An in-situ soldering device, soldering method and coiling apparatus

Abstract

The application relates to the field of high-temperature superconducting material welding technology, and particularly discloses an in-situ welding device, a welding method and a winding equipment. The in-situ welding device comprises: a tool support which is installed on a vertically arranged positioning shaft in a height-adjustable mode, the positioning shaft can be penetrated by multiple groups of double-deck coils; a servo driving element which is installed on the tool support; a heating and welding die which is installed on the output end of the servo driving element through a universal hinge element, the side, away from the servo driving element, of the heating and welding die is provided with an arc-shaped welding surface which is concave, the servo driving element can drive the heating and welding die to move along a horizontal straight line direction so that the arc-shaped welding surface is close to or far away from the outer peripheral wall of the double-deck coil, and the heating and welding die can weld the double-deck coil through temperature rising; and a pressure sensor which is arranged between the heating and welding die and the universal hinge element and is used for detecting the reverse force suffered by the heating and welding die when the heating and welding die is pressed against the double-deck coil. The in-situ welding device can solve the problems of the welding quality and consistency of the outer joint of the pie-shaped coil.

Description

Technical Field

[0001] This invention relates to the field of high-temperature superconducting material welding technology, and in particular to an in-situ welding device, welding method and winding equipment. Background Technology

[0002] High-temperature superconducting (HTS) tape technology has matured significantly, and superconducting magnets made from second-generation HTS tapes are widely used in controlled nuclear fusion magnetic confinement, particle accelerators, and magnetic resonance imaging. Superconducting magnets are typically composed of multiple stacked biplane coils, and low-resistance superconducting connectors are needed to connect these coils in series. The performance of these external connectors directly affects the magnet's performance and operation.

[0003] Because disc coils have a certain curvature, current YBCO strip joint welding equipment is mainly used for internal coil joints, and cannot meet the needs of preparing external joints for disc coils in magnets. Therefore, welding is almost always done manually. Manual welding is greatly affected by human factors, making it impossible to precisely control process parameters such as welding pressure, which significantly impacts the uniformity and mechanical properties of the joint. Furthermore, welding disc coils requires moving them to other fixed fixtures after winding, leading to the risk of damage during secondary clamping and failing to meet the consistency requirements of subsequent large-scale industrial production. Summary of the Invention

[0004] The purpose of this invention is to provide an in-situ welding device, welding method, and winding equipment to solve the problem of welding quality and consistency of the outer connector of a disc coil.

[0005] In a first aspect, the present invention provides an in-situ welding apparatus, the in-situ welding apparatus comprising: The tooling bracket is height-adjustable and mounted on a vertically positioned positioning shaft, through which multiple sets of double-pane coils can be threaded. The servo drive is mounted on the tooling bracket; A heating welding mold is mounted on the output end of the servo drive via a universal joint. The heating welding mold has a concave arc-shaped welding surface on the side away from the servo drive. The arc-shaped welding surface extends horizontally and matches the curvature of the outer connector area to be welded of the double-pane coil. The servo drive can drive the heating welding mold to move in a horizontal straight line so that the arc-shaped welding surface approaches or moves away from the outer peripheral wall of the double-pane coil. The heating welding mold can weld the double-pane coil by heating. A pressure sensor is located on the force transmission path between the servo drive and the heating welding mold, and is disposed between the heating welding mold and the universal joint. The pressure sensor is used to detect the reverse force experienced by the heating welding mold when it presses against the double-pane coil.

[0006] As an optional technical solution, a heating element is embedded in the heating welding mold; The heating and welding mold has heating holes, and the heating element is installed through the heating holes; or, the heating and welding mold is a cast aluminum plate structure, and the heating element includes multiple heating wires, which are distributed in the heating and welding mold through a casting pre-embedding process.

[0007] As an optional technical solution, the heating welding mold is provided with a cooling channel, which extends through the heating welding mold along the width direction and is used for the flow of cooling fluid medium.

[0008] As an optional technical solution, the cooling channel is arranged along a straight path; or... The cooling channel is arranged along an arc-shaped path adapted to the arc-shaped welding surface; or, The cooling channel is arranged along a meandering curved path.

[0009] As an optional technical solution, the in-situ welding device further includes at least two temperature sensors, both of which are installed on the heating welding mold.

[0010] As an optional technical solution, the temperature sensor includes a first temperature sensor and a second temperature sensor, and the heating welding mold is provided with: An edge temperature measuring hole is provided on a side wall adjacent to the arc-shaped welding surface, and the first temperature sensor is embedded in the edge temperature measuring hole; A central temperature measuring hole is inserted through the heating and welding mold along the height direction. The central temperature measuring hole is arranged adjacent to the arc-shaped welding surface. The second temperature sensor is embedded in the central temperature measuring hole.

[0011] As an optional technical solution, the cooling channel is disposed between the heating element and the arc-shaped welding surface; and / or Both the edge temperature measuring hole and the center temperature measuring hole are located between the cooling channel and the arc-shaped welding surface.

