Self-propelled self-referencing vehicle magnet winding method and system

Abstract

This application describes an apparatus and method for winding an electrical coil (electromagnet). A self-propelled self-referencing winding carrier uses features on a winding bobbin to guide the direction and / or orientation of the carrier while laying down an electrical conductor material (e.g., high temperature superconducting (HTS) tape) as the carrier traverses the bobbin. The carrier can wind an electrical coil having a complex shape. In some embodiments, the self-propelled self-referencing (SPSR) carrier can perform other magnet manufacturing and assembly procedures.

Description

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 007,676, filed April 9, 2020, entitled “Self-Propelled Self-Referencing Vehicle Magnet Winding Method,” the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention generally relates to the winding of electric coils (electromagnets), and more specifically, to the winding of electric coils with complex shapes. Electric coils with complex shapes can be found in superconducting magnet energy storage systems, particle accelerator systems, and magnetic fusion energy systems, among others. Background Technology

[0003] Electromagnets are typically planar in shape and are wound using a turntable technique. In this technique, a continuous electrical conductor material (e.g., a wire or conductor strip) is supplied from a fixed point in space and wound onto a planar spool (e.g., part of a spool structure) by a bobbin that rotates on a turntable.

[0004] A rotating spool includes a winding groove. Conductive material is wound from a stationary point, and as the spool rotates, the winding groove continuously receives layers of conductor material within it, thus forming a coil.

[0005] However, if the magnet to be wound has a complex shape (e.g., three-dimensional, non-uniform, asymmetrical, etc.), then this technique may not be easy to apply (or sometimes impossible to apply).

[0006] The "direct winding" technique developed by Brookhaven National Laboratory involves applying malleable conductors to more complex turntables with greater degrees of freedom (Parker et al., BNL Direct Wind Superconducting Magnets, 22nd International Conference on Magnet Technology, September 9-16, 2011). However, direct winding relies on a fixed application point and a turntable-like setup. Therefore, it cannot apply conductors (e.g., electrically conductive strips) to arbitrarily complex surfaces, and such techniques may require the application to be "orientable" (e.g., the application must be representable in a two-dimensional coordinate system or on a plane). Furthermore, anisotropic conductors, such as high-temperature superconducting (HTS) strips, may be less suitable for direct winding, as it relies on malleable isotropic conductors.

[0007] Therefore, there is a need for improved methods that wrap electrical conductor material around structures that may be more complex (e.g., in applications that may not be represented in a two-dimensional coordinate system), although the techniques described herein can also be used to wrap simple structures in other embodiments.

[0008] Due to their inherent steady-state operation and low recycle power, stellarators offer significant conceptual advantages over tokamaks in commercial applications. One potential application of this technology is the concept of stellarator magnetic confinement fusion energy. Early stellarators suffered from poor confinement, leading to their neglect until the concepts of quasi-symmetry and quasi-omnigeneity proved to be effective means of controlling neoclassical energy losses. However, implementing these concepts requires complex, high-precision coil construction, which can, for example, hinder construction plans and result in unacceptably long assembly times (e.g., exceeding 100 hours).

[0009] Therefore, a core challenge of stellarators needs to be addressed: the construction of complex coils. Solving this difficulty can improve the overall attractiveness of the stellarator. Other applications exist for complex magnetic geometries as well. Summary of the Invention

[0010] This application describes an apparatus and method for winding an electric coil (electromagnet). A self-propelled self-referenced winding carrier uses features on a winding spool to guide the carrier's orientation and / or orientation while laying an electrically conductive material (e.g., high-temperature superconducting (HTS) tape) as it traverses the spool. The carrier can wind an electric coil with a complex shape. In some embodiments, the self-propelled self-referenced (SPSR) carrier can perform other magnet manufacturing and assembly procedures.

[0011] This application describes an apparatus, system, and method for winding an electrically conductive material. One or more embodiments of the apparatus, system, and method include a stationary bobbin and a carrier, the stationary bobbin including continuous looped winding grooves, the carrier including a frame and movably coupled to the stationary bobbin, and continuously dispensing continuous electrically conductive material into continuous looped winding grooves as the carrier traverses the bobbin, wherein coils of multiple electrically conductive materials are placed in the winding grooves.

[0012] This application describes a method, apparatus, non-transitory computer-readable medium, and system for winding an electrically conductive material. One or more embodiments of the method, apparatus, non-transitory computer-readable medium, and system include a carrier traversing a stationary bobbin, wherein the bobbin includes a continuous annular winding groove configured to continuously receive and dispense electrically conductive material from the carrier into the annular winding groove as the carrier traverses the stationary bobbin, wherein coils of a plurality of electrically conductive materials are placed in the winding groove.

[0013] This application describes a method, apparatus, non-transitory computer-readable medium, and system for winding an electrically conductive material. One or more embodiments of the method, apparatus, non-transitory computer-readable medium, and system include manufacturing a bobbin comprising a continuous annular winding groove, supporting the bobbin above a fixed base in a rest position, manufacturing a winding carrier, and movably coupling the carrier to the bobbin such that the carrier is configured to continuously dispense electrically conductive material into the winding groove as the carrier traverses the bobbin along the winding groove, wherein the carrier includes a frame and is configured to continuously dispense continuous electrically conductive material. Attached Figure Description

[0014] Figure 1 An example of a portion of a bobbin structure for winding electrical conductor material is shown according to aspects of this disclosure.

[0015] Figure 2 Examples of force diagrams for wound electrical conductor materials are shown according to aspects of this disclosure.

[0016] Figure 3 Examples of electromagnetic coils are shown according to aspects of this disclosure.

[0017] Figures 4 to 7 Examples of magnet winding systems are shown according to aspects of this disclosure.

[0018] Figure 8 Examples of integrated magnet assemblies are shown according to aspects of this disclosure.

[0019] Figure 9 An example of a process of winding an electrical conductor material is shown according to aspects of this disclosure.

[0020] Figure 10 Examples of processes for manufacturing a system for winding electrical conductor materials are shown according to aspects of this disclosure.

