Superconducting coil precise winding step length control method and system for nuclear fusion device

Abstract

The invention discloses a superconducting coil precise winding step length control method and system for a nuclear fusion device, and the method comprises the steps: obtaining all material parameters of a YBCO strip, determining a reference step length according to all the parameters, and generating a servo initial feeding instruction based on the reference step length, so as to start the winding of a superconducting coil; actual attitude data and environment temperature of the superconducting coil during winding are acquired in real time; according to the actual attitude data and the environment temperature which are acquired in real time, determining a step length dynamic compensation amount at the current moment; and adjusting servo feeding according to the reference step length and the step length dynamic compensation amount at the current moment. The device utilizes the method. The winding precision can be remarkably improved, the method effectively adapts to material discreteness, quality closed-loop control is achieved, and the system reliability is improved.

Description

Technical Field

[0001] This invention belongs to the field of nuclear fusion engineering and superconducting magnet manufacturing technology, specifically relating to a method and system for precision winding step size control of superconducting coils for nuclear fusion devices. Background Technology

[0002] Nuclear fusion energy, as a clean, efficient, and sustainable new energy source, boasts significant advantages such as abundant fuel reserves, environmental friendliness, and the absence of long-lived radioactive waste, making it a crucial development direction for addressing the global energy crisis. Superconducting magnets are one of the core components of nuclear fusion devices, and their performance directly determines the stability and efficiency of the nuclear fusion reaction. With the continuous advancement of nuclear fusion technology, fusion devices are developing towards higher field strengths and larger sizes, placing unprecedentedly stringent requirements on the manufacturing precision of superconducting coils.

[0003] In superconducting magnet coils used in nuclear fusion devices, CICC (Cable-in-Conduit Conductor) type superconducting magnet coils are widely used in large-scale nuclear fusion devices such as CFETR (China Experimental Reactor for Fusion Engineering) and ITER (International Thermonuclear Experimental Reactor) due to their excellent current-carrying capacity, thermal stability, and mechanical strength. In the manufacturing process of CICC type superconducting magnet coils, the precision winding of the superconducting coil is one of the key processes. The control accuracy of the step-size servo motor's feed rate directly affects the coil's geometry, inter-turn gap, stress distribution, and other core indicators, thus affecting the magnetic field performance and operational reliability of the superconducting magnet.

[0004] However, existing step-size servo machine feed control technology in the superconducting coil winding process faces many key technical challenges, severely restricting the improvement of superconducting coil manufacturing precision. These key technical challenges are mainly manifested in: (1) The problem of material property dispersion: Currently, the superconducting coils used in nuclear fusion devices mainly use high-temperature superconducting materials such as YBCO (yttrium barium copper oxide) superconducting tape. Different batches, and even the same batch of YBCO superconducting tape, have significant differences in key material parameters such as elastic modulus, yield strength, and coefficient of thermal expansion. Traditional control methods use fixed control parameters and calculation models, which are difficult to adapt to this variability in material properties, resulting in large step size errors during winding and affecting the consistency of coil accuracy.

[0005] (2) Insufficient dynamic error compensation capability: During the winding process, the motion state of the servo motor, the attitude change of the coil, and the fluctuation of the ambient temperature are all dynamic changes, which will introduce real-time errors. The error compensation of existing control systems mostly adopts static compensation strategy and lacks a dynamic compensation mechanism based on real-time monitoring data. It is difficult to respond quickly to dynamic errors, resulting in insufficient real-time performance and accuracy of feed control.

[0006] (3) Lack of systematic quality control: Existing technologies mostly rely on post-production inspection to assess the quality of superconducting coil winding, lacking a real-time quality assessment and feedback mechanism. This makes it impossible to detect and adjust quality problems in a timely manner during the winding process, resulting in a high rate of defective products and increasing manufacturing costs and time.

[0007] To address the aforementioned technical challenges, there is an urgent need in this field to develop a superconducting coil precision winding step-size servo feed control system and method that can adapt to the discreteness of material properties, consider the coupling effect of multiple physical fields, and possess dynamic error compensation capabilities and real-time quality control functions, so as to meet the high precision requirements of nuclear fusion devices for superconducting coil manufacturing. Summary of the Invention

[0008] To address the aforementioned problems, this invention provides a method and system for controlling the step length during the precision winding of superconducting coils for nuclear fusion devices. This method solves the problem of step length control during the precision winding of superconducting coils and is particularly suitable for the precision winding process of CICC-type superconducting magnet coils for nuclear fusion devices. It enables high-precision and dynamic control of the step length servo motor feed rate.

[0009] The present invention adopts the following technical solution: According to a first aspect of the present invention, a method for precision winding step size control of superconducting coils for nuclear fusion devices is provided. The method includes: Obtain the various material parameters of YBCO tape, determine the reference step size based on the parameters, and generate the initial feed command of the servo machine based on the reference step size to start the superconducting coil winding; Real-time acquisition of the actual attitude data and ambient temperature of the superconducting coil during the winding process; Based on the real-time acquired actual attitude data and ambient temperature, determine the dynamic compensation amount of the step size at the current moment. The servo feed is adjusted based on the reference step size and the current step size dynamic compensation.