[0012] As an optional technical solution, the in-situ welding device further includes a heating plate base, the heating welding mold and the universal hinge are provided with the heating plate base, the heating welding mold is detachably installed on the heating plate base, and a heat insulation pad is provided between the heating welding mold and the heating plate base.

[0013] As an optional technical solution, the tooling bracket includes: A horizontal support plate is provided along the horizontal direction, and its first end is connected to the positioning shaft in adjustable height. A vertical support plate is set vertically, and its upper end is connected to the horizontal support plate. The installation position of the vertical support plate and the distance between the first end of the horizontal support plate are adjustable. The servo drive is installed on the vertical support plate.

[0014] As an optional technical solution, the tooling bracket further includes: A stabilizing arm, one end of which is connected to the positioning shaft, and the other end of which is connected to the second end of the support plate. The stabilizing arm is used to limit the second end of the support plate from tilting upwards.

[0015] As an optional technical solution, the positioning shaft is configured as a screw structure, and the in-situ welding device further includes an installation and adjustment assembly, which includes: A limiting nut is threaded to the positioning shaft, and the top of the limiting nut supports the first end of the bracket cross plate. A locking element, the bottom of which can press against the first end of the support cross plate to limit the vertical movement of the support cross plate; The locking element is configured as a fixed nut threadedly connected to the positioning shaft; or, the locking element is configured as a clamp sleeved on and selectively locked to the positioning shaft.

[0016] Secondly, a welding method is also provided as an optional technical solution, implemented by the in-situ welding apparatus described above, including the following steps: S1. Adjust the installation height of the tooling bracket on the positioning shaft so that the heating welding mold is directly facing any of the external welding points of the double-pancake coil; S2. The servo drive pushes the heating welding mold toward the double-pane coil, so that the arc-shaped welding surface presses against the outer welding point of the double-pane coil to achieve pre-pressing; S3. The pressure sensor measures the pre-pressure applied to the arc welding surface, and the servo drive adjusts the output pressure according to the difference between the measured pre-pressure and the preset pre-pressure using a PID algorithm. S4. The heating and welding mold is heated to the first preset temperature value; S5. The servo drive increases the pressure of the arc welding surface against the double-panel coil to a preset welding pressure value; S6. Maintain the first preset temperature value and the preset welding pressure value for a preset duration.

[0017] As an optional technical solution, the heating welding mold is equipped with a heating element and a temperature sensor, and the heating element is communicatively connected to the temperature sensor; Step S4 specifically includes: S41. The heating element heats the heating welding mold; S42. The temperature sensor measures the real-time temperature of the heating welding mold, and the heating element adjusts the heating power according to the difference between the real-time temperature and the first preset temperature value through a PID algorithm.

[0018] As an optional technical solution, the heating welding mold is provided with a cooling channel, which is used for the circulation of cooling fluid medium; After step S6, the following is also included: S7. Turn off the heating output on the heating welding mold, stop heat preservation, and continue to maintain the preset welding pressure value; S8. A cooling fluid medium is introduced into the cooling channel to cool the heating welding mold to a second preset temperature value, which is lower than the first preset temperature value.

[0019] As an optional technical solution, the heating welding mold is equipped with a temperature sensor, and the temperature sensor is signal-connected to the electrically controlled water pump, electrically controlled valve and liquid inlet temperature control component that supply the cooling fluid medium. Step S8 specifically includes: S81. A cooling fluid medium is introduced into the cooling channel; S82. The temperature sensor measures the real-time temperature of the heating welding mold; S83. If the measured temperature drop of the heating and welding mold is less than the preset temperature drop value within a preset unit time interval, then execute S84; if the measured temperature drop of the heating and welding mold is greater than the preset temperature drop value, then execute S85. S84. Perform at least one of the following actions: increase the speed of the electrically controlled water pump, increase the opening degree of the electrically controlled valve, and increase the cooling power of the liquid inlet temperature control component; S85. Perform at least one of the following actions: reduce the speed of the electrically controlled water pump, reduce the opening of the electrically controlled valve, and reduce the cooling power of the liquid inlet temperature control element.

[0020] Thirdly, a winding device is also provided, including a winding machine and an in-situ welding device as described above. The winding machine is provided with a material unloading station, and the positioning shaft and the in-situ welding device are both located at the material unloading station.

[0021] The beneficial effects of in-situ welding apparatus and welding methods include at least the following: This in-situ welding device, through a tooling bracket with adjustable height along the positioning axis, can precisely align the welding points on the outer periphery of different layers of double-pane coils. During the welding process, a servo drive first propels the heating welding mold horizontally towards the outer wall of the coil. Due to the specific curvature of the pane coil's outer periphery, when the heating welding mold with its concave arc welding surface presses against the welding point, the universal joint allows the heating welding mold to adapt to local angular deviations of the double-pane coil, ensuring complete contact between the arc welding surface and the outer wall of the double-pane coil, eliminating uneven contact caused by tilting angles in manual welding. Simultaneously, based on the feedback pressure value measured by the pressure sensor, the servo drive dynamically adjusts and precisely applies corresponding pressure at different stages using a PID algorithm: precise pre-pressure is applied at initial contact, and the pressure is further increased to the preset welding pressure and maintained constant after the heating welding mold heats up. In summary, the in-situ welding device and welding method significantly improve the welding quality and consistency of the double-pane coil, meeting the stringent requirements of subsequent large-scale industrial production.

