Based on the above parameters, a three-dimensional mechanical model of the arc DCT coil skeleton is established;

[0056] S3 uses an arc-shaped skeleton, intercepts a certain azimuth range of the fan-shaped skeleton unit in its middle region or uses a straight cylindrical skeleton, intercepts a certain straight section of the skeleton length range of the trapezoidal skeleton unit in its middle region;

[0057] S4. Batch production of arc-shaped skeleton units and / or trapezoidal skeleton units;

[0058] S5. Assemble the arc-shaped skeleton units and / or trapezoidal skeleton units according to the alignment of the wire troughs, and assemble them with the skeleton ends to form a complete arc-shaped DCT coil skeleton.

[0059] Specifically, in step S1, the side surface of the arc-shaped DCT coil skeleton can be any shape such as circular, elliptical, rectangular, etc.;

[0060] Specifically, in step S2, the arc-shaped DCT coil bobbin includes an end structure and a middle arc segment structure;

[0061] Specifically, in step S1, the current density on the side of the arc-shaped DCT coil skeleton satisfies the Cos(nθ) distribution, and the wire slot distribution of the middle arc segment structure has a certain periodicity along the arc length direction;

[0062] Specifically, in step S3, the arc-shaped skeleton unit or the trapezoidal skeleton unit may be a whole, two halves, or cut according to the wire slot distribution period;

[0063] Specifically, in step S4, the arc-shaped skeleton unit or the trapezoidal skeleton unit can be manufactured by CNC machine tool processing, 3D printing, injection molding, etc.;

[0064] Specifically, in step S3, the size of the arc-shaped skeleton unit or the trapezoidal skeleton unit should be determined in combination with different manufacturing methods. CNC machine tool processing mainly considers factors such as processing cost and precision. 3D printing mainly considers factors such as material cost and printing size limitation. Injection molding mainly considers factors such as draft angle and shrinkage coefficient.

[0065] Specifically, in step S4, the arc-shaped skeleton unit or the trapezoidal skeleton unit is in a low-temperature working condition, and the materials used are metal (stainless steel, aluminum alloy, etc.) and non-metal (G10 / G11, PEEK / PEI, etc.) according to different manufacturing methods;

[0066] Specifically, in step S5, the arc-shaped skeleton unit or the trapezoidal skeleton unit should include positioning grooves, holes and other structures for positioning and connection during the assembly process to ensure the positioning accuracy and structural stability of the assembly.

[0067] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "top", "bottom", "inside", "outside" and the like indicating an orientation or positional relationship, they are based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting this patent. In addition, if there are terms such as "first" and "second" are used only for descriptive purposes, they are mainly used to distinguish different devices, elements or components (the specific types and structures may be the same or different), and are not used to indicate or imply the relative importance and quantity of the indicated devices, elements or components, and cannot be understood as indicating or implying relative importance. In addition, the term "and / or" used herein includes any and all combinations of one or more related listed items.

[0068] In the present invention, unless otherwise expressly specified or limited, the terms "connected," "connected," "fixed," etc. should be understood in a broad sense. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0069] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Those skilled in the art will appreciate that other variations or modifications can be made based on the above description. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. A method for preparing an arc-shaped skeleton based on a DCT coil configuration, characterized in that: The steps include: S1. Determine the inner and outer radii, deflection radius and angle, side azimuth distribution, and slot size parameters for each layer of the arc-shaped DCT coil to be formed based on the superconducting magnet electromagnetic scheme; S2. Based on the above parameters, a three-dimensional mechanical model of the arc DCT coil skeleton is established; S3 using an arc-shaped skeleton, intercepting a certain azimuth range of the arc-shaped skeleton unit in its middle region or using a straight cylindrical skeleton, intercepting a certain straight segment of the skeleton length range of the trapezoidal skeleton unit in its middle region; S4. Batch production of arc-shaped skeleton units or trapezoidal skeleton units; S5. Assemble the arc-shaped skeleton units or trapezoidal skeleton units according to the alignment of the wire troughs, and assemble them with the skeleton ends to form a complete arc-shaped DCT coil skeleton.

2. The method for preparing an arc-shaped skeleton based on a DCT coil configuration according to claim 1, characterized in that: In step S1 , the current density on the side of the arc-shaped DCT coil bobbin satisfies the Cos(nθ) distribution, and the slot distribution has a certain periodicity along the arc length direction.

3. The method for preparing an arc-shaped skeleton based on a DCT coil configuration according to claim 1, characterized in that: The skeleton unit is an integrated structure or a spliced ​​structure.

4. The method for preparing an arc-shaped skeleton based on a DCT coil configuration according to any one of claims 1 to 3, characterized in that: The skeleton unit is manufactured by CNC machine processing, 3D printing or injection molding.

5. An arc-shaped skeleton based on a DCT coil configuration, characterized by: The arc-shaped skeleton is prepared by the preparation method according to any one of claims 1 to 4, and comprises a plurality of skeleton units, wherein the plurality of skeleton units are spliced ​​end to end.

6. The arc-shaped skeleton based on the DCT coil configuration according to claim 5, characterized in that: The skeleton unit includes a fan-shaped skeleton unit and / or a trapezoidal skeleton unit.

7. The arc-shaped skeleton based on the DCT coil configuration according to claim 6, characterized in that: The side surfaces of the sector-shaped skeleton unit and the trapezoidal skeleton unit are identical in size and shape.

8. The arc-shaped skeleton based on the DCT coil configuration according to claim 5, characterized in that: The side surface of the skeleton unit is circular, elliptical or rectangular.

9. The arc-shaped skeleton based on the DCT coil configuration according to claim 5, characterized in that: A wire groove is provided on one side of the skeleton unit, and the wire grooves on multiple skeleton units correspond to each other.

10. The arc-shaped skeleton based on the DCT coil configuration according to claim 5, characterized in that: The skeleton unit is provided with a positioning groove and / or a positioning hole, and a plurality of the skeleton units are assembled through the positioning groove and / or the positioning hole.

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