[0010] Furthermore, based on the aforementioned parameters, the reference step size L0 is determined, including: The baseline step size L0 is determined according to the following formula:

[0011] in, This is a material correction factor. For elastic modulus, For strip thickness, For yield strength, It is Poisson's ratio.

[0012] Furthermore, based on the real-time acquired actual attitude data and ambient temperature, the dynamic compensation amount of the step size at the current moment is determined, including: Determine the step size tolerance at the current moment based on various material parameters and the current ambient temperature; Based on the actual attitude data and ambient temperature, the step size deviation value at the current moment is determined, and then the process standard deviation of the step size deviation value is determined by combining the historical step size deviation values. The process capability index is obtained based on the current step size tolerance and process standard deviation. Based on the process capability index, the initial proportional coefficient and initial integral coefficient are adjusted to obtain the proportional coefficient and integral coefficient at the current moment. The dynamic compensation amount of the step size at the current moment is determined based on the current step size deviation value, the historical step size deviation value, and the proportional coefficient and integral coefficient at the current moment.

[0013] Furthermore, based on various material parameters and the current ambient temperature, the step size tolerance for the current moment is determined, including: The step size tolerance is determined according to the following formula. :

[0014] in, The design diameter of the superconducting coil, This refers to the total number of turns of the strip. This represents the difference between the current ambient temperature and the initial ambient temperature. The coefficient of thermal expansion of the material. This is the process correction factor.

[0015] Furthermore, based on the actual attitude data and ambient temperature, the current step size deviation is determined, and then the standard deviation of the step size deviation is determined by combining it with historical step size deviation values, including: Based on the ambient temperature, predict the deformation error of the superconducting tape at the current moment: The actual step size at the current moment is obtained based on the actual attitude data. The deformation error and the reference step size are subtracted from the actual step size at the current moment to obtain the step size deviation at the current moment.

[0016] Furthermore, based on the current step size tolerance and process standard deviation, the process capability index is obtained, including: The process capability index is obtained using the following formula. :

[0017] in, This represents the process standard deviation.

[0018] Furthermore, based on the process capability index, the initial proportional coefficient and initial integral coefficient are adjusted to obtain the proportional coefficient and integral coefficient at the current moment, including: The proportional coefficient at the current moment can be obtained using the following formula. and integral coefficient :

[0019]

[0020] in, and These are the initial proportional coefficient and the initial integral coefficient, respectively. As a regulating factor; When the process capability index Greater than or equal to the first threshold hour, ; When the process capability index is less than the first threshold And greater than the second threshold hour: ; When the process capability index is less than or equal to the second threshold hour: , where n is the nonlinear enhancement factor.

[0021] Furthermore, based on the current step size deviation value, historical step size deviation values, and the proportional coefficient and integral coefficient at the current moment, the dynamic compensation amount for the current step size is determined, including: The current time is determined by the following formula. t Step size dynamic compensation amount

[0022]

[0023] in, and Each represents the current time. t proportionality coefficient and integral coefficient, For the current moment t The step size deviation value.

[0024] According to a second aspect of the present invention, a precision winding step-size control system for superconducting coils in a nuclear fusion device using the method described in the first aspect of the present invention is provided. The system includes: The reference step size determination module is used to obtain various material parameters of YBCO strip, determine the reference step size based on the parameters, and generate an initial feed command for the servo machine based on the reference step size to start the superconducting coil winding. The sensing module is used to acquire the actual attitude data and ambient temperature of the superconducting coil in real time during the winding process; The compensation determination module is used to determine the dynamic compensation amount of the step size at the current moment based on the actual attitude data and ambient temperature acquired in real time. The adjustment module is used to adjust the servo feed based on the reference step size and the current step size dynamic compensation amount.

[0025] According to a third aspect of the present invention, a terminal is provided, comprising a processor and a storage medium; the storage medium is used to store instructions; the processor is used to operate according to the instructions to perform the steps of the method according to the first aspect of the present invention.

[0026] Compared with the prior art, the present invention has the following significant advantages: 1. Significantly improves winding accuracy: By combining the reference step length calculation model with the dynamic compensation algorithm, the accurate simulation of coil winding and the real-time compensation of dynamic errors are realized. The step length error is controlled within ±0.0005 mm and the coil diameter error is controlled within ±0.1 mm, which is significantly higher than the accuracy level of traditional control technology and meets the high precision requirements of nuclear fusion devices for superconducting coils.

[0027] 2. Effectively adapts to material dispersion: Through the material correction coefficient k and PID parameter self-tuning algorithm, the control parameters can be dynamically adjusted according to the characteristic parameters of different batches of superconducting tapes, effectively compensating for the errors caused by the dispersion of material characteristics, ensuring the consistency of winding accuracy of different batches of materials, and improving the product qualification rate.