[0022] The beneficial effects of winding equipment include at least the following: This winding equipment achieves seamless integration of coil winding and joint welding processes by directly integrating the in-situ welding device onto the positioning shaft of the unloading station on the winding machine. During production, the double-coil coil, after winding at the winding station, does not require unloading and can directly enter the welding process at the unloading station. At this point, the in-situ welding device utilizes the existing unloading station for in-situ welding of the coil, instead of developing independent clamping fixtures or constructing complex three-dimensional motion welding platforms. It directly utilizes the existing positioning structure and spatial reference to complete welding alignment and pressing, eliminating the cumbersome process of unloading the coil from the winding machine, transferring it to an independent welding station, and readjusting its posture for secondary clamping in traditional processes. This significantly simplifies the process, effectively avoids the potential damage risk caused by uneven force or impacts during multiple handling and secondary clamping of the double-coil coil, and significantly shortens the overall process flow. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the in-situ welding device in an embodiment of the present invention; Figure 2 This is a partial structural schematic diagram of the in-situ welding device in an embodiment of the present invention; Figure 3 This is a schematic diagram of the in-situ welding device in another embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the heating and welding mold in an embodiment of the present invention; Figure 5 This is a schematic diagram of the internal structure of the heating and welding mold in an embodiment of the present invention; Figure 6This is a schematic diagram of the internal structure of a heating welding mold in another embodiment of the present invention; Figure 7 This is a flowchart illustrating the steps of the welding method in an embodiment of the present invention; Figure 8 This is a flowchart illustrating the specific steps of step S4 in an embodiment of the present invention. Figure 9 This is a flowchart illustrating the specific steps of step S8 in an embodiment of the present invention.

[0024] In the picture: 1. Tooling bracket; 11. Horizontal plate of the bracket; 111. Long strip-shaped adjustment hole; 12. Vertical plate of the bracket; 13. Stabilizing lever arm; 14. Connecting bolts; 2. Servo drive components; 3. Heating and welding mold; 31. Arc-shaped welding surface; 32. Heating hole; 33. Cooling channel; 34. Edge temperature measuring hole; 35. Center temperature measuring hole; 4. Universal hinge; 5. Pressure sensor; 6. Heating element; 7. Temperature sensor; 81. Heating plate base; 82. Heat insulation pad; 83. Guide rod; 91. Limit nut; 92. Locking component; 10. Positioning shaft; 101. Bearing plate; 102. Pressure plate; 100. Double-sided coil. Detailed Implementation

[0025] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. Furthermore, "above," "on top of," and "over" the first feature in relation to the second feature includes the first feature directly above and diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "under," and "below" the first feature in relation to the second feature includes the first feature directly below and diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0029] like Figure 1 As shown, this embodiment provides a winding device, including a winding machine and an in-situ welding fixture. The winding machine is used to wind superconducting tape to form a disc-shaped superconducting coil. Two adjacent superconducting coils constitute a double disc coil 100. The winding machine is provided with a feeding station, and the feeding station is provided with a positioning shaft 10 arranged in the vertical direction. Multiple double disc coils 100 can be coaxially mounted on the positioning shaft 10. The in-situ welding fixture is installed on the positioning shaft 10 and is also located at the feeding station.

[0030] Furthermore, such as Figure 1 and Figure 2As shown, the in-situ welding fixture includes a fixture support 1 for bearing and adjusting the height, a servo drive 2 for providing linear propulsion and precise pressure control, a heating welding mold 3 for performing heating welding and directly contacting the outer periphery of the coil, a universal hinge 4 for realizing adaptive angle fine adjustment of the mold, and a pressure sensor 5 for real-time feedback of welding pressure. Specifically, the tooling bracket 1 is height-adjustable and mounted on the vertically positioned positioning shaft 10, and the servo drive 2 is mounted on the tooling bracket 1; the heating welding mold 3 is mounted on the output end of the servo drive 2 via the universal hinge 4. The heating welding mold 3 has a concave arc-shaped welding surface 31 on the side away from the servo drive 2. The arc-shaped welding surface 31 extends horizontally and matches the curvature of the outer joint area to be welded of the double-pane coil 100, so as to achieve a tight fit of the joint area. The servo drive 2 can drive the heating welding mold 3 to move in a horizontal straight line so that the arc-shaped welding surface 31 is close to or away from the outer peripheral wall of the double-pane coil 100. The heating welding mold 3 can weld the double-pane coil 100 by heating. The pressure sensor 5 is located on the force transmission path between the servo drive 2 and the heating welding mold 3, specifically between the heating welding mold 3 and the universal hinge 4. The pressure sensor 5 is used to detect the reverse force received by the heating welding mold 3 when it presses against the double-pane coil 100.

