LINEAR MEDIA HANDLING SYSTEM AND DEVICES PRODUCED THEREFROM - Patent application

Abstract

Improved systems for handling delicate linear media, particularly methods and apparatus for winding delicate linear media such as superconducting wire or tape or optical fiber on a spool or former, and electric machines produced thereby. A combination of direct closed loop control and media routing design facilitates handling of delicate media without causing damage. Axial tension in the linear media can be tightly controlled during winding with a feedback control loop that uses tension measurements to control the rotational speed of the unwinding and winding spools. Furthermore, during winding, the delicate linear media is exposed only to large radius bends without any back bends. Finally, commercial or other output devices and features enabled by the handling of delicate linear media are revealed. This includes advanced SC devices and features.

Description

[Technical field]

[0001] This PCT application claims the benefit of U.S. Patent Application No. 17 / 159,047, filed on January 26, 2021, published as U.S. Patent Application Publication No. 2021 / 0229946, which is a continuation-in-part of U.S. Patent Application No. 15 / 927,877, filed on March 21, 2018 (now U.S. Patent No. 10,899,575, issued on January 26, 2021), which is a continuation-in-part of PCT / US2016 / 053174, filed on September 22, 2016, published on March 30, 2017 as WO2017 / 053611, the entire disclosure of which is incorporated herein by reference. No. PCT / US2016 / 053174 claims the benefit of U.S. Provisional Patent Application No. 62 / 221,910, filed September 22, 2015, U.S. Provisional Patent Application No. 62 / 242,393, filed October 16, 2015, and U.S. Provisional Patent Application No. 62 / 243,966, filed October 20, 2015, the entire disclosures of which are hereby incorporated by reference.

[0002] This application is related to U.S. Patent Application No. 14 / 569,314, filed December 12, 2014 (now U.S. Patent No. 9,624,068, issued April 18, 2017), which is a continuation-in-part of abandoned U.S. Patent Application No. 13 / 114,012, filed May 23, 2011 (now U.S. Patent No. 8,936,209, issued January 20, 2015), which is a continuation-in-part of abandoned U.S. Patent Application No. 13 / 269,549, filed October 7, 2011, which claims the benefit of expired U.S. Provisional Patent Application No. 61 / 347,374, filed May 21, 2010, the entire disclosure of which is incorporated herein by reference.

[0003] Embodiments of the present invention relate generally to devices and apparatus for handling and manipulating sensitive linear media, and more particularly to apparatus and methods for winding linear media, such as superconducting linear media. Other embodiments of the present invention are products and devices made from the output of the apparatus, particularly winding superconductors around magnets, cables, and / or cable magnets. [Background technology]

[0004] Superconductors (sometimes referred to herein as "SC") are expected to provide pure efficiency (i.e., 100% efficiency), which will enable the manufacture of innovative devices that can accommodate increased energy and power requirements in compact packaging and provide reduced cryogenic requirements through the use of LN2 through the use of HTS. Current commercially available advanced SC products, such as magnets, cables, and cable magnets, including those that can withstand higher temperatures, are virtually nonexistent due to the fragility of superconductors. Thus, the winding process must take into account the fragile SC medium during handling, winding, and final operation.

[0005] HTS machines are desired across industries from individual devices to corresponding electrical system solutions. Traditional copper (Cu) and permanent magnet (PM) machines are limited by air gap flux density (B), torque, heat, and power output. The need for Cu cooling is also large and increases system weight. Traditional machines use iron (Fe) to increase their air gap B, but at the expense of weight. HTS direct drive machines do not have any heat losses and have a torque limit six times greater than traditional machines due to B output. The air gap is the non-magnetic space between the primary and secondary of any electromagnetic device.

[0006] Even after decades, no HTS or MTS devices, including electric machines (especially motors and generators), have advanced beyond laboratory-based demonstration levels. Due to winding limitations, other HTS wound machine attempts have focused on making pancake stack machine field coils with only limited protection from HTS winding and operating stresses. Pancake stacks increase harmonic content and move the coils farther away from the air gap, which lowers the air gap B and therefore cannot be used for complex windings such as armature coils. Furthermore, pancake stacks are not curved to protect the HTS tape from quenching due to the high B location. Due to the difficulties of winding HTS armature coils, no attempt has been made to create a complete HTS via a fully cryogenic machine, with both the armature and rotor cryogenically cooled, which leads to machines that get less than half the SC operating benefit. Other MTS solutions have lower material costs, but are much more fragile when reacted, and have higher cryostat costs and complexity given their lower operating temperatures and potentially more dangerous cryogens.

[0007] Those skilled in the art will appreciate that manufacturing for HTS applications requires that complex geometry materials undergo low winding stress, which in turn allows for increased operating values. This requirement is exacerbated when manufacturing complex geometry magnets, categorized by their primary mounting and rotation needs, including solenoidal (often mounted on a common central pivoting platform), planar (such as racetrack coils or curved planar cosine-theta magnets, often mounted on cylindrical tools), and spherical (such as baseball or yin-yang magnets). Advances in HTS operating values, their performance, reliability of cryogenic systems, connections, etc., and understanding that HTS material costs will decline during production collectively target SC manufacturing as a remaining issue for commercial SC applications. Summary of the Invention [Means for solving the problem]

[0008] One aspect of the embodiments is to provide an innovative manufacturing method for producing high temperature superconducting (HTS) and medium temperature superconducting (MTS) commercial applications and devices across all relevant industries, including corresponding field-available superconducting devices and corresponding electrical systems that would not be possible without the use of HTS. The disclosed manufacturing process reduces stress and enables complex magnet, cable, and cable magnet configurations. For example, the method of one embodiment produces robust magnet configurations configured for use in the first fully cryogenic (liquid cryogen) HTS linear, rotating, curved, etc. electric machines (motors / generators). The envisioned method may also enable the manufacture of reliable, robust, power dense HTS cable cores that operate from DC to transients including AC and pulsed power with negligible reactance and acceptable power losses compared to existing practices. The cables, magnets, cable cores, cable magnets, etc. produced by the methods described herein are designed to function at liquid nitrogen (LN2) temperatures using existing HTS. Thus, the disclosed magnets, cables, and superconductor winding capabilities of the cable magnets disclosed herein enable the highest power density, highest specific power, highest energy density, and highest specific energy electric and magnetic based products ever created, particularly embodiments utilizing HTS.

[0009] The winding machines of some embodiments of the present invention provide the ability to directly monitor and actively control the location, tension, and bending of all conductors and insulations used to create the magnets, cables, and / or cable magnets at every moment of production. This aspect is often critical to generating optimal magnets, cables, and / or cable magnets from fragile media. The use of sensors and control algorithms is also often critical for the most complex parts of the disclosed winding solutions. Independent, yet electronically coordinated, active control of each conductor and insulation winding spool for a single product provides the functionality required.

[0010] Degrees of Freedom (DoF) control. As used herein, the term "DoF" will be used to describe the control of routing elements and structures to adjust the orientation of the elements and structures to provide linear and / or rotational degrees of freedom to facilitate the handling of delicate media without causing damage.

[0011] Accordingly, one embodiment of the present invention includes an unwinding spool subassembly comprising a frame having an upper portion and a base portion, a first linear actuator interconnected to the base, a first rotary actuator interconnected to the first linear actuator, a second linear actuator interconnected to the first rotary linear actuator, an unwinding frame interconnected to the second linear actuator, and a rotatable unwinding spool adapted to transport a linear media, operatively interconnected to the unwinding frame, the unwinding spool subassembly being connected to a cross member of the upper portion of the frame. a third linear actuator connected to the first linear actuator, the third linear actuator being oriented substantially with the first linear actuator; a second rotary actuator interconnected to the third linear actuator; a plate interconnected to the plate; at least one riser interconnected to the at least one riser; at least one beam operatively associated with the at least one beam; a tensiometer interconnected to the at least one beam and spaced from the tensiometer; a transverse beam, a pivot fork rotatably interconnected to the transverse beam, the pivot fork terminating in a parallel guide adapted to receive a linear material, a fourth linear actuator interconnected to the pivot fork and a frame member associated with the plate, the fourth linear actuator configured to urge the first arm in a direction non-parallel to the third linear actuator, a fifth linear actuator interconnected to the frame member associated with the plate, the fifth linear actuator configured to urge the second arm in a direction non-parallel to the third linear actuator, a sixth linear actuator interconnected to the fifth linear actuator and the fourth linear actuator, the sixth linear actuator configured to urge the third arm in a direction orthogonal to the fourth linear actuator, and a seventh linear actuator interconnected to the sixth linear actuator and the fifth linear actuator, the seventh linear actuator configured to urge the fourth arm in a direction orthogonal to the fifth linear actuator.a seventh linear actuator, a third rotary actuator interconnected to the sixth linear actuator, a fourth rotary actuator interconnected to the seventh linear actuator, an eighth linear actuator interconnected to the third rotary actuator, the eighth linear actuator configured to urge the fifth arm in a direction toward the linear medium; a ninth linear actuator interconnected to the eighth linear actuator and the fourth rotary actuator, the ninth linear actuator configured to urge the sixth arm in a direction toward the linear medium; a follower subassembly including a ninth linear actuator configured to bias the arm, a first take-up guide interconnected to an end of the fifth arm, and a second take-up guide interconnected to an end of the sixth arm; at least one tenth linear actuator interconnected to the base portion; at least one eleventh linear actuator interconnected to the base portion; a twelfth linear actuator interconnected to the tenth and twelfth linear actuators; and a fifth rotary actuator interconnected to the twelfth linear actuator. a winding form subassembly including a winding frame interconnected to the fifth rotary actuator, a sixth winding arc rotation interconnected to the fifth rotary actuator, and a winding spool operatively interconnected to the winding frame, the winding spool configured to rotate and adapted to receive a linear media, the linear media being taken from the unwinding spool, transitioned about a tensiometer, and wound onto the winding spool to form a magnet, the pivot fork, the first winding guide, and the second winding guide being connected to the first linear actuator. and selective movement of at least one of a first linear actuator, a second linear actuator, a third linear actuator, a fourth linear actuator, a fifth linear actuator, a sixth linear actuator, a seventh linear actuator, an eighth linear actuator, a ninth linear actuator, a tenth linear actuator, an eleventh linear actuator, a twelfth linear actuator, a first rotary actuator, a second rotary actuator, a third rotary actuator, a fourth rotary actuator, a fifth rotary actuator, or a sixth winding arc rotation;To provide a winding machine that may be capable of 20 DoF to control the position of the linear media. A take-up spool associated with a sixth rotating device at the spool location provides a winding arc rotation, thereby allowing the take-up spool to be selectively tilted, including embodiments such as a goniometer or rack and pinion arc mechanism.

