Dual phase tangent drop method and system suitable for three-dimensional coil winding of star simulator

Abstract

The application discloses a two-phase tangent drop die method and system suitable for three-dimensional coil winding of a star simulator, and the method comprises the following steps: adjusting the spatial position and posture of a winding die according to a preset winding track. Wherein, the winding track comprises the spatial position and posture of the winding die at each winding node in the winding process, which is determined based on the geometric parameters of the three-dimensional coil to be wound. The conductor to be wound is guided to the entrance of the winding die at a preset angle, and when the conductor to be wound drops into the die, the spatial position and posture of the winding die are adjusted so that the conductor to be wound is tangent to the side winding reference and the bottom winding reference at the same time. By dynamically adjusting the spatial position and posture of the winding die when winding the coil, the method can avoid the conductor to be wound from deviating or swinging in the process of winding the coil, and improves the winding precision and the quality of the coil winding.

Description

Technical Field

[0001] This invention relates to the field of superconducting coil winding technology, and in particular to a two-phase cutting die method and system suitable for three-dimensional coil winding of stellarators. Background Technology

[0002] The rotary tables used for winding three-dimensional coils in existing stellarators are often single- or low-degree-of-freedom structures, capable only of basic rotation around an axis or rotation in a single direction. For example, the most common method is for the rotary table to drive the winding mold to rotate around a preset axis, and then the superconducting coil is wound turn by turn sequentially. This method only involves basic rotation around the axis. However, in the process of winding three-dimensional coils for stellarators, because the winding mold is a three-dimensional curve, to complete the winding of the coil, it is not only necessary to rotate the winding mold along the axis, but also to fit the conductor to be wound into the three-dimensional curve. It is easy for the conductor to shift axially or radially during the fixing process, which increases the difficulty and workload of subsequent calibration work. In order to ensure the coil forming accuracy, manual forced calibration is required to correct the shift, or the conductor needs to be manually bent to fit the winding mold. This process will cause stress concentration inside the conductor, which can cause damage to the internal structure of the conductor in severe cases, affecting the stability of the coil, or even causing the coil to be scrapped.

[0003] Therefore, in the existing technology, when winding the three-dimensional coil of the stellarator, the conductor is prone to displacement, and manual correction of the conductor or fitting of the winding mold may cause damage to the internal structure of the conductor, resulting in defects or even scrapping of the three-dimensional coil of the stellarator. Summary of the Invention

[0004] The purpose of this invention is to solve the problem in the prior art that when winding the three-dimensional coil of a stellarator, the conductor is prone to misalignment, and manual correction of the conductor or fitting of the winding mold may cause damage to the internal structure of the conductor, resulting in defects or even scrap of the three-dimensional coil of the stellarator.

[0005] To address the aforementioned technical problems, embodiments of the present invention disclose a two-phase drop die method suitable for winding three-dimensional coils for stellarators. This method includes: adjusting the spatial position and orientation of the winding die according to a preset winding trajectory. The winding trajectory is determined based on the geometric parameters of the three-dimensional coil to be wound, and includes the spatial position and orientation of the winding die at each winding node during the winding process.

[0006] The conductor to be wound is guided to the entrance of the winding mold at a preset angle. When the conductor to be wound is placed into the mold, the spatial position and attitude of the winding mold are adjusted so that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference.

[0007] By adopting the above technical solution, the spatial position and attitude of the winding mold are adjusted according to the preset winding trajectory. The spatial position and attitude of the winding mold are dynamically adjusted during the winding of the coil, so that the movement trajectory of the winding mold is adapted to the three-dimensional curved surface of the stellarator three-dimensional coil to be wound. In other words, the position of the conductor remains basically still, but is transported along the predetermined route. The spatial position and attitude of the winding mold are dynamically adjusted during the winding process, which improves the winding accuracy and avoids the occurrence of conductor friction or damage during the winding process.

[0008] The preset winding trajectory includes the spatial position and attitude of the winding mold at each winding node during the winding process. Therefore, when adjusting the spatial position and attitude of the winding mold, the movement of the winding mold is rotation and oscillation. That is to say, taking the winding of one coil as an example, the trajectory of one coil is divided into multiple winding nodes, and the rotation position and oscillation position of each node are different.

[0009] Furthermore, by adjusting the spatial position and orientation of the winding mold, the conductor to be wound can be simultaneously tangent to the side winding reference and the bottom winding reference. This can prevent the conductor from shifting or swaying during the winding process, resulting in higher winding accuracy. Moreover, since the adjustment is made to the spatial position and orientation of the winding mold, there is no need to correct the conductor. This avoids defects such as deformation of the internal cable structure, damage to the insulation layer, and damage to the core caused by external force squeezing and bending. This reduces the amount of scrap in the production of stellarator three-dimensional coils, improves the winding accuracy and quality of the coil, and further increases the finished product qualification rate.

[0010] The present invention discloses a two-phase cutting die method for winding a three-dimensional coil of a stellarator. During the winding process, the side winding reference and the bottom winding reference are the side wall of the winding die and the bottom wall of the winding die, respectively.

[0011] Alternatively, the side winding reference and the bottom winding reference are the adjacent sidewalls of the already wound conductor and the bottom wall of the winding mold, respectively.

[0012] Alternatively, the side winding reference and the bottom winding reference can be the side wall of the winding mold and the top wall of the conductor that has been wound, respectively.

[0013] Alternatively, the side winding reference and the bottom winding reference are the side wall and top wall of the conductor that has been wound, respectively.

[0014] By adopting the above technical solution, during the winding of the stellarator three-dimensional coil on the winding mold, when winding each winding node of each turn of the coil, the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference. The winding accuracy of the coil is guaranteed throughout the winding process, and there is no need to adjust the position of the conductor to be wound. It is suitable for winding complex three-dimensional curved surfaces and effectively improves the finished product qualification rate and production efficiency.

[0015] The present invention discloses a two-phase drop die method for winding a three-dimensional coil of a stellarator. The geometric parameters include the spatial contour of the coil. The step of determining the winding trajectory based on the geometric parameters of the three-dimensional coil to be wound includes: discretizing the spatial contour curve of the three-dimensional coil to be wound into multiple pose nodes to form a pose node sequence. Each pose node includes the three-dimensional coordinates of the spatial position of the winding die and the three-dimensional attitude angle. A continuous pose transition path is generated between adjacent pose nodes using an interpolation method. Each pose node corresponds to a winding node.

[0016] By adopting the above technical solution, the overall spatial contour curve of the coil is divided into multiple pose nodes, and the complex three-dimensional irregular contour is decomposed into standardized discrete units. During winding, the winding mold is controlled by the controller to move to each pose node in sequence, making the attitude transition smoother and matching the motion trajectory of the winding mold with the three-dimensional coil of the stellarator.

[0017] The present invention discloses a two-phase drop die method for winding a three-dimensional coil for a stellarator. Each turn of the spatial contour curve of the three-dimensional coil to be wound corresponds to an angle of 360°. When the number of discrete pose nodes of the spatial contour curve is n, n pose node sequences are formed. The degree of the central angle corresponding to any two adjacent pose node sequences is set to be the same or different.

[0018] Using the above technical solution, since the stellarator's three-dimensional coil is composed of multiple coils, the angle corresponding to each coil is divided into n equal parts. Based on the curvature of different regions of the coil, the spatial position and attitude of the winding mold are controlled.