[0031] The in-situ welding device, by setting a tooling bracket 1 whose height can be adjusted along the positioning axis 10, can accurately align the welding points on the outer periphery of the double-pane coils 100 of different layers. During the welding process, the servo drive 2 first drives the heating welding mold 3 to advance horizontally towards the outer periphery of the coil. Since the outer periphery of the pane coil has a specific curvature, when the heating welding mold 3 with the concave arc welding surface 31 presses against the welding point, the heating welding mold 3 can adapt to the local angular deviation of the double-pane coil 100 through the degree of freedom adjustment of the universal hinge 4, ensuring that the arc welding surface 31 and the outer periphery of the double-pane coil 100 are completely in contact, eliminating the uneven contact caused by the tilt of the angle in manual welding. At the same time, the servo drive 2 dynamically adjusts and accurately applies the corresponding pressure at different stages according to the feedback pressure value measured by the pressure sensor 5: achieving precise pre-pressure at the initial contact, and further increasing to the preset welding pressure and maintaining constant pressure after the heating welding mold 3 heats up. In summary, the in-situ welding device and welding method significantly improve the welding quality and consistency of the double-pancake coil 100, perfectly meeting the stringent requirements of subsequent large-scale industrial production.

[0032] The winding equipment achieves seamless connection between coil winding and joint welding by directly integrating the in-situ welding device onto the positioning shaft 10 of the unloading station of the winding machine. During production, the double-panel coil 100, after winding at the winding station, does not require unloading and can directly enter the welding process at the unloading station. At this point, the in-situ welding device utilizes the existing unloading station for in-situ welding of the coil, instead of developing independent clamping fixtures or constructing complex three-dimensional motion welding platforms. It directly utilizes the existing positioning structure and spatial reference to complete welding alignment and pressing, eliminating the cumbersome process of unloading the coil from the winding machine, transferring it to an independent welding station, and readjusting its posture for secondary clamping in traditional processes. This significantly simplifies the process, effectively avoids the potential damage risk to the double-panel coil 100 due to uneven force or impacts during multiple handling and secondary clamping, and significantly shortens the overall process flow.

[0033] For example, such as Figure 1 and Figure 2 As shown, the tooling bracket 1 includes a horizontal bracket 11 arranged in the horizontal direction and a vertical bracket 12 arranged in the vertical direction. The first end of the horizontal bracket 11 is height-adjustably connected to the positioning shaft 10; the upper end of the vertical bracket 12 is connected to the horizontal bracket 11. To accommodate double-panel coils 100 of different diameters or specifications, the distance between the mounting position of the vertical bracket 12 and the first end of the horizontal bracket 11 is adjustable. Specifically, this can be achieved by opening an elongated adjustment hole 111 on the horizontal bracket 11, and locking the vertical bracket 12 to any position within the elongated adjustment hole 111 using locking bolts to achieve horizontal mounting position adjustment. The servo drive 2 is rigidly mounted on the vertical bracket 12.

[0034] For example, such as Figure 1 and Figure 2 As shown, the positioning shaft 10 is configured as a screw structure. The in-situ welding device also includes an adjustment assembly, which includes a limit nut 91 and a locking element 92. The limit nut 91 is threaded onto the positioning shaft 10. The top of the limit nut 91 supports the first end of the support horizontal plate 11. By rotating the limit nut 91, the tooling bracket 1 can be driven to rise and fall smoothly in the vertical direction. The bottom of the locking element 92 can press against the first end of the support horizontal plate 11 to limit the vertical movement of the support horizontal plate 11. Through the upper and lower clamping cooperation of the limit nut 91 and the locking element 92 on the positioning shaft 10, the tooling bracket 1 is steplessly and precisely positioned in the vertical direction, so that the heating welding mold 3 can be strictly aligned with the height of the outer connector of the target double-pane coil 100. After one connector is welded, the tooling bracket 1 is raised or lowered by the adjustment assembly, and the heating welding mold 3 is moved to the next connector to be welded, until all connectors are welded.

[0035] In this embodiment, as Figure 1 and Figure 2As shown, to improve ease of operation, the locking element 92 is configured as a quick-release clamp that sleeves onto and can be selectively locked to the positioning shaft 10. In some embodiments, such as Figure 3 As shown, the locking element 92 can also be configured as a fixed nut that is threadedly connected to the positioning shaft 10.

