Pouring tool for super-long CS coil

Abstract

The utility model discloses a pouring tooling of super-long type CS coil, including mould core, frame subassembly, bottom plate and top plate, frame subassembly dismountably set up in the periphery of mould core, bottom plate and top plate set up in mould core and frame both ends, mould core includes a plurality of sub-mould core, first locating piece and second locating piece, the plurality of sub-mould core is distributed in the annular shape, the first locating piece is located in the first locating piece, and the second locating piece is located in the second locating piece. The mutual contact surfaces of every two adjacent sub-mold cores are inclined surfaces, the plurality of sub-mold cores are encircled to form a main mold core, the first positioning block and the second positioning block are arranged at the two ends of the main mold core, the first positioning block penetrates through the bottom plate, and the second positioning block penetrates through the top plate. The mold core is arranged to be of a detachable structure and comprises the sub-mold cores, the first positioning block and the second positioning block, the contact faces of the sub-mold cores are all inclined faces, through cooperation of the inclined faces, friction force is reduced, the demolding process is smoother, demolding convenience is greatly improved, and meanwhile the risk that a coil is damaged due to demolding is reduced.

Description

Technical Field

[0001] This utility model relates to the field of coil casting technology, and in particular to a casting fixture for an ultra-long CS coil. Background Technology

[0002] In the manufacturing process of nuclear fusion devices, the CS coil is a key component, and its quality and performance directly affect the overall operation of the device. The CS coil involved in this case has unique dimensions, reaching a length of 3.1 meters after casting, with an outer diameter of 0.45 meters, an inner diameter of 0.32 meters, and a wall thickness of 6.5 centimeters. Compared with conventional coils, its length is significantly increased, and the wall thickness results in a relatively narrow internal space.

[0003] Existing coil casting fixtures present several unresolved problems when dealing with such extra-long CS coils. Firstly, the considerable length of the cast CS coil presents significant challenges to existing demolding methods. Common demolding methods, such as relying solely on manual labor or simple mechanical assistance, are not only difficult to operate with such long coils but also highly susceptible to damage. This is because significant frictional forces must be overcome during demolding; uneven force application can lead to localized deformation of the coil, affecting its electromagnetic properties and even rendering it unusable, thus increasing production costs. Furthermore, the existing coil casting mold core is a one-piece structure, which negatively impacts the ease of subsequent demolding. Utility Model Content

[0004] The purpose of this invention is to provide a casting fixture for an ultra-long CS coil to solve the above-mentioned technical problems.

[0005] The technical solution adopted in this utility model is as follows:

[0006] A casting fixture for an ultra-long CS coil includes a mold core, a frame assembly, a base plate, and a top plate. The frame assembly is detachably disposed around the mold core. The base plate and the top plate are disposed at both ends of the mold core and the frame assembly. The mold core includes a plurality of sub-mold cores, a first positioning block, and a second positioning block. The plurality of sub-mold cores are arranged in a ring, and the contact surfaces between adjacent sub-mold cores are all inclined surfaces. The plurality of sub-mold cores are joined together to form a main mold core. The first positioning block and the second positioning block are disposed at both ends of the main mold core. The first positioning block penetrates the base plate, and the second positioning block penetrates the top plate.

[0007] Preferably, the system also includes locating pins, with each of the sub-mold cores connected to the first locating block and the second locating block respectively via the locating pins.

[0008] Preferably, the system also includes a liquid inlet pipe, which is provided on the base plate, and a pouring channel is formed between the mold core and the frame assembly.

[0009] The base plate has a first flow channel groove and a first sealing groove on the side near the frame assembly. The first sealing groove is located around the first flow channel groove. The liquid inlet pipe is connected to the first flow channel groove, and the first flow channel groove is connected to the pouring channel.

[0010] Preferably, the system also includes a flange observation window, which is provided on the top plate.

[0011] Preferably, the border component includes a plurality of borders;

[0012] Each of the frame components includes a half frame and a flange end plate. Two half frames are spliced ​​together to form a cylindrical structure. Two flange end plates are provided at both ends of the cylindrical structure. Two flange end plates facing each other in two adjacent frame components are connected by a first bolt.