[0019] The present invention discloses a two-phase drop die method for winding three-dimensional coils for stellarators. The step of adjusting the spatial position and orientation of the winding die according to a preset winding trajectory further includes:

[0020] Real-time acquisition of the actual spatial position and orientation of the winding mold.

[0021] The actual spatial position and attitude are compared with the spatial position and attitude of the corresponding winding node in the preset winding trajectory.

[0022] The spatial position and orientation of the winding die are adjusted in real time based on the deviation obtained from the comparison.

[0023] By adopting the above technical solution, the actual position and posture parameters of the mold are collected in real time, and the actual spatial position and posture are compared with the spatial position and posture of the corresponding winding node in the preset winding trajectory. When the comparison determines that the deviation is greater than the threshold, the spatial position and posture of the winding mold are adjusted in real time to reduce the error during winding and ensure the accuracy of coil winding.

[0024] The present invention discloses a two-phase die-cutting method suitable for three-dimensional coil winding of stellarators, the method further comprising:

[0025] Determine if the current turn is the last turn.

[0026] If so, then end the winding process.

[0027] If not, continue to adjust the winding mold to the next winding node according to the preset winding trajectory, and repeat the above steps until all turns are wound to obtain the stellarator three-dimensional coil.

[0028] The present invention discloses a two-phase cut-and-drop die system suitable for three-dimensional coil winding of a stellarator, for performing any of the above-mentioned two-phase cut-and-drop die methods suitable for three-dimensional coil winding of a stellarator. The two-phase cut-and-drop die system includes a controller, a pose adjustment device, and a winding die.

[0029] The controller is used to determine the preset winding trajectory based on the geometric parameters of the three-dimensional coil to be wound. The winding trajectory includes the spatial position and attitude of the winding mold at each winding node during the winding process, and sends the spatial position and attitude commands of each winding node to the posture adjustment device.

[0030] The position adjustment device is connected to the controller and is used to drive the winding die to move according to the winding trajectory in order to adjust the spatial position and posture of the winding die.

[0031] The present invention discloses a two-phase drop die system suitable for three-dimensional coil winding of a stellarator. The system further includes: a position and orientation acquisition device, which is communicatively connected to a controller, for real-time acquisition of the actual spatial position and orientation of the winding die and transmission to the controller. The controller also compares the actual spatial position and orientation of the winding die with the spatial position and orientation of the corresponding winding node in the preset winding trajectory, and sends a spatial position and orientation adjustment command to the position and orientation adjustment device based on the deviation obtained from the comparison, so as to adjust the spatial position and orientation of the winding die in real time.

[0032] The present invention discloses a two-phase cutting die system suitable for three-dimensional coil winding of stellarator. The posture adjustment device includes a rotary drive mechanism and a swing drive mechanism. The swing drive mechanism is fixedly installed at the output end of the rotary drive mechanism, and the winding die is fixed at the output end of the swing drive mechanism.

[0033] The rotary drive mechanism is used to drive the overall structure consisting of the oscillating drive mechanism and the winding mold to rotate around a preset axis, so that the conductor guided to the entrance of the winding mold is gradually wound around the winding mold to obtain the stellarator three-dimensional coil.

[0034] The oscillating drive mechanism is used to drive the winding die to oscillate, so as to adjust the posture of the winding die at each winding node.

[0035] Using the above technical solution, the rotary drive mechanism drives the oscillating drive mechanism and the winding mold to rotate around a preset axis. The advantage of this design is that when adjusting the rotation, the angle can be adjusted first, and then the spatial angle position of the winding mold can be adjusted. The adjustment is more precise, and the rotary adjustment and the oscillating adjustment will not interfere with each other, making the adjustment more accurate.

[0036] The present invention discloses a two-phase cut-and-drop die system suitable for three-dimensional coil winding of a stellarator. The winding die includes a support die, an inner winding die, and an outer winding die, which together form a winding groove.

[0037] And / or, the system also includes a support base, a rotary drive mechanism mounted on the support base, the rotary drive mechanism including a drive component and a rotary support component, the rotary support component including a fixed outer ring and a rotatable inner ring in an annular shape, a rolling element disposed between the fixed outer ring and the rotatable inner ring, the fixed outer ring being fixedly connected to the support base, the rotatable inner ring being drively connected to the drive component, and the rotatable inner ring protruding beyond the fixed outer ring along the height direction of the support base, a support platform being fixedly mounted above the rotatable inner ring, the swing drive mechanism being fixedly mounted on the support platform, the drive component being able to drive the integral structure consisting of the rotatable inner ring, the support platform, the swing drive mechanism and the winding mold to rotate around the axis of the rotatable inner ring, the axis of the rotatable inner ring being a preset axis.

[0038] And / or, the swing drive mechanism includes a six-degree-of-freedom operating mechanism, which includes six telescopic components spaced apart on the support platform. One end of each telescopic component is fixed to the side of the support platform away from the rotary drive mechanism, and the other end is a telescopic end that is rotatably disposed at the bottom of the support mold.

[0039] By adopting the above technical solution, a rotatable inner ring is set on the support base. The driving component can smoothly drive the rotatable inner ring to rotate relative to the support base, thereby causing the overall structure consisting of the support platform, the swing drive mechanism, and the winding mold to rotate around the axis of the rotatable inner ring, ensuring the rotational accuracy during coil winding. The swing drive mechanism is set as a six-degree-of-freedom operating mechanism, which has the advantages of higher adjustment freedom and adjustment accuracy.

[0040] In summary, by combining the rotary drive mechanism and the six-degree-of-freedom operating mechanism, the spatial position and attitude of the winding mold at each winding node can be adjusted during the winding process, so that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference. This avoids the conductor to be wound from shifting or swaying during the winding process, resulting in higher winding accuracy of the three-dimensional coil and improving the yield of the wound product. Attached Figure Description

[0041] Figure 1 A flowchart of a two-phase die-cutting method for three-dimensional coil winding of a stellarator provided in an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram of the side winding reference and the bottom winding reference when the first turn of the first layer of the coil is initially wound in the two-phase cutting die method for winding three-dimensional coils of a stellarator, as provided in an embodiment of the present invention.

[0043] Figure 3 This is a schematic diagram of the side winding reference and the bottom winding reference when winding the second turn of the first layer of coil in the two-phase drop die method for winding three-dimensional coils of stellarators provided in the embodiments of the present invention.

[0044] Figure 4 This is a schematic diagram of the side winding reference and the bottom winding reference when winding the first turn of the second layer of the coil in the two-phase drop die method for winding three-dimensional coils of a stellarator provided in an embodiment of the present invention.

[0045] Figure 5 This is a schematic diagram of the side winding reference and the bottom winding reference when winding the second layer and second turn of the coil in the two-phase cutting die method for winding three-dimensional coils of stellarators provided in the embodiments of the present invention.

[0046] Figure 6 A flowchart illustrating real-time detection and correction in a two-phase die-cutting method for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention;

[0047] Figure 7 This is a flowchart illustrating the process of determining the end of winding in a two-phase drop-die method for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention.

[0048] Figure 8 This is a schematic diagram of a two-phase drop die system for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention.