[0036] For example, to resist the overturning torque generated by the cantilever structure under pressure, the tooling bracket 1 also includes a stabilizing arm 13. The stabilizing arm 13 is set at an angle to the horizontal plane and is located above the bracket horizontal plate 11. One end of the stabilizing arm 13 is connected to the positioning shaft 10, and the other end of the stabilizing arm 13 is connected to the second end of the bracket horizontal plate 11. Specifically, the second end of the supporting horizontal plate is threaded with a connecting bolt 14. One end of the stabilizing arm 13 is fitted onto the positioning shaft 10, and the other end is fitted onto the connecting bolt 14. When the servo drive 2 drives the heating welding mold 3 to press against the double-panel coil 100, the tooling bracket 1 will be subjected to an upward overturning torque in the opposite direction. The positioning shaft 10 applies a downward tilting resistance force to the second end of the bracket horizontal plate 11 through the stabilizing arm 13 to suppress the second end of the bracket horizontal plate 11 from tilting upward, ensuring the structural rigidity and posture stability of the entire tooling bracket 1 during the dynamic pressure welding process, avoiding the tilting of the welding surface caused by the elastic deformation of the bracket, ensuring the horizontal straightness of the pressure direction, and improving the welding stability and quality.

[0037] For example, such as Figure 2 As shown, a heating element 6 is embedded in the heating and welding mold 3 for heating the heating and welding mold 3.

[0038] Optional, such as Figure 4 and Figure 5 As shown, the heating and welding mold 3 can be configured as a cast aluminum plate structure, and the heating element 6 includes multiple heating wires, which are distributed and arranged in the heating and welding mold 3 through a casting pre-embedding process.

[0039] Optional, such as Figure 6 As shown, the heating and welding mold 3 has a heating hole 32, and the heating element 6 can also be a single-headed electric heating rod that is inserted into the heating hole 32.

[0040] Optional, such as Figure 4 As shown, a cooling channel 33 is provided on the heating and welding mold 3. The cooling channel 33 extends through the heating and welding mold 3 along its width and is used for the flow of cooling fluid medium. In order to increase the heat exchange area, such as... Figure 5 As shown, the cooling channel 33 is arranged along an arc-shaped path adapted to the arc-shaped welding surface 31; in other embodiments, the cooling channel 33 may also be arranged along a meandering curved path (such as an S-shaped or serpentine path).

[0041] In another embodiment of the invention, such as Figure 6As shown, the cooling channel 33 can also be configured as a through hole extending along a straight path.

[0042] For example, such as Figure 2 , Figures 4-6 As shown, the in-situ welding device also includes at least two temperature sensors 7, both of which are installed on the heating welding mold 3 to achieve multi-point temperature measurement. Specifically, the temperature sensor 7 includes a first temperature sensor and a second temperature sensor. Correspondingly, the heating welding mold 3 is provided with: an edge temperature measuring hole 34, which is opened on a side wall adjacent to the arc-shaped welding surface 31, and the first temperature sensor is embedded in the edge temperature measuring hole 34; and a center temperature measuring hole 35, which passes through the heating welding mold 3 along the height direction and is arranged adjacent to the arc-shaped welding surface 31, and the second temperature sensor is embedded in the center temperature measuring hole 35.

[0043] For example, in order to optimize the heat conduction path, a cooling channel 33 is provided between the heating element 6 and the arc-shaped welding surface 31.

[0044] For example, both the edge temperature measuring hole 34 and the center temperature measuring hole 35 are located between the cooling channel 33 and the arc-shaped welding surface 31 to maximize the accuracy of measuring the temperature of the arc-shaped welding surface 31.

[0045] Specifically, through the composite design of the heating element 6 and the cooling channel 33, the heating welding mold 3 possesses both efficient heating and controlled rapid cooling capabilities. The edge temperature measuring holes 34 and the center temperature measuring hole 35 are respectively arranged near the edge and center of the arc-shaped welding surface 31, enabling real-time and accurate capture of the true two-dimensional temperature distribution of the welding interface. Through a precise dynamic temperature control algorithm, the heating element 6 can adjust the heating power based on the feedback of multi-point real-time temperature using a PID algorithm, ensuring extremely high temperature uniformity of the arc-shaped welding surface 31 during the welding heat preservation stage. During the cooling stage after welding, forced convection heat transfer is achieved by introducing a cooling fluid medium (water in this embodiment) into the cooling channel 33. Combined with feedback from the two temperature measuring points near the arc-shaped welding surface 31, the flow rate or velocity of the cooling fluid medium can be dynamically adjusted, achieving precise control of the cooling rate during the crystallization and solidification process of the superconducting joint. This effectively avoids superconducting tape peeling or microcrack damage caused by thermal stress due to excessive local temperature differences, further ensuring the electromagnetic and mechanical properties of the superconducting joint.

[0046] In this embodiment, the heating welding mold 3 is made of a material insensitive to brazing filler metal (such as aluminum alloy), or its surface is titanium-plated to reduce the surface roughness of the arc-shaped welding surface 31. During the welding process, after the brazing filler metal melts, the servo drive 2 continuously applies pressure to expel excess filler metal and air, and under pressure holding, the temperature is rapidly reduced below the melting point of the filler metal by introducing a cooling fluid medium, allowing the filler metal to solidify and complete the welding. The embedded cooling channel 33 improves the cooling rate, effectively reduces the time the joint structure is exposed to high temperatures, effectively reduces the thickness of the intermetallic compound (IMCs) layer and the precipitation of the second phase, thereby effectively reducing the joint resistance.