[0012] Material handling. Yet another aspect of embodiments of the present invention is to provide enhanced material handling capabilities. More specifically, current SC winding methods produce various stress / strain points that lead to material failure and lower critical SC values, which degrade operational performance. Stress / strain points will often survive winding and subsequent quality assurance processes, but will lead to failure during worst case scenarios of highest system power or energy operation.

[0013] Tensiometers and guides. Another aspect of some embodiments of the present invention is to provide a linear media tensiometer and guide. More specifically, the LMHS can manually or automatically induce and maintain tension on both the unwound and wound portions of a cable, magnet, or cable magnet while allowing individual SC operations such as SC criticality testing, splicing operations, and unwound spool shuffling to be performed.

[0014] Winding arc rotation. Automated and / or manual rotation of the winding mold allows for significant winding DoF capabilities. The objective is to enable simple to highly complex magnet, cable, and cable magnet winding capabilities comparable to human winding interaction and to a level not possible with other semi-automated to fully automated winding machines. Embodiments include goniometer or rack and pinion arc mechanization systems such as for complex solenoid, planar, and / or spherical magnet winding.

[0015] No back bend linear media routing design.Some embodiments of the present invention use a routing design that follows strict design rules when transporting linear media from a storage location / reacted unwinding spool to the desired take-up spool (or bobbin or former). It is highly desirable that the media routing paths, especially the HTS and reacted MTS, do not have any reverse bends.

[0016] Bend radius control. It is also highly preferred that as the media is routed through the winding machine, each bend, including the unwind and take-up spools and any pulleys over which the media passes, should maintain a minimum bend radius. This minimum radius, which may also be expressed as the minimum radius of curvature, is determined by the nature of the media material being processed.

[0017] dynamic surface. To minimize media stresses and strains through friction and rubbing, which not only increase the axial tension on the media but also tend to damage any wire insulation, all of the surfaces touched by the wire during the winding process will preferably provide low friction surfaces without any sharp edges or dynamic routing surfaces that move in the direction of the media motion (i.e., pulleys or wheels).

[0018] Direct closed loop axial control. According to some embodiments of the invention, axial tension is measured and used as input data for a primary control loop that influences system operation. Preferably, closed loop control is used whereby the winding process is initiated by a motor that pivots either the unwinding spool or the take-up spool (or both).

[0019] Direct closed loop lateral control. Side bending and stress should also be controlled in some embodiments of the invention. The superconductor wire should be unwound from the unwinding spool, passed around the tension sensor wheel (preferably wrapped circumferentially around about 180 degrees to ensure accurate measurement of tension) and wound onto the take-up spool while remaining in substantially the same plane.

[0020] A side sensor on the winding guide is placed perpendicular to or adjacent to the winding direction. This sensing derives the level of guide force on the media, which is then compared to other sensors, such as machine vision, to adjust the control.

[0021] Non-contact sensor. Yet another aspect of the invention is to provide machine vision, including optical, including 3D vision, laser, including 3D laser profiling, and / or non-contact precision sensors, such as proximity sensors. For example, some LMHS embodiments employ non-contact media position or winding pattern sensor systems, such as vision or laser, or non-contact tension sensing electromagnetic, resistive, or inductive measurement sensors from one to multiple sensing directions.

[0022] Angle on / off winding. An active control loop based on the axial tension value, as one embodiment of a global control master and a hierarchy of master / slave relationships, provides a means to vary the pitch angle to precisely maintain a desired performance, such as a constant axial tension.

[0023] End of layer sensing. A critical transition in the winding occurs when the edge of the take-up spool is encountered. In multi-layer windings, a change of direction must be overcome at this transition.

[0024] Proof of performance. Some embodiments of the present invention provide proof of performance integrity after winding. More specifically, values ​​such as tension and shedding occurrence are recorded throughout the length of each SC strand and therefore at the final cable and magnet.

[0025] Tension control for each turn. Another aspect of some embodiments of the present invention is to provide tension control on a turn-by-turn basis, or to vary tension control continuously throughout the winding process. For example, some LMHSs allow an operator to set a winding tension value for each layer, and even for each turn of each layer in a winding.

[0026] Reverse winding. The winding operation onto the bobbin generally involves a single bobbin rotation direction. Another aspect of some embodiments of the present invention is to provide an LMHS that performs reverse winding onto the bobbin.

[0027] Reduce joint pain. The LMHS of one embodiment provides the ability to reduce, and in some cases eliminate, the number of splices required for any linear media, such as SC wire or tape, due to the large number of controllable degrees of freedom (DoF).

[0028] Cryostat cladding and cable jackets. The LMHS of one embodiment of the present invention provides an in-line cryostat cladding station, cable jacketing station, etc., that completes the cable wound cores, facilitating the development of large commercial cable magnets and commercial power cables.

[0029] Integrated winding components.Yet another aspect of some embodiments of the present invention is to provide a winding machine configured to integrate an energy storage system (ESS), power electronics, sensors, etc., into a cable, magnet, or cable magnet. Cable embodiments can be wrapped for finite, intermittent, or complete cable lengths and / or when used in cryogen environments. Those skilled in the art will appreciate that common energy storage systems that may be incorporated, for example, by winding into or onto a cable, magnet, or cable magnet are ultracapacitors (identical to supercapacitors), capacitors, batteries, or similar devices. Furthermore, "power electronics" is often understood to be solid-state, linear-based, etc. non-solid-state, etc. electronic devices that selectively control and convert electrical power. Sensors provide sensing of the ESS, power electronics, cable, magnet, cable magnet, etc., which can then be recorded and / or used in a controlled response. The integrated ESS, power electronics, sensors, etc. are lighter, smaller, and safer than traditional ESS packs / boxes that employ ESS housings, bus bars, nuts and bolts, etc. The ESS and power electronics may be wound separately or together as a combined solution in automated and / or manual stations.

[0030] One cable embodiment components are periodically wrapped around a cable core, either in a helical wrapping process or in one embodiment formed into long strips for separate helical wrapping. In a further example, an ultracapacitor (UC) passively protects the remainder of the ESS, such as a battery, from stresses that would otherwise require heavy and expensive power electronics. This functionality provides a distributed grid solution and, with respect to electric aircraft embodiments, a distributed electric propulsion (DEP) solution. In separate or combined embodiment examples, a wound battery will often be used to provide long-lasting energy to power capability and the UC will be used to provide peak power capability, one or both of which may include power electronics and sensors.

[0031] In one UC embodiment, the cable cladding chemical UC is placed in the non-cryoagent region. Another UC, e.g., nanowhiskers (nw), is placed in the cryogen, resulting in a more efficient and thinner UC, allowing for AC / DC / pulsed power transmission. Placing the UC in the cryogen eliminates the need to periodically break through the cryostat to connect the UC to the superconductor, which is important for thermal management and increased reliability. The cryogen will also provide added electromagnetic (EM) shielding to the exterior of the SC device. Additionally, the cryogenic temperature increases the conductivity of the copper (Cu) electrodes, further aiding in a more efficient and thinner UC. Specifically, placing the UC in the cryogen should result in a lower equivalent series resistance (ESR), which improves the UC's ability to deliver large amounts of power, since ESR is inversely proportional to peak power. Power electronics and sensor embodiments provide active sensing and control of any element cladded on the cable, magnet, and / or cable magnet as envisioned herein.

[0032] Adjustable winding guide.Adjustable winding guides, such as independent follower guides or hoisting guides, are utilized by some embodiments of the present invention to enable winding equivalent to a human operator. The guides envisioned provide automated and / or manual capabilities to control the wound media. The hoisting guides can be low friction surfaces, rollers, rods, or guides located on one or more sides of the media in space. In one embodiment, the hoisting guides are set to the linear media width and hold the media in place. Guides are used for the need for added lateral alignment forces, either directly or via a separate pusher. In an embodiment, the software can code splines or equivalents from computer-aided design (CAD), computer-aided manufacturing (CAM), or equivalents for multiple DoFs to follow to create a more precise winding profile. All adjustable winding guide embodiments can connect to any winding machine sensors and controls and automatically control their motion. Human interaction via a control panel may also be used.

[0033] The guide is intended to provide a machine-equivalent solution for human interaction to control sensitive media. Thus, one benefit of some embodiments is that the media is handled appropriately. In addition, by providing machine-calculated variable tension control at some to all winding layup points, mechanical stresses in radial and angular directions are controlled. Using these techniques, the system neutral stress axis stress is also located, which can be exploited to neutralize the final operating stress. Typically, negative radial or inward winding stresses are selected, thereby reducing the overall winding stress from mechanical winding stresses such as magnet hoops and radial stresses. Finally, more DoF provides further ability to actively minimize stress and bending and achieve more complex final geometries.

