Superconducting coil winding machine

Abstract

The invention discloses a superconducting coil winding machine, and relates to the technical field of superconducting equipment manufacturing, the superconducting coil winding machine comprises a rack, and a take-up mechanism, a wire guide mechanism, a tension pay-off mechanism and a control system which are arranged on the rack in sequence, and the control system is electrically connected with the tension pay-off mechanism and the take-up mechanism; the tension pay-off mechanism comprises two pay-off wheels, a torque motor I for driving the pay-off wheels and a magnetic powder controller, the magnetic powder controller is connected with the torque motor I to control the output torque of the torque motor I, and the wire guide mechanism comprises a guide wheel support, a wire inlet guide wheel, a tension guide wheel and a wire outlet guide wheel, a pressure sensor is arranged on the side of a rotating shaft of the tension guide wheel and is in communication connection with a magnetic powder controller, so that the magnetic powder controller can feed back and adjust the rotating speed of the torque motor I according to detected pressure information. And the equipment cost and resource consumption are reduced.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of superconducting device manufacturing, and particularly relates to a superconducting coil winding machine. BACKGROUND

[0002] As a core component of a superconducting device, the winding precision of a superconducting coil directly affects the performance of the device. At present, the winding of a superconducting coil mainly relies on a special winding machine. High-temperature superconducting wires and low-temperature superconducting wires need to be wound by different winding machines due to differences in material and specifications, and the following problems exist: 1. High equipment cost: enterprises need to purchase multiple special winding machines, and the market price of a single machine is 800-1200 thousand yuan, which increases the production cost; 2. Poor production flexibility: when the type of wound wire changes, the entire machine needs to be replaced, and the switching cycle is long (usually 1-2 days), which cannot quickly respond to multi-specification order requirements; 3. Low tension control precision: the existing winding machines mostly use open-loop control or simple closed-loop control, and the tension fluctuation amplitude is generally greater than or equal to 8%, which easily leads to wire deformation, fracture, or strip wrinkling, affecting the quality of the coil; 4. Low resource utilization rate: multiple machines occupy a large space in the factory building, and the idle rate of the equipment is high (when the order of a certain type of wire decreases, the corresponding winding machine is idle), and the wire loss rate is as high as 3%, causing resource waste.

[0003] Therefore, how to provide a superconducting coil winding machine device suitable for both high-temperature superconducting wires and low-temperature superconducting wires has become a technical problem to be solved by those skilled in the art. SUMMARY

[0004] Therefore, the application provides a superconducting coil winding machine suitable for the precise winding of high-temperature superconducting wires and low-temperature superconducting wires, and can be applied to the production of superconducting coils in the fields of energy transmission, medical imaging, nuclear fusion, etc.

[0005] In order to achieve the above-mentioned purposes, the application adopts the following technical solutions: The application discloses a superconducting coil winding machine, which comprises a rack, a tension pay-off mechanism, a wire guide mechanism, a take-up mechanism and a control system, wherein the take-up mechanism, the wire guide mechanism and the tension pay-off mechanism are sequentially arranged at the front end, the middle end and the rear end of the rack, the control system is arranged on the rack and is electrically connected with the tension pay-off mechanism and the take-up mechanism, the tension pay-off mechanism comprises a pay-off wheel, a torque motor and a magnetic powder controller, the pay-off wheel is provided with two kinds, the magnetic powder controller is connected with the torque motor to control the output torque of the torque motor, the wire guide mechanism comprises a guide wheel support and sequentially arranged wire-in guide wheels, a tension guide wheel and a wire-out guide wheel on the guide wheel support, the rotation shaft side of the tension guide wheel is provided with a pressure sensor for detecting the pressure of a superconducting wire or tape applied to the tension guide wheel, and the pressure sensor is in communication connection with the magnetic powder controller, so that the magnetic powder controller can adjust the rotating speed of the torque motor according to the pressure information detected by the pressure sensor, thereby realizing constant tension control.

[0006] Further, the two kinds of pay-off wheels comprise a first pay-off wheel suitable for high-temperature superconducting tapes and a second pay-off wheel suitable for low-temperature superconducting wires, and the first pay-off wheel and the second pay-off wheel are installed on the output shaft of the torque motor through a quick replacement mechanism.

[0007] Further, the wire guide mechanism further comprises at least two kinds of guide wheel groups, the guide wheel groups are installed on the guide wheel support through a sliding module, and the guide wheel groups comprise a flat guide wheel group suitable for guiding tapes and a V-shaped groove guide wheel group suitable for guiding wires.

[0008] Further, the flat guide wheel group suitable for guiding tapes is provided with a flattening mechanism, the flattening mechanism is composed of a pair of parallel roller wheels with adjustable spacing, and is used for flattening the superconducting tapes before winding.