[0013] A second sealing groove is provided on both sides of one of the half-frames.

[0014] As a further preferred embodiment, each half-frame is provided with two reinforcing ribs on both sides, and the two corresponding reinforcing ribs on the two half-frames are connected by a second bolt, and the two ends of each reinforcing rib are respectively connected to the two flange end plates.

[0015] As a further preferred embodiment, a second flow channel and a third flow channel are provided on the inner wall of the cylindrical structure. The second flow channel is arranged along the circumference of the cylindrical structure, and the third flow channel is arranged along the axial direction of the cylindrical structure. The third flow channel is connected to the second flow channel.

[0016] As a further preferred embodiment, the outer wall of the cylindrical structure is provided with a plurality of vent holes, the plurality of vent holes being connected to the same third flow channel groove, and each vent hole being provided with a transparent flexible tube.

[0017] As a further preferred embodiment, both the inner wall of the cylindrical structure and the outer wall of the mold core are provided with a Teflon layer.

[0018] Preferably, the bottom plate has a first positioning protrusion on the side near the frame assembly, and the top plate has a second positioning protrusion on the side near the frame assembly.

[0019] The above technical solution has the following advantages or beneficial effects:

[0020] (1) In this utility model, the mold core is set as a detachable structure, including a sub-mold core, a first positioning block and a second positioning block, and the surfaces that come into contact with each other between the sub-mold cores are all inclined surfaces. By using inclined surfaces, the friction is reduced, making the demolding process smoother and greatly improving the convenience of demolding. At the same time, it also reduces the risk of damage to the coil caused by demolding.

[0021] (2) In this utility model, the frame assembly adopts a segmented design, which is convenient for installation and disassembly. The second and third flow channels are set on the inner wall of the frame assembly, and the exhaust holes are set in conjunction with them. This can guide the epoxy material to flow evenly over a long distance, ensuring full filling. At the same time, the gas generated during the casting process is discharged in time to avoid residual bubbles and ensure the quality of the coil. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the casting fixture for the extra-long CS coil in this utility model;

[0023] Figure 2 This is a side view of the casting fixture for the extra-long CS coil in this utility model.

[0024] Figure 3 yes Figure 2 Sectional view along the middle AA direction;

[0025] Figure 4 This is a schematic diagram of the structure of the base plate in this utility model;

[0026] Figure 5 This is a schematic diagram of the top plate structure in this utility model;

[0027] Figure 6 This is a schematic diagram of the frame in this utility model;

[0028] Figure 7 yes Figure 6 Enlarged view of point B in the middle;

[0029] Figure 8 yes Figure 6 A magnified view of point C in the middle.

[0030] In the diagram: 1. Mold core; 101. Sub-mold core; 102. First positioning block; 103. Second positioning block; 104. Positioning pin; 2. Frame assembly; 201. Frame; 202. Half frame; 203. Flange end plate; 204. First bolt; 205. Second sealing groove; 206. Reinforcing rib; 207. Second bolt; 3. Base plate; 4. Top plate; 5. Liquid inlet pipe; 6. First flow channel groove; 7. First sealing groove; 8. Flange observation window; 9. Second flow channel groove; 10. Third flow channel groove; 11. Vent hole; 12. Transparent hose; 13. First positioning convex ring; 14. Second positioning convex ring. Detailed Implementation

[0031] The technical solution of this utility model 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 this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0032] In the description of this utility model, 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 this utility model 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 limitations on this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 utility model based on the specific circumstances.