[0049] Figure 9 A schematic diagram of the starting winding stage of a two-phase drop die system for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention.

[0050] Figure 10A partial schematic diagram of the starting winding stage of a two-phase drop die system for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention.

[0051] Figure 11 A schematic diagram of the structure of the two-phase drop die system for three-dimensional coil winding of a stellarator provided in an embodiment of the present invention after winding is completed;

[0052] Figure 12 A schematic diagram of the winding die structure of a two-phase drop die system for winding three-dimensional coils of a stellarator, provided in an embodiment of the present invention;

[0053] Figure 13 A schematic diagram of the rotary drive mechanism for a two-phase drop die system suitable for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention;

[0054] Figure 14 A schematic diagram of the rotary support component of a two-phase drop die system for three-dimensional coil winding of a stellarator provided in an embodiment of the present invention;

[0055] Figure 15 A cross-sectional view of the rotary support component of a two-phase drop die system for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention;

[0056] Figure 16 A schematic diagram of the swing drive mechanism for a two-phase drop die system suitable for three-dimensional coil winding of a stellarator, provided in an embodiment of the present invention.

[0057] Explanation of reference numerals in the attached figures:

[0058] 10. Winding mold; 20. Controller; 30. Position adjustment device; 40. Position acquisition device; 101. Side winding reference; 102. Bottom winding reference; 11. Side wall; 12. Bottom wall;

[0059] 110. Support mold; 120. Winding inner mold; 130. Winding outer mold;

[0060] 200. Conductor;

[0061] 300. Support base;

[0062] 400. Rotary drive mechanism;

[0063] 410. Drive components; 411. Drive gears;

[0064] 420. Slewing bearing components;

[0065] 421. Fixed outer ring; 422. Rotatable inner ring; 423. Rolling element; 424. Support platform;

[0066] 500. Swing drive mechanism;

[0067] 510. Telescopic components;

[0068] 511. Servo electric cylinder; 512. Piston rod; 513. Upper seat of Hooke's hinge; 514. Upper rotating shaft; 515. Lower rotating shaft; 516. Lower seat of Hooke's hinge;

[0069] 520. Mold platform. Detailed Implementation

[0070] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0071] This invention discloses a two-phase tangential die-dropping method suitable for winding three-dimensional coils for stellarators. First, it needs to be explained that a three-dimensional coil for stellarators is a type of three-dimensional coil used in stellarators. This three-dimensional coil has a certain three-dimensional trajectory, and the coil is ring-shaped, exhibiting an irregular curved surface shape during winding. Two-phase tangential refers to the conductor to be wound being simultaneously tangent to both the side winding reference and the bottom winding reference. Die-dropping refers to the conductor to be wound falling into the die, i.e., winding the conductor in the winding die, where the die refers to the winding mold.

[0072] In the two-phase drop die method for winding three-dimensional coils for stellarators provided by this invention, the method includes adjusting the spatial position and orientation of the winding die according to a preset winding trajectory. The winding trajectory is determined based on the geometric parameters of the three-dimensional coil to be wound, and includes the spatial position and orientation of the winding die at each winding node during the winding process.

[0073] Guide the conductor to be wound at a preset angle to the entrance of the winding die (see...). Figure 9 When the conductor to be wound is placed into the mold, the spatial position and orientation of the winding mold are adjusted so that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference.

[0074] Specifically, according to the preset winding trajectory, when the winding die changes its spatial position and orientation during coil winding, the position of the conductor to be wound remains basically unchanged; the conductor is simply conveyed forward (for example, see [reference]). Figure 9(Conductors 200 are fed horizontally only). By adjusting the position and orientation of the winding die (e.g., through the coordination of the rotational and oscillating movements of the winding die), the position of the conductor to be wound is adapted to ensure that the conductor to be wound is simultaneously tangent to both the side and bottom winding references. This means the conductor can accurately fall into the winding die without needing to adjust its position or angle. The spatial position of the conductor remains unchanged; the spatial position of the winding die is adjusted to fit the conductor. This avoids conductor correction or alignment during coil winding, prevents stress concentration within the conductor, and also prevents wear or damage to the outer insulation layer caused by friction or collision between the conductor and other components. This results in higher winding accuracy and improves the yield of the stellarator's three-dimensional coils.

[0075] The spatial position includes, but is not limited to, the rotation angle of the winding mold and the distance between it and the conductor to be wound; the orientation includes, but is not limited to, the deflection angle and orientation of the winding mold relative to the conductor to be wound. Making the conductor to be wound tangent to both the side winding reference and the bottom winding reference simultaneously can be achieved by precisely contacting the side wall and bottom wall of the conductor with the side winding reference and the bottom winding reference respectively, or by actively tangenting the side wall and bottom wall of the conductor perpendicularly to the side wall and bottom wall of the conductor. This embodiment does not limit this to a single method.

[0076] It should be further noted that the geometric parameters of the three-dimensional coil to be wound include the spatial profile of the coil, the number of winding layers, the number of turns, and the cross-sectional dimensions of the conductor. The spatial profile of the coil can be the curved surface shape of the winding area of ​​the winding mold. For example, the spatial profile of the coil can also refer to the irregular bending direction, spatial arrangement, surface curvature, and overall outer dimensions of the stellarator three-dimensional coil in three-dimensional space. The number of winding layers refers to the number of layers in the thickness direction of the coil, such as 2, 3, 4, 6, or other numbers. The number of turns refers to the total number of turns in the radial direction of one layer of coil. The cross-sectional dimensions of the conductor can be the diameter of the conductor (corresponding to a circular conductor) or the length and width of the conductor (corresponding to a square conductor).

[0077] Furthermore, the winding trajectory can be constructed by discretizing the complete coil spatial contour curve into several ordered pose nodes after integrating and calibrating all geometric parameters, thus forming a continuous sequence of pose nodes. Each pose node corresponds to an independent winding node, and each pose node accurately carries the three-dimensional coordinates and three-dimensional attitude angles of the winding mold, fully covering the position and attitude parameters required by the mold during the winding process. A smooth and continuous pose transition path is generated between adjacent pose nodes through an interpolation algorithm.

[0078] In this embodiment, guiding the conductor to be wound to the entrance of the winding mold at a preset angle means that the conductor to be wound as a whole is at an angle relative to the winding mold (see, for example, [reference needed]). Figure 9 and Figure 10 In this embodiment, the preset angle is such that the conductor to be wound is parallel to the horizontal plane, and then it is guided to the entrance of the winding mold, and the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference.

[0079] The bottom winding reference provides a vertical support and positioning reference for the conductor, limiting the conductor's settlement position and fitting height in the vertical dimension, and avoiding problems such as conductor moving up and down, floating offset, and inconsistent height; the side winding reference provides a horizontal lateral limiting reference for the conductor, limiting the conductor's lateral arrangement position and lateral posture, and preventing the conductor from having positioning defects such as lateral tilting, misalignment, and swaying.

[0080] The side winding reference and the bottom winding reference work together to form a spatial orthogonal limit, ensuring that the conductor to be wound is completely tangential and in contact with the mold without gaps or angles when it is lowered, achieving precise positioning of the conductor cross-section from all directions. At the same time, combined with the aforementioned continuous winding trajectory planned based on coil geometry parameters, the mold dynamically adjusts its posture according to the curvature changes of the three-dimensional coil spatial contour and the layered winding process, always ensuring that the conductor maintains a tangential and contacted state with the two references at any winding node and any three-dimensional bending position, and will not experience contact failure or single-point detachment from the references due to changes in the coil spatial curvature or multiple layers and turns of winding.