[0009] Further, the take-up mechanism comprises a take-up wheel and a torque motor, and the torque motor is electrically connected with the control system.

[0010] Further, the application further comprises a tension detection control system, the tension detection control system is integrated in the control system, the pressure sensor is in communication connection with the magnetic powder controller through the tension detection control system, an encoder is arranged on the wire-in guide wheel two, the encoder is connected with the tension detection control system and is used for detecting the wire speed and participating in the closed-loop control of tension.

[0011] Further, the control system is integrated with a programmable logic controller, which is used for setting and storing winding parameters corresponding to different superconducting materials, the winding parameters comprise a target tension value, a winding wire speed and a layer number parameter, and the control system is further provided with a broken wire detection device and a wire arrangement visual monitoring device.

[0012] Further, the position corresponding to the wire guide mechanism on the rack is provided with a constant temperature drying air cover for heating and dehumidifying the high-temperature superconducting material during the winding process.

[0013] The present application has the following remarkable beneficial effects: 1. The present application integrates a quick-switchable pay-off wheel and guide wheel set through modular design, so that a single device can efficiently adapt to the winding requirements of different types and specifications of superconducting wires or tapes such as high-temperature and low-temperature. This fundamentally overcomes the disadvantages of single function of traditional special-purpose equipment, significantly reduces the number of equipment purchases and capital investment required by enterprises to meet the production of multiple varieties, and saves valuable factory space. The improvement of equipment utilization also effectively reduces the waste of idle equipment due to order changes, showing high economic efficiency and production flexibility; 2. The present application adopts a closed-loop tension control system based on real-time feedback of pressure sensors, which can accurately and continuously dynamically adjust the output torque of the pay-off mechanism. This active control strategy greatly suppresses the tension fluctuation during winding, ensuring the high stability of the wire tension. Thus, problems such as wire deformation, breakage or tape wrinkling caused by uneven tension are effectively avoided, providing a core guarantee for obtaining high-quality superconducting coils with compact structure and uniform performance, significantly improving the product qualification rate and consistency; 3. The present application integrates an intelligent control system, which can preset and store the winding process parameters of different materials, realizing one-key switching and automatic operation of the winding process. This not only greatly shortens the preparation and debugging time required for switching between different working conditions, but also improves the overall winding speed through optimized control logic. At the same time, auxiliary visual monitoring and safety protection functions further reduce manual intervention, reduce the difficulty and intensity of operation, making the production process more efficient, reliable and intelligent; 4. For superconducting materials, especially high-temperature superconducting tapes, the present application can be equipped with flattening mechanisms and online environmental control devices (such as constant temperature drying air covers), which can flatten the tape before winding and maintain a suitable environment during winding, effectively eliminating potential defects that may affect the critical current and other key performance of the coil, ensuring the superiority and stability of the performance of the final product. BRIEF DESCRIPTION OF DRAWINGS

[0014] Fig. 1 is a front view of the present application; Fig. 2 is a top view of the present application.

[0015] In the diagram: 1. Motion base; 2. Torque motor one; 3. Pay-off reel; 4. Inlet guide wheel one; 5. Inlet guide wheel two; 6. Tension guide wheel; 7. Outlet guide wheel; 8. Pressure sensor; 9. Guide wheel bracket; 10. Take-up reel; 11. Control system; 12. Frame; 13. Torque motor two; 14. Magnetic powder controller; 15. Encoder. Detailed Implementation

[0016] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0017] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "horizontal," "inner," "outer," and "one side," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0018] Example 1

[0019] like Figs. 1-2 As shown in the figure, this embodiment discloses a superconducting coil winding machine, which mainly includes a frame 12, a tension wire feeding mechanism, a wire feeding mechanism, a wire taking-up mechanism, and a control system 11.

[0020] Frame 12: Constructed with high-strength aluminum alloy profiles, providing a stable supporting foundation for the entire equipment. The motion base 1 is installed below the frame 12. The frame 12 is divided into three functional areas along its length: front, middle, and rear.

[0021] Tension pay-off mechanism: installed at the rear end of the frame 12. The core of the mechanism is the torque motor 2, whose output shaft is installed with a pay-off wheel 3 through a set of quick-change mechanism (such as flange and quick-release pin). This embodiment is equipped with two kinds of pay-off wheels: one is an aluminum alloy pay-off wheel with a groove width of 6mm, which is used for 4mm wide high temperature superconducting tapes (such as YBaCuO tapes), and the initial set torque is 8N·m; the other is a stainless steel pay-off wheel with a groove width of 4.5mm, which is used for 4mm×0.1mm low temperature superconducting tapes (such as NbTi tapes), and the initial set torque is 5N·m. Torque motor 2 is driven and controlled by magnetic powder controller 14.