[0034] Figure 1 This is a three-dimensional structural diagram of the casting fixture for the extra-long CS coil in this utility model; Figure 2 This is a side view of the casting fixture for the extra-long CS coil in this utility model. Figure 3 yes Figure 2 Sectional view along the middle AA direction; Figure 4 This is a schematic diagram of the structure of the base plate in this utility model; Figure 5 This is a schematic diagram of the top plate structure in this utility model; Figure 6 This is a schematic diagram of the frame in this utility model; Figure 7 yes Figure 6 Enlarged view of point B in the middle; Figure 8 yes Figure 6 A magnified view of point C. Please see below. Figures 1 to 8The image shows a preferred embodiment of a casting fixture for an extra-long CS coil, comprising a mold core 1, a frame assembly 2, a base plate 3, and a top plate 4. The frame assembly 2 is detachably disposed around the mold core 1. The base plate 3 and the top plate 4 are disposed at both ends of the mold core 1 and the frame 201. The mold core 1 includes several sub-mold cores 101, a first positioning block 102, and a second positioning block 103. The several sub-mold cores 101 are arranged in a ring, and the surfaces in contact between adjacent sub-mold cores 101 are all inclined surfaces. The several sub-mold cores 101 are arranged together to form a main mold core 1. The first positioning block 102 and the second positioning block 103 are disposed at both ends of the main mold core 1. The first positioning block 102 penetrates the base plate 3, and the second positioning block 103 penetrates the top plate 4. In this embodiment, the mold core 1 is divided into three sub-mold cores 101 of equal length. Each sub-mold core 101 has a pre-machining allowance on its outer circumference. An inclined surface is provided on the contact surface between the sub-mold cores 101 to form a wedge-shaped structure. This multi-part wedge-shaped structure effectively reduces the contact area between the mold core 1 and the coil during demolding, reducing friction and making the demolding process smoother. This greatly improves the convenience of demolding and also reduces the risk of damage to the coil during demolding. The machining precision of this inclined surface is controlled within a very small range to ensure a tight fit between each individual mold core 1, creating conditions for smooth subsequent demolding.

[0035] With the setting of the first positioning block 102 and the second positioning block 103, and each sub-mold core 101 connected to the first positioning block 102 and the second positioning block 103 respectively by positioning pins 104, this positioning method not only ensures the stability of the sub-mold core 101 after installation, but also allows for the precision machining of the outer circle of the three sub-mold cores 101 and the outer circle of the second positioning block 1 using the outer circle of the first positioning block 102 as a reference, ensuring coaxiality. This satisfies the high-precision coaxiality requirement of the CS coil for the mold core 1, laying the foundation for controlling the outer dimensions of the coil.

[0036] Furthermore, as a preferred embodiment, it also includes a liquid inlet pipe 5, which is provided on the base plate 3, and a pouring channel is formed between the mold core 1 and the frame assembly 2.

[0037] The base plate 3 has a first flow channel groove 6 and a first sealing groove 7 on the side near the frame assembly 2. The first sealing groove 7 is located on the periphery of the first flow channel groove 6. The liquid inlet pipe 5 is connected to the first flow channel groove 6, and the first flow channel groove 6 is connected to the casting channel. The liquid inlet pipe 5 facilitates the introduction of epoxy resin into the casting channel, and the first sealing groove 7 is used to install the first sealing ring.

[0038] Furthermore, as a preferred embodiment, the border component 2 includes a plurality of borders 201;

[0039] Each frame 201 includes a half frame 202 and a flange end plate 203. The two half frames 202 are spliced ​​together to form a cylindrical structure. Two flange end plates 203 are provided at both ends of the cylindrical structure. The two flange end plates 203 facing each other in two adjacent frames 201 are connected by a first bolt 204.

[0040] A second sealing groove 205 is formed on both sides of one half of the frame 202. In this embodiment, the frame assembly 2 adopts a segmented design, see [reference]. Figure 1 As shown, the frame assembly 2 is divided into three sections, two of which are 1.05 meters long and one is 1.04 meters long. Each frame section 201 consists of two half-frames 202 with flange end plates 203 welded to both ends and four reinforcing ribs 206 welded in the middle. This segmented structure not only facilitates processing and transportation but also allows for greater flexibility during installation, which helps ensure the accuracy and stability of the entire frame assembly 2.

[0041] A second sealing strip can be installed in the second sealing groove 205 opened on the half-frame 202 for sealing between the two half-frames 202 to prevent epoxy material leakage.