[0021] Those skilled in the art will understand that the elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various embodiments of the invention. Furthermore, common and easily understood elements that are useful or necessary in commercially viable embodiments are generally not depicted in order to help reduce obstacles to observation of different embodiments of the invention. Detailed Implementation

[0022] The following description should not be construed as limiting, but is merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.

[0023] Throughout this specification, references to "an embodiment," "embodiment," or similar language mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the invention. Therefore, the phrases "an embodiment," "embodiment," and similar language appearing in this specification may, but do not necessarily, refer to the same embodiment.

[0024] Furthermore, the features, structures, or characteristics described in this invention can be combined in one or more embodiments in any suitable manner. Numerous specific details, such as programming examples, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., are provided in the following description to provide a thorough understanding of embodiments of the invention. However, those skilled in the art will recognize that the invention can be practiced without one or more specific details or with other methods, elements, materials, etc. In other instances, well-known structures, materials, or operations have not been shown or described in detail to avoid obscuring aspects of the invention.

[0025] This application describes a method for manufacturing nonplanar coils, for example, using a high-temperature superconductor (HTS). The embodiments described herein can significantly improve the cost and schedule associated with fusion concepts utilizing nonplanar coils (e.g., stellarators). Furthermore, the embodiments described herein can be used as a technique for realizing non-fusion applications of high-field magnets. The techniques described herein can provide a simpler (e.g., less complex, less time-consuming, etc.) and more cost-effective way to lay electrical conductor material on complex coil geometries.

[0026] For example, some techniques for nonplanar coils involve rotating the wound cable by manipulating the entire spool while slowly supplying the electrical conductor material from a fixed position. In the case of complex nonplanar coils, multi-spool tables can be implemented, which may be ineffective for conductors wound in a compressed manner. Furthermore, certain geometries may present difficulties (or impossibilities) in using spools because the resulting spool movement could cause collisions between the spool and the coil.

[0027] The techniques described herein are less sensitive to the geometry of the bobbin (e.g., and may depend on the size of the winding carrier relative to the bobbin). The winding carrier can be smaller compared to the winding reel. As a result, the embodiments described herein allow for greater design freedom, which is particularly important, for example, when considering the use of HTS conductors in the fabrication of complex coils (e.g., for stellarator magnetic fusion energy concepts). HTS conductors can be in the form of thin strips (e.g., electrically conductive strips) that are easily bent perpendicular to the strip surface but are not resistant to strain on the flat surface of the strip.

[0028] In some examples, HTS materials can be used in fusion energy applications (e.g., tokamaks). Using HTS tape to quickly, easily, and efficiently wind stellarator coil geometries is advantageous. According to the embodiments described herein, the complexity of the coil geometry can be overcome by a spool with winding grooves and an integrated guide (e.g., a track or runway) that allows a self-propelled and self-referenced vehicle to traverse the coil track while laying the electrical conductor material.

[0029] The techniques described herein can be applied to complex nonplanar coils made of HTS strip conductor material with strain limitations, but this description should not be construed as limiting it to such constructions.

[0030] The techniques described in this paper allow for the extension of non-insulated HTS (NI-HTS) magnets to complex non-planar geometries by: 1) deploying winding angle optimization techniques and using 3D printing to create bobbins with continuous runways (e.g., winding runways) at optimized angles; 2) deploying self-propelled self-referenced (SPSR) winding vehicles (e.g., in some cases, vehicles) to wind bare HTS tape onto the bobbins in a double-disc shape; and 3) using conductive cooling to address the low-temperature requirements of integrated magnets.

[0031] The novel, general-purpose, scalable, and parallelizable embodiments described herein offer simplification and consequent cost reduction (e.g., for fusion concepts benefiting from nonplanar coils, example applications include stellarators). The embodiments described herein enable device simplification, thereby reducing system costs. In addition to simplification and cost reduction, the use of HTS conductors allows for higher magnetic fields than conventional superconductors, thus opening a technically feasible path to increasing the achievable magnetic fields, such as those in stellarator concepts.

[0032] In one embodiment, the method takes the fabrication and demonstration of a medium-hole (approximately 50 cm) HTS stellarator coil operating at 500 kA / T coil current at 20 K as its central objective, estimating approximately 7.5 Tesla (T) on the coil surface and approximately 1 T on the tube. These methods can be extended to higher fields and larger holes.

[0033] This description provides a simplified approach to fabricating nonplanar coils using the NI-HTS method. Innovations in winding angle optimization, fixtures, and integrated components offer a unique and scalable pathway to fabricating large-aperture, high-field nonplanar magnets capable of operating at 20T and 20K (FOA Sec.ID1.iv), with the added benefit of parallelizability in fabrication. For example, experience in stellarator construction can identify geometry and precision requirements as key cost drivers that ultimately lead to fatal cost overruns. See R. Strykowsky et al., Postmortem Cost and Schedule Analysis – Lessons Learned On NCSX, PPL Report 4742 (2012), https: / / www.osti.gov / servlets / purl / 1074357, incorporated herein by reference. The combination of 3D-printed coils (defining geometry and precision) and fixture methods (realizing winding) impacts both of these cost drivers.

[0034] Figure 1 An example of a bobbin structure for winding an electrically conductive material 115 is shown according to an aspect of this disclosure. The example shown includes a portion of a bobbin structure 100, a winding groove 105, a winding path 110, and the electrically conductive material 115.

[0035] A portion of the illustrated bobbin structure 100 includes a winding groove 105. The groove receives a continuous layer of electrical conductor material 115 in the winding groove 105, thereby forming a coil.

[0036] Figure 2 An example diagram of the wound conductor material 210 is shown according to an aspect of this disclosure. The example shown includes a portion of a bobbin structure 200, a winding groove 205, and the conductor material 210. The portion of the bobbin structure 200 is a reference. Figure 1 Examples of the corresponding components described or including aspects thereof. The winding groove 205 is a reference. Figure 1 Examples of the corresponding elements described or including aspects thereof. Electrical conductor material 210 is a reference. Figure 1 , Figure 6 and Figure 8 Examples of the corresponding elements described or including their aspects.