[0028] 3. Achieve closed-loop quality control: By calculating the process capability index Cp in real time and establishing a quality grading and evaluation mechanism, quality problems can be detected and dynamically adjusted in a timely manner during the winding process. This achieves closed-loop control of the entire process from parameter setting, real-time monitoring, dynamic compensation to quality evaluation, reducing the rate of defective products and manufacturing costs.

[0029] 4. High system reliability and strong scalability: The system adopts a modular design and a distributed servo drive architecture. The modules communicate with each other through standardized interfaces, which has good scalability and maintainability. At the same time, it has multiple fault protection and self-diagnosis functions, and the system has high operational reliability and can adapt to the harsh environmental requirements of nuclear fusion device manufacturing.

[0030] 5. Easy to operate and highly practical: The human-machine interface is intuitive and clear, supporting functions such as manual / automatic mode switching, parameter setting, status monitoring, and fault diagnosis, making it easy to operate; the system can be used for winding superconducting coils for nuclear fusion devices of different specifications and types, and has broad practicality and promotional value.

[0031] In summary, this invention effectively solves the technical problems existing in the prior art, such as material property dispersion, multi-physics coupling, insufficient dynamic error compensation, and lack of systematic quality control. It significantly improves the manufacturing precision and consistency of superconducting coils, provides key technical support for the stable operation of nuclear fusion devices, and has important engineering application value and broad market prospects. Attached Figure Description

[0032] The accompanying drawings, which are part of the specification of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an improper limitation of the invention.

[0033] Figure 1 This is a flowchart illustrating a method for controlling the precision winding step size of a superconducting coil for a nuclear fusion device according to the present invention. Figure 2 This is a schematic diagram of the architecture of a precision winding step-size control system for a superconducting coil used in a nuclear fusion device according to the present invention. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this invention. The embodiments described in this application are merely some embodiments of this invention, and not all embodiments. Based on the spirit of this invention, other embodiments obtained by those skilled in the art without creative effort are all within the protection scope of this invention.

[0035] The present invention will be further described below with reference to specific embodiments. According to a first aspect of the present invention, a method for precision winding step size control of superconducting coils for nuclear fusion devices is provided.

[0036] like Figure 1 In one embodiment, the method includes the following steps: S1. Obtain the various material parameters of the YBCO strip, determine the reference step size based on the parameters, and generate the initial feed command of the servo machine based on the reference step size to start the superconducting coil winding.

[0037] The materials may include: the elastic modulus of the superconducting tape. ,thickness Yield strength Poisson's ratio Material properties and coil design diameter Total number of turns of strip Process parameters, etc. These parameters can be obtained through tensile testing during the preparation stage before starting winding, and then input into the terminal's memory for storage via the human-machine interface.

[0038] Determining the baseline step size involves the following process: First, assume that the YBCO strip meets the following conditions: 1. It is an isotropic linear elastic material. In the early stage of winding, it undergoes elastic deformation, and in the later stage, it enters elastoplasticity but is mainly elastic. 2. It is a thin plate, meaning its thickness is much smaller than its width and length, which meets the applicable conditions of the "thin plate bending theory"; 3. The winding is a planar bend, that is, the bending direction is along the thickness direction of the strip, and the neutral axis is parallel to the width direction of the strip; 4. Ignoring the effects of body force and shear force, the winding tension is uniform, and the contribution of shear force to bending stress can be ignored.

[0039] First, since the winding is a planar bend, the linear strain of the outer fiber layer of the thin plate is:

[0040] in, This is the distance from the outer fiber to the neutral axis. The radius of curvature is the radius of curvature of the neutral axis.

[0041] According to Hooke's Law, the normal stress of the outer fiber for:

[0042] Bending moment on the cross section of the strip M This is the integral result of stress:

[0043] in, b This refers to the width of the strip.

[0044] Will Substitution M The expression, when integrated, yields:

[0045] Calculate the integral ,therefore:

[0046] In actual winding, the strip is under planar stress (unconstrained in the width direction), so Poisson's ratio needs to be introduced. Modified elastic modulus (equivalent to "plane stress elastic modulus").

[0047] At this point, the formula for bending moment is revised to:

[0048] During winding, the stress in the outer layer of the strip must not exceed the yield strength. Otherwise, irreversible plastic deformation will occur. Therefore, the maximum stress in the outer layer must meet the following requirements:

[0049] Combining the corrected formula for bending moment and the expression for maximum stress in the outer layer, we obtain:

[0050] Substituting the above formula into the corrected formula for bending moment, we can obtain the bending radius. R The expression:

[0051] During winding, the reference step size It refers to the "minimum characteristic length that ensures stable bending deformation", which is usually taken as the arc length of the bending arc (or the characteristic segment length of a single turn).

