Online detection and correction device and method for cross section of conductor wound by armored superconducting coil for fusion
By using an online detection and correction device and a pre-reduction compensation process, the problem of weakened armor mechanical properties during the winding of armored superconducting conductors was solved, and the dimensional accuracy and stability of the conductor during the coil winding process were improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-03-10
AI Technical Summary
During the winding of armored superconducting conductors into coils, the mechanical properties of the conductor armor are weakened and stress is concentrated due to displacement deformation, and existing technologies have failed to effectively solve this problem.
An online detection and correction device is adopted, including a forming system, a straightening system, a measurement and control system, and a control system. A phased array laser rangefinder is used for real-time ranging and control. Combined with the dual-degree-of-freedom adjustment of the roller group and the pre-shrinking compensation process, the dimensional accuracy and mechanical properties of the conductor are ensured during the winding process.
By using pre-shrinkage compensation technology and real-time monitoring, the distortion of the conductor armor is reduced, the bending stiffness and mechanical properties of the conductor are improved, the requirements of high-precision manufacturing are met, and the stability and dimensional accuracy of the conductor are achieved during the coil winding process.
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Figure CN121632011A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of manufacturing armored superconducting conductors for nuclear fusion reactors, and specifically to an online detection and correction device and method for the cross-section of conductors wound with armored superconducting coils for fusion. Background Technology
[0002] Tokamak devices are widely recognized as ideal devices for achieving fusion energy, and the magnet system is the core component of a tokamak device. To obtain higher magnetic field strength, nuclear fusion reactor magnet systems all use armored superconducting conductors to manufacture magnets. Their excellent mechanical properties, good cooling channels, and mature manufacturing processes are widely used by fusion researchers both domestically and internationally.
[0003] During the manufacturing process of armored superconducting conductors, the conductor's armor needs to be reduced in diameter. Rollers are used to compress the armor, minimizing the gap between the superconducting cable and the armor, ensuring a tight seal between them. However, during the winding of the conductor into a coil, the superconducting conductor undergoes varying degrees of displacement and deformation towards the outer and inner diameter sides of the coil center. This causes changes in the mechanical properties of the conductor armor, such as weakened strength and stress concentration. Summary of the Invention
[0004] To address the aforementioned technical problems, this invention provides an online detection and correction device and method for the conductor cross-section of a fusion-grade armored superconducting coil, comprising a conductor diameter reduction forming system, a straightening system, and a measurement and control system. Based on the conductor material parameters of the superconducting conductor, the pre-reduction amount is calculated. The armored superconducting conductor, after being threaded through a tube, is fed into the conductor diameter reduction forming system. The forming angle and applied force of the roller module are adjusted to complete the conductor diameter reduction forming. A phased array laser rangefinder is used with a measurement system to perform real-time ranging and control during the forming process. After the diameter reduction forming is completed, the pre-formed armored superconducting conductor is fed into the straightening system. The straightness of the conductor is adjusted through a channel formed by the center holes of the horizontal and vertical adjustment devices. During the forming and straightening process, a water lubrication device is pumped to a spray system, spraying the water in a mist onto the active and passive forming ports to lubricate them, greatly improving the surface finish of the conductor.
[0005] To achieve the above objectives, the present invention adopts the following technical solution:
[0006] An online detection and correction device for the conductor cross-section of a fusion-use armored superconducting coil includes a forming system, a straightening system, a measurement and control system, and a control system. The forming system includes a support and an active forming system and a passive forming system mounted on the support. Both the active and passive forming systems include roller groups consisting of four rollers, which are mounted on a dual-degree-of-freedom adjustable base. The straightening system, located behind the forming system, includes a support and two sets of horizontal and two sets of vertical adjustment devices mounted on the support. Each horizontal and vertical adjustment device includes two rollers. The two rollers of the horizontal adjustment device are symmetrically distributed on both sides of a baseline, and the two rollers of the vertical adjustment device are symmetrically distributed at the upper and lower ends of the baseline. The horizontal and vertical adjustment devices are installed crosswise. The measurement and control system includes a multi-module phased array laser rangefinder. The multi-module phased array laser rangefinder is positioned above the forming and straightening systems and is electrically connected to the control system. The control system includes a central control console, which is electrically connected to the forming system, the straightening system, and the measurement and control system.