[0034] One embodiment is designed to fabricate classical magnet armature windings or any angled, curved, or concave cross-section windings. The added "push" is used for areas equivalent to a human pusher tool. For applications calling for curved armature magnets, a single to multiple position pusher setup is employed on top of the linear media to hold the media layer positioned within a contoured slot to achieve a curved stack instead of a linear pancake coil. In another process, an optional axial tension is generated between the spool and bobbin / form to "pull" the taught media. In another embodiment, an independent follower guide arm is used with multiple DoFs, such as linear and rotational motion of the follower to provide motion relative to the form.

[0035] In another embodiment, one pusher may be configured to push one or both sides of the linear media with a suitable tool, while the other pusher may be used for other operations such as holding it in place or pressing down on the linear media to coat around difficult corners.

[0036] In all embodiments, the adjustable winding guides can help to obtain a tighter packing ratio and prevent any winding contamination. The adjustable winding guides can also help to control the winding installation area.

[0037] Winding division. In particular, in hybrid to air core designs for superconductors, the need to use continuous iron to direct magnetic flux density is eliminated, which allows for winding into assembled sections. Embodiments include any electrical winding, such as electric machines, transformers, fault current limiters, NMR / MRI, and SMES. In electric machine embodiments, both the stator and rotor can then be constructed to wind, 3D printed, or otherwise created, and assembled in wound sections for connection when forming the final device. These sections are wound and / or created externally from the final device for easy assembly, including providing a means to activate the line replaceable units and / or TFMs outside of the final machine.

[0038] Multi-turn magnet. Winding multiple separate magnets at once provides the ability to wind multiple magnets without any seams between the magnets. Embodiments include multiple magnets such as multiple electric machine primary windings and / or secondary windings on the same phase, etc. Other embodiments include concentric rings for transformers or fault current limiters or SMES embodiments. Other embodiments include multiple cylindrical coils for use in high energy physics particle accelerators or NMR / MRI.

[0039] 3D printing of superconducting windings into application components.One aspect is to provide 3D printed parts specific to superconducting, particularly HTS and MTS applications. That is, 3D printed parts can be used in electric machines, MRI and NMR, normal to high frequency transformers, fault current limiters, SMES, general to specialized magnetic device cores, winding formers and tools, etc. Due to the need and benefits that extremely high superconductor currents and magnetic fields enable, the use of 3D printing for end uses and products can be extremely beneficial, such as fully cryogenically low temperature and power dense devices, rotating electric machines with high structural capabilities at high speeds, thermally conductive paths, special materials such as titanium (Ti) for SC use, and supporting the development and operation of lower mass devices and systems. Linear, rotary, arc, and all other electric machine embodiments include elements to complete electric machine rotors and stators to hold field and armature windings, including winding supports to the final operating formers, including hybrid to fully air-core formers, and other magnetic elements such as trapped field magnets (TFMs) and permanent magnets, and non-magnetic elements. Any magnets, cables, and / or cable magnet devices may include magnetic paths, cryostats and cryogenic cooling and conductive paths, gas paths (e.g., cryogenic liquid to gas expansion paths), electromagnetic (EM) shields and shield mounts, support and control of EM and mechanical effects such as via mechanical and / or electrical high speed and frequency induced EM effects, conductive cooling and quench support, 3D printing for structural support, allowing for increased manufacturability of components to systems, a means to minimize part count and cost, increased reliability, etc.

[0040] All electric machine or similar inventions described herein apply to rotating, linear, arc, etc. types of kinetic AC or DC devices. In a rotating or arc electric machine, the stator is the stationary part and the rotor is the moving part. The rotor is generally radially inward, but either can be on the radially inward or outward. Parts of this disclosure refer to the "primary" and "secondary" parts of an electric machine. The "primary" is the active main moving part of the electric machine, which is the location of the armature, i.e., the component of the electric machine that carries the AC current in an AC machine. The "secondary" is responsive to the primary of the electric machine. In an AC machine, the secondary comprises the magnetic field producing elements (magnetic coils, permanent magnets, trapped field magnets, etc., or some combination) used in AC synchronous machines, which will be described in more detail below, and the passive conductors used in AC induction machines.

[0041] Winding HTS and MTS generally requires very large bend radii and tensiometer wheels to hold the tensiometer (e.g., tension measuring device) and linear media and sense that the linear media must be large in diameter for the HTS, especially the reacted MTS, and well balanced in all directions to provide part of the continuous measurement of Newton-level tension. Such wheels do not exist in the industry.

[0042] Rolling syringe.Some versions of the winding machine envisioned employ automated and / or manual winding injectors for placement of adhesive, UV adhesive, thermal compound, spot, linear, pattern, etc., in the windings. In one embodiment, the winding injector is used for windings that are concave, convoluted, or open on one or both ends. In another embodiment, the winding injector is held for a short time to dry, then used in conjunction with a follower guide or pusher for continuous winding or slow winding. Full transposition provides an embodiment option for better cooling paths, where each layer thermally shields the layer below, providing better quench and fault current protection, versus the more common Cu or equivalent thermal stabilizer use. These cooling paths include HTS to HTS winding voids that house entrained thermally conductive material or injected cryogen. In either case, the voids can be match-wound to allow for direct cooling of the cryogen to all layers. By orienting the internally wrapped thermally conductive material, the wrapped cooling path can be connected to the external conductive cooling path at a length that is repeated following the cable, such as 0.5 meter contact or mesh contact, while still allowing cryogen flow. In all cases, voids or any magnet, cable, cable magnet locations can be epoxy filled or filled for other needs such as improved structural support, magnetic path support, etc.

[0043] Rolled filler. Another aspect of some embodiments of the present invention provides an LMHS that incorporates wound-wound fillers or bridges that prevent sharp bends from occurring in the wound material, particularly during flexing, movement, or other induced movements in the wound magnet, cable, or cable magnet. The applied fillers can be solid or liquid.

[0044] Magnet station.One embodiment of the present invention provides an in-line magnet and cable magnet station that facilitates the development of commercial magnets and cable magnets. The magnet station improves the capacity, reliability, cost, and production rate of complex magnet and cable magnet configurations while incorporating partial to full transposition and braiding of modern SC magnets and cable magnets. Industrial use embodiments include High Energy Physics (HEP), Nuclear Fusion, NMR / MRI, transformers, fault current limiters, superconducting energy storage rings (SMES), motor / generator magnets, and cable magnets.

[0045] Advanced sensing and control. The LMHS in one embodiment employs advanced control processes, techniques, algorithms, and supporting sensor types, installations, and use that go beyond those used by winding systems to date. A key embodiment is an axial tension sensor that is uniquely developed and used as the basis for all winding feed rate and tension control.

[0046] Variable media. A reviewer of this application and the applications described above will understand that in some respects the type of media being wound or transported is not relevant. More specifically, the wound media can be any type of delicate material (e.g., superconducting wire, tape, cable, thermal to electrical insulators, etc.) that is wound or transported from one location to another. Those skilled in the art will also recognize that the apparatus and methods described in these applications can be used to create cables, magnets, cable magnets, or any other device known in the art that incorporates wire or cable or linear media.

[0047] Any flux type superconducting electric machine.Yet another aspect of some embodiments of the present invention is to provide radial, axial, transverse, and any other type of flux type devices employing HTS where the stator and / or rotor portions of the motor are cryogenically cooled. Transverse flux motor components may also be partially or semi-cryogenic. In one envisioned AC induction machine, the field coil side may be replaced with conductive material such as shorted passive HTS tape, perhaps in the form of a coil, squirrel cage, or sheet equivalent.

[0048] One embodiment of the envisioned invention is an air-core AC or DC superconducting machine with HTS EM armature coils and HTS EM and trapped field magnet (TFM) field poles that maximizes rotational speed, eliminates all possible losses, and provides the most efficient, power dense, high specific power machine possible with today's technology. A complete HTS electric machine, including multiple turns of complex curves per laminar HTS field and armature coils, will increase efficiency and power for much lower mass and volume than any other currently possible in the same rotor speed range, especially for smaller sized machines. The conversion benefits of a fully cryogenic HTS electric machine with curved HTS coils include: 1) highest efficiency (>99.0%), 2) highest power and power density, 3) lightest weight, 4) smallest size, 5) highest torque, 6) highest air gap B, 7) no internal heat generation, 8) no resistive losses (especially beneficial for short axial length machines such as most circumferential machines), 9) safely wound HTS commercially produced magnets, 10) first ever multiple turns of complex curves per layer HTS field and armature coils, 11) fully cryogenic machine, 12) TFM integrated with EM coils in the field poles, 13) TFM activation inside the machine due to combined field and armature EM coil activation method, 14) minimum amount of conductor tape / wire required, and 15) easy fabrication from windings to modular storable / replaceable subassemblies for all frame sizes. In this embodiment, HTS primary losses are eliminated by 85%. The machine performance increase is related to the number of magnets that are converted to HTS, starting with the elimination of all magnet resistance losses.