[0037] This specification describes winding angle optimization, which in some cases can be applied to non-planar NI-HTS magnets. This work is described in detail in C. Paz-Soldan, Non-Planar Coil Winding Angle Optimization for Compatibility with Non-Insulated High-Temperature Superconducting Magnets, Journal of Plasma Physics (2021), http: / / arxiv.org / abs / 2003.02154, and is incorporated herein by reference. Due to the high current density in NI-HTS magnets, the current path can be filamentary, and the winding angle is an unconstrained degree of freedom available. HTS performance can be degraded by unwanted strain within the tape and by the perpendicular magnetic field. Optimizing the winding angle essentially maximizes the performance of the HTS tape in terms of current capacity against these limitations. Figure 2 It shows the degrees of freedom of the winding angle compared to the magnetic field and curvature.

[0038] Figure 3 An example of an electromagnetic coil 300 is shown according to aspects of this disclosure. In one embodiment, the coil 300 includes a local radius of curvature 305.

[0039] Figure 3 An example is shown where the final optimized winding angle and strain produced in an example nonplanar coil 300 are calculated. For clarity, the same nonplanar coil 300 is shown oriented in three different directions. Strain is represented by graphical values ​​of the coil 300 (i.e., light values ​​on the coil 300 represent larger strains). Arrows indicating the direction and extent of the local radius of curvature 305 are shown in the figure. The light value arrows indicate the optimal strain at that location. Peak strain occurs between bends in the nonplanar coil 300, with both bending and torsion predicted.

[0040] like Figure 2 and Figure 3 As shown, the winding angle (θ) wind The optimization mitigates the degradation of electrical conductor materials caused by strain due to incorrect bending and twisting (torsion) of the electrical conductor material, as well as the effects of the vertical field (e.g., HTS tape degradation).

[0041] Figure 4 An example of a magnet winding system is shown according to aspects of this disclosure. The example shown includes a spool 400 and a carrier 405. The spool 400 is a reference. Figure 5-7 Examples of the corresponding elements described or including aspects thereof. Vehicle 405 is a reference. Figure 5-7Examples of the corresponding elements described or including their aspects.

[0042] This description provides a simplified approach to fabricating nonplanar coils using the NI-HTS method. Innovative manufacturing techniques, including winding angle optimization, the carrier 405, and integrated components, enable large-aperture, high-field nonplanar magnets operating at 20T and 20K (FOA Sec.ID1.iv), offering a unique and scalable pathway with the added benefit of parallelization in manufacturing. For example, experience building stellarators can identify geometry and precision requirements as key cost drivers that ultimately lead to fatal cost overruns. The combination of 3D-printed bobbins 400 (defining geometry and precision) and the carrier 405 approach (enabling winding) impacts both of these cost drivers.

[0043] Figure 4 The image illustrates an exemplary magnet winding system including a self-propelled self-winding (SPSR) winding carrier 405 (vehicle). The winding carrier 405 (e.g., SPSR winding carrier 405) and the bobbin 400 are shown. The SPSR carrier 405 is a vehicle-driven motor that traverses the bobbin 400 and lays an electrical conductor material (e.g., an electrical conductor strip) during traversal. Self-reference of the carrier 405 (i.e., the carrier 405 automatically oriented relative to the bobbin 400 so that the electrical conductor material is laid within the winding grooves of the bobbin 400) can be provided via a built-in guide rail (guide track). In some examples, the track / track can be formed on the bobbin 400 during additive (3D) printing of the bobbin 400, or can be machined onto the bobbin 400 after printing.

[0044] The carrier 405 includes at least one self-referencing member configured to engage with the spool 400 so that the carrier 405 is self-referential during winding (e.g., as further described herein, such as a reference). Figure 5-7 In some embodiments, the self-reference member is a wheel coupled to the carrier 405 such that each wheel rides along a track or rail, thereby maintaining the proper orientation of the carrier 405 relative to the track / rail. In some embodiments, multiple tracks / rails are used. In other embodiments, the spool 400 has a single track / rail. In other embodiments, the spool 400 may have two, three, four, or more than four tracks / rails. Although wheels may be shown, any suitable self-reference member can be used that allows the carrier 405 to advance along a track while maintaining a specific orientation of the carrier 405 relative to a winding slot (or multiple winding slots). Multiple self-reference members may ride on each track / rail. This apparatus and method can be used to lay electrical conductor material (e.g., HTS tape) onto complex spool 400 shapes (i.e., forming non-planar coils), but any ductile conductor material can also be laid onto any spool 400 shape.

[0045] According to some embodiments, the spool 400 includes a continuous annular winding groove. In some examples, the spool 400 comprises copper, steel, aluminum, or any mixture thereof. In some examples, the spool 400 is formed by additive manufacturing. In some examples, the spool 400 includes a shape at least partially formed by additive manufacturing. In some examples, the spool 400 includes a shape at least partially formed by machining.

[0046] According to some embodiments, a carrier 405 includes a frame and is movably coupled to a stationary bobbin 400. The carrier 405 is configured to traverse the bobbin 400 and, as it traverses the bobbin 400, continuously dispense a continuous electrical conductor material into a continuous annular winding groove, wherein multiple coils of the electrical conductor material are placed in the winding groove. In some examples, the system is configured to automatically orient the carrier 405 relative to the continuous annular winding groove as the carrier 405 traverses the bobbin 400. In some examples, the automatic orientation carrier 405 is constructed including a continuous track in the bobbin 400 and at least one carrier self-reference member 405 coupled to the continuous track.

[0047] In some examples, the carrier 405 also includes at least one articulating structure coupled to the spool 400 to facilitate self-referencing of the carrier 405. In some examples, the carrier 405 is configured to self-propel along a groove. In some examples, self-propelling includes the carrier 405 using a drive motor coupled to the frame to rotate a set of wheels of the carrier 405, wherein the operation of the drive motor causes the carrier 405 to roll along the winding groove. In some examples, the carrier 405 is configured to store undistributed electrical conductor material and to distribute electrical conductor material. In some examples, the electrical conductor is stored on a rotating spool rotatably coupled to the carrier 405 and distributed by the rotating spool. In some examples, the carrier 405 is configured to receive electrical conductor material from an off-vehicle location before distributing the electrical conductor material. In some examples, the carrier 405 is configured to traverse the spool 400 by manual advancement along the winding groove.