[0007] Furthermore, the roller assembly is evenly distributed in the four quadrants circumferential direction around the same baseline.
[0008] Furthermore, the dual-degree-of-freedom adjustment base enables independent adjustment of the roller's axial tilt angle and radial spacing.
[0009] Furthermore, the axial tilt angle of the roller can be adjusted from 15° to 75°.
[0010] Furthermore, the radial spacing of the rollers can be adjusted from 0.5 mm to 5 mm.
[0011] Furthermore, the measurement and control system calculates the pre-shrinkage amount based on the material parameters of the armored superconducting conductor, and the control system controls the roller group to perform pre-shrinkage compensation on the armored superconducting conductor based on the pre-shrinkage amount.
[0012] Furthermore, a square forming channel is formed between the inner surfaces of the rollers.
[0013] Furthermore, it also includes a digital pressure acquisition system, which includes a pressure sensor and a piezoelectric signal acquisition card. The digital pressure acquisition system and the control system are connected in series via analog signals to form a closed-loop control.
[0014] Furthermore, a square forming channel is formed between the inner wheel surfaces of the horizontal adjustment device and the vertical adjustment device.
[0015] This invention also provides an online detection and correction method for the conductor cross-section of a fusion-use armored superconducting coil, employing the aforementioned online detection and correction device for the conductor cross-section of a fusion-use armored superconducting coil, comprising the following steps:
[0016] Input the conductor material parameters of the armored superconducting conductor and set the pre-shrinkage amount;
[0017] Adjust the roller assembly of the forming system to the target tilt angle and initial spacing;
[0018] The armored superconducting conductor enters the active forming system, where rollers pull the armored superconducting conductor into the forming channel for diameter reduction forming. Then it enters the passive forming system for size optimization, and finally enters the straightening system for flatness correction.
[0019] The measurement and control system uses a multi-module phased array laser rangefinder to scan the armored superconductor in real time and transmits the measurement data to the control system. The control system adjusts the roller gap and process parameters based on the comparison results of the measurement data and the preset threshold, thereby achieving closed-loop control.
[0020] Beneficial effects:
[0021] 1. During the conductor coil winding process, the outer armor thins due to bending, while the inner wall thickens, affecting armor performance. Previously, superconducting conductors for fusion applications were directly manufactured using equipment like diameter reduction machines without pre-reduction compensation (the forming process preceded the conductor winding process). In the subsequent bending process, the changes in the inner and outer diameter sides of the outer armor (such as a specially designed square-outer, round-inner tube) are drastically different, significantly impacting the metal's mechanical strength. The cross-sectional distortion is more pronounced than with ordinary round or square tubes, leading to reduced load-bearing capacity, stress concentration, and decreased stability. Therefore, in the conductor forming process (where the conductor undergoes diameter reduction), based on the bending radius and conductor dimensions, and simulating the deformation during coil winding, a portion of the outer dimension is reserved during diameter reduction, while the inner dimension is reduced. This allows the conductor to compensate for the deformation caused by bending during coil winding, ensuring the conductor armor's load-bearing capacity and stability. By adopting a pre-shrinkage compensation process, the risk of distortion of the inner and outer webs of the metal armor can be greatly reduced, the bending stiffness of the conductor during the coil winding process can be increased, the deformation resistance can be reduced, and the mechanical properties of the coil can be guaranteed.