[0047] For example, such as Figure 2 As shown, the in-situ welding device also includes a heating plate base 81. The heating welding mold 3 is positioned between the heating plate base 81 and the universal hinge 4. The heating welding mold 3 is detachably mounted on the heating plate base 81, for example, by screw fastening. To block heat conduction, a heat insulation pad 82 is provided between the heating welding mold 3 and the heating plate base 81. The heat insulation pad 82 can be made of ceramic heat insulation board, epoxy resin board, or other high-temperature resistant and low thermal conductivity materials.

[0048] For example, such as Figure 1 and Figure 2 As shown, in order to guide the linear movement of the heating and welding mold 3, two parallel and horizontally arranged guide rods 83 are provided on each of the left and right sides of the support vertical plate 12. One end of the guide rod 83 is connected to the heating plate base 81. The extension direction of the guide rod 83 is the same as the extension and retraction direction of the servo drive 2, which is used to assist in the linear guidance of the heating and welding mold 3.

[0049] For example, the servo drive 2 can be a linear drive element such as a servo electric actuator or a servo hydraulic cylinder.

[0050] For example, the universal joint 4 can be a ball joint, universal joint or other universal connection element.

[0051] For example, such as Figure 1 As shown, the bottom of the positioning shaft 10 is also provided with a support plate 101 for carrying the bottom layer coil. The positioning shaft 10 is also fitted with a pressure plate 102. The pressure plate 102 is limited to moving upward by a nut that is threaded to the positioning shaft 10. The support plate 101 and the pressure plate 102 together clamp multiple sets of double-pane coils 100 in the vertical direction to limit the axial position of the latter.

[0052] like Figure 7 As shown, this embodiment also provides a welding method, implemented using the above-described in-situ welding apparatus, including the following steps: S1. Adjust the installation height of the tooling bracket 1 on the positioning shaft 10 so that the heating welding mold 3 is directly facing the external welding point of any double-pane coil 100; S2, the servo drive 2 pushes the heating welding mold 3 toward the double-panel coil 100, so that the arc welding surface 31 presses against the outer welding point of the double-panel coil 100 to achieve pre-pressing; S3, pressure sensor 5 measures the pre-pressure applied to the arc welding surface 31, and servo drive 2 adjusts the output pressure according to the difference between the measured pre-pressure and the preset pre-pressure through PID algorithm. S4. Heat the welding mold 3 to the first preset temperature value; S5, the servo drive component 2 increases the pressure of the arc welding surface 31 against the double pancake coil 100 to the preset welding pressure value; S6. Maintain the first preset temperature value and preset welding pressure value for the preset duration; S7. Turn off the heating output on the heating welding mold 3, stop heat preservation, and continue to maintain the preset welding pressure value; S8. Cooling fluid medium is introduced into the cooling channel 33 to cool the heating welding mold 3 to a second preset temperature value, which is lower than the first preset temperature value. S9, the servo drive 2 drives the heating welding mold 3 to move away from the double pancake coil 100, so that the arc welding surface 31 is separated from the external welding point of the double pancake coil 100. S10. Wipe the welded joint area with alcohol.

[0053] Specifically, this welding method utilizes a combination of universal bonding and pressure PID algorithm adjustment to construct an extremely uniform and quantified pre-stress field across the entire contact surface. Through dynamic timing control—first heating to the welding temperature, then precisely solidifying and pressurizing to the preset welding pressure—it ensures that the solder layer at the interface of the superconducting tape outer joint is subjected to uniform and appropriately sized mechanical extrusion when reaching its optimal molten state. This dynamic collaborative mechanism promotes the full wetting and spreading of the solder at the microscopic level between the superconducting tapes, efficiently expelling internal bubbles and forming a low-resistance metallurgical bonding layer with consistent thickness and no voids or defects, eliminating uncertainties caused by human factors.

[0054] For example, such as Figure 8 As shown, the heating element 6 is communicatively connected to the temperature sensor 7. Step S4 specifically includes: S41, Heating element 6, heating and welding mold 3; S42, Temperature sensor 7 measures the real-time temperature of the heating welding mold 3, and heating element 6 adjusts the heating power according to the difference between the real-time temperature and the first preset temperature value through a PID algorithm.

[0055] Specifically, the control system dynamically adjusts the real-time heating power of the heating element 6 using a PID algorithm based on the difference between the measured temperature and the first preset temperature value. During the dynamic heating and heat preservation process, it ensures that the extended arc welding surface 31 has extremely high spatial temperature uniformity and time control stability, ensuring that when large-area welding is performed at the outer joint of the superconducting tape, the solder at each point melts synchronously and solidifies uniformly, avoiding local unmelted areas or overheating burns, and significantly improving the uniformity of the joint current transmission performance.