[0049] Tape curvature and alignment for B path. For best B path operation, which is especially important for HTS tapes, linear media are intricately wound and curved. Iron, which controls the B path (including the normal B into the air gap), is absent in air-core devices. Hence, curved winding patterns are used to accommodate the B path needs. Properly designed intricate 3D shaped SC magnets allow compact and lighter sizing for high efficiency and B without exceeding HTS critical values. Multi-layer magnets such as electromechanical field coils incorporate radii at their corners to curve the B path and minimize HTS placement in the highest B regions, such as electromechanical Fe tooth curves to limit motor saturation. The highest HTS induced current occurs when the external B is perpendicular to the tape width, so in another unique design step, each HTS tape is placed and oriented to set the HTS width parallel to the highest B. When this configuration is not possible, such as with certain armature configurations, HTS EM shields deflect the highest B away from the tape width.

[0050] Flat fan magnetic coil.The winding capabilities described herein turn the considered negative aspects of HTS tape geometries into advantages. Planar fan compact coil embodiments range from general EM-based devices to radial, linear, arc, and circumferential electric machines (examples include motors for aircraft turbofans and generators for wind turbines), transformers, fault current limiters, superconducting energy storage rings (SMES), NMR / MRI, cable magnets, thrust tubes such as for exo-satellite ion propulsion, nuclear fusion reactors, and any EM-specialized device such as high energy physics particle accelerator beam compression / recompression and focusing into deflection magnets. For electric machine embodiments, this increases the electric machine performance far beyond any other machine attempt with electric machines, approaching an ideal sinusoidal machine as far as current technology allows for discrete multiple turn windings. In an electric machine, any stator or rotor coils (both primary (armature) and secondary (field, passive secondary, etc.) coil sides) can be in a flat fan configuration, some field pole configurations can include TFM, and the stator or rotor can be on the inner radius, either of which can include an armature or field coil.

[0051] Any type of extremely high power compact device is also possible since HTS has no internal heat generation at any non-critical current levels, except for micro solder joints and EM transient conductor heating. No heat generation means there are no current thermal limitations, no EM shielded winding cooling beyond cryogenic cooling, no parallel windings required for internal current heating, etc. Assuming there are no significant heat generation concerns, specialized and complex HTS winding installations turn the very thin nature of HTS to advantage, allowing new "flat fan" coils to be built and installed in new configurations. Flat fan coils use thin tape geometries such as HTS (often 0.1 mm with 1 micrometer for HTS) by installing HTS tape widths (often 2-12 mm) with the width oriented along a straight length, as in shallow saddle coils that are tightly packed and curved. B acts in a direction transverse to the surface currents, which are highest parallel to the longest length, so orienting the tape width perpendicular or nearly perpendicular to the air gap gives the highest B across the air gap. Long winding depths are no longer required for single (pancake), double, or, as expected, only a few layers of windings at most are allowed. As B travels from the farthest (e.g., outer) layer tape to the air gap where the thin HTS maintain their path, it enters the air gap due to flux exclusion. When compacted into a pancake coil that curves into the air gap, this configuration places the thickness of all the armature and secondary coil turns on the surface adjacent to the air gap, and no layer moves the HTS away from the air gap, but with hundreds to thousands of turns, all at high current. This configuration maximizes the air gap B while minimizing losses. When B is overlapped for many parallel discrete turns aligned together, extremely high B is achieved. The limit is then defined by the maximum B per HTS tape group area where the discrete B loops are separated across the circumference versus the overlap of many turns into deep teeth for a typical radial machine embodiment.

[0052] The flat fan HTS magnet design allows for minimization of slot and harmonic losses with small air gaps and elimination of support for magnetic and mechanical forces, which are major issues with slotless windings. The high air gap B that HTS provides allows for an air core machine, which eliminates all hysteresis losses along with not using any PM. Exhaust or no air gaps eliminate all windage losses. Cryogenic cooling losses are comparable to conventional cooling losses. The slotless armature allows for good armature backplate cooling, including high rpm, elimination of slot losses, easy construction, and elimination of the need to separate coil turns and coil groups for cooling purposes. The armature phases and field coils can then be installed next to each other with or without interphase HTS shielding layers, and then all HTS phases can be structurally combined into a single armature and / or field coil ring. Since there are no slots, only shallow surface coils, the diameter, which is the best mechanical dimension for reducing sizing and weight reduction needs, is minimized with only structural support and cooling beyond the radially outermost coils.

[0053] Secondary coils such as field coils follow a similar winding to the armature to provide thermal support. Short thin teeth or equivalent can also be incorporated if operation including quench does not structurally or thermally permit slotless windings. Harmonics are minimized in this highly distributed armature and secondary winding with each turn (possibly hundreds of turns for small size electrical rotary, linear, arc, etc. machines, only increasing for larger size machines) next to the air gap providing a small B electromotive force (emf) step relative to the slot generated emf from the concentrated windings with most turns far from the air gap. The coil is then a compact series of either vertical or angled HTS turns. In the individual HTS angle cases, each turn is wound to overlap one another to further eliminate harmonics and further reduce any unwanted induced B in the tape width while providing the highest air gap B, this V pattern helps create a coil seat turn by always turning the HTS thickness side into the turn. For this case, the HTS of the armature and / or secondary coil halves are angled in an overlapping V pattern with respect to the B path. The assumed angle may be small due to the aspect ratio common to HTS, i.e., long length and relatively thin width.

[0054] The armature phase half windings in one embodiment are turned inward relative to the secondary to accommodate the secondary B moving past the armature. To provide the highest induced B in the secondary, the secondary windings are expected to turn inward relative to the secondary poles to accommodate any B moving past the poles. Adding a skew angle is also a possibility. A fractional pitch winding can further eliminate any remaining harmonics. Without harmonics, due in large part to the highly distributed windings, all non-leakage Bs fall into the power producing fundamental frequency, thus approximating a pure sine wave machine.

[0055] If stray B is minimized, the critical HTS current is not approached and any desired tape width can be used for either the armature or field coil embodiment, provided that B across the tape width is acceptable. For high current machines, larger HTS widths provide higher current output with faster response time. At the lower end, smaller HTS widths allow more ampere turns for multi-layer coils or high power very compact HTS single layer machines. Electrically, more turns give higher emf with natural current filtering if the HTS is already high current output. More layers provide higher power density within the B and current critical limits.

[0056] Flat fan seat winding. The end turns of conventional devices often suffer from leakage flux and Cu losses due to the lack of rear iron and the geometry that moves the end turns away from the air gap and not orthogonal to the secondary. To use the end turns as part of the magnetic length, the end turns can be oriented in the electric machine so that the poles overlap the end turns on one or both sides and make them part of the magnetic length due to 1) the flat fan geometry of the HTS end turns, 2) the short end turn air gap, 3) the 45 degree or smaller end turn angle to the straight armature length, and 4) no end turn resistive losses. For primarily air-core and compact and / or short axial machines where the end turns are a large axial length percentage, this adds power density and efficiency by increasing the usable axial length and eliminating leakage inductance for the end turns and nearby straight magnetic length. When the phase power is not smooth due to lack of phase transition areas such as coding, phase overlap, sufficient induced delay, etc., the end turn magnet length smooths the phase power by automatically overlapping.

[0057] Curved flat fan coils and TFM.In one electromechanical embodiment, the field coil is a general coil or flat fan with multi-dimensional curved sides to control the B path and further accommodate trapped field magnets (TFMs), such as, but not limited to, HTS TFMs, to further increase air gap B and power performance. The TFMs can be activated to different pole orientations, which is a great benefit for varying the power output from the same electric machine without the need to rebuild the electric machine, such as replacing the secondary. In a further electromechanical embodiment of an HTS electric machine, the outside of the EM coil is curved to encapsulate all the TFMs while maximizing B for small air gap pole areas that overlap multiple armature phases. The HTS EM field poles 1) activate the TFM in the machine, 2) maximize the field B, 3) enhance and control B for a higher, more efficient fundamental B per rpm, and 4) shape the power generation waveform when in self-excited mode with the armature. The TFM B forms an equilateral triangular shape with a maximum value at the mid-surface of the pack, so in one embodiment the TFM is installed side-by-side, angled to the air gap, providing the maximum averaged air gap B. The entire pole is then curved to reduce the curved air gap, allowing the highest B without quenching while providing variable air gap length at each pole end, further reducing harmonics. The field coil TFM is epoxied in place, which protects the TFM and facilitates rotor manufacture. Sensors and heaters installed with the TFM control deactivation. The rotor poles are connected to form a cylinder for structural support.

[0058] TFM activation in conventional or half HTS EM wound machines is a major concern due to the limitations of Cu windings and the maximum B and Fe limits they can hold across the TFM. This concern is eliminated for superconducting EM such as HTS and MTS due to the high B without any heat generation and further with the air core benefits from hybrid. In one embodiment, TFM activation is achieved by aligning the field poles to specific armature phase locations and applying DC B in the same direction across both the armature and field HTS coils.

[0059] EM shielding. In the electric machine embodiment, options for electromagnetic (EM) shielding and cryogen cooling of SCs such as HTS or conventional conductors, both options allowing high conductivity and significantly increasing EM shielding, are employed across the field poles, between the armature phases, and across the non-magnetic long base turns. These unique EM shield windings, of which HTS is an embodiment, 1) reduce quenching issues, 2) support higher B in tightly contained paths, especially in smaller magnets, 3) reduce mass by eliminating the need for Fe and HTS windings, and 4) optimize efficiency by minimizing stray and hysteresis B losses while allowing more current per HTS strand. For the armature magnetic long and base turn EM shielding embodiment, one to multiple single strips of parallel HTS with possibly soldered ends are used. In the armature long, HTS strips and / or damper winding bars are installed between the phases. The end turns would use shorted HTS strip EM shields between phases to protect against high frequency losses such as power conditioning system (PCS) switching, which is a bigger concern when resistance is eliminated. In some embodiments, field pole EM shielding for armature transients is required to minimize transient EM losses. In such cases, if a field cryostat is required, stainless steel or aluminum or titanium or equivalent conductive metal cryostat walls would be considered for EM shielding, or shorted HTS strips would be installed across the field poles. Due to the high conductivity and skin depth of all metals at cryogenic temperatures, any high frequency metallic EM shields are very thin. A cryogenic cooling path for all EM shields can provide an excellent inductively generated heat removal mechanism.