[0022] 2. This invention includes an angle-adjustable four-roller diameter reduction mechanism and a phased-array laser measurement and control unit. The roller assembly adopts a dual-degree-of-freedom adjustment mechanism to achieve continuous adjustment of the roller tilt angle from 15° to 75°, enabling the processing of square and trapezoidal cross-section conductors. A phased-array laser rangefinder performs real-time three-dimensional contour scanning, and adjusts the roller gap in real time through online measurement data feedback. A pre-diameter reduction compensation process is introduced, calculating the over-compression amount based on the conductor material characteristics to achieve pre-compensation for winding deformation. This invention can improve the dimensional accuracy and forming efficiency of CICC conductors, meeting the precision manufacturing requirements of ITER, CFETR, and other devices for ultra-large cross-section conductors, and realizing continuous correction of variable dimensions and precise measurement and closed-loop control of cross-section dimensions for large-section stiffness CICC conductors. This invention has the advantages of simple structure, convenient installation, high accuracy, strong practicality, and the ability to predict the relatively accurate amount of adhesive in advance.
[0023] 3. In traditional conductor reduction forming machines, there is no real-time monitoring of conductor dimensions during the reduction process, which may lead to quality problems such as undersized conductors, making it impossible to confirm whether the conductor meets quality requirements. By employing phased array laser rangefinder technology, real-time monitoring of each conductor surface at each node (forming system, straightening system) can be performed throughout the entire process. The current conductor dimension is compared with the required quality dimension in real time, and deviation analysis is conducted. When the deviation value exceeds a threshold, the data is transmitted to the control center. Algorithms are used to adjust the roller group, predict the conductor forming dimension for the next node, and compare it again with the required quality dimension to update process parameters. When the deviation value is less than the threshold, the quality requirements are met, and continuous monitoring ensures full tracking and closed-loop control of the superconducting conductor during the forming process. Attached Figure Description
[0024] Figure 1 This is a flowchart of an online detection and correction method for the conductor cross-section of a fusion-grade armored superconducting coil according to the present invention.
[0025] Figure 2 This is a front view of an online detection and correction device for the conductor cross-section of a fusion-grade armored superconducting coil according to the present invention.
[0026] Figure 3 This is a side view of an online detection and correction device for the conductor cross-section of a fusion-grade armored superconducting coil according to the present invention.
[0027] Figure 4 This is a schematic diagram of the compensation mechanism for diameter reduction processing.
[0028] The attached figures are labeled as follows: 1. Forming system; 2. Support; 3. Forming system roller group; 4. Armored superconducting conductor; 5. Straightening and adjustment system; 6. Horizontal adjustment device; 7. Vertical adjustment device; 8. Square forming channel. Detailed Implementation
[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other. The invention will be further described below with reference to specific embodiments.
[0030] like Figure 2 , Figure 3 As shown, the present invention discloses an online detection and correction device for the conductor cross-section of a fusion-grade armored superconducting coil, applicable to the manufacture of large-scale fusion-grade armored superconducting conductors, comprising:
[0031] 4. The armored superconducting conductor is a fusion armored superconducting conductor after being threaded through a tube.
[0032] The forming system 1 includes a support 2, on which an active forming system and a passive forming system are mounted. Each active forming system and the passive forming system includes a forming system roller group 3, each group consisting of four rollers, all surrounding the same baseline and evenly distributed in the circumferential direction of the four quadrants of the baseline at 45°. The roller group has an adjustable dual-degree-of-freedom adjustable base, which realizes independent adjustment of the roller axial tilt angle θ (15°≤θ≤75°) and radial spacing δ (0.5-5mm). The inner wheel surfaces of the rollers of the active forming system and the passive forming system form a square forming channel 8 for the armored superconducting conductor 4 to enter.