[0081] The three-dimensional coil of the stellarator in this embodiment is not limited. For example, it can be a three-dimensional cryogenic superconducting coil, a three-dimensional high-temperature superconducting coil, or a conventional copper coil. It should be understood that the cryogenic and high-temperature superconducting coils mentioned here are described using superconductors as an example. The conductor used to wind the coil includes, but is not limited to, CICC superconducting conductors and conventional copper conductors. The shape of the conductor used to wind the coil can be a circular conductor or a square conductor. Please refer to [link to relevant documentation]. Figure 2 and Figure 10 In this embodiment, a square conductor is used as an example for illustration.

[0082] This invention adjusts the spatial position and orientation of the winding mold according to a preset winding trajectory. During the winding of the coil, the spatial position and orientation of the mold are dynamically adjusted so that the motion trajectory of the winding mold matches the three-dimensional curved surface of the stellarator three-dimensional coil to be wound. The preset winding trajectory includes the spatial position and orientation of the winding mold at each winding node during the winding process. Therefore, when adjusting the spatial position and orientation of the winding mold, the movement of the winding mold is rotation and oscillation. That is to say, taking the winding of one coil as an example, the trajectory of one coil is divided into multiple winding nodes, and the rotation position and oscillation position of each node are different.

[0083] Furthermore, by adjusting the spatial position and orientation of the winding mold, the conductor to be wound can be simultaneously tangent to the side winding reference and the bottom winding reference. This can prevent the conductor from shifting or swaying during the winding process, resulting in higher winding accuracy. Moreover, since the adjustment is made to the spatial position and orientation of the winding mold, there is no need to correct the conductor. This avoids defects such as deformation of the internal cable structure, damage to the insulation layer, and damage to the core caused by external force squeezing and bending. This reduces the amount of scrap in the production of stellarator three-dimensional coils, improves the winding accuracy and quality of the coil, and further increases the finished product qualification rate.

[0084] For example, see Figure 1 In one specific implementation, the two-phase drop die method for three-dimensional coil winding of a stellarator disclosed in this invention includes:

[0085] Step S1: Determine the winding trajectory based on the geometric parameters of the three-dimensional coil to be wound.

[0086] Step S2: The controller sends a command to the pose adjustment device based on the preset winding trajectory.

[0087] Step S3: The position adjustment device adjusts the spatial position and posture of the winding mold.

[0088] Step S4: When the conductor to be wound is placed into the mold, it is simultaneously tangent to the side winding reference and the bottom winding reference.

[0089] Step S5: Repeat the winding process to obtain the stellarator three-dimensional coil.

[0090] The embodiments of the present invention also disclose a two-phase drop die method for winding a three-dimensional stellarator coil. For the winding process, please refer to... Figure 2 For the first turn of the coil initially wound, the side winding reference 101 and the bottom winding reference 102 are the side wall 11 and the bottom wall 12 of the winding mold, respectively. This ensures that the conductor to be wound is tangent to both the side winding reference and the bottom winding reference simultaneously. At this time, when the conductor 200 is lowered into the mold, one side wall of the conductor is tangent to and tightly fitted with the side wall 11 of the winding mold, and the bottom wall of the conductor 200 is tangent to and tightly fitted with the bottom wall 12 of the winding mold.

[0091] After the first turn of winding is completed, for example, when winding the second, third, or other turns, the side winding reference 101 and the bottom winding reference 102 are respectively the adjacent sidewalls of the already wound conductor 200 and the bottom wall 12 of the winding mold, so that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference. Please refer to Figure 3For example, when winding the second turn of the first layer, when the conductor 200 is dropped into the mold, one side wall is tangent to and tightly fitted with the adjacent side wall of the conductor 200 that has already been wound, and the bottom wall is still tangent to and tightly fitted with the bottom wall 12 of the winding mold.

[0092] After one layer of coil winding is completed, for example, when winding the first turn of the second layer, the first turn of the third layer, or other turns, the side winding reference 101 and the bottom winding reference 102 are respectively the side wall 11 of the winding mold and the top wall of the already wound conductor 200, so that the conductor to be wound is simultaneously tangent to both the side winding reference and the bottom winding reference. Please refer to... Figure 4 For example, when winding the first turn of the second layer, one side wall of conductor 200 is tangent to and tightly fitted with the side wall 11 of the winding mold when it is dropped into the mold, and the bottom wall is tangent to and tightly fitted with the top wall of conductor 200, which has already completed the winding of the first layer of coil.

[0093] After the first turn of the second layer is wound, for example, when winding the second turn of the second layer, the second turn of the third layer, or other turns, the side winding reference 101 and the bottom winding reference 102 are respectively the side wall and top wall of the already wound conductor 200, so that the conductor to be wound is simultaneously tangent to both the side winding reference and the bottom winding reference. Please refer to... Figure 5 For example, when winding the second layer and the second turn, when the conductor 200 is dropped into the mold, one side wall is tangent to and tightly fitted with the side wall 11 of the conductor 200 that has already been wound, and the bottom wall is tangent to and tightly fitted with the top wall of the conductor 200 that has already been wound.

[0094] By adopting this scheme, during the winding of the stellarator's three-dimensional coil on the winding mold, the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference when winding each winding node of each turn of the coil. The winding accuracy of the coil is guaranteed throughout the entire winding process, and there is no need to adjust the position of the conductor to be wound. It is suitable for winding complex three-dimensional curved surfaces and effectively improves the finished product qualification rate and production efficiency.

[0095] The embodiments of the present invention also disclose a two-phase drop die method suitable for winding three-dimensional coils of stellarators. The geometric parameters include the spatial contour of the coil. The step of determining the winding trajectory based on the geometric parameters of the three-dimensional coil to be wound includes: discretizing the spatial contour curve of the three-dimensional coil to be wound into multiple pose nodes to form a pose node sequence. Each pose node includes the three-dimensional coordinates of the spatial position of the winding die and the three-dimensional attitude angle. A continuous pose transition path is generated between adjacent pose nodes using an interpolation method. Each pose node corresponds to a winding node.

[0096] Specifically, in one possible implementation, the above method further includes: discretizing the spatial contour curve of the three-dimensional coil to be wound into multiple pose nodes, and assembling the multiple pose nodes into a pose node sequence.

[0097] A continuous pose transition path is generated between any two adjacent pose nodes using an interpolation method.

[0098] Connect all pose nodes and their corresponding pose transition paths to form the winding trajectory.

[0099] Each pose node corresponds to one of the winding nodes.

[0100] Each pose node contains the three-dimensional coordinates of the spatial position of the winding mold and the three-dimensional pose angle.