[0048] In some examples, the final assembly of the system involves the use of welding materials. In some examples, the electrical conductor material is a high-temperature superconducting tape or high-temperature superconducting wire. In some examples, the electrical conductor material is a low-temperature superconducting wire. In some examples, the electrical conductor material is a component comprising a group of different electrical conductor materials. In some examples, one of the different electrical conductor materials is an electrically insulating material. In some examples, the winding groove is a double-disc winding groove.

[0049] According to some embodiments, a carrier 405 traverses a stationary bobbin 400, wherein the bobbin 400 includes a continuous annular winding groove configured to receive electrically conductive material. In some examples, as the carrier 405 traverses the stationary bobbin 400, the carrier 405 continuously dispenses electrically conductive material from the carrier 405 into the annular winding groove, wherein a coil of electrically conductive material is placed in the winding groove.

[0050] In some examples, the carrier 405 engages with the bobbin 400 to automatically orient itself relative to the annular winding groove as it traverses the stationary bobbin 400. In some examples, the engagement of the carrier 405 with the bobbin 400 includes a continuous track in the bobbin 400 and a self-referencing member of the carrier 405 engaged with the continuous track. In some examples, the carrier 405 includes at least one hinged structure engaged with the bobbin 400 to facilitate self-referencing of the carrier 405. In some examples, the carrier 405 forms an electromagnetic coil with the set of coils due to the placement of electromagnetic conductor material in the groove. In some examples, the carrier 405 traversing the bobbin 400 includes a self-propelled carrier 405 along the bobbin 400. In some examples, the self-propelling of the carrier 405 includes a drive motor of the carrier 405 operating a set of wheels of the carrier 405, wherein the operation of the drive motor causes the carrier 405 to roll along the groove.

[0051] In some examples, carrier 405 is configured to store undistributed electrical conductor material. In some examples, the undistributed electrical conductor material is stored on a rotating spool movably coupled to carrier 405. In some examples, the electrical conductor material is received from an external location 405 of carrier 405 prior to distribution. In some examples, carrier 405 traversing spool 400 includes manually advancing carrier 405 along spool 400. In some examples, the electrical conductor material is a high-temperature superconducting tape or high-temperature superconducting wire. In some examples, the electrical conductor material is a low-temperature superconducting wire. In some examples, the electrical conductor material is an assembly comprising a group of different electrical conductor materials. In some examples, one of the different electrical conductor materials is an electrically insulating material. In some examples, the winding groove is a double-disc winding groove.

[0052] Figure 5 An example of a magnet winding system is shown according to aspects of this disclosure. The example shown includes a carrier 500 and a spool 560.

[0053] exist Figure 5The image illustrates an embodiment of a magnet winding system. It shows a frame 505, multiple Hall effect sensors 515, a bobbin 510, an electrical conductor material, an electrical conductor material guide 520, a drive motor 525, a motor controller 530, a motor driver 535, multiple articulated legs, a slot guide 550, a fixed wheel 555, a drive wheel 545, a bobbin 560, a double-disc winding slot 570, a bobbin 560, and a track 565. Figure 5 In this embodiment, utilizing a 3D-printed bobbin 560, a vehicle 500 (vehicle) uses an onboard drive motor 525 and electronics (e.g., a motor controller 530 and a motor driver 535) to traverse the bobbin 560 along a predetermined track 565. As the vehicle 500 traverses the bobbin 560, it gradually unspools an electrical conductor material (in this example, HTS tape) onto one slot of a double-disc winding groove 570, gradually winding half of the double-disc coil. Continuous tension is provided by a Hall effect sensor on the bobbin 510, which directly actuates the torque of the drive motor 525 in a feedback loop controlled by the onboard electronics.

[0054] In one embodiment, the carrier 500 includes and is battery-operated, allowing unobstructed passage through the entire continuous spool 560 slot. In at least some embodiments, the complexity of the 3D-printed spool 560 is entirely transferred to the non-planar coil, as the carrier 500 operates locally without regard to coil complexity. Welded joints using welding material are used to extend the length of the electrical conductor material, thereby achieving the hundreds of turns (winding) required to reach very high fields. Note that a large number of turns results in a very high inductance magnet, a characteristic compatible with direct current (DC) or quasi-DC concepts such as stellarators. Although a double-disc winding slot is shown, it should be understood that in other embodiments, the spool 560 has a single winding slot.

[0055] Vehicle 500 is for reference. Figure 4 , 6 Examples of the corresponding elements described in 7 or including aspects thereof. In one embodiment, the carrier 500 includes a frame 505, a spool 510, a Hall effect sensor 515, an electrical conductor material guide 520, a motor 525, a motor controller 530, a motor driver 535, an articulated structure 540, a drive wheel 545, a slot guide 550, and a stationary wheel 555.

[0056] Frame 505 is an example of or includes aspects of the corresponding element described with reference to 4, 6, and 7. Spool 510 is a reference to... Figure 6 and 7 Examples of the corresponding elements described or including aspects thereof. The conductor material guide 520 is a reference. Figure 6 and 7 Examples of the corresponding elements described or aspects thereof are included. Hinged structure 540 is a reference. Figure 6 and 7 Examples of the corresponding components described or including aspects thereof. Drive wheel 545 is a reference. Figure 6 and 7 Examples of the corresponding components described or including aspects thereof. Fixed wheel 555 is a reference. Figure 6 and 7 Examples of the corresponding elements described or including their aspects.

[0057] 560mm spool is for reference. Figure 4 , 6 Examples of the corresponding elements described in 7 or including aspects thereof. In one embodiment, the bobbin 560 includes a raceway 565 and a double-disc winding groove 570. Raceway 565 is a reference. Figure 6 and 7 Examples of the corresponding elements described or including aspects thereof. The double-disc winding groove 570 is a reference. Figure 6 and 7 Examples of the corresponding elements described or including their aspects.