[0042] Furthermore, as a preferred embodiment, two reinforcing ribs 206 are provided on both sides of each half-frame 202. The two corresponding reinforcing ribs 206 on the two half-frames 202 are connected by second bolts 207. The two ends of each reinforcing rib 206 are respectively connected to two flange end plates 203. The two half-frames 202 are positioned and installed by the second bolts 207 at the reinforcing ribs 206, while the two opposite flange end plates 203 in adjacent half-frames 201 are connected by first bolts 204. This design not only ensures the tightness of the connection of the frame assembly 2, but also effectively prevents the leakage of epoxy material during the casting process through the second sealing groove 205 and the bolt connection.

[0043] Furthermore, as a preferred embodiment, a second flow channel 9 and a third flow channel 10 are formed on the inner wall of the cylindrical structure. The second flow channel 9 is arranged circumferentially along the cylindrical structure, and the third flow channel 10 is arranged axially along the cylindrical structure, connecting to the second flow channel 9. Simultaneously, several vent holes 11 are formed on the outer wall of the cylindrical structure, each connected to the same third flow channel 10. A transparent flexible tube 12 is installed inside each vent hole 11. This design guides the epoxy material to flow uniformly over a long distance, ensuring full filling and timely venting of gases generated during the pouring process, preventing air bubbles and ensuring coil quality. Additionally, a flange observation window 8 is included on the top plate 4, allowing operators to easily observe the internal epoxy pouring process, further ensuring the pouring effect.

[0044] Furthermore, as a preferred embodiment, both the inner wall of the cylindrical structure and the outer wall of the mold core 1 are provided with a Teflon layer. By plating the outer wall of the mold core 1 and the inner wall of the cylindrical structure with Teflon to form a Teflon layer, the extremely low coefficient of friction of Teflon material is utilized to further reduce the adhesion between the mold core 1 and the coil, making demolding easier and avoiding scratches or other damage to the coil surface during the demolding process, thus ensuring the quality of the coil.

[0045] Furthermore, as a preferred embodiment, the bottom plate 3 has a first positioning protrusion 13 on the side near the frame assembly 2, and the top plate 4 has a second positioning protrusion 14 on the side near the frame assembly 2. In this embodiment, both the first positioning protrusion 13 and the second positioning protrusion 14 extend into the frame assembly 2 to achieve positioning and assembly of the frame assembly 2.

[0046] In this embodiment, the mold core 1 adopts a multi-piece wedge structure, and the contact surfaces of adjacent sub-mold cores 101 are fitted with inclined surfaces, which greatly reduces the contact area and friction between the mold core 1 and the coil during demolding. Compared with the traditional one-piece mold core 1, this design makes the demolding process smoother, and the operator no longer needs to overcome huge demolding resistance, significantly reducing the difficulty of demolding operation.

[0047] In this embodiment, Teflon plating is applied to the outer wall of the mold core 1 and the inner wall of the frame assembly 2 (the inner wall of the cylindrical structure formed by the two half-frames 202). Thanks to the extremely low coefficient of friction of Teflon, the risk of scratching and damage to the coil surface during demolding is further reduced. This effectively ensures the integrity of the coil, avoids local deformation caused by demolding, thereby ensuring that the electromagnetic performance of the coil is not affected, improving the product qualification rate, and reducing production costs.

[0048] In this embodiment, the segmented design of the frame component 2 facilitates processing, transportation and assembly, and the multi-part mold core 1 simplifies the demolding process. These designs effectively shorten the tooling preparation time and the coil production cycle, thereby improving overall production efficiency.

[0049] During assembly, the three pre-processed sub-mold cores 101 are first spliced ​​together according to the design requirements. Then, the first positioning block 102 and the second positioning block 103 are assembled together with the sub-mold cores 101 using positioning pins 104 to ensure the overall stability of the mold core 1. Next, the two pre-processed half-frames 202 are assembled around the mold core 1. Then, the flange end plates 203 in the two frame 201 are connected together using the first bolt 204, and the corresponding reinforcing ribs 206 are connected together using the second bolt 207. Then, the bottom plate 3 and the top plate 4 are installed from both ends. The position of the frame assembly 2 is adjusted, and the flange end plates 203 in the frame assembly 2 are connected to the bottom plate 3 and the top plate 4 to complete the assembly.