[0060] Induction SC electric machine.To obtain high induced B, use wound secondary SC coils and / or squirrel cage configurations, and / or use HTS such as stacked or similarly parallel many turns to provide an induced current path for starting torque and / or oscillation damping. SC machines do not have the inherent resistive damping of conventional machines that can lead to rotor oscillation. Embodiments to eliminate damping include embedding Cu or Aluminum (Al) damper winding bars, variable external resistors, and / or power electronics drives, any of the listed devices may include cryogen cooling to increase performance. These solutions also help control the speed / torque characteristics of induction machines. For example, a wound secondary motor with poles equal to the armature can be started with the highest torque and low inrush current by inserting a high resistance into the rotor circuit. As the motor accelerates, the secondary resistance is reduced and the coil can be shorted at maximum speed to maintain maximum power. In all operating modes, the benefits of SC are achieved due to the extremely high induced emf. An embodiment is an HTS flat fan wound secondary with LN2 cooled damping bars between the windings and potential skew opposite to or instead of armature skew of the armature coils to achieve high performance output.

[0061] Combined induction and synchronous SC electric machines.A complete HTS electric machine with many turns at small packing ratios, with high currents, without any resistive losses, has the benefit of combining two AC machine types: induction and synchronous. The same electric machine operates as an induction machine with secondary inductive passive B, or as a synchronous machine with secondary active B. This allows for extreme combined B for both inductive and synchronous machine modes, and therefore high power and efficiency across all speeds. The present HTS machine embodiment has higher HTS cost and control complexity from the machine to the power conditioning system (PCS), but the benefits from this first-of-its-kind machine can be significant for certain applications from industrial to electric vehicles (EV). The HTS wound induction solution offers high self-starting torque across frequency range and efficiency due to high induction currents without any losses. High starting torque and higher efficiency and power across the speed range allows for better total life cost (TLC) for high torque motion and start / stop EVs (off-road construction, buses, A / C lift, and tugboats). The HTS synchronous solution allows for extreme efficiency and power at optimum speed, where the secondary B is varied to maximize torque at the desired speed. Optionally, a TFM can be incorporated and activated for synchronous mode to greatly increase power and / or close circuit the secondary in passive mode to the external network, but otherwise not activate the TFM for inductive mode operation.

[0062] Combined inductive and synchronous SC electromechanical modes and operating damping.The secondary coil is shorted for induction machine response, and coils are active with or without TFM or permanent magnets (PM) for synchronous machine response. Precise control is required to achieve optimal torque-speed when moving between induction mode (for variable speed and / or slower speed with higher torque) and synchronous mode (for optimized constant speed). Induction machines mirror the armature poles, so in one embodiment, the wound induction secondary can go into common induction machine mode with external resistance or shorted coils, or go into synchronous mode by DC feeding different pole configurations as set through connections for different pole numbers. The selected synchronous poles are DC fed to lock into synchronous mode with limited hunting oscillations from induction slip. SC machines do not have the inherent resistive damping of conventional machines that can lead to rotor oscillations. In another embodiment, an external resistor with conductive cryogenic cooling is an extra rotor damping option, but is typically not expected to be required due to the extreme air gap B stiffness and damping for much lower motor output power draw leaving only high frequency low power oscillations that HTS and HTS coatings should accommodate. Another embodiment includes variable pole options for how the rotor based persistent switch closes as a passive induction or active field coil.

[0063] Compact advanced superconducting devices.Another aspect of some embodiments of the present invention is to provide advanced compact devices made from superconductors. The superconductors may be created or processed using the techniques described herein. Contemplated compact SC devices include, but are not limited to, motor and generator machines, magnetic resonance imaging (MRI), nuclear magnetic resonance (NMR), surface NMR (SNMR) [including surface MRI (SMRI) herein], fault current limiters (FCL), and any device that includes or uses high EM fields and / or currents generated in part to entirely by advanced SC. Advanced SC allows for superconducting operation at higher temperatures and generally contains materials that are more mechanically weak or significantly more mechanically weak. The disclosed devices can be used for motors and generators, medical applications, geoscience applications, wind energy generators, hydroelectric generators, hybrid or all-electric vehicles, oil and gas applications, magnetic confinement, high energy physics (HEP) and nuclear fusion applications including high B magnets above 16 Tesla (T) magnets, power systems, aviation and aerospace applications, EM propulsion (Magprop), EM levitation (Maglev), space EM shielding, marine systems, ground transportation, military, utilities, agriculture, construction, mining, environmental, resource management, disaster relief, archaeology, and any industry that uses EM systems. While portions of this disclosure focus on compact systems, one skilled in the art will understand that SC devices of any size may be manufactured.

[0064] A compact superconducting device. A compact advanced SC of an embodiment is a high power and / or resolution device that is compact in size and weight. Some compact SC devices may be personnel portable, employing power, energy storage, control, data acquisition (DAQ), operator interface, and cryogenic systems.

[0065] Component-based superconducting devices. Another embodiment of the present invention includes an SC magnet set and other elements that are replaceable components or line replaceable units (LRUs).

[0066] Hybrid superconducting magnetic materials. The magnetic bodies include hybrid embodiments involving conventional electromagnet (EM) conductors and / or permanent magnets to complete wound SCs and / or bulk TFM type SCs. Embodiments include using one type of source magnetic body, such as a controlled and wound SC, to control and shape another type of source magnetic body, such as a TFM or permanent magnet, whether or not they are part of the same magnet or pole.

[0067] Combined superconducting magnets and speed. Another embodiment of the present invention is the combination of increasing the speed of partial to full SC devices, further increasing the energy density and specific energy, while not compromising efficiency due to speed induced transient losses. In electromechanical embodiments, maximizing B with full HTS devices and high (5,000 rpm and above) to extreme (10,000 rpm and above) speeds supports the highest power and size savings, leading to ultra-high power and compact size through improved specific power / energy and power / energy density.

[0068] Superconducting magnetic prime mover power system approach. The focus of magnetic prime mover power systems is atypical for SC machines. Large scale efficiency and performance increases for any electric machine are typically achieved through energy system means of increased relative motion of the magnetic reference frame, e.g., armature and exciter field coils in synchronous motors and / or generator machines, and / or by maximizing magnetic air gap flux density (B) for a particular operating temperature (T). This energy system approach will be the future of SC machines once SC materials allow further increases. This general approach is not the direct focus of the present embodiment. Instead, the present embodiment incorporates a power system approach from the benefits of increased current density (J) from a systems perspective.

[0069] Magprop.The windings for use herein of all electric machines and the like described, as applied to electromagnetic propulsion (magprop), include HTS and MTS embodiments applied to any and all SC linear or curved electric machines of any type for terrestrial to extraterrestrial use, including magnetic levitation (maglev) train propulsion and vehicle launchers including space launch systems.

[0070] Superconducting inertial propulsion. The windings for application descriptions herein, such as all electric machine descriptions as applied to electromagnetic inertial propulsion, include HTS and MTS embodiments applied to any and all types of SC inertial propulsion for extraterrestrial use, including terrestrial to space, including ion propulsion systems.

[0071] Maghreb. The windings for application descriptions herein, such as all electric machine descriptions as applied to magnetic levitation (Maglev), include HTS and MTS embodiments applied to any and all SC linear curved electric machines of any type for terrestrial to extraterrestrial use, including magnetic levitation (Maglev) train levitation and vehicle launchers including space launch systems.

[0072] Superconducting transformer. The windings for the application description herein as applied to transformers include HTS and MTS normal to high frequency transformer embodiments, one embodiment of such a transformer may include a 3D printed core to support higher demands such as high frequency switching operations.

[0073] Superconducting fault current limiter. Windings for the application description herein as applied to superconducting fault current limiters (FCLs) include HTS and MTS conventional to high transient and power FCL embodiments.

[0074] Superconducting magnetic energy storage. The windings for the application description herein as applied to superconducting magnetic energy storage (SMES) include HTS and MTS SMES embodiments.

[0075] Superconducting flywheel energy storage.The windings for the application description herein as applied to superconducting flywheel energy storage include HTS and MTS conventional to high speed and power flywheel embodiments.

[0076] Superconducting high-field magnet. Windings for the application descriptions herein as applied to superconducting high field magnets include HTS and MTS high field magnet embodiments for High Energy Physics (HEP) and fusion applications above 3 Tesla (T) magnets.

[0077] Superconducting space EM shielding. The windings for the application description herein as applied to superconducting electromagnetic (EM) shielded magnets include embodiments of HTS and MTS EM shielded magnets.

[0078] Thus, one aspect of an embodiment of the present invention is an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from a layer of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component.

[0079] Another aspect of some embodiments of the invention is to provide an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from a layer of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, the rectangular cross-section being defined by long and short edges, the short edges positioned adjacent to the air gap, and the long edges associated with lateral sides of the superconducting tape extending away from the air gap.

[0080] Another aspect of some embodiments of the invention is to provide an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from a layer of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, the rectangular cross-section being defined by long and short edges, the short edges positioned adjacent to the air gap, the long edges associated with lateral sides of the superconducting tape extending away from the air gap, the lateral sides being non-normal to the curvature of the air gap.