[0101] The following is a brief explanation of the three-dimensional coordinates and three-dimensional attitude angles of the winding die. The three-dimensional coordinates refer to the spatial position of the winding die in the spatial coordinate system (X-axis, Y-axis, Z-axis). The three-dimensional attitude angles are (α, β, γ), where α (yaw angle) is the horizontal turning angle of the winding die in the horizontal plane, controlling the left and right yaw and winding direction, based on rotation around the Z-axis. β (pitch angle) is the vertical tilt angle of the die, controlling the height of the winding surface, based on rotation around the Y-axis. γ (roll angle) is the circumferential twist angle of the die, controlling the tilt angle of the winding layer and the wire arrangement posture, based on rotation around its own X-axis. The three-dimensional attitude angles uniquely determine the spatial orientation, tilt, and twisting posture of the winding die at that node, adapting it to the spatial shape of the three-dimensional coil.

[0102] Specifically, for example, based on the spatial contour of the three-dimensional coil to be wound, the number of winding layers, the number of turns, and the conductor cross-sectional dimensions, a complete three-dimensional spatial contour curve of the coil is constructed. This contour curve accurately reproduces the bending trajectory, deflection angle, spatial height, and radial position of each turn and each layer of the coil in three-dimensional space, which is the original design reference for the subsequent winding trajectory generation.

[0103] Based on this, the continuous smooth spatial contour curve is discretized, that is, the entire continuous spatial curve is divided into several spatially independent and ordered feature points according to the winding accuracy requirements, resulting in multiple pose nodes. All pose nodes are arranged sequentially according to the coil winding progress order, forming a pose node sequence that completely covers the entire winding range of the coil, thereby realizing the transformation of continuous complex spatial geometry into a discrete digital sequence for controller recognition and execution.

[0104] Each pose node is a control point containing complete spatial motion information, not just recording a single position. It simultaneously carries the three-dimensional coordinates of the winding mold's spatial position and the three-dimensional attitude angle. The three-dimensional spatial coordinates are used to precisely define the X, Y, and Z spatial positions of the winding mold in the three-dimensional coordinate system, ensuring the mold's positioning accuracy. The three-dimensional attitude angle is used to characterize the mold's spatial deflection angle, pitch angle, and torsion angle at the current position, enabling the mold's attitude to match the tangent and normal directions of the coil's local curved surface. This ensures that the conductor's drop angle always conforms to the designed winding attitude, adapting to the irregular bending and spatial torsion characteristics of the three-dimensional coil at any position.

[0105] Since each discretized pose node is an independent feature point with a finite interval between nodes, directly controlling the mold movement by node jumps can easily cause abrupt changes in mold pose, movement jerks, and angle jumps, potentially leading to problems such as sudden changes in conductor stress, local distortion, and loose fit. Therefore, this invention uses interpolation to smooth the transition between adjacent pose nodes. Through interpolation, the position and attitude data of two adjacent nodes are continuously transitioned, generating a pose transition path without abrupt changes or jumps, exhibiting a uniform overall change. It should be noted that, in addition to interpolation, polynomial fitting transition calculations, spline curve smoothing transition calculations, etc., can also be used when transitioning the positions of two adjacent nodes. Those skilled in the art can design or select according to actual needs, and this embodiment does not specifically limit this.

[0106] The pose transition path generated by interpolation enables the spatial position and three-dimensional attitude angle of the mold to change continuously between adjacent nodes, allowing the displacement, deflection and torsion of the mold to transition smoothly throughout the entire process. It perfectly fits the continuous surface features of the original coil spatial contour, avoiding the defects of stiff trajectory segmentation and discontinuous motion caused by discrete nodes, and making the overall winding trajectory have both node positioning accuracy and smooth motion throughout the entire process.

[0107] By adopting the above technical solution, the overall spatial contour curve of the coil is divided into multiple pose nodes, and the complex three-dimensional irregular contour is decomposed into standardized discrete units. During winding, the winding mold is controlled by the controller to move to each pose node in sequence, making the attitude transition smoother and matching the motion trajectory of the winding mold with the three-dimensional coil of the stellarator.

[0108] This invention discloses a two-phase drop die method for winding three-dimensional coils for stellarators. After determining the winding trajectory based on the aforementioned method, the coil is wound according to the preset winding trajectory. During winding, the angle corresponding to each turn in the spatial contour curve of the three-dimensional coil to be wound needs to be 360°. When the number of discrete pose nodes of the spatial contour curve is n, n pose node sequences are formed. The degree of the central angle corresponding to any two adjacent pose node sequences is set to be the same or different.

[0109] The number n of discrete pose nodes for the spatial contour curve can be 72, 120, 360, or other numbers. For example, when the degree of the central angle corresponding to any two adjacent pose node sequences is set to be the same, when the number of pose nodes n is 72, the angle of the central angle corresponding to the two adjacent pose nodes is 5°. When the number of pose nodes n is 120, the angle of the central angle corresponding to the two adjacent pose nodes is 3°. When the degree of the central angle corresponding to any two adjacent pose node sequences is set to be different, for example, when the number of pose nodes n is 72, at the position where the change gradient of the three-dimensional curved surface of the winding mold is large, the degree of the corresponding central angle can be set to be small, such as 2° or 3°. At the position where the change gradient of the three-dimensional curved surface of the winding mold is relatively gentle, the degree of the corresponding central angle can be set to be large, such as 7° or 8°. Those skilled in the art can design or select according to actual needs. This embodiment does not make specific limitations in this regard.

[0110] Using the above technical solution, since the stellarator's three-dimensional coil is composed of multiple coils, the angle corresponding to each coil is divided into n parts. Based on the curvature of different regions of the coil, the spatial position and attitude of the winding mold are controlled.

[0111] This invention discloses a two-phase drop die method suitable for winding three-dimensional coils for stellarators. It should be noted that during the winding process, the actual spatial position and orientation of the winding die may deviate from the preset spatial position and orientation. Therefore, it is necessary to adjust the spatial position and orientation of the winding die to match the actual spatial position and orientation. Thus, the step of adjusting the spatial position and orientation of the winding die according to the preset winding trajectory further includes:

[0112] Real-time acquisition of the actual spatial position and orientation of the winding mold.

[0113] The actual spatial position and attitude are compared with the spatial position and attitude of the corresponding winding node in the preset winding trajectory.

[0114] The spatial position and orientation of the winding die are adjusted in real time based on the deviation obtained from the comparison.

[0115] Please refer to the following for details. Figure 6 One possible implementation of this method is:

[0116] Step S31: The pose acquisition device acquires the actual spatial position and posture of the winding mold in real time.

[0117] Step S32: Compare the actual spatial position and attitude with the spatial position and attitude of the corresponding winding node in the preset winding trajectory.

[0118] Step S33: Adjust the spatial position and orientation of the winding mold in real time based on the deviation obtained from the comparison.

[0119] It should be noted that when adjusting the spatial position and attitude of the winding mold in real time based on the deviation obtained from the comparison, the adjustment method is to compare the actual spatial position and attitude with the spatial position and attitude of the corresponding winding node in the preset winding trajectory. When the deviation is greater than a certain threshold, for example, the threshold is 0.3mm, the winding mold is adjusted and corrected to the actual position so as to ensure that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference.