[0052] For wound structures, arc length L With bending radius R They are usually directly proportional; however, in actual processes, empirical correction coefficients need to be introduced. To match the dimensions, adjustments need to be made in conjunction with the "multi-turn dispersion effect" or "geometric characteristics of the step size" during winding (in engineering, this is usually converted into a cubic root form to adapt to process parameters), ultimately yielding:

[0053] in, This is a material correction factor, with a value ranging from 0.7 to 0.9. The specific value is determined based on batch characteristic experiments of superconducting tapes.

[0054] S2. Real-time acquisition of the actual attitude data and ambient temperature of the superconducting coil during the winding process.

[0055] In this step, the actual attitude data can be acquired via a six-dimensional attitude real-time monitoring unit. This monitoring system is used to collect servo motor motion parameters and superconducting coil state parameters during the winding process. It includes position sensors, velocity sensors, acceleration sensors, and attitude sensors, and is used to monitor the real-time data of the servo motor's position, velocity, and acceleration parameters, as well as the superconducting coil's attitude deviation. Real-time ambient temperature is acquired by a temperature sensor. This sensor data is transmitted in real-time to the control center of the real-time monitoring system via industrial Ethernet.

[0056] Preferably, the sampling frequency of the six-dimensional attitude real-time monitoring unit is not less than 1000Hz, and the position detection accuracy is not less than ±0.001mm.

[0057] S3. Based on the real-time acquired actual attitude data and ambient temperature, determine the dynamic compensation amount of the step size at the current moment.

[0058] This step may specifically include: S31. Determine the step size tolerance at the current moment based on the various material parameters and the ambient temperature at the current moment.

[0059] Thermal expansion and geometric transmission of winding structure: After the strip is wound into a structure (such as a coil or winding), temperature changes will cause the strip to expand / contract thermally. This microscopic material size change of a single turn will be transmitted to the macroscopic winding structure, and will ultimately manifest as the step size tolerance of the strip.

[0060] According to the linear expansion formula for strip materials, the total expansion change of the superconducting coil is... Represented as:

[0061] in, Design the diameter for the coil. The coefficient of thermal expansion of the material. This is the difference between the current ambient temperature and the initial ambient temperature.

[0062] When the total number of turns of the strip is At that time, the change in perimeter of a single turn of strip is the total change in expansion. Divide by Thus, the strip step length tolerance is obtained. for:

[0063] in, The process correction factor is introduced to take into account factors such as processing errors and assembly allowances. Its value ranges from 1.05 to 1.2 and is dynamically adjusted according to the number of coil winding layers and tension parameters.

[0064] S32. Based on the actual attitude data and ambient temperature, determine the step size deviation value at the current moment, and then combine it with the historical step size deviation values ​​to determine the process standard deviation of the step size deviation value.

[0065] Specifically, this step includes the following sub-steps: S321. Based on the ambient temperature, predict the deformation error of the superconducting tape at the current moment.

[0066] The deformation error at the current moment can be determined by combining the current ambient temperature with the step size tolerance. The calculation formula is used to obtain the result.

[0067] S322. Obtain the actual step size at the current moment based on the actual attitude data.

[0068] In this step, the actual step size is obtained from the actual attitude data collected by the six-dimensional attitude real-time monitoring unit. This can be referenced from existing technologies in the field, and generally includes: First, based on the collected raw real-time attitude data of the winding process (including servo position, velocity, acceleration, and radial / axial attitude deviation of the superconducting coil), standardized and effective measurement data are obtained through moving average noise reduction, unit unification conversion (such as converting the number of servo pulses to length units), and abnormal threshold filtering (truncating when the attitude deviation exceeds the safety threshold).

[0069] Next, based on the standardized real-time position data of the servo machine at the current moment, the difference between the servo machine position data at the previous sampling moment is calculated (the absolute value is taken to eliminate the influence of the motion direction) to obtain the servo base step size at the current moment; further, based on the servo base step size and the fixed sampling period, the real-time motion speed of the servo is calculated. If the speed exceeds the normal operating range of the device, the outlier value is replaced by the average effective base step size of the historical N periods to obtain the verified servo base step size.

[0070] Finally, based on the real-time radial / axial attitude deviation data of the superconducting coil, combined with the offline calibrated attitude-step correction coefficient (characterizing the proportion of the influence of attitude deviation on the actual feed length of the strip), the attitude correction factor is calculated; based on the verified servo base step size, multiplied by the attitude correction factor, the interference of coil attitude deviation on step size measurement is eliminated, and the actual step size measurement value at the current moment is obtained.

[0071] In addition to this preferred option, the measured values ​​can also be verified. The verification process includes: calculating the step size change rate based on the actual step size measurement values ​​of multiple consecutive sampling periods; if the change rate exceeds the allowable range of the process, it is marked as an abnormal measurement value and replaced by the actual step size measurement value of the previous valid period; based on the servo acceleration parameters, verifying the matching between the actual step size measurement value and the acceleration (e.g., there should be no abnormal jump in step size when the acceleration changes abruptly), further verifying the validity of the measurement value, and obtaining the final actual step size measurement value.