[0022] Wire guide mechanism: set in the middle of the frame 12. It includes a guide wheel support 9, on which two sets of integral switchable guide wheel groups (not shown in the figure) are installed through a set of precision sliding module. One is a flat guide wheel group, which is used to guide the tape, and the entry guide wheel one 4, the entry guide wheel two 5, the tension guide wheel 6 and the exit guide wheel 7 are all flat wheels; the other is a V-shaped groove guide wheel group, which is used to guide the round wire. For the flat guide wheel group, an unfolding mechanism is integrated after the entry guide wheel one 4, which is composed of a pair of parallel rollers with adjustable spacing (for example, the adjustment range is 0.1mm to 0.2mm), which is used to flatten the superconducting tape before winding to eliminate the initial bending stress. The side of the tension guide wheel 6's rotating shaft bearing seat is installed with a high-precision pressure sensor 8, which is used to detect the pressure of the wire on the guide wheel in real time. The pressure value directly reflects the actual tension of the wire.

[0023] Take-up mechanism: located at the front end of the frame 12. It includes torque motor 13 and take-up wheel 10 directly driven by it. The speed of torque motor 13 is accurately controlled by control system 11.

[0024] Control system 11: integrated with programmable logic controller (PLC), installed in the electrical control cabinet at the front end of the frame 12. Control system 11 is connected with magnetic powder controller 14, pressure sensor 8, torque motor 13, encoder 15, etc. through lines. The signal of pressure sensor 8 is sent to the tension detection control system integrated in control system 11, which constitutes a closed loop control circuit with magnetic powder controller 14. In addition, encoder 15 is installed on entry guide wheel two 5, which is used to monitor the wire speed in real time. Industrial camera (i.e. wire arranging visual monitoring device) and broken wire detection sensor are also set on the frame 12, and their signals are connected to control system 11. In the wire guide mechanism area, a constant temperature drying air hood can be optionally installed, which is used to provide local heating and dehumidification environment when winding high temperature superconducting tapes sensitive to humidity.

[0025] Example 2

[0026] This embodiment discloses the winding work flow taking high temperature YBaCuO tapes and low temperature NbTi tapes as examples, which includes: Equipment preparation: select the corresponding pay-off wheel 3 and guide wheel set according to the type of wire to be wound. For example, when winding high-temperature YBaCuO tape, select aluminum alloy pay-off wheel and flat guide wheel set integrated with flattening mechanism, and adjust the roller spacing of the flattening mechanism to 0.12 mm. When winding low-temperature NbTi tape, select stainless steel pay-off wheel and another set of flat guide wheel set. Push the selected guide wheel set into the working position through the sliding module and lock it.

[0027] Material preparation: dry the high-temperature superconducting tape in an oven at 80°C for 2 hours to remove moisture.

[0028] System calibration: on the touch screen of the control system 11, call the preset process recipe. For example, set the high-temperature tape winding parameters: target tension 10 N, pay-off / take-up speed 1.8 m / min, total number of layers 35; set the low-temperature tape winding parameters: target tension 12 N, pay-off speed 1.5 m / min, take-up speed 1.575 m / min (considering the wire increment), total number of layers 25. At the same time, calibrate the range of the pressure sensor 8 (for example, 5-30 N corresponds to 0.5-3.0 V output), and enable the tension upper and lower limit protection, wire breakage protection and temperature monitoring functions.

[0029] Winding operation: the operator starts the winding program on the control system 11. The take-up mechanism first runs at low speed to tension the wire.

[0030] Subsequently, the pay-off mechanism and the take-up mechanism are synchronized to the set value. The tension detection control system starts to work: the pressure sensor 8 collects the tension signal in real time, the encoder 15 provides speed feedback, the PLC of the control system 11 runs the PID control algorithm, and dynamically adjusts the output current of the magnetic powder controller 14, so as to accurately control the torque (i.e. the reverse drag force) of the torque motor 2, so that the winding tension is stabilized near the target value, and the fluctuation amplitude is significantly lower than that of traditional equipment.

[0031] During the entire winding process, the industrial camera continuously monitors the arrangement of the wire on the take-up wheel to ensure that the wire is arranged neatly. The control system automatically records the key parameters every 100 meters of length, and can trigger an online size measurement to ensure the size accuracy of the coil.

[0032] Post-processing and equipment maintenance: after winding is completed, the coil is removed, and post-processing procedures such as wrapping protective tape and vacuum drying at 120°C are performed. Finally, the coil is tested for critical current (≥100 A is required in this embodiment) and is put into storage after passing the test.