[0120] In the actual winding process of a stellarator's three-dimensional coil, the winding die needs to follow a complex three-dimensional irregular trajectory, undergoing multi-degree-of-freedom, continuous pose transformations. Factors such as equipment mechanical transmission clearance, cumulative errors from continuous motion, and interpolation trajectory transition errors can all cause slight deviations between the actual motion pose of the winding die and the preset standard trajectory. Without real-time monitoring and correction, these minute deviations will accumulate with the continuous winding process, causing conductor drop point offset, insufficient fit, and failure of lateral and bottom surface tangency, leading to defects such as conductor twisting, misalignment, uneven interlayer gaps, and coil profile deviations. To address this, this invention adds a full-process real-time pose detection, deviation comparison, and dynamic correction method to achieve dynamic and precise adjustment of the winding process.

[0121] Real-time acquisition of the actual spatial position and attitude of the winding mold refers to the continuous acquisition of the mold's current three-dimensional spatial coordinates and real-time three-dimensional attitude angle data through a pose detection component throughout the entire process of the mold's continuous movement along the preset winding trajectory. For example, the pose detection component includes, but is not limited to, high-speed cameras, infrared sensors, and radar. The acquisition process covers every winding node and the trajectory transition interval between nodes, accurately capturing subtle positional and angular deviations generated during continuous attitude adjustment and displacement of the mold, ensuring that the actual working condition is measurable and controllable.

[0122] The real-time closed-loop comparison and verification process of the system involves comparing the actual spatial position and attitude with the spatial position and attitude of the corresponding winding node in the preset winding trajectory. The controller maps and matches the acquired actual mold pose information to the corresponding winding node position of the preset winding trajectory in real time, extracts the standard preset spatial position parameters and standard three-dimensional attitude parameters corresponding to the node, and performs a differential comparison between the actual parameters and the preset parameters item by item to calculate the spatial position deviation and attitude angle deviation. Through precise point-to-point comparison, different types of deviations such as position offset and attitude deflection error can be accurately distinguished, and the location and magnitude of the error can be accurately located, avoiding the problem of fuzzy judgment of the overall error.

[0123] The system adjusts the spatial position and orientation of the winding die in real time based on the compared deviations, constituting the final dynamic correction process. Based on the compared position and orientation deviations, the system generates corresponding real-time compensation control values ​​and outputs them immediately to the orientation adjustment device. This dynamically fine-tunes and compensates for the real-time spatial position and three-dimensional orientation of the winding die, rapidly converging the actual orientation of the die to the standard orientation range of the preset winding node. This adjustment method provides real-time, dynamic, and uninterrupted micro-compensation throughout the entire process, requiring no machine stoppage for calibration or manual intervention. It ensures that deviation correction is completed while the die is in continuous motion and winding, without interrupting the normal winding process.

[0124] The above scheme collects the actual position and posture parameters of the mold in real time, and compares the actual spatial position and posture with the spatial position and posture of the corresponding winding node in the preset winding trajectory. When the comparison determines that the deviation is greater than the threshold, the spatial position and posture of the winding mold are adjusted in real time to reduce the error during winding and ensure the accuracy of coil winding.

[0125] The present invention discloses a two-phase die-cutting method suitable for three-dimensional coil winding of stellarators. Please refer to [link to relevant documentation]. Figure 7 The method also includes:

[0126] Determine if the current turn is the last turn.

[0127] If so, then end the winding process.

[0128] If not, continue to adjust the winding mold to the next winding node according to the preset winding trajectory, and repeat the above steps until all turns are wound to obtain the stellarator three-dimensional coil.

[0129] It should be noted that after determining that the current turn is not the last turn, the following steps are repeated: Figure 1 Steps S3 and S4 in the process are still to adjust the position and orientation of the winding mold according to the next winding node, so that the conductor to be wound is tangent to the side winding reference and the bottom winding reference at the same time when it is dropped from the mold.

[0130] The present invention discloses a two-phase drop die system suitable for three-dimensional coil winding of stellarators, for performing any of the above-described two-phase drop die methods suitable for three-dimensional coil winding of stellarators. Please refer to [link to relevant documentation]. Figure 8 as well as Figure 9 The dual-phase cutting die system includes a controller 20, a position adjustment device 30, and a winding die 10.

[0131] The controller 20 is used to determine a preset winding trajectory based on the geometric parameters of the three-dimensional coil to be wound. Before winding the coil, the operator imports the design file of the three-dimensional coil into the controller. As mentioned above, the geometric parameters include the spatial contour curve of the coil, the number of turns, the number of layers, and the conductor cross-sectional dimensions. The winding trajectory includes the spatial position and orientation of the winding mold 10 at each winding node during the winding process, and sends the spatial position and orientation commands of each winding node to the posture adjustment device 30.

[0132] The position adjustment device 30 is communicatively connected to the controller 20 and is used to drive the winding mold 10 to move according to the winding trajectory in order to adjust the spatial position and attitude of the winding mold 10.

[0133] Specifically, in this embodiment, the specific selection of controller 20 is not limited. For example, controller 20 can be a PLC programmable logic controller, motion controller, industrial PC controller, etc. This embodiment does not make specific limitations on this.

[0134] It should be noted that the controller 20 can determine the preset winding trajectory based on the geometric parameters of the three-dimensional coil to be wound, or the preset winding trajectory can be directly imported into the controller 20. The controller 20 further controls the pose adjustment device 30 to adjust the spatial position and attitude of the winding mold 10. For example, when adjusting the spatial position and attitude of the winding mold 10, it can be adjusted by rotation and swing.

[0135] The present invention discloses a two-phase drop die system suitable for three-dimensional coil winding of stellarators. Please refer to [link to relevant documentation]. Figure 8 The system also includes a pose acquisition device 40, which is communicatively connected to the controller 20. It is used to acquire the actual spatial position and attitude of the winding mold 10 in real time and transmit it to the controller 20. The controller 20 also compares the actual spatial position and attitude of the winding mold 10 with the spatial position and attitude of the corresponding winding node in the preset winding trajectory. Based on the deviation obtained from the comparison, it sends a spatial position and attitude adjustment command to the pose adjustment device 30 to adjust the spatial position and attitude of the winding mold 10 in real time.

[0136] Specifically, in this application, the pose acquisition device 40 is not limited in any particular way. For example, it can be a laser displacement sensor, a high-speed camera, a visual positioning camera, etc. This embodiment does not make any specific limitation on it.

[0137] Furthermore, when the controller 20 compares the actual spatial position and orientation of the winding mold 10 with the spatial position and orientation of the corresponding winding node in the preset winding trajectory, a preset judgment threshold can be set. The judgment threshold can be 0.3mm, 0.5mm, or other values. When the difference between the actual spatial position and orientation and the spatial position and orientation of the winding node in the preset trajectory is within the judgment threshold range, the spatial position and orientation of the winding mold 10 is not adjusted. When the difference between the actual spatial position and orientation and the spatial position and orientation of the winding node in the preset trajectory is greater than the judgment threshold, a spatial position and orientation adjustment command is sent to the pose adjustment device 30 based on the deviation obtained from the comparison, so as to adjust the spatial position and orientation of the winding mold 10 in real time.

[0138] The present invention discloses a two-phase drop die system suitable for three-dimensional coil winding of stellarators. Please refer to [link to relevant documentation]. Figure 11 , Figure 13 as well as Figure 15 The posture adjustment device 30 includes a rotary drive mechanism 400 and a swing drive mechanism 500. The swing drive mechanism 500 is fixedly installed at the output end of the rotary drive mechanism 400, and the winding mold 10 is fixed at the output end of the swing drive mechanism 500.