[0072] S323. Subtract the deformation error and the reference step size from the actual step size at the current time to obtain the step size deviation at the current time.

[0073] S33. Based on the current step size tolerance and process standard deviation, obtain the process capability index.

[0074] In this step, the process capability index It can be obtained through the following formula:

[0075] in, This represents the process standard deviation.

[0076] From the above formula, we can see that the process capability index The lower, The larger the value, the greater the process fluctuation, the weaker the capability, and the greater the need for strong compensation.

[0077] S34. Adjust the initial proportional coefficient and initial integral coefficient according to the process capability index to obtain the proportional coefficient and integral coefficient at the current moment.

[0078] Specifically, in this step, the scaling factor at the current moment is obtained by the following formula. and integral coefficient :

[0079]

[0080] in, and These are the initial proportional coefficient and the initial integral coefficient, respectively. As a regulating factor; When the process capability index Greater than or equal to the first threshold hour, ; When the process capability index is less than the first threshold And greater than the second threshold hour: ; When the process capability index is less than or equal to the second threshold hour: , It is a nonlinear enhancement factor, which can be taken as 1.5~2.0 (n=1.8 is recommended for superconducting coil winding scenarios to balance strong compensation and stability).

[0081] In this way, depending on the process capability index, when the process capability index is large (i.e., exceeding the first threshold), the initial proportional coefficient and the initial integral coefficient remain unchanged; when the process capability index is small (i.e., between the first and second thresholds), a linear adjustment method is adopted to avoid overcompensation leading to oscillation; when the process capability index is too small (i.e., less than or equal to the second threshold), a nonlinear enhanced adjustment method is adopted, which can better and faster increase the compensation intensity to suppress deviations.

[0082] As an example, preferably, the first threshold can be selected as 1.33, and the second threshold can be selected as 1.0. When When the value is 1.2, λ≈1.108, and Kp and Ki increase by approximately 10.8% from their initial values, thus slightly enhancing the compensation strength. When When the value is 0.8 and n=1.8, λ≈2.6, Kp and Ki increase by about 160% from their initial values, significantly enhancing the compensation effect.

[0083] Furthermore, preferably, quality control assessment can also be conducted based on process capability indices. For example, when A warning signal is issued when the value is less than 1. When the value is less than 0.67, an emergency adjustment procedure is initiated, and a quality analysis report is generated, which includes data such as process capability index, deviation trend curve, and temperature change curve.

[0084] S35. Determine the dynamic compensation amount of the step size at the current moment based on the current step size deviation value, the historical step size deviation value, and the proportional coefficient and integral coefficient at the current moment.

[0085] In this step, the current time is determined according to the following formula. t Step size dynamic compensation amount :

[0086] in, and Each represents the current time. t proportionality coefficient and integral coefficient, For the current moment t The step size deviation value.

[0087] More preferably, step S3 further includes: S36. Obtain a preset temperature fluctuation threshold, determine the maximum step size tolerance based on the temperature fluctuation threshold, and stop the winding of the superconducting coil once the absolute value of the current step size dynamic compensation exceeds the maximum step size tolerance.

[0088] As an example, the preset temperature fluctuation threshold can be set to ±5℃.

[0089] In this way, by setting a temperature fluctuation threshold, the maximum step size tolerance can be determined. This can effectively improve the winding quality of the coil.

[0090] S4. Adjust the servo feed according to the reference step size and the current step size dynamic compensation amount.

[0091] In this step, the adjusted step size is obtained by adding the current dynamic compensation amount to the base step size. Adjusting the servo motor with the adjusted step size can significantly improve the winding accuracy, meeting the high precision requirements of superconducting coils in nuclear fusion devices.

[0092] More preferably, the method may further include: S5. Monitor in real time whether the number of coil turns has reached the preset total number of strip turns. When the total number of strip turns is reached, stop winding.

[0093] The following specific examples further illustrate the precision winding step size control method for superconducting coils used in nuclear fusion devices according to the present invention.

[0094] STEP 1: Preparation Phase Materials testing: The elastic modulus of this batch of YBCO superconducting tapes was tested through tensile testing. =80 GPa, yield strength =300 MPa, Poisson's ratio =0.32, coefficient of thermal expansion of material =12×10 -6 / ℃; Parameter settings: Input material property parameters, coil design parameters (D=2000 mm, N=1000 turns, winding speed v=5 mm / s), and control parameters (material correction factor k=0.8, process correction factor) through the human-machine interface. =1.1); System debugging: In manual mode, test the servo drive unit, six-dimensional attitude real-time monitoring unit, and communication unit to confirm that each module is operating normally.