[0033] To ensure long-term stable operation of the equipment, regular maintenance is performed: check the tightening of key bolts and clean the guide wheels every day; calibrate the sensor and clean the control system fan once a month; replace the transmission bearing and detect the transmission accuracy of the entire machine (not more than 0.02 mm / m) every year.

[0034] Through the above structure and workflow, the superconducting coil winding machine described in the embodiment realizes high-precision and high-efficiency winding of various superconducting materials by a single device. The modular design of the pay-off wheel and the guide wheel group makes the working condition switching quick and simple, greatly improving the utilization rate of the device and the production flexibility. The closed-loop tension control system based on real-time feedback ensures the high stability of the winding tension, effectively improving the winding quality and the qualified rate of the coil. The intelligent control system reduces the operation difficulty, ensures the repeatability and reliability of the production process. Therefore, the present application effectively overcomes the defects of high equipment cost, poor flexibility, insufficient tension control precision and the like in the prior art, and is particularly suitable for large-scale and multi-variety production of superconducting coils.

[0035] Although the specific embodiments of the present application are described above in combination with the drawings, it is not a limitation on the protection scope of the present application, and those skilled in the art should understand that various modifications or changes made by those skilled in the art on the basis of the technical solutions of the present application without creative labor are still within the protection scope of the present application.

Claims

1. A superconducting coil winding machine characterized by, The device comprises a rack (12), a tension pay-off mechanism, a wire guide mechanism, a take-up mechanism and a control system (11), the take-up mechanism, the wire guide mechanism and the tension pay-off mechanism are sequentially arranged at the front, middle and rear ends of the rack, the control system is arranged on the rack (12) and electrically connected with the tension pay-off mechanism and the take-up mechanism, the tension pay-off mechanism comprises a pay-off wheel (3), a torque motor (2) for driving the pay-off wheel (3) and a magnetic powder controller (14), the pay-off wheel (3) is provided with two kinds, the magnetic powder controller (14) is connected with the torque motor (2) to control the output torque thereof, the wire guide mechanism comprises a guide wheel support (9) and an incoming wire guide wheel (4), an incoming wire guide wheel (5), a tension guide wheel (6) and an outgoing wire guide wheel (7) which are sequentially arranged on the guide wheel support (9), a pressure sensor (8) is arranged on the side of the rotating shaft of the tension guide wheel (6) to detect the pressure applied by the superconducting wire or strip on the tension guide wheel (6), the pressure sensor (8) is communicatively connected with the magnetic powder controller (14), so that the magnetic powder controller (14) can adjust the rotating speed of the torque motor (2) according to the pressure information detected by the pressure sensor (8), thereby realizing constant tension control.

2. A superconducting coil winding machine according to claim 1, wherein, The two kinds of pay-off wheels (3) comprise a first pay-off wheel suitable for high-temperature superconducting strips and a second pay-off wheel suitable for low-temperature superconducting wires, and the first pay-off wheel and the second pay-off wheel are installed on the output shaft of the torque motor (2) through a quick replacement mechanism.

3. A superconducting coil winding machine according to claim 1, wherein, The wire guide mechanism further comprises at least two guide wheel groups, the guide wheel groups are installed on the guide wheel support (9) through a sliding module, and the guide wheel groups comprise a flat guide wheel group suitable for guiding strips and a V-shaped groove guide wheel group suitable for guiding wires.

4. A superconducting coil winding machine according to claim 3, wherein, The flat guide wheel group is provided with a flattening mechanism, the flattening mechanism is composed of a pair of parallel rollers with adjustable spacing, and is used for flattening the superconducting strips before winding.

5. A superconducting coil winding machine according to claim 1, wherein, The take-up mechanism comprises a take-up wheel (10) and a torque motor (13) for driving the take-up wheel (10), and the torque motor (13) is electrically connected with the control system (11).

6. A superconducting coil winding machine according to claim 1, wherein, The device further comprises a tension detection control system, the tension detection control system is integrated in the control system (11), the pressure sensor (8) is communicatively connected with the magnetic powder controller (14) through the tension detection control system, an encoder (15) is arranged on the incoming wire guide wheel (5), the encoder (15) is connected with the tension detection control system and is used for detecting the wire speed and participating in the tension closed-loop control.

7. A superconducting coil winding machine according to claim 1, wherein, The control system (11) is integrated with a programmable logic controller, which is used for setting and storing winding parameters corresponding to different superconducting materials, the winding parameters include target tension value, winding wire speed and layer number parameter, the control system (11) is further provided with a broken wire detection device and a wire arrangement visual monitoring device.

8. A superconducting coil winding machine according to claim 1, wherein, A constant-temperature drying air cover is arranged on the rack (12) corresponding to the position of the wire guide mechanism, which is used for heating and dehumidifying the high-temperature superconducting material during the winding process.

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