[0058] Figure 6 An example of a magnet winding system is shown according to aspects of this disclosure. The example shown includes a carrier 600 and a spool 640.

[0059] exist Figure 6 The image illustrates an embodiment of a magnet winding system. It shows a winding carrier 600, a bobbin 640, multiple raceways 645, a double-disc winding groove 650, a frame 605, multiple articulated legs, multiple wheels, a spool 610, an electrical conductor material guide 620, and an electrical conductor material 615. Figure 5 Similar to the implementation examples, in Figure 6 In one embodiment, an electrical conductor material 615 is wound on a spool 610 rotatably coupled to a frame 605 via pins. As the carrier 600 moves along the spool 640, the electrical conductor material 615 is automatically laid into a groove. Multiple wheels travel on a track 645, causing the carrier 600 to self-reference relative to the winding groove. In this embodiment, the frame 605 includes articulated legs coupled to the wheels. Each articulated leg is rotatable about a leg axis generally perpendicular to the groove direction. Figure 6 In one embodiment, the winding carrier 600 can be propelled by hand, but it is understood that motor components can be introduced to propel the carrier 600.

[0060] Vehicle 600 is for reference. Figure 4 , 5 Examples of the corresponding elements described in 7 or including aspects thereof. In one embodiment, the carrier 600 includes a frame 605, a spool 610, an electrical conductor material 615, an electrical conductor material guide 620, a hinge structure 625, a drive wheel 630, and a stationary wheel 635.

[0061] Frame 605 is a reference Figure 5 and 7 Examples of the corresponding elements described or including their aspects. Spool 610 is a reference. Figure 5 and 7 Examples of the corresponding elements described or including aspects thereof. Electrical conductor material 615 is a reference. Figure 1 , 2 Examples of the corresponding elements described in 8 or including aspects thereof. The conductor material guide 620 is referenced. Figure 5 and 7 Examples of the corresponding elements described or aspects thereof are included. Hinged structure 625 is a reference. Figure 5 and 7 Examples of the corresponding components described or including aspects thereof. Drive wheel 630 is a reference. Figure 5 and 7 Examples of the corresponding components described or including aspects thereof. Fixed wheel 635 is a reference. Figure 5 and 7 Examples of the corresponding elements described or including their aspects.

[0062] 640 is a reference size for spools. Figure 4 , 5 Examples of the corresponding elements described in 7 or including aspects thereof. In one embodiment, the bobbin 640 includes a raceway 645 and a double-disc winding groove 650. Raceway 645 is a reference. Figure 5 and 7 Examples of the corresponding elements described or including aspects thereof. The double-disc winding groove 650 is a reference. Figure 5 and 7 Examples of the corresponding elements described or including their aspects.

[0063] Figure 7 An example of a magnet winding system is shown according to aspects of this disclosure. The example shown includes a carrier 700, a spool 740, a base 765, and a spool support 770.

[0064] exist Figure 7 The image shows a third embodiment of a magnet winding system. It illustrates a winding carrier 700, a bobbin 740, multiple upper tracks 750, a lower track 755, a winding groove, multiple fixed wheels 730 (e.g., lower wheels), a frame 705, a spool 710, an electrical conductor material guide 715, a lower extension 735, and multiple articulated legs (e.g., articulated structures 720). Figure 7In this embodiment, the articulated legs are pivotable on an axis angled to the winding direction. A lower extension 735 of the frame 705 extends downward beyond the side of the spool 740. Two wheels are sequentially rotatably coupled to the lower extension 735. Each wheel engages with and travels within a lower runway 755. This increases the stability of the vehicle as it traverses the spool 740. The stationary spool 740 is supported on a fixed base 765 by a spool bracket 770 extending from the spool 740 to a base below it. The spool bracket 770 is spaced apart from and attached to the spool 740 such that it supports the spool 740 in the correct position while allowing the vehicle 700 to pass through the supported position without interfering with the winding operation.

[0065] refer to Figure 4-7 Some coil winding techniques for nonplanar coils involve rotating the wound cable by manipulating the entire spool 740 while slowly supplying the conductor material from a fixed position. In the case of complex nonplanar coils, multi-axis winding spools may be required, which may be ineffective for conductor materials to be wound in a compressed manner. Furthermore, some geometries make it difficult (or impossible) to use winding spools because the required movement of the spool 740 can cause collisions between the winding spool and the spool 740. For example, applications where the conductor material is twisted from the outer radial direction of the spool 740 to the inner diameter and then wound back to the outer diameter cannot be wound without collisions from a fixed point in space.

[0066] The proposed SPSR winding method is less sensitive to the geometry of the bobbin 740. The carrier 700 is typically smaller than the winding reel, although the relative dimensions of the bobbin 740 and carrier 700 can vary based on implementation details. As a result, the proposed system and method allow for greater design freedom. One application of the SPSR carrier 700 is the use of high-temperature superconductors (HTS). This medium is anisotropic (exhibiting a stripe factor) and is strain-constrained when bent. HTS electrical conductor materials allow for higher magnetic fields and / or higher temperature operation, offering advantages over many systems such as superconducting magnetic energy storage, particle accelerators, and magnetic fusion energy systems (e.g., stellarators). HTS conductors can be in the form of thin strips, which are easily bent perpendicular to the strip surface but are not strain-resistant on the surface plane of the strip. Utilizing optimization techniques published in peer-reviewed literature, for a given nonplanar coil geometry, this strain can be mitigated by using complex winding angles built into the continuous runways 745 (e.g., winding runways 745) of the bobbin 740.

[0067] The SPSR vehicle 700 technology can be used to deliver electrical conductor material (e.g., HTS tape) at any winding angle using a predefined complex bobbin 740 and runway 745 geometry. Additive manufacturing can be used to manufacture the complex bobbin 740, but other technologies may also be used. Embodiments of the system may include an SPSR vehicle 700 propelled by an onboard drive system (although power may be supplied externally via power cables) and without external reference, the orientation of which is determined by the runway 745 or a track feature integral with the bobbin 740. The vehicle 700 described herein can use an onboard drive system to traverse the bobbin 740, laying the electrical conductor material as it traverses. The self-reference of the SPSR vehicle 700 is provided by an integrated guide rail or runway 745 formed on the bobbin 740. In one embodiment, the bobbin 740 runway 745 / track may be formed by additive manufacturing, or in another embodiment, by complex machining.