[0095] STEP2: Baseline Parameter Calculation Stage Baseline step size calculation: Substitute the material parameters into the baseline step size calculation model:

[0096] get ≈3.2 mm (Unit conversion and coefficient correction were taken into account in the calculation). Calculation of the maximum step size tolerance range: Initial temperature T0 = 25℃, set temperature change ΔT ≤ ±5℃, substitute into the step size tolerance calculation model to obtain the maximum step size tolerance. =(πD / N)·α·ΔT·β≈0.000414 mm; Step length specification limits: USL=L0+ΔL≈3.2 mm+0.000414 mm≈3.200414 mm, LSL=L0-ΔL≈3.2 mm-0.000414 mm≈3.199586 mm.

[0097] STEP3: Winding and Dynamic Control Stage Start winding: The system switches to automatic mode, the servo motor starts, the initial feed command is 3.2 mm, and the winding speed is 5 mm / s; Real-time monitoring: The attitude sensor in the six-dimensional attitude real-time monitoring unit collects data at a sampling frequency of 1000Hz, and the temperature sensor detects that the temperature rises to a maximum of 28℃ (ΔT=3℃) during the winding process. Deviation calculation: Based on the real-time ambient temperature (i.e., 28℃), the deformation error of the superconducting tape at this temperature is predicted to be 0.0001 mm. Based on the actual attitude data collected by the six-dimensional attitude real-time monitoring unit, the actual real-time step size of τ at the current moment is 3.2001 mm. The step size deviation value of τ at the current moment is calculated as e(τ) = 3.2001 mm - 3.2 mm - 0.0001 mm = 0 mm. Dynamic compensation: Substituting into the core equation of the dynamic compensation algorithm, assuming Kp=0.3 and Ki=0.05 at this time, the dynamic compensation amount of the step size at the current moment is calculated. =0 mm, feed command remains at 3.2 mm; Precise drive: The distributed servo drive control unit drives the servo motor according to the feed command to continuously wind the superconducting coil. The actual step length is stable between 3.1998 mm and 3.2002 mm, indicating that the dynamic compensation of the step length is within ±0.0002 mm. Its absolute value is less than the maximum step length tolerance of 0.000414 mm calculated in the previous STEP2 stage, so there is no need to interrupt the winding of the superconducting coil.

[0098] STEP 4: Quality Control and Adjustment Phase Quality Assessment: The quality control assessment platform collects step error data in real time and calculates the process standard deviation. =0.0001mm, process capability index =(3.200414-3.199586) / (6×0.0001)=0.000828 / 0.0006≈1.38, the quality grade is excellent; Parameter adjustment: due to If the value exceeds the first threshold of 1.33, keep the current control parameters unchanged and continue the winding process; Data recording: The quality control and assessment platform records data such as step error, temperature change, and process capability index, and generates quality analysis reports.

[0099] STEP 5: Final Stage: When 1000 turns have been wound, the system automatically stops, completing the winding of the YBCO poloidal field coil. The coil's dimensions are checked, and the actual diameter error is measured to be ±0.1 mm, and the inter-turn gap error is ±0.001 mm, meeting the design requirements of the CFETR project.

[0100] According to a second aspect of the present invention, a precision winding step-size control system for superconducting coils in a nuclear fusion device using the method described in the first aspect of the present invention is provided. The system includes: The reference step size determination module is used to obtain various material parameters of YBCO strip, determine the reference step size based on the parameters, and generate an initial feed command for the servo machine based on the reference step size to start the superconducting coil winding. The monitoring module is used to acquire the actual attitude data and ambient temperature of the superconducting coil in real time during the winding process; The compensation determination module is used to determine the dynamic compensation amount of the step size at the current moment based on the actual attitude data and ambient temperature acquired in real time. The adjustment module is used to adjust the servo feed based on the reference step size and the current step size dynamic compensation amount.

[0101] According to a third aspect of the present invention, a terminal is provided, comprising a processor and a storage medium; the storage medium is used to store instructions; the processor is used to operate according to the instructions to perform the steps of the method according to the first aspect of the present invention.

[0102] Furthermore, the terminal also includes a distributed servo drive control unit. This distributed servo drive control unit comprises multiple servo drivers and servo motors, employing a master-slave control architecture. The master controller is responsible for command distribution and coordinated control, while the slave controllers are responsible for the precise driving of individual servo motors, with a drive response time of no more than 1ms. This distributed servo drive control unit communicates via an EtherCAT bus with a bus cycle of no more than 100μs, and the positioning accuracy of the servo motors is no less than ±0.005mm.

[0103] Furthermore, the terminal also includes a six-dimensional attitude real-time monitoring unit for collecting servo motor motion parameters and superconducting coil state parameters during the winding process. This unit includes position sensors, velocity sensors, acceleration sensors, temperature sensors, and attitude sensors. The sensor data is transmitted to the control center in real time via industrial Ethernet. Specifically, the temperature sensor in this six-dimensional attitude real-time monitoring unit has a measurement range of -50℃ to 150℃ and a measurement accuracy of ±0.1℃; the attitude sensor has an angle measurement accuracy of ±0.01°.