[0033] The straightening system 5, located behind the forming system 1, includes a support. Two sets of horizontal adjusting devices 6 and two sets of vertical adjusting devices 7 are mounted on the support, each including two rollers. The two rollers of the horizontal adjusting device 6 are symmetrically distributed on both sides of the baseline, and the two rollers of the vertical adjusting device 7 are symmetrically distributed at the upper and lower ends of the baseline. The two sets of horizontal adjusting devices 6 and vertical adjusting devices 7 are installed crosswise, and their inner surfaces form a square forming channel 8 for the armored superconducting conductor 4 to enter.
[0034] The measurement and control system, namely the multi-module phased array laser rangefinder, employs an antenna element array and phase control to achieve electronic scanning of the conductor dimensions at multiple nodes during the forming and straightening process, with extremely high scanning speed. The multi-module phased array laser rangefinder is positioned above the forming system 1 and the straightening system 5, and consists of a large number of identical antenna elements (small antennas) arranged in an array. Through phase shifter components, the phase of the signal fed to each antenna element is precisely controlled. By adjusting each phase shifter in real time and rapidly via a computer, the beam direction can be quickly changed, achieving inertial-free scanning, which is thousands of times faster than mechanical scanning. Therefore, phased array ranging can achieve inertial-free scanning, electronic beam steering with almost no delay, and can change direction within microseconds. It can simultaneously track, search, and identify a large number of targets. The measured data is transmitted back to the control system in real time, and closed-loop control can be achieved through algorithmic coordination.
[0035] The control system includes a central control console, which features functions such as fine-tuning of the diameter reduction dimension, digital display of forming force, adjustment and display of roller radial displacement, measurement of diameter reduction length, lubrication control, and working speed adjustment. During system operation, the central control console enables remote control and adjustment of the system. It can independently control the synchronous operation of the four rollers of forming system 1 or the individual operation of any single roller, adjusting the roller speed and angle. An alarm will sound if any abnormality occurs, prompting manual intervention or parameter setting.
[0036] The digital pressure acquisition system uses pressure sensors and piezoelectric signal acquisition cards to acquire and record the magnitude of the molding force.
[0037] like Figure 1 As shown, the present invention also provides an online detection and correction method for the conductor cross-section of a fusion-grade armored superconducting coil, comprising the following steps:
[0038] Step 1. Input the conductor material parameters of the armored superconducting conductor, including the initial conductor diameter and cross-sectional dimensions, and set the pre-shrinkage amount to compensate for the slight deformation generated during subsequent coil winding;
[0039] Step 2. Adjust the roller assembly of the forming system to the target tilt angle and initial spacing;
[0040] Step 3. The armored superconducting conductor enters the active forming system. Four synchronously rotating rollers pull the armored superconducting conductor into the square forming channel. The first set of rollers acts on all four sides of the armored superconducting conductor simultaneously, causing the diameter of the armored superconducting conductor to be reduced. After one forming, the required size is achieved. Then, the armored superconducting conductor enters the passive forming system to obtain better dimensions. Finally, the armored superconducting conductor enters the straightening system, where the bending of the armored superconducting conductor is corrected under the action of the square forming channel formed by the rollers, so that the conductor surface obtains better straightness.
[0041] Step 4. Connect the digital pressure acquisition system and the control system in series using analog signals to form a closed-loop control.
[0042] like Figure 4 As shown, during the coil winding process of a normal-sized armored superconducting conductor, the uneven deformation of the inner and outer tube walls directly leads to changes in the mechanical properties of the tube, such as reduced strength (measured by outer diameter), stress concentration, and residual stress. However, when the inner and outer tube walls are recessed during the conductor forming process to compensate, the tension and compression in different parts are neutralized, thus achieving stable conductor mechanical strength and meeting the usage requirements. Figure 4 In the diagram, R represents the direction of the conductor's cross-section, and ABCD represents the four corners of the conductor.
[0043] The above description is merely a preferred embodiment of the present invention and is not restrictive. The accompanying drawings also show only one embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.