[0081] Yet another aspect of some embodiments of the invention is to provide an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from layers of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, wherein the at least one coil of the primary component is comprised of layers of superconducting tape having a rectangular profile.

[0082] Yet another aspect of some embodiments of the present invention is to provide an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from a layer of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, wherein the at least one coil of the primary component is comprised of a layer of superconducting tape having a rectangular profile, and the layer of superconducting tape of the primary or secondary component is comprised of a plurality of magnets wound with a continuous connection of wire or tape.

[0083] Another aspect of some embodiments of the invention is to provide an electric machine comprising: a primary component comprising at least one coil; and a secondary component having at least one coil formed from a layer of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, wherein the at least one coil of the primary component is comprised of a layer of superconducting tape having a rectangular outline, the rectangular cross-section being defined by long and short edges, the short edges being positioned adjacent to the air gap, and the long edges being associated with lateral sides of the superconducting tape extending away from the air gap.

[0084] Another aspect of some embodiments of the present invention is to provide an electric machine comprising a primary component comprising a plurality of superconducting coils; and a secondary component positioned adjacent to the primary component, the secondary component separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, the superconducting coils being formed from layers of superconducting tape having a rectangular cross-section.

[0085] Another aspect of some embodiments of the present invention is to provide an electric machine comprising a primary component comprising a plurality of superconducting coils; and a secondary component positioned adjacent to the primary component, the secondary component separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component, the superconducting coils being formed from layers of superconducting tape having a rectangular cross-section, the rectangular cross-section being defined by long and short edges, the short edges being positioned adjacent to the air gaps, the long edges being associated with lateral sides of the superconducting tape extending away from the air gaps.

[0086] Yet another aspect of some embodiments of the invention is to provide a method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross-section, the method including the steps of initially energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiates rotation of the secondary component, and energizing at least one superconducting coil to selectively alter the rotation of the secondary component.

[0087] Yet another aspect of some embodiments of the invention is to provide a method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross-section, the method including the steps of initially energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiate rotation of the secondary component, and energizing at least one superconducting coil to selectively alter the rotation of the secondary component, the secondary component further comprising at least one of a coil or bar conductor, a superconducting tape, a permanent magnet, and a trapping field magnet.

[0088] Another aspect of some embodiments of the invention is to provide a method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross-section, the method including the steps of initially energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiate rotation of the secondary component, and energizing at least one superconducting coil to selectively alter the rotation of the secondary component, the step of energizing the superconducting coil occurring when the rotational speed of the secondary component approaches a predetermined rate.

[0089] Another aspect of some embodiments of the invention is to provide a method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross-section, the method including the steps of initially energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiate rotation of the secondary component, and energizing at least one superconducting coil to selectively alter the rotation of the secondary component, the rectangular cross-section being defined by long and short edges, the short edges being positioned adjacent the air gap and the long edges being associated with lateral sides of the superconducting tape extending away from the air gap.

[0090] Another aspect of some embodiments of the invention is to provide a method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross-section, the method including the steps of initially energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiate rotation of the secondary component, and energizing at least one superconducting coil to selectively alter the rotation of the secondary component, the superconducting coil of the secondary component having a passive use mode and an active use mode in which current passes therethrough, the superconducting coil being in the passive use mode when the primary component is initially energized.

[0091] Another aspect of some embodiments of the invention includes an unwinding spool subassembly including a frame having an upper portion and a base portion, a first linear actuator interconnected to the base, a first rotary actuator interconnected to the first linear actuator, a second linear actuator interconnected to the first rotary linear actuator, an unwinding frame interconnected to the second linear actuator, and a rotatable unwinding spool adapted to transport a linear media operatively interconnected to the unwinding frame, a third linear actuator interconnected to a cross member of the upper portion of the frame, the third linear actuator being oriented substantially with the first linear actuator, a second rotary actuator interconnected to the third linear actuator, a plate, at least one riser interconnected to the plate, at least one beam interconnected to the at least one riser, a tensiometer operatively associated with the at least one beam, and at least one a transverse beam interconnected to the beam and spaced from the tensiometer; a pivot fork rotatably interconnected to the transverse beam, the pivot fork terminating in a parallel guide adapted to receive a linear material; a fourth linear actuator interconnected to a frame member associated with the plate, the fourth linear actuator configured to urge the first arm in a direction non-parallel to the third linear actuator; a fifth linear actuator interconnected to a frame member associated with the plate, the fifth linear actuator configured to urge the second arm in a direction non-parallel to the third linear actuator; a sixth linear actuator interconnected to the fourth linear actuator, the sixth linear actuator configured to urge the third arm in a direction perpendicular to the fourth linear actuator; and a seventh linear actuator interconnected to the fifth linear actuator, the seventh linear actuator configured toa seventh linear actuator configured to urge the fourth arm in a direction perpendicular to the fifth linear actuator; a third rotary actuator interconnected to the sixth linear actuator; a fourth rotary actuator interconnected to the seventh linear actuator; an eighth linear actuator interconnected to the third rotary actuator, the eighth linear actuator configured to urge the fifth arm in a direction toward the linear medium; and a ninth linear actuator interconnected to the fourth rotary actuator. a follower subassembly including a ninth linear actuator configured to urge the sixth arm in a direction toward the linear media, a first take-up guide interconnected to an end of the fifth arm, and a second take-up guide interconnected to an end of the sixth arm; at least one tenth linear actuator interconnected to the base portion; at least one eleventh linear actuator interconnected to the base portion; and a twelfth linear actuator interconnected to the tenth and twelfth linear actuators. a winding former subassembly including a fifth rotary actuator interconnected to the twelfth linear actuator, a fifth rotational actuator interconnected to the twelfth linear actuator, a take-up frame interconnected to the fifth rotational actuator, a sixth winding arc rotary actuator interconnected to the fifth rotational actuator, and a take-up spool operatively interconnected to the take-up frame, the take-up spool configured to rotate and adapted to receive a linear media, the linear media being taken from the unwinding spool, transitioned about a tensiometer, and wound onto the take-up spool. , forming a magnet, a pivot fork, a first winding guide, and a second winding guide, a first linear actuator, a second linear actuator, a third linear actuator, a fourth linear actuator, a fifth linear actuator, a sixth linear actuator, a seventh linear actuator, an eighth linear actuator, a ninth linear actuator, a tenth linear actuator, an eleventh linear actuator, a twelfth linear actuator, a first rotary actuator, a second rotary actuator, a third rotary actuator, a fourth rotary actuator,A winding machine that may be capable of 20 DoF controls the position of the linear media with selective movement of at least one of a fifth rotary actuator, or a sixth winding arc rotation. A take-up spool associated with the sixth rotary device at the spool location provides a winding arc rotation, thereby allowing the take-up spool to be selectively tilted, including embodiments such as a goniometer or rack and pinion arc mechanism.

[0092] Yet another aspect of some embodiments is a linear guide assembly including an unwinding spool adapted to transport a linear media; a take-up spool adapted to receive the linear media; and a follower subassembly positioned between the unwinding spool and the take-up spool, at least one actuator associated with the at least one take-up guide subassembly, the at least one actuator configured to selectively impart lateral motion, transverse motion, or a combination thereof, relative to the take-up spool, on the at least one take-up guide subassembly, the at least one take-up guide subassembly including a linear guide actuator operably interconnected to the rotary guide actuator. and a follower subassembly comprising at least one actuator, the actuator comprising a take-up guide operably interconnected to the linear guide actuator, the linear guide actuator providing at least selective movement of an end of the take-up guide toward or away from the take-up spool, and the rotary guide actuator providing selective arcuate translational movement of an end of the take-up guide, wherein linear media is taken from an unwinding spool and wound onto the take-up spool to form a magnet, cable, or cable magnet, and selective movement of the linear guide actuator or the rotary guide actuator controls the position of the linear media as it is placed on the take-up spool.

[0093] Yet another aspect of some embodiments is to provide a winding machine for use with linear media comprising a linear media supply spool adapted to store linear media from which the linear media is removed, a cable core, magnet, or cable magnet associated with an unwind spool, at least one motor that translates the cable core, magnet, or cable magnet, thereby transferring the cable core, magnet, or cable magnet onto a take-up spool, a deposition station configured to deposit linear media strands from the linear media supply spool onto the cable core, magnet, or cable magnet, and a component consolidation station that adds components to the cable core, magnet, or cable magnet before, during, or after the cable core, magnet, or cable magnet is wound onto a take-up spool or former.

[0094] The Summary of the Invention is not intended, nor should it be construed, as representative of the complete scope and scope of the invention. That is, these and other aspects and advantages will be apparent from the disclosure of the invention set forth herein. Moreover, the embodiments, aspects, objects, and configurations described above are neither complete nor exhaustive. As will be understood, other embodiments of the invention are possible using one or more of the features described above or below, either alone or in combination. Also, references made herein to the "invention" or aspects thereof should be understood to mean certain embodiments of the invention, and should not necessarily be construed as limiting all embodiments to a particular description. The invention is described in various levels of detail in the Summary of the Invention and the accompanying drawings and detailed description, and no limitation on the scope of the invention is intended by either the inclusion or non-inclusion of elements, components, etc. in the Summary of the Invention. Additional aspects of the invention will become more readily apparent from the detailed description, particularly when considered in conjunction with the drawings.

[0095] The advantages, embodiments, and / or features described above are not necessarily complete or exhaustive, particularly with respect to the patentable subject matter disclosed herein. Other advantages, embodiments, and / or features of the present invention may be utilized alone or in combination, as described above and / or in the accompanying figures and / or in the description of this specification below.