[0068] The carrier 700 / spool 740 system and method can be used to lay electrical conductor material (e.g., HTS tape) onto complex spool 740 shapes, but the same method can, in principle, lay any ductile conductor onto any spool 740 shape. In one embodiment, the SPSR carrier 700 may include articulated structures 720 (e.g., articulated legs) to assist traversing the spool 740, facilitating a reference runway 745 / track. These articulated members allow for a fixed reference point at the point where the electrical conductor material is inserted into the winding groove, while allowing for greater overall stability and stronger force / torque reaction of the carrier 700.

[0069] Vehicle 700 is for reference. Figure 4-6 Examples of the corresponding elements described may include aspects thereof. In one embodiment, the carrier 700 includes a frame 705, a spool 710, an electrical conductor material guide 715, a hinge structure 720, a drive wheel 725 (e.g., an upper wheel), a fixed wheel 730 (e.g., a lower wheel), and a lower extension 735.

[0070] Frame 705 is a reference Figure 5 and 6 The figure illustrates examples of corresponding elements or includes aspects thereof. The spool 710 is a reference. Figure 5 and 6 Examples of the corresponding elements described or including aspects thereof. The conductor material guide 715 is a reference. Figure 5 and 6 Examples of the corresponding elements described or aspects thereof are included. The hinge structure 720 is a reference. Figure 5 and 6 Examples of the corresponding components described or including aspects thereof. Drive wheel 725 is a reference. Figure 5 and 6 Examples of the corresponding components described or including aspects thereof. The fixed wheel 730 is a reference. Figure 5 and 6 Examples of the corresponding elements described or including their aspects.

[0071] 740 is the reference size for the spool. Figure 4-6 Examples of the corresponding elements described may include aspects thereof. In one embodiment, the bobbin 740 includes a raceway 745 and a winding groove 760. The raceway 745 is a reference. Figure 5 and Figure 6 Examples of the corresponding elements described may include aspects thereof. In one embodiment, runway 745 includes an upper runway 750 and a lower runway 755. In some examples, winding groove 760 is referenced. Figure 5 and Figure 6 Examples of the corresponding elements described or including their aspects.

[0072] Figure 8 Examples of integrated magnet assemblies are shown according to aspects of this disclosure. In one embodiment, a vacuum container 800 includes a radiation shield 805, a clamp 810, a thermal path 815, a structural member 820, a mating piece 825, a strip-shaped disc 830, a conformal layer 835, and an electrical conductor material 840. The electrical conductor material 840 is a reference... Figure 1 , 2 Examples of the corresponding elements described in 6, or including their aspects.

[0073] exist Figure 8 The image shows an integrated magnet assembly. The wound, non-planar coil can be integrated into the complete magnet assembly, including cryogenic devices. Figure 8 An embodiment of a design for integrating a complete magnet assembly is illustrated. An exemplary design may include a coolant-free magnet in which a copper thermal path 815 is integrated into a 3D-printed bobbin 100 for conductive cooling. The bobbin 100 is 3D-printed in steel with a mechanical support and utilizes structural rods (e.g., to counteract any Lorentz forces on a vacuum container 800). The original bobbin fitting also supports the main HTS double disc member against internal Lorentz forces. The HTS current lead can have a low current per turn. The described winding angle optimization and self-propelled, self-referenced winding carrier, along with the advanced additive manufacturing of the bobbin and the cryogenic solution for conductive cooling, provide simplification and cost reduction for non-planar magnets operating at high fields. In one embodiment, an NI-HTS non-planar magnet capable of generating a 500 kAt coil current at 20 K and having a warm bore of approximately 50 cm was fabricated according to the description herein.

[0074] Figure 9Examples of processes for winding an electrically conductive material according to aspects of this disclosure are shown. In some examples, these operations are performed by a system including a processor that executes a set of code to control functional elements of a device. Additionally or alternatively, some processes are performed using dedicated hardware. Typically, these operations are performed using methods and processes described according to aspects of this disclosure. In some cases, the operations described herein consist of various sub-steps or are performed in combination with other operations.

[0075] In operation 900, the carrier engages with the bobbin to automatically orient the carrier relative to the annular winding groove as the carrier traverses the stationary bobbin. In some cases, this step refers to... Figure 4-7 The vehicle described, or the action that can be performed by a vehicle.

[0076] In operation 905, the carrier traverses a stationary spool, wherein the spool includes a continuous annular winding groove configured to receive electrically conductive material. In some cases, this step refers to... Figure 4-7 The vehicle described, or the action that can be performed by a vehicle.

[0077] In operation 910, as the carrier traverses the stationary spool, it continuously distributes conductive material into the annular winding slots, where a coil of conductive material is placed. In some cases, this step refers to... Figure 4-7 The vehicle described, or the action that can be performed by a vehicle.

[0078] Figure 10 Examples of processes for manufacturing a system for winding an electrically conductive material are shown according to aspects of this disclosure. In some examples, these operations are performed by a system including a processor that executes a set of code to control functional elements of the device. Additionally or alternatively, certain processes are performed using dedicated hardware. Typically, these operations are performed according to the methods and processes described in aspects of this disclosure. In some cases, the operations described herein consist of various sub-steps or are performed in combination with other operations.

[0079] In operation 1000, the system manufactures a bobbin consisting of a continuous annular winding groove.

[0080] In operation 1005, the system supports the spool above the fixed base and keeps it in a stationary position.

[0081] In operation 1010, the system manufactures a winding carrier, wherein the carrier includes a frame and is configured to continuously distribute continuous electrical conductor material.

[0082] In operation 1015, the system movably couples the carrier to the bobbin, such that the carrier is configured to continuously distribute electrical conductor material into the bobbin as it traverses the bobbin along the winding groove.

[0083] Therefore, this disclosure includes the following embodiments.