Claims
1. An online detection and correction device for the conductor cross-section of a fusion-grade armored superconducting coil, characterized in that: The device comprises a forming system, a straightening system, a measurement and control system, and a control system; the forming system comprises a support and a main forming system and a passive forming system erected on the support, the main forming system and the passive forming system each comprise a roller set composed of four rollers, and the roller set is arranged on a double-degree-of-freedom adjusting base; the straightening system is located behind the forming system and comprises a support and two groups of horizontal adjusting devices and two groups of vertical adjusting devices erected on the support, the horizontal adjusting device and the vertical adjusting device each comprise two rollers, the two rollers of the horizontal adjusting device are symmetrically distributed on both sides of a reference line, the two rollers of the vertical adjusting device are symmetrically distributed on the upper and lower ends of the reference line, and the horizontal adjusting device and the vertical adjusting device are cross-mounted; the measurement and control system comprises a multi-module phased array laser range finder; the multi-module phased array laser range finder is arranged above the forming system and the straightening system and is electrically connected with the control system; and the control system comprises a central control console, which is electrically connected with the forming system, the straightening system, and the measurement and control system.
2. The device for on-line inspection and correction of the cross-section of the conductor for the toroidal field winding of a fusion reactor according to claim 1, characterized in that: The roller sets are uniformly distributed in four-quadrant circumferential directions around the same reference line.
3. The device for on-line inspection and correction of the cross-section of the conductor for the toroidal field winding of a fusion reactor according to claim 1, characterized in that: The double-degree-of-freedom adjusting base realizes independent adjustment of the axial inclination and the radial spacing of the rollers.
4. The device for on-line inspection and correction of the cross-section of the conductor for the toroidal field winding of a fusion reactor according to claim 3, characterized in that: The adjustment range of the axial inclination of the rollers is 15° to 75°.
5. The device for on-line inspection and correction of the cross section of the conductor for the toroidal field coil of a fusion reactor according to claim 3, characterized in that: The adjustment range of the radial spacing of the rollers is 0.5 mm to 5 mm.
6. The device for on-line inspection and correction of the cross section of the conductor for the toroidal field winding of a fusion reactor according to claim 1, characterized in that: The measurement and control system calculates a pre-shrinkage amount according to the parameters of the armored superconducting conductor material, and the control system controls the roller sets to perform pre-shrinkage compensation on the armored superconducting conductor according to the pre-shrinkage amount.
7. The device for on-line inspection and correction of the cross section of the conductor for the toroidal field coil of a fusion reactor according to claim 1, characterized in that: The inner wheel surfaces of the rollers form a square forming channel.
8. The device for on-line inspection and correction of the cross section of the conductor for the toroidal field winding of a fusion reactor according to claim 1, characterized in that: A digital pressure acquisition system is further included, which comprises a pressure sensor and a piezoelectric signal acquisition card, and the digital pressure acquisition system and the control system form a closed-loop control through analog signal series connection.
9. The device for on-line inspection and correction of the cross-section of the conductor for the toroidal field winding of a fusion reactor according to claim 1, characterized in that: The inner wheel surfaces of the horizontal adjusting device and the vertical adjusting device form a square forming channel.
10. A method of on-line inspection and correction of the cross section of a conductor for a fusion use armored superconducting coil winding, characterized by, The device for detecting and correcting the conductor cross section of the armored superconducting coil for fusion wound according to any one of claims 1 to 9 comprises the following steps: Input the conductor material parameters of the armored superconducting conductor and set a pre-shrinkage amount; Adjust the roller sets of the forming system to a target inclination and an initial spacing; The armored superconducting conductor enters the main forming system, the rollers pull the armored superconducting conductor into the forming channel for shrinkage forming, then enters the passive forming system for size optimization, and finally enters the straightening system for flatness correction; The measurement and control system performs real-time scanning on the armored superconducting conductor through the multi-module phased array laser range finder, transmits the measurement data to the control system, and adjusts the roller gap and the process parameters according to the comparison result of the measurement data and the preset threshold value to realize closed-loop control.