[0096] The phrases "at least one," "one or more," and "and / or" as used herein are open-ended expressions that are both conjunctive and disjunctive in operation. For example, the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" mean, respectively, A only, B only, C only, A and B together, A and C together, B and C together, or A, B, and C together.

[0097] Unless otherwise indicated, all figures expressing quantities, dimensions, conditions and the like used in this specification and the drawings are to be understood as approximations which may be modified in all instances as required for the particular application of the novel assemblies and methods described herein.

[0098] As used herein, the term "a" or "an" entity refers to one or more of that entity. Thus, the terms "a" (or "an"), "one or more," and "at least one" can be used interchangeably herein.

[0099] The use of "including," "comprising," or "having," and variations thereof herein are meant to encompass the items listed thereafter, and equivalents thereof and additional items. Thus, the terms "including," "comprising," or "having," and variations thereof, can be used interchangeably.

[0100] It is to be understood that the term "means" as used herein is to be given its broadest possible interpretation pursuant to 35 USC, Section 112(f). Thus, any claim incorporating the term "means" is intended to cover all structure, material, or acts described herein, and all equivalents thereof. Furthermore, the structure, material, or acts, and equivalents thereof, are intended to include everything described in the Summary, Brief Description of the Drawings, Detailed Description, and accompanying drawing figures. [Brief description of the drawings]

[0101] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the present invention and, together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.

[0102] [Figure 1] FIG. 1 is a perspective view of a solid core SC cable according to one embodiment of the present invention showing its internal components.

[0103] [Diagram 2] FIG. 2 is a perspective view of a hollow core SC cable according to one embodiment of the present invention.

[0104] [Diagram 3] FIG. 3 is a perspective view of a compact superconducting motor / generator according to one embodiment of the present invention.

[0105] [Figure 4] FIG. 4 is an exploded view of FIG.

[0106] [Diagram 5] FIG. 5 is an exploded perspective view of a magnet that may be used in a compact superconducting motor / generator of one embodiment of the present invention.

[0107] [Figure 6] FIG. 6 is a perspective view, with portions removed, of a complete HTS and fully cryogenically cooled electric machine (motor / generator) of one embodiment of the present invention.

[0108] [Figure 7] FIG. 7 is a perspective view of a rotor employed by the electric machine shown in FIG.

[0109] [Figure 8] FIG. 8 is a perspective view of a stator employing high temperature superconducting elements in the form of a planar fan employed by the electric machine shown in FIG.

[0110] [Figure 8A] FIG. 8A is a cross-sectional representation of an HTS winding and associated air gap of one embodiment.

[0111] [Figure 9] FIG. 9 is a detailed view of FIG.

[0112] [Figure 10] FIG. 10 shows a perspective view of an electric machine of another embodiment of the present invention employing a high temperature superconducting element in the form of a flat fan.

[0113] [Figure 11] FIG. 11 shows an embodiment of an SC wound magnet around a grouping of SC bulk trapping field magnets (TFMs).

[0114] [Figure 12] FIG. 12 shows an embodiment of an SC wound magnet around and above a single SC bulk trapping field magnet (TFM).

[0115] [Figure 13] FIG. 13 is a perspective view of a winding machine according to one embodiment of the present invention.

[0116] [Figure 14]FIG. 14 is a top plan view of the winding machine shown in FIG.

[0117] [Figure 15] FIG. 15 is an unwinding spool subassembly of the winding machine shown in FIG.

[0118] [Figure 16] FIG. 16 is a follower subassembly of the winding machine shown in FIG.

[0119] [Figure 17] FIG. 17 is a detailed view of FIG.

[0120] [Figure 18] FIG. 18 is a winding subassembly of the winding machine shown in FIG.

[0121] The following list of components and associated numbering found in the drawings is provided to aid in the understanding of one embodiment of the present invention. [Table 1-1] [Table 1-2]

[0122] It should be understood that the drawings are not necessarily to scale. In some instances, details that are not necessary for an understanding of the invention or that make other details difficult to perceive may have been omitted. Of course, it should be understood that the invention is not necessarily limited to the specific embodiments illustrated herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0123] Detailed Description An embodiment of the present invention is directed to a Linear Media Handling System (LMHS), an example of which is shown in Figures 13-18. The envisioned LMHS may include a partially to fully automated in-line cryostat station that allows the entire LMHS to be deployed into the magnetic field for use in continuous lengths similar to the splicing concepts described herein. A prime example is the use of the LMHS for cable production at the cable installation site. In this example, one or more LMHS developed SC cables can be wound to include any desired cable twist or weave by using a further embodiment of the LMHS installed down in the SC cable winding system, then in-line inserting or cladding into a cable cryogen vessel or cryostat, which is then fed into the facility. Figure 1 shows a cable with a cable core 2, where the cryostat cladding and jacket and outer wall of insulation 6 and 10 are installed around the superconductor core 14. Those skilled in the art will appreciate that EM shielding may be located outside the superconductor and insulation. In some embodiments, power elements are inserted into areas 6 and 14, such as the integrated winding components of a spirally deposited ultracapacitor, as in the nanowhisker form of an energy storage system embodiment.

[0124] FIG. 2 shows a further embodiment of the invention functioning as an HTS cable similarly shown in FIG. 1. The device shown here is a magnetic field-operable superconducting device and can function as a primary element of a magnetic field-operable superconducting system. FIG. 2 shows an embodiment of a three-phase hollow core superconducting cable 20. The cable 20 has three HTS layers 24 separated by conductive stabilizer and / or insulating layers 28. In some embodiments, cryogen flows within areas 32 and 36. In some embodiments, a power element is inserted into area 36, ​​such as an integrated winding component of a helically clad ultracapacitor, as a nanowhisker form of an energy storage system embodiment.

[0125] 3-5 show a compact superconducting motor / generator 1100. The motor / generator may be used in a field-operable SC personal portable device. The machine may be half or completely HTS and therefore half or completely cryogen-cooled electric machine (motor / generator) of any armature windings. Cryogenic cooling may be achieved by conductive cooling or partial bath cooling, and no stator cryostat is currently shown. For ease of illustration, many cryogenic, armature core, and other elements are removed or simplified. The motor / generator 1100 includes a housing 1180 that supports a stator coil 1185, which may be the armature coil group configuration shown in FIG. 5 to limit splices. That is, FIG. 5 shows multiple magnets 504 wound together without continuous connection of wire or tape 508 to eliminate or limit the number of splices. A rotor 1182 is positioned within the stator 1185. The rotor consists of a shaft 1186 that supports a number of field poles 1187 .

[0126] Trapped field magnets (TFMs) 1774 or permanent magnets 1190 are mounted in groups within the field poles 1767 or 1187 and surrounded by the field coils 1778 or 1188. A magnetic field focusing cover 1189 provides a transient electromagnetic (EM) shielding option for all the field TFMs and coils. The entire field poles 1187 can be constructed separately and assembled as a unit into an electric machine, even if fully HTS, including the option for superconducting TFM activation outside the machine. This case of a completely cold cryogenic motor or generator is possible through a non-thermally conductive hollow shaft 1186, which may have non-metallic sections such as optional locations 1183 of rotor bearings, with rotating cryogenic couplers with buried slip-ring based power and data cables.

[0127] Motor and / or generator type machine embodiments include any motor and / or generator use such unit. A motor and / or generator embodiment that is personnel portable if sufficiently compact is shown in Figs. 3-5 with certain cryostat elements removed to show the SC coil 1185. Motor and generator embodiments span all types of rotating and linear AC such as synchronous and induction machines, and DC machines for both hybrid to full SC armatures and / or hybrid to full SC active and / or passive exciter secondary or field coils, with poles ranging from one or combination of individual components, windings, TFM, PM, solid poles, etc. Embodiments also include rear iron, or particularly hybrid core and / or air core motors, where the removal of rear iron allows for lighter machines and reduced frequency losses given the SC magnetics allowing for compact machines. The air gap of the superconducting machine includes vented or non-air gaps to remove water icing from the air, but also removes all windage losses. An air gap is the non-magnetic space between the primary and secondary of any electromagnetic device. Motor and generator machine embodiments span a vast number of industries and applications that are so extensive that they cannot be easily enumerated. One embodiment is a wind or water turbine generator. Another embodiment is a hybrid or all-electric air, land, sea, or space vehicle motor and generator, including partial to full SC type motor or generator embodiments. Hybrid to all-electric aircraft embodiments of all types and sizes are expected to take great advantage of the present invention on their own, and in certain embodiments with the combined superconducting magnetic and speed invention disclosure and potentially with the hybrid superconducting magnetic invention disclosure.

[0128] 6-8A and 10 show the installation, location, support, and operational support of other magnetic elements such as common to the magnet coils, trapped field magnets (TFM) and permanent magnets, flux paths, cryostat and cryogenic cooling and conductive paths, gas paths (e.g., cryogenic liquid to gas expansion paths), electromagnetic (EM) shields and shield mounts of another embodiment electric machine with hybrid or full air-core winding forms, and flat fan invention disclosure. The electric machine 1750 is a compact advanced superconducting device that can function as a magnetic field operable superconducting device and can function as a primary element of a magnetic field operable superconducting system. The high magnetic flux density (B) provided by the machine 1750 allows for combined induction and synchronous machines. The envisioned machine is also a hybrid to air-core electric machine where tape curvature and alignment for the B path is provided in all armature and field coils. Here, an air-core 1754 is provided on the rotor core rear area, but for any air-core section, non-magnetic material is used to be considered as air-core in terms of magnetic flux density.