[0056] For example, such as Figure 9 As shown, temperature sensor 7 is signal-connected to the electrically controlled water pump, electrically controlled valve, and inlet temperature control component that supply the cooling fluid medium. Step S8 specifically includes: S81. Cooling fluid medium is introduced into cooling channel 33; S82, Temperature sensor 7 measures the real-time temperature of the heating welding mold 3; S83. If the measured temperature drop of the heating and welding mold 3 is less than the preset temperature drop value within the preset unit time interval, then execute S84; if the measured temperature drop of the heating and welding mold 3 is greater than the preset temperature drop value, then execute S85. S84. Perform at least one of the following actions: increase the speed of the electrically controlled water pump, increase the opening of the electrically controlled valve, and increase the cooling power of the liquid inlet temperature control component. S85. Perform at least one of the following actions: reduce the speed of the electrically controlled water pump, reduce the opening of the electrically controlled valve, and reduce the cooling power of the inlet temperature control component.

[0057] Specifically, by calculating the cooling slope in real time within a preset unit time interval, and by dynamically adjusting the speed of the electrically controlled water pump, the opening degree of the electrically controlled valve, or the power of the liquid inlet temperature control component, a closed-loop correction control is performed on the heat exchange rate within the cooling channel 33. This ensures that the cooling curve of the heating welding mold 3 strictly conforms to the preset safe crystallization curve, achieving controlled rapid cooling. While ensuring production efficiency, the residual thermal stress inside the superconducting tape outer joint is dissipated within a safe threshold, reducing the risk of stress damage during the cooling process and significantly enhancing the mechanical fatigue life and superconducting stability of the superconducting tape outer joint.

[0058] For example, prior to step S1, the following steps are also included: Clean the lead-out end and bridging strip of the double-pane coil 100 with ethanol or acetone to remove the surface oxide layer. Apply flux to the area to be soldered of the double-pane coil 100; Stack the bridging strip, sheet solder, and double-panel coil 100 in sequence, or clad a layer of solder in the area to be soldered.

[0059] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An in-situ welding device, characterized in that, include: The tooling bracket (1) is height-adjustable and mounted on a vertically positioned positioning shaft (10). Multiple sets of double-pane coils (100) can be threaded through the positioning shaft (10). Servo drive (2) is mounted on the tooling bracket (1); A heating welding mold (3) is mounted on the output end of the servo drive (2) via a universal joint (4). The heating welding mold (3) has a concave arc welding surface (31) on the side away from the servo drive (2). The arc welding surface (31) extends horizontally and matches the curvature of the outer joint area to be welded of the double-pane coil (100). The servo drive (2) can drive the heating welding mold (3) to move in a horizontal straight line so that the arc welding surface (31) is close to or away from the outer peripheral wall of the double-pane coil (100). The heating welding mold (3) can weld the double-pane coil (100) by heating. The pressure sensor (5) is located on the force transmission path between the servo drive (2) and the heating welding mold (3), and is located between the heating welding mold (3) and the universal hinge (4). The pressure sensor (5) is used to detect the reverse force when the heating welding mold (3) presses against the double pancake coil (100).

2. The in-situ welding apparatus according to claim 1, characterized in that, The heating welding mold (3) is equipped with a heating element (6); The heating welding mold (3) has a heating hole (32) and the heating element (6) is installed through the heating hole (32); or, the heating welding mold (3) is a cast aluminum plate structure and the heating element (6) includes multiple heating wires, which are distributed in the heating welding mold (3) by casting and pre-embedding process.

3. The in-situ welding apparatus according to claim 2, characterized in that, The heating and welding mold (3) is provided with a cooling channel (33), which extends through the heating and welding mold (3) in the width direction and is used to circulate cooling fluid medium.

4. The in-situ welding apparatus according to claim 3, characterized in that, The cooling channel (33) is arranged along a straight path; or, The cooling channel (33) is arranged along an arc-shaped path adapted to the arc-shaped welding surface (31); or, The cooling channel (33) is set along a meandering curved path.

5. The in-situ welding apparatus according to claim 3, characterized in that, The in-situ welding device also includes at least two temperature sensors (7), and at least two of the temperature sensors (7) are installed on the heating welding mold (3).

6. The in-situ welding apparatus according to claim 5, characterized in that, The temperature sensor (7) includes a first temperature sensor and a second temperature sensor, and the heating welding mold (3) is provided with: An edge temperature measuring hole (34) is provided on a side wall adjacent to the arc welding surface (31), and the first temperature sensor is embedded in the edge temperature measuring hole (34). A central temperature measuring hole (35) is inserted through the heating and welding mold (3) along the height direction. The central temperature measuring hole (35) is arranged adjacent to the arc welding surface (31). The second temperature sensor is embedded in the central temperature measuring hole (35).

7. The in-situ welding apparatus according to claim 6, characterized in that, The cooling channel (33) is located between the heating element (6) and the arc-shaped welding surface (31); and / or The edge temperature measuring hole (34) and the center temperature measuring hole (35) are both located between the cooling channel (33) and the arc-shaped welding surface (31).