[0084] This application describes an apparatus for winding an electrical conductor material. One or more embodiments of the apparatus include a stationary spool and a carrier. The stationary spool includes a continuous annular winding groove, and the carrier includes a frame and is movably coupled to the stationary spool. The carrier is configured to traverse the spool and, while traversing the spool, continuously dispense a continuous stream of electrical conductor material into the continuous annular winding groove, wherein coils of multiple electrical conductor materials are placed in the winding groove.

[0085] A system for winding an electrical conductor material includes: a stationary bobbin including a continuous annular winding groove and a carrier including a frame and movably coupled to the stationary bobbin, the carrier being configured to traverse the bobbin and, while traversing the bobbin, continuously dispensing a continuous stream of electrical conductor material into the continuous annular winding groove, wherein coils of a plurality of electrical conductor materials are placed in the winding groove.

[0086] This application describes a method for manufacturing an apparatus for winding an electrical conductor material. The method includes manufacturing a stationary bobbin including a continuous annular winding groove and a carrier including a frame and movably coupled to the stationary bobbin, the carrier being configured to traverse the bobbin and continuously dispensing a continuous electrical conductor material into the continuous annular winding groove as it traverses the bobbin, wherein coils of multiple electrical conductor materials are placed in the winding groove.

[0087] This application describes a method using an apparatus for winding an electrical conductor material. The method includes a stationary spool and a carrier comprising a continuous annular winding groove. The carrier comprises a frame and is movably coupled to the stationary spool. The carrier is configured to traverse the spool and, while traversing the spool, continuously dispense a continuous electrical conductor material into the continuous annular winding groove, wherein coils of multiple electrical conductor materials are placed in the winding groove.

[0088] In some examples, the system is configured to automatically orient the vehicle relative to a continuous annular winding groove as the vehicle traverses the bobbin. In some examples, the automatic orientation vehicle is constructed including a continuous track within the bobbin and at least one self-referencing member of the vehicle engaging with the continuous track. In some examples, the vehicle also includes at least one articulated structure engaging with the bobbin to facilitate self-referencing of the vehicle.

[0089] In some examples, the carrier is configured to self-propel along the slot. In some examples, self-propelledness involves the carrier using a drive motor coupled to the frame to rotate multiple wheels of the carrier, wherein the operation of the drive motor causes the carrier to roll along the winding slot. In some examples, the carrier is configured to store undistributed electrical conductor material and to distribute electrical conductor material. In some examples, the electrical conductor is stored on a rotating spool rotatably coupled to the carrier and distributed by the rotating spool.

[0090] In some examples, the carrier is configured to receive the electrical conductor material from an external location prior to dispensing it. In some examples, the carrier is configured to traverse the spool by being manually advanced along a winding groove. In some examples, the spool comprises copper, steel, aluminum, or any mixture thereof. In some examples, the spool is formed by additive manufacturing. In some examples, the spool includes a shape at least partially formed by additive manufacturing. In some examples, the spool includes a shape at least partially formed by machining.

[0091] In some examples, the final assembly of the system involves the use of welding materials. In some examples, the electrical conductor material is a high-temperature superconducting tape or high-temperature superconducting wire. In some examples, the electrical conductor material is a low-temperature superconducting wire. In some examples, the electrical conductor material is a component comprising several different electrical conductor materials. In some examples, one of the different electrical conductor materials is an electrically insulating material. In some examples, the winding groove is a double-disc winding groove.

[0092] This application describes a method for winding an electrical conductor material. One or more embodiments of the method involve a carrier traversing a stationary bobbin, wherein the bobbin includes a continuous annular winding groove configured to receive and continuously distribute the electrical conductor material from the carrier into the annular winding groove as the carrier traverses the stationary bobbin, wherein coils of multiple electrical conductor materials are placed in the winding groove.

[0093] This application describes an apparatus for winding an electrically conductive material. The apparatus includes a processor, a memory in electronic communication with the processor, and instructions stored in the memory. The instructions are operable to cause the processor to perform the step of a carrier traversing a stationary bobbin, wherein the bobbin includes a continuous annular winding groove configured to receive the electrically conductive material and to continuously dispense the electrically conductive material from the carrier into the annular winding groove as the carrier traverses the stationary bobbin, wherein coils of multiple electrically conductive materials are placed in the winding groove.

[0094] Some examples of the methods, apparatus, non-transitory computer-readable media, and systems described above also include engaging a carrier with a bobbin to automatically orient the carrier relative to an annular winding groove as the carrier traverses a stationary bobbin. In some examples, the carrier engaging with the bobbin includes a continuous runway in the bobbin and a self-referencing member of the carrier engaging with the continuous runway. In some examples, the carrier includes at least one hinged structure engaging with the bobbin to facilitate self-referencing of the carrier.

[0095] Some examples of the methods, apparatus, non-transitory computer-readable media, and systems described above also include an electromagnetic coil having multiple coils formed by electromagnetic conductor material placed in the slot. In some examples, the carrier traversing the spool includes a self-propelled carrier along the spool. In some examples, the self-propelling of the carrier includes a drive motor of the carrier operating multiple wheels of the carrier, wherein operation of the drive motor causes the carrier to roll along the slot. In some examples, the carrier is configured to store undistributed electrical conductor material.

[0096] In some examples, undistributed conductive material is stored on a rotating spool movably coupled to the carrier. In some examples, the conductive material is received from an external location before distribution. In some examples, the carrier traversing the spool involves manually advancing the carrier along the spool. In some examples, the conductive material is a high-temperature superconducting tape or high-temperature superconducting wire. In some examples, the conductive material is a low-temperature superconducting wire. In some examples, the conductive material is an assembly comprising several different conductive materials. In some examples, one of the different conductive materials is an electrically insulating material. In some examples, the winding groove is a double-disc winding groove.

[0097] This application describes a method for manufacturing a system for winding an electrical conductor material. One or more embodiments of the method include manufacturing a bobbin including a continuous annular winding groove, supporting the bobbin in a stationary position above a fixed base, manufacturing a winding carrier, wherein the carrier includes a frame and is configured to continuously dispense a continuous electrical conductor material, and movably coupling the carrier to the bobbin such that the carrier is configured to continuously dispense the electrical conductor material into the winding groove as it traverses the bobbin along the winding groove.