[0104] Furthermore, the terminal also includes a human-machine interface for parameter setting, status display, data storage and query, supports manual / automatic mode switching, and has fault diagnosis and alarm functions.

[0105] Furthermore, the terminal also includes a communication unit for enabling signal transmission between the various units and the memory, the controller, and between the controller and an external receiver.

[0106] In summary, compared with the prior art, the present invention has the following significant advantages: 1. Significantly improves winding accuracy: By combining the reference step length calculation model with the dynamic compensation algorithm, the accurate simulation of coil winding and the real-time compensation of dynamic errors are realized. The step length error is controlled within ±0.0005 mm and the coil diameter error is controlled within ±0.1 mm, which is significantly higher than the accuracy level of traditional control technology and meets the high precision requirements of nuclear fusion devices for superconducting coils.

[0107] 2. Effectively adapts to material dispersion: Through the material correction coefficient k and PID parameter self-tuning algorithm, the control parameters can be dynamically adjusted according to the characteristic parameters of different batches of superconducting tapes, effectively compensating for the errors caused by the dispersion of material characteristics, ensuring the consistency of winding accuracy of different batches of materials, and improving the product qualification rate.

[0108] 3. Achieve closed-loop quality control: Through real-time calculation of process capability index By establishing a quality grading and evaluation mechanism, quality problems can be detected and dynamically adjusted in a timely manner during the winding process. This achieves closed-loop control of the entire process from parameter setting, real-time monitoring, dynamic compensation to quality evaluation, thereby reducing the rate of defective products and manufacturing costs.

[0109] 4. High system reliability and strong scalability: The system adopts a modular design and a distributed servo drive architecture. The modules communicate with each other through standardized interfaces, which has good scalability and maintainability. At the same time, it has multiple fault protection and self-diagnosis functions, and the system has high operational reliability and can adapt to the harsh environmental requirements of nuclear fusion device manufacturing.

[0110] 5. Easy to operate and highly practical: The human-machine interface is intuitive and clear, supporting functions such as manual / automatic mode switching, parameter setting, status monitoring, and fault diagnosis, making it easy to operate; the system can be used for winding superconducting coils for nuclear fusion devices of different specifications and types, and has broad practicality and promotional value.

[0111] In summary, this invention effectively solves the technical problems existing in the prior art, such as material property dispersion, multi-physics coupling, insufficient dynamic error compensation, and lack of systematic quality control. It significantly improves the manufacturing precision and consistency of superconducting coils, provides key technical support for the stable operation of nuclear fusion devices, and has important engineering application value and broad market prospects.

[0112] This disclosure can be a system, method, and / or computer program product. A computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for causing a processor to implement various aspects of this disclosure.

[0113] Computer-readable storage media can be tangible devices capable of holding and storing instructions for use by an instruction execution device. Computer-readable storage media can be, for example—but not limited to—electrical storage devices, magnetic storage devices, optical storage devices, electromagnetic storage devices, semiconductor storage devices, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of computer-readable storage media include: portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), static random access memory (SRAM), portable compact disc read-only memory (CD-ROM), digital multifunction disc (DVD), memory sticks, floppy disks, mechanical encoding devices, such as punch cards or recessed protrusions storing instructions thereon, and any suitable combination of the foregoing. The computer-readable storage media used herein are not to be construed as transient signals themselves, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through waveguides or other transmission media (e.g., light pulses through fiber optic cables), or electrical signals transmitted through wires.

[0114] The computer-readable program instructions described herein can be downloaded from computer-readable storage media to various computing / processing devices, or downloaded via a network, such as the Internet, local area network, wide area network, and / or wireless network, to an external computer or external storage device. The network may include copper transmission cables, fiber optic transmission, wireless transmission, routers, firewalls, switches, gateway computers, and / or edge servers. A network adapter card or network interface in each computing / processing device receives the computer-readable program instructions from the network and forwards them to the computer-readable storage media in the respective computing / processing device.

[0115] Computer program instructions used to perform the operations of this disclosure may be assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine-dependent instructions, microcode, firmware instructions, status setting data, or source code or object code written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Smalltalk, C++, etc., and conventional procedural programming languages ​​such as the "C" language or similar programming languages. The computer-readable program instructions may execute entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving a remote computer, the remote computer may be connected to the user's computer via any type of network—including a local area network (LAN) or a wide area network (WAN)—or may be connected to an external computer (e.g., via the Internet using an Internet service provider). In some embodiments, electronic circuitry, such as programmable logic circuitry, field-programmable gate arrays (FPGAs), or programmable logic arrays (PLAs), is personalized by utilizing the status information of the computer-readable program instructions to implement various aspects of this disclosure.