[0139] The rotary drive mechanism 400 is used to drive the overall structure consisting of the swing drive mechanism 500 and the winding mold 10 to rotate around a preset axis, so that the conductor 200 guided to the entrance of the winding mold 10 is gradually wound on the winding mold 10 to obtain a stellarator three-dimensional coil.

[0140] The swing drive mechanism 500 is used to drive the winding die 10 to swing, so as to adjust the posture of the winding die 10 at each winding node.

[0141] Specifically, in this embodiment, the specific structure or selection of the rotary drive mechanism 400 and the swing drive mechanism 500 is not limited. For example, the rotary drive mechanism 400 can be a servo rotary table mechanism, a slewing bearing drive mechanism, a gear meshing rotary mechanism, etc., and the swing drive mechanism 500 can be a servo swing angle mechanism, an electric push rod swing mechanism, a worm gear swing mechanism, etc.

[0142] Using the above technical solution, the overall structure consisting of the rotary drive mechanism 400 and the winding mold 10 rotates around a preset axis. The advantage of this design is that when adjusting the rotation, the angle can be adjusted first, and then the spatial angle position of the winding mold 10 can be adjusted. The adjustment is more precise, and the rotation adjustment and the swing adjustment will not interfere with each other, making the adjustment more accurate.

[0143] The present invention discloses a two-phase drop die system suitable for three-dimensional coil winding of stellarators. Please refer to [link to relevant documentation]. Figure 12The winding mold 10 includes a support mold 110, an inner winding mold 120, and an outer winding mold 130. The support mold 110, the inner winding mold 120, and the outer winding mold 130 together form a winding groove.

[0144] Optionally, please see Figure 11 and Figure 13 The system also includes a support base 300, and a rotary drive mechanism 400 is mounted on the support base 300. The rotary drive mechanism 400 includes a drive component 410 and a rotary support component 420. Please refer to [link to documentation]. Figure 14 and Figure 15 The rotary support component 420 includes a fixed outer ring 421 and a rotatable inner ring 422 in an annular shape. A rolling element 423 is provided between the fixed outer ring 421 and the rotatable inner ring 422. The fixed outer ring 421 is fixedly connected to the support base 300, and the rotatable inner ring 422 is drivenly connected to the drive component 410. The rotatable inner ring 422 protrudes from the fixed outer ring 421 along the height direction of the support base 300. A support platform 424 is also fixedly provided above the rotatable inner ring 422. The swing drive mechanism 500 is fixedly provided on the support platform 424. The drive component 410 can drive the overall structure consisting of the rotatable inner ring 422, the support platform 424, the swing drive mechanism 500 and the winding mold 10 to rotate around the axis of the rotatable inner ring 422. The axis of the rotatable inner ring 422 is a preset axis.

[0145] Please continue reading Figure 13 The inner ring of the rotatable inner ring 422 is also provided with internal meshing teeth. A drive gear 411 is also provided at the output end of the drive component 410. Furthermore, a reduction gear set can be provided at the output end of the drive component 410 as needed. (See [reference]) Figure 13 The driving component 410 drives the driving gear 411 to rotate, and the driving gear 411 meshes with the rotatable inner ring 422. This drives the entire structure consisting of the rotatable inner ring 422, the support platform 424, the swing driving mechanism 500, and the winding mold 10 to rotate around the axis of the rotatable inner ring 422. A rolling element 423 is provided between the fixed outer ring 421 and the rotatable inner ring 422, which reduces rolling friction and also prevents motion interference between them. It should be noted that those skilled in the art can also provide other methods or structures for the rotary driving mechanism 400 according to requirements; this embodiment is not limited to this.

[0146] Optionally, please see Figure 11 and Figure 16The swing drive mechanism 500 includes a six-degree-of-freedom operating mechanism, which includes six telescopic components 510 spaced apart on the support platform 424. One end of each telescopic component 510 is fixed to the side of the support platform 424 away from the rotary drive mechanism 400, and the other end is a telescopic end and is rotatably disposed at the bottom of the support mold 110.

[0147] Specifically, see Figure 16 The six-degree-of-freedom operating mechanism includes six telescopic components 510. The six telescopic components 510 have the same structure, differing only in their arrangement. Each telescopic component 510 includes a servo electric cylinder 511. The output end of the servo electric cylinder 511 is a piston rod 512. The output end of the piston rod 512 is rotatably connected to the bottom of the mold platform 520 via an upper rotating shaft 514, a Hooke hinge upper seat 513, and the shaft itself. It should be noted that... (See...) Figure 16 In this embodiment, a mold platform 520 is also provided at the bottom of the supporting mold 110. The bottom end of the servo electric cylinder 511 is connected to the supporting platform 424 through a lower rotating shaft 515 and a Hooke hinge lower seat 516. With this structure, when it is necessary to adjust the angle or position of the winding mold 10, the overall angle or position of the winding mold 10 can be adjusted by adjusting the length of the piston rod 512 of one or more of the servo electric cylinders 511. It should be noted that those skilled in the art can also use other methods to achieve the swing or position adjustment of the winding mold 10, and this embodiment does not limit it to this only method.

[0148] By adopting the above technical solution, a rotatable inner ring 422 is provided on the support base 300. The driving component 410 can smoothly drive the rotatable inner ring 422 to rotate relative to the support base 300, thereby causing the overall structure consisting of the support platform 424, the swing drive mechanism 500, and the winding mold 10 to rotate around the axis of the rotatable inner ring 422, ensuring the rotational accuracy during coil winding. The swing drive mechanism 500 is set as a six-degree-of-freedom operating mechanism, which has the advantages of higher adjustment freedom and adjustment accuracy.

[0149] In summary, by cooperating with the rotary drive mechanism 400 and the six-degree-of-freedom operating mechanism, the winding mold 10 can adjust its spatial position and attitude at each winding node during the winding process, so that the conductor 200 to be wound is simultaneously tangent to the side winding reference 101 and the bottom winding reference 102. This avoids the conductor 200 to be wound from shifting or swaying during the winding process, resulting in higher winding accuracy of the three-dimensional coil and improved yield of the wound product.

[0150] Finally, a brief description is given of the method disclosed in this invention for use in a two-phase drop die system suitable for three-dimensional coil winding of stellarators:

[0151] Please see Figure 1 and Figure 9 The method includes: determining the winding trajectory based on the geometric parameters of the three-dimensional coil to be wound; the controller 20 sending a command to the pose adjustment device 30 based on the preset winding trajectory; the pose adjustment device 30 adjusting the spatial position and orientation of the winding mold 10; the conductor 200 to be wound being simultaneously tangent to the side winding reference 101 and the bottom winding reference 102 when it is unwound from the mold; and repeating the winding process to complete all turns to obtain the stellarator three-dimensional coil. In other words, the conductor 200 to be wound remains stationary during the coil winding process. By adjusting the spatial position and orientation of the winding mold 10, the conductor 200 is simultaneously tangent to the side winding reference 101 and the bottom winding reference 102 when it is unwound from the mold, making the stellarator three-dimensional coil winding more precise. Guiding the conductor 200 to be wound at a preset angle to the entrance of the winding mold 10 can be found in [reference needed]. Figure 9 The state of double tangency can be seen in [reference]. Figure 2 and Figure 10 The rotary drive mechanism 400 in the pose adjustment device 30, such as Figure 13 As shown, the swing drive mechanism 500 is as follows Figure 16 As shown, the final three-dimensional coil of the stellarator is as follows: Figure 11 As shown.