8. The in-situ welding apparatus according to any one of claims 1-7, characterized in that, The in-situ welding device also includes a heating plate base (81), the heating welding mold (3) and the universal hinge (4) are provided with the heating plate base (81), the heating welding mold (3) is detachably installed on the heating plate base (81), and a heat insulation pad (82) is provided between the heating welding mold (3) and the heating plate base (81).

9. The in-situ welding apparatus according to any one of claims 1-7, characterized in that, The tooling bracket (1) includes: The support horizontal plate (11) is set in the horizontal direction, and its first end is connected to the positioning shaft (10) in adjustable height; The support vertical plate (12) is set in the vertical direction, and its upper end is connected to the support horizontal plate (11). The installation position of the support vertical plate (12) and the distance between the first end of the support horizontal plate (11) are adjustable. The servo drive (2) is installed on the support vertical plate (12).

10. The in-situ welding apparatus according to claim 9, characterized in that, The tooling bracket (1) also includes: A stabilizing arm (13) is provided, one end of which is connected to the positioning shaft (10), and the other end of which is connected to the second end of the support plate (11). The stabilizing arm (13) is used to limit the second end of the support plate (11) from tilting upward.

11. The in-situ welding apparatus according to claim 9, characterized in that, The positioning shaft (10) is configured as a screw structure, and the in-situ welding device further includes an installation adjustment assembly, which includes: A limiting nut (91) is threaded to the positioning shaft (10), and the top of the limiting nut (91) supports the first end of the bracket cross plate (11); Locking member (92), the bottom of which can press against the first end of the support plate (11) to limit the vertical movement of the support plate (11); The locking element (92) is configured as a fixed nut threadedly connected to the positioning shaft (10); or, the locking element (92) is configured as a clamp sleeved on and selectively locked to the positioning shaft (10).

12. A welding method, characterized in that, Implemented by the in-situ welding apparatus as described in any one of claims 1-11, comprising the following steps: S1. Adjust the installation height of the tooling bracket (1) on the positioning shaft (10) so that the heating welding mold (3) is directly facing the external welding point of any of the double-pancake coils (100); S2. The servo drive (2) pushes the heating welding mold (3) toward the double-pane coil (100) so that the arc welding surface (31) presses against the outer welding point of the double-pane coil (100) to achieve pre-pressing. S3. The pressure sensor (5) measures the pre-pressure applied to the arc welding surface (31), and the servo drive (2) adjusts the output pressure according to the difference between the measured pre-pressure and the preset pre-pressure through a PID algorithm. S4. The heating and welding mold (3) is heated to the first preset temperature value; S5. The servo drive (2) increases the pressure of the arc welding surface (31) pressing against the double-panel coil (100) to a preset welding pressure value; S6. Maintain the first preset temperature value and the preset welding pressure value for a preset duration.

13. The welding method according to claim 12, characterized in that, The heating welding mold (3) is equipped with a heating element (6) and a temperature sensor (7), and the heating element (6) is communicatively connected to the temperature sensor (7); Step S4 specifically includes: S41, The heating element (6) heats the heating welding mold (3); S42. The temperature sensor (7) measures the real-time temperature of the heating welding mold (3), and the heating element (6) adjusts the heating power according to the difference between the real-time temperature and the first preset temperature value through a PID algorithm.

14. The welding method according to claim 12, characterized in that, The heating welding mold (3) is provided with a cooling channel (33), which is used for the flow of cooling fluid medium; After step S6, the following is also included: S7. Turn off the heating output on the heating welding mold (3), stop heat preservation, and continue to maintain the preset welding pressure value; S8. Cooling fluid medium is introduced into the cooling channel (33) to cool the heating welding mold (3) to a second preset temperature value, which is lower than the first preset temperature value.

15. The welding method according to claim 14, characterized in that, The heating welding mold (3) is equipped with a temperature sensor (7), which is signal-connected to the electrically controlled water pump, electrically controlled valve and liquid inlet temperature control component that supply the cooling fluid medium; Step S8 specifically includes: S81. Cooling fluid medium is introduced into the cooling channel (33); S82, The temperature sensor (7) measures the real-time temperature of the heating welding mold (3); S83. If the measured cooling value of the heating and welding mold (3) is less than the preset cooling value within a preset unit time interval, then execute S84; if the measured cooling value of the heating and welding mold (3) is greater than the preset cooling value, then execute S85. S84. Perform at least one of the following actions: increase the speed of the electrically controlled water pump, increase the opening degree of the electrically controlled valve, and increase the cooling power of the liquid inlet temperature control component; S85. Perform at least one of the following actions: reduce the speed of the electrically controlled water pump, reduce the opening of the electrically controlled valve, and reduce the cooling power of the liquid inlet temperature control element.

16. A winding device, characterized in that, It includes a winding machine and an in-situ welding device as described in any one of claims 1-11, wherein the winding machine is provided with a material unloading station, and the positioning shaft (10) and the in-situ welding device are both located at the material unloading station.

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