[0116] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A method for precise winding step size control of superconducting coils for nuclear fusion devices, characterized in that, include: Obtain the various material parameters of YBCO tape, determine the reference step size based on the parameters, and generate the initial feed command of the servo machine based on the reference step size to start the superconducting coil winding; Real-time acquisition of the actual attitude data and ambient temperature of the superconducting coil during the winding process; Based on the real-time acquired actual attitude data and ambient temperature, determine the dynamic compensation amount of the step size at the current moment. The servo feed is adjusted based on the reference step size and the current step size dynamic compensation.

2. The method for precise winding step size control of superconducting coils for nuclear fusion devices according to claim 1, characterized in that, Based on the aforementioned parameters, the baseline step size is determined, including: The reference step size is determined according to the following formula. : in, This is a material correction factor. For elastic modulus, For strip thickness, For yield strength, It is Poisson's ratio.

3. The method for precise winding step size control of superconducting coils for nuclear fusion devices according to claim 1, characterized in that, Based on the real-time acquired actual attitude data and ambient temperature, determine the dynamic compensation amount of the step size at the current moment, including: Determine the step size tolerance at the current moment based on various material parameters and the current ambient temperature; Based on the actual attitude data and ambient temperature, the step size deviation value at the current moment is determined, and then the process standard deviation of the step size deviation value is determined by combining the historical step size deviation values. The process capability index is obtained based on the current step size tolerance and process standard deviation. Based on the process capability index, the initial proportional coefficient and initial integral coefficient are adjusted to obtain the proportional coefficient and integral coefficient at the current moment. The dynamic compensation amount of the step size at the current moment is determined based on the current step size deviation value, the historical step size deviation value, and the proportional coefficient and integral coefficient at the current moment.

4. The method for precision winding step size control of superconducting coils for nuclear fusion devices according to claim 3, characterized in that, Based on various material parameters and the current ambient temperature, determine the step size tolerance for the current moment, including: The step size tolerance is determined according to the following formula. : in, The design diameter of the superconducting coil, This refers to the total number of turns of the strip. This represents the difference between the current ambient temperature and the initial ambient temperature. The coefficient of thermal expansion of the material. This is the process correction factor.

5. The method for precision winding step size control of superconducting coils for nuclear fusion devices according to claim 4, characterized in that, Based on the actual attitude data and ambient temperature, the step size deviation value at the current moment is determined, and then the standard deviation of the step size deviation value is determined by combining it with historical step size deviation values, including: Based on the ambient temperature, predict the deformation error of the superconducting tape at the current moment; The actual step size at the current moment is obtained based on the actual attitude data. The deformation error and the reference step size are subtracted from the actual step size at the current moment to obtain the step size deviation at the current moment.

6. The method for precision winding step size control of superconducting coils for nuclear fusion devices according to claim 5, characterized in that, Based on the current step size tolerance and process standard deviation, the process capability index is obtained, including: The process capability index is obtained using the following formula. : in, This represents the process standard deviation.

7. The method for precision winding step size control of superconducting coils for nuclear fusion devices according to claim 6, characterized in that, Based on the process capability index, the initial proportional coefficient and initial integral coefficient are adjusted to obtain the proportional coefficient and integral coefficient at the current moment, including: The proportional coefficient at the current moment can be obtained using the following formula. and integral coefficient : in, and These are the initial proportional coefficient and the initial integral coefficient, respectively. As a regulating factor; When the process capability index Greater than or equal to the first threshold hour, ; When the process capability index is less than the first threshold And greater than the second threshold hour: ; When the process capability index is less than or equal to the second threshold hour: , where n is the nonlinear enhancement factor.

8. The method for precision winding step size control of superconducting coils for nuclear fusion devices according to claim 7, characterized in that, Based on the current step size deviation value, historical step size deviation values, and the proportional and integral coefficients at the current moment, determine the dynamic compensation amount for the current step size, including: The current time is determined by the following formula. t Step size dynamic compensation amount in, and Each represents the current time. t proportionality coefficient and integral coefficient, For the current moment t The step size deviation value.

9. A precision-winding step-size control system for superconducting coils in a nuclear fusion device using the method described in any one of claims 1-8, characterized in that, include: The reference step size determination module is used to obtain various material parameters of YBCO strip, determine the reference step size based on the parameters, and generate an initial feed command for the servo machine based on the reference step size to start the superconducting coil winding. The monitoring module is used to acquire the actual attitude data and ambient temperature of the superconducting coil in real time during the winding process; The compensation determination module is used to determine the dynamic compensation amount of the step size at the current moment based on the actual attitude data and ambient temperature acquired in real time. The adjustment module is used to adjust the servo feed based on the reference step size and the current step size dynamic compensation amount.

10. A terminal, comprising a processor and a storage medium; characterized in that: The storage medium is used to store instructions; The processor is configured to operate according to the instructions to perform the steps of the method according to any one of claims 1-8.

Images