[0152] It should be noted that, in addition to the specific embodiments described above, those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention is presented in conjunction with preferred embodiments, this does not mean that the features of the invention are limited to these embodiments. On the contrary, the purpose of describing the invention in conjunction with the embodiments is to cover other options or modifications that may be derived based on the claims of the present invention. To provide a deep understanding of the invention, many specific details are included in the above description, and the invention may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of the invention, some specific details will be omitted in the description. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0153] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0154] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of the invention is usually placed in during use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0155] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0156] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "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 embodiment based on the specific circumstances.

[0157] While the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the invention to these descriptions. Various changes in form and detail can be made by those skilled in the art, including several simple deductions or substitutions, without departing from the spirit and scope of the invention.

Claims

1. A two-phase drop die method suitable for three-dimensional coil winding of a stellarator, characterized in that, include: The spatial position and orientation of the winding mold are adjusted according to the preset winding trajectory; wherein, the winding trajectory is determined based on the geometric parameters of the three-dimensional coil to be wound, the winding trajectory includes the spatial position and orientation of the winding mold at each winding node during the winding process, and the geometric parameters include the spatial contour of the coil. The conductor to be wound is guided to the entrance of the winding mold at a preset angle. When the conductor to be wound is placed into the mold, the spatial position and attitude of the winding mold are adjusted so that the conductor to be wound is simultaneously tangent to the side winding reference and the bottom winding reference. The side winding reference and the bottom winding reference are the side wall and the bottom wall of the winding mold, respectively. The steps of adjusting the spatial position and orientation of the winding die according to the preset winding trajectory include: Real-time acquisition of the actual spatial position and orientation of the winding mold; The actual spatial position and attitude are compared with the spatial position and attitude of the corresponding winding node in the preset winding trajectory; The spatial position and orientation of the winding die are adjusted in real time based on the deviation obtained from the comparison.

2. The two-phase cutting die method for three-dimensional coil winding of a stellarator as described in claim 1, characterized in that, During the winding process, the side winding reference and the bottom winding reference can also be: The side winding reference and the bottom winding reference are respectively the adjacent sidewalls of the conductor that has been wound and the bottom wall of the winding mold; Alternatively, the side winding reference and the bottom winding reference are respectively the side wall of the winding mold and the top wall of the conductor that has been wound. Alternatively, the side winding reference and the bottom winding reference may be the side wall of the conductor that has been wound and the top wall of the conductor that has been wound, respectively.

3. The two-phase cutting die method for three-dimensional coil winding of a stellarator as described in claim 1, characterized in that, The steps for determining the winding trajectory based on the geometric parameters of the three-dimensional coil to be wound include: The spatial contour curve of the three-dimensional coil to be wound is discretized into multiple pose nodes to form a pose node sequence. Each pose node includes the three-dimensional coordinates of the spatial position of the winding mold and the three-dimensional attitude angle. A continuous pose transition path is generated between adjacent pose nodes using an interpolation method. Each pose node corresponds to one winding node.

4. The two-phase drop die method for three-dimensional coil winding of a stellarator as described in claim 3, characterized in that, Each turn of the spatial contour curve of the three-dimensional coil to be wound corresponds to an angle of 360°. When the number of discrete pose nodes of the spatial contour curve is n, n pose node sequences are formed. The degree of the central angle corresponding to any two adjacent pose node sequences is set to be the same or different.

5. The two-phase die-cutting method for three-dimensional coil winding of a stellarator as described in any one of claims 1-4, characterized in that, The method further includes: Determine if the current turn is the last turn; If so, then end the winding process; If not, continue to adjust the winding mold to the next winding node according to the preset winding trajectory, and repeat the above steps until all turns are wound to obtain the stellarator three-dimensional coil.

6. A two-phase drop die system suitable for three-dimensional coil winding of a stellarator, characterized in that, The two-phase cut-and-drop die system is used to perform the two-phase cut-and-drop die method for three-dimensional coil winding of stellarator as described in any one of claims 1 to 5, wherein the two-phase cut-and-drop die system includes a controller, a pose adjustment device, and a winding die. The controller is used to determine a preset winding trajectory based on the geometric parameters of the three-dimensional coil to be wound. The winding trajectory includes the spatial position and attitude of the winding mold at each winding node during the winding process, and sends the spatial position and attitude commands of each winding node to the posture adjustment device. The posture adjustment device is communicatively connected to the controller and is used to drive the winding mold to move according to the winding trajectory in order to adjust the spatial position and posture of the winding mold.

7. The two-phase drop die system for three-dimensional coil winding of a stellarator as described in claim 6, characterized in that, The system also includes: The pose acquisition device is communicatively connected to the controller and is used to acquire the actual spatial position and attitude of the winding mold in real time and transmit it to the controller. The controller also compares the actual spatial position and attitude of the winding mold with the spatial position and attitude of the corresponding winding node in the preset winding trajectory, and sends a spatial position and attitude adjustment command to the pose adjustment device according to the deviation obtained from the comparison, so as to adjust the spatial position and attitude of the winding mold in real time.

8. The two-phase drop die system for three-dimensional coil winding of a stellarator as described in claim 6 or 7, characterized in that, The posture adjustment device includes a rotation drive mechanism and a swing drive mechanism. The swing drive mechanism is fixedly installed at the output end of the rotation drive mechanism, and the winding mold is fixed at the output end of the swing drive mechanism. The rotary drive mechanism is used to drive the overall structure consisting of the swing drive mechanism and the winding mold to rotate around a preset axis, so that the conductor guided to the entrance of the winding mold is gradually wound around the winding mold to obtain a stellarator three-dimensional coil. The swing drive mechanism is used to drive the winding die to swing, so as to adjust the posture of the winding die at each winding node.

9. The two-phase drop die system for three-dimensional coil winding of a stellarator as described in claim 8, characterized in that, The winding mold includes a supporting mold, an inner winding mold, and an outer winding mold, which together form a winding groove. And / or, the system further includes a support base, the rotary drive mechanism is disposed on the support base, the rotary drive mechanism includes a drive component and a rotary support component, the rotary support component includes a fixed outer ring and a rotatable inner ring in an annular shape, a rolling element is disposed between the fixed outer ring and the rotatable inner ring, the fixed outer ring is fixedly connected to the support base, the rotatable inner ring is drively connected to the drive component, and the rotatable inner ring protrudes from the fixed outer ring along the height direction of the support base. A support platform is also fixedly disposed above the rotatable inner ring, the swing drive mechanism is fixedly disposed on the support platform, and the drive component can drive the integral structure consisting of the rotatable inner ring, the support platform, the swing drive mechanism and the winding mold to rotate around the axis of the rotatable inner ring, the axis of the rotatable inner ring being the preset axis; And / or, the swing drive mechanism includes a six-degree-of-freedom operating mechanism, which includes six telescopic components spaced apart on the support platform. One end of each telescopic component is fixed to the side of the support platform away from the rotary drive mechanism, and the other end is a telescopic end that is rotatably disposed at the bottom of the support mold.

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