[0050] Before casting, the inside of the tooling is cleaned to remove any impurities and oil. Simultaneously, the epoxy material is prepared according to the specified formula and degassed to reduce air bubble formation during casting. The prepared epoxy material is then injected into the casting channel within the tooling through the inlet pipe 5 on the base plate 3. Guided by the various runners, the epoxy material flows evenly along the space between the mold core 1 and the frame assembly 2, filling the CS coil. During casting, the progress of epoxy casting and the internal gas discharge are closely monitored through the transparent hose 12 and the observation window on the top cover. Once the epoxy material casting is complete and the specified curing time has been reached, demolding is performed. Because the mold core 1 uses a multi-piece wedge structure and is coated with a Teflon layer, and the inner surface of the frame 201 also has a Teflon layer, the cast CS coil can be easily removed by disassembling the tooling components in a specific order. After removal, the CS coil is visually inspected and its dimensions measured to ensure it meets design requirements.

[0051] The above description is only a preferred embodiment of the present utility model and does not limit the implementation method and protection scope of the present utility model. Those skilled in the art should realize that all solutions obtained by equivalent substitutions and obvious changes made based on the description and illustrations of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A casting fixture for an ultra-long CS coil, characterized in that, The device includes a mold core, a frame assembly, a base plate, and a top plate. The frame assembly is detachably disposed around the mold core. The base plate and the top plate are disposed at both ends of the mold core and the frame assembly. The mold core includes several sub-mold cores, a first positioning block, and a second positioning block. The several sub-mold cores are arranged in a ring, and the contact surfaces between adjacent sub-mold cores are all inclined surfaces. The several sub-mold cores together form a main mold core. The first positioning block and the second positioning block are disposed at both ends of the main mold core. The first positioning block penetrates the base plate, and the second positioning block penetrates the top plate.

2. The casting fixture for the ultra-long CS coil as described in claim 1, characterized in that, It also includes positioning pins, with each of the sub-mold cores connected to the first positioning block and the second positioning block respectively via the positioning pins.

3. The casting fixture for the ultra-long CS coil as described in claim 1, characterized in that, It also includes a liquid inlet pipe, which is provided on the base plate, and a pouring channel is formed between the mold core and the frame assembly; The base plate has a first flow channel groove and a first sealing groove on the side near the frame assembly. The first sealing groove is located around the first flow channel groove. The liquid inlet pipe is connected to the first flow channel groove, and the first flow channel groove is connected to the pouring channel.

4. The casting fixture for the ultra-long CS coil as described in claim 1, characterized in that, It also includes a flange observation window, which is provided on the top plate.

5. The casting fixture for the ultra-long CS coil as described in claim 1, characterized in that, The border component includes several borders; Each of the frame components includes a half frame and a flange end plate. Two half frames are spliced ​​together to form a cylindrical structure. Two flange end plates are provided at both ends of the cylindrical structure. Two flange end plates facing each other in two adjacent frame components are connected by a first bolt. A second sealing groove is provided on both sides of one of the half-frames.

6. The casting fixture for the ultra-long CS coil as described in claim 5, characterized in that, Two reinforcing ribs are provided on both sides of each half-frame, and the two corresponding reinforcing ribs on the two half-frames are connected by a second bolt. The two ends of each reinforcing rib are respectively connected to the two flange end plates.

7. The casting fixture for the ultra-long CS coil as described in claim 5, characterized in that, The inner wall of the cylindrical structure is provided with a second flow channel and a third flow channel. The second flow channel is arranged along the circumference of the cylindrical structure, and the third flow channel is arranged along the axial direction of the cylindrical structure. The third flow channel is connected to the second flow channel.

8. The casting fixture for the ultra-long CS coil as described in claim 7, characterized in that, The outer wall of the cylindrical structure is provided with a number of vent holes, and the number of vent holes are connected to the same third flow channel groove. Each vent hole is provided with a transparent flexible tube.

9. The casting fixture for the ultra-long CS coil as described in claim 5, characterized in that, The inner wall of the cylindrical structure and the outer wall of the mold core are both provided with a Teflon layer.

10. The casting fixture for the ultra-long CS coil as described in claim 1, characterized in that, The bottom plate has a first positioning protrusion on the side near the frame assembly, and the top plate has a second positioning protrusion on the side near the frame assembly.

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