[0098] Although the invention has been described herein by way of specific embodiments, examples and applications thereof, those skilled in the art may make many modifications and alterations thereto without departing from the scope of the invention as defined by the claims.

Claims

1. A system for winding an electrical conductor material, comprising a stationary spool, a carrier including a frame, and a continuous electrical conductor material, comprising: The stationary bobbin includes a continuous annular winding groove and a continuous runway; The carrier, which is movably coupled to the stationary bobbin, includes: An onboard drive motor for traversing the bobbin, the onboard drive motor being configured to rotate a plurality of wheels of the vehicle, thereby causing the vehicle to roll along the winding groove. At least one self-referenced component of the vehicle engaged with the continuous runway, thereby automatically orienting the vehicle relative to the continuous annular winding groove as the vehicle traverses the spool; and A rotating spool, rotatably coupled to the carrier, is used to continuously distribute the continuous electrical conductor material into the continuous annular winding groove as it traverses the spool, thereby placing coils of the multiple electrical conductor materials in the winding groove.

2. The system for winding an electrical conductor material as claimed in claim 1, wherein the carrier further comprises at least one hinge structure engaging with the spool to facilitate self-referencing of the carrier.

3. The system for winding an electrical conductor material as claimed in claim 1, wherein the carrier is further configured to self-propel along the groove.

4. The system for winding electrical conductor material as claimed in claim 1, wherein the carrier is further configured to store undistributed electrical conductor material and distribute the electrical conductor material via the rotating spool rotatably coupled to the carrier.

5. The system for winding an electrical conductor material as claimed in claim 1, wherein the carrier is further configured to receive the electrical conductor material from an external location prior to dispensing the electrical conductor material.

6. The system for winding an electrical conductor material as claimed in claim 1, wherein the spool further comprises copper, steel, aluminum, or any mixture thereof.

7. The system for winding an electrical conductor material as claimed in claim 1, wherein the shape of the spool is formed at least in part by one of additive manufacturing and machining.

8. The system for winding an electrical conductor material as claimed in claim 1, wherein the welding material is used in the final assembly of the system.

9. The system for winding an electrical conductor material as claimed in claim 1, wherein the electrical conductor material is a high-temperature superconducting tape material or a high-temperature superconducting wire material.

10. The system for winding an electrical conductor material as claimed in claim 1, wherein the electrical conductor material is a low-temperature superconducting wire material.

11. The system for winding an electrical conductor material as claimed in claim 1, wherein the electrical conductor material is a component comprising a variety of different electrical conductor materials.

12. The system for winding an electrical conductor material as claimed in claim 11, wherein one of the different electrical conductor materials is an electrical insulating material.

13. The system for winding an electrical conductor material as claimed in claim 1, wherein the winding groove is a double-disc winding groove.

14. A method for winding an electrical conductor material, comprising: A vehicle traverses a stationary bobbin comprising a continuous runway, the vehicle being movably coupled to the bobbin, the vehicle including a frame, an onboard drive motor, at least one self-reference member, and a rotating spool rotatably coupled to the vehicle, the onboard drive motor operating a plurality of wheels of the vehicle, thereby causing the vehicle to roll along the runway, the rotating spool for continuously dispensing continuous electrical conductor material, wherein the bobbin includes a continuous annular winding groove configured to receive the electrical conductor material; When the vehicle traverses the stationary bobbin, the at least one self-reference member engages with the continuous runway to automatically orient the vehicle relative to the continuous annular winding groove; as well as As the carrier traverses the stationary bobbin, the electrical conductor material is continuously distributed from the rotating spool of the carrier into the annular winding groove, thereby placing multiple coils of the electrical conductor material in the winding groove.

15. The method for winding an electrical conductor material as claimed in claim 14, wherein the carrier further comprises at least one hinge structure engaging with the spool to facilitate self-referencing of the carrier.

16. The method for winding an electrical conductor material as described in claim 14, further comprising the following steps: An electromagnetic coil having the plurality of coils is formed by placing an electromagnetic conductor material in the groove.

17. The method for winding an electrical conductor material as claimed in claim 14, wherein the carrier traversing the spool includes a self-propelled carrier along the spool.

18. The method for winding an electrical conductor material as claimed in claim 14, wherein the carrier is configured to store undistributed electrical conductor material.

19. The method for winding an electrical conductor material as claimed in claim 18, wherein the undistributed electrical conductor material is stored on the rotating spool movably coupled to the carrier.

20. The method for winding an electrical conductor material as claimed in claim 14, wherein the electrical conductor material is received from an external location on the carrier prior to dispensing.

21. The method for winding an electrical conductor material as described in claim 14, wherein the electrical conductor material is a high-temperature superconducting tape material or a high-temperature superconducting wire material.

22. The method for winding an electrical conductor material as described in claim 14, wherein the electrical conductor material is a low-temperature superconducting wire material.

23. The method for winding an electrical conductor material as claimed in claim 14, wherein the electrical conductor material is a component comprising a variety of different electrical conductor materials.

24. The method for winding an electrical conductor material as described in claim 23, wherein one of the different electrical conductor materials is an electrical insulating material.

25. The method for winding an electrical conductor material as claimed in claim 14, wherein the winding groove is a double-disc winding groove.

26. A method for manufacturing a system for winding an electrical conductor material, comprising: Manufacturing bobbins that include continuous annular winding grooves and continuous runways; The spool is supported above the fixed base and is in a stationary position. Manufacturing a winding carrier, wherein the carrier includes a frame, a self-reference member, an onboard drive motor for traversing the spool, and a rotating spool rotatably coupled to the carrier, the onboard drive motor being configured to rotate a plurality of wheels of the carrier, the rotating spool being used to continuously dispense a continuous electrical conductor material; By engaging the self-reference member with the continuous runway to movably couple the carrier to the bobbin, the carrier is automatically oriented relative to the continuous annular winding groove as it traverses the bobbin, such that the carrier is configured to continuously distribute the electrical conductor material into the winding groove as it traverses the bobbin along the winding groove.

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