[0129] The armature coil 1759 consists of a flat fan magnet coil with end turns 1758, in this embodiment the armature is associated with the stator. A secondary coil, such as a field coil or a wound induction embodiment, may be formed as an overlapping flat fan magnet coil, such as secondary coil 1760. FIG. 10 shows such a magnet coil 1760 with a rotor diameter 1764 larger than that of the stator, thus placing the armature on the inside of the rotor. Of course, the magnet coils may be reversed, with the field coil located on a smaller diameter rotor positioned within a larger diameter stator, which is the more common electric machine configuration as shown in FIGS. 3 and 6. Reversing the primary on the outer radius and the secondary on the inner radius, or vice versa, to similarly swap sides of an arc or linear device to create an electromagnetic device such as an electric machine, will also occur to those skilled in the art. As shown in FIG. 9, the flat fan end includes turns 1765 on the primary that can be configured to add electric machine magnetic length 1759 and 1764, respectively (FIG. 10 shows turns 1762 on the secondary). This configuration also curves the B path, minimizing HTS placement in the highest B regions. The complex 3D shaped SC magnet allows for compact and lighter sizing for high efficiency and B without exceeding HTS critical values. Additionally, as seen in FIG. 6, the end turns are oriented so that the poles can overlap the end turns on one or both sides, making them part of the magnetic length and therefore part of the prime mover of the electric machine.

[0130] In this embodiment, both curved flat fan coils and TFMs are used with field poles 1766 on the rotor 1767. More specifically, the envisioned field coils may be general coils or flat fans with multi-dimensional curved sides to control the B path and further accommodate trapped field magnets (TFMs), such as, but not limited to, HTS TFMs, to further increase the air gap B and power performance. The TFMs can be activated in different pole orientations. Specialized HTS EM shields 1189 are provided over the field poles 1766 with field pole spacers 1770, between the armature phases, and over the non-magnetic long seat turns. In this hybrid superconducting magnetic configuration, the trapped field magnets (TFMs) 1774 or permanent magnets are placed in the field coils in groups with the surrounding field coils 1778. The entire field poles 1766, even if fully HTS, can be built separately and assembled as a unit into the electric machine, including the option for superconducting TFM activation outside the machine. In one embodiment, the field poles 1766 have a cryogen reservoir 1782 below the conductive cooling area to assist with cryogenic cooling needs. Here, a fully cryogenic motor or generator is possible through a non-thermally conductive hollow shaft 1786, which may include a non-metallic section 1790 with a rotating cryogenic coupler with buried slip-ring based power and data cable connections. Exhaust or non-air (e.g., non-aqueous gas displacement, such as noble gas, nitrogen, cryogen cooling system gas, etc.) air gap embodiments, which may include evacuating other machine areas, such as rear area 1794, support a fully cryogenic electric machine by eliminating icing concerns while also eliminating windage losses.

[0131] 6-8A and 10 show the application of winding sections where separately constructed winding sections are 3D printed or otherwise created and wound separately and then assembled and connected to form each magnet or each phase group of the armature core 1759. 3D printing, flat fan windings, the need for TFM activation as separate poles on the outside of the device and when activating inside the device, and hybrid to air core machines take great advantage of this capability such as the elimination of the need for continuity of magnetic material both separately and together.

[0132] 3D printing further provides benefits including structure, magnetic pathways, EM shielding, electrical pathways, cooling pathways, and gas to fluid pathways for any purpose such as those of Figures 4 and 6. A 3D printed component embodiment is shown in Figure 13 for a tensiometer wheel 1328 with the need for extreme precision.

[0133] The assumed flat fan coil 1760 of FIG. 10 for the secondary embodiment and 1759 of FIG. 8 for the armature embodiment use a thin tape profile (often 0.1 mm with 1 micrometer for HTS) such as HTS by placing the HTS tape width (often 2-12 mm) oriented width-wise along a straight length as a shallow saddle coil that is tightly packed and curved. B acts in the direction across the surface current, which is highest parallel to the longest length, so orienting the tape width perpendicular or nearly perpendicular to the air gap gives a very distributed winding with the highest B across the air gap and the lowest losses. Long winding depths are no longer required for single (pancake), double, or as expected, only a few layers of winding at most. This differs from typical radial flux machines (i.e., most common electric machines) where the B source is further into the slot of the machine and therefore away from the air gap, which in turn increases losses such as stray losses.

[0134] Embodiments of the invention, such as induced SC electric machines, employ wound secondary SC coils and / or squirrel cage configurations to obtain high induced B, and / or use HTS such as stacked or similar parallel many turns to provide an induced current path for starting torque and / or oscillation damping. Some embodiments eliminate damping by embedding Cu or Aluminum (Al) damper winding bars, variable external resistors, and / or power electronics drives, any of the listed devices may include cryogen cooling to increase performance. An embodiment of the primary of the electric machine is FIG. 8 with FIG. 10 orientation reversed as the secondary when the secondary is shorted.

[0135] 8A is a cross-sectional representation of an HTS winding of one embodiment of the present invention generally illustrating the enhanced magnetic flux density (B) concept referred to above. The HTS tape member 1800 shown includes a flat strip of superconducting material 1802, typically a few microns thick. The HTS winding is shown as a plurality of HTS tape members 1800 installed such that the smallest tape dimension is oriented toward an air gap 1806 provided between, for example, a primary and secondary component of an electric motor. The tape members may be separated by small gaps 1808 to aid in the desired B flow outside the tape. One skilled in the art will appreciate that the side surfaces of adjacent tape members may abut.

[0136] In one embodiment, the flat fan HTS winding includes a second layer 1810 deposited over a portion of the first layer 1812 adjacent the air gap 1806. The first layer 1812 and the second layer 1810 produce magnetic fluxes B' and B". Because the magnetic flux B" from the second layer 1810 cannot pass through the HTS in the tape of the first layer 1812 as it is superconducting, it must pass through the gap 1806 provided between the HTS tape member and the non-superconducting elements of the HTS tape member 1800. Thus, the magnetic flux B″ from the second layer 1810 adds to the magnetic flux B′ from the first layer 1812 to define a collective magnetic flux B provided by the flat fan winding, maximizing the magnetic flux in the air gap 1806. Although two winding layers are shown, one skilled in the art will understand that additional layers can be added to increase the collective magnetic flux B, or a single layer can also be used. Thus, the flat fan winding configuration contemplated herein allows for the production of increased magnetic flux in a reduced size component that does not suffer from the drawbacks of conventional windings, such as magnetic flux crosstalk, field irregularities, highly separated slots or other windings and all associated problems. In one embodiment, the currents directed to the first and second layers are controllable such that the magnetic flux provided by each layer and group of tapes can be selectively modified.

[0137] One embodiment of the present invention is a combined induction and synchronous SC electric machine. The machine is similar to the induction SC electric machine described above with a secondary SC coil to form an induced passive B (induction) or active B (synchronous) type electric machine where configurations such as switching operationally vary the machine type. The secondary SC coil may be shorted for an induction machine response, and the coil is active with or without a TFM or permanent magnet (PM) for a synchronous machine response. Oscillation damping can be controlled using embodiments such as a high B fixed rotor, introduced inductance effects, external resistance with optional cryogenic cooling effects, etc. Another embodiment includes variable pole options for how the rotor-based electrical switches are closed as passive induction or active field coils.

[0138] A further embodiment, which is not a compact system in the strict sense of personnel portable, but is compact in that all elements must be as light as possible, is exemplified in spacecraft EM shielding. In this case, a set of large SC coils are arranged around the spacecraft providing a B-shield to protect the spacecraft and crew from harmful EM radiation and ions. Although the coils are very large, they take on many of the properties of compact coils, such as increased specific power and power density, the need to be launched into space and then used in space, and long-term robustness without failure. Thus, all appropriate embodiments apply to this larger system.

[0139] One embodiment allows for large B in the air gap, which in turn allows for higher power systems, including higher speed and torque propulsion systems, and higher energy levitation systems for the combined use of maglevs and magprops. One embodiment is an SC-based linear motor for vehicle launch purposes, such as aviation and aerospace. Another embodiment is an advanced SC, such as HTS-based superconducting maglevs and / or magprops, including commercial train speeds to high speed vehicles beyond commercial train limits, including test sleds at or above Mach 1.

[0140] These hybrid magnetic embodiments include conventional magnetics to hybrid motors and generators. In the motor and generator embodiments, the SC to full SC armature, exciter field coils, and AC induction machine passive conductors. Such embodiments of various magnetic options, especially combining SC windings and TFM, not only allow for the right magnetic solution for a given task, but especially allow for very compact machines.

[0141] In motor and / or generator embodiments, any magnetic type including SC combination units are held down via epoxy and / or mechanical bolts and / or dovetails and / or banding / retaining rings, this increases stray losses through larger air gaps, then different banding options are often adopted for high speed machines etc.

[0142] Historically, SC bulk and wire materials have been used separately across applications, and the combined benefits of both have not been utilized in a single unit to date.

[0143] In one embodiment, a system is presented for combining SC wires and trapped field bulk materials. This combination offers the ability to capture the full benefits of both SC types in a common cryogenic condition. The benefits include bulk material activation from magnetic field formation.

[0144] An important embodiment for any SC device is a wound SC, such as a magnetic coil, wound around a single TFM magnet or group of magnets and used for both activating and then modifying the magnetic field of the TFM. As a further embodiment, these combined SC type poles can be made as separate units for inclusion in a machine for easy assembly and activation of the TFM outside the SC device or partially or fully in place in the final SC device. This embodiment also allows for a line replaceable unit (LRU) solution.

[0145] The present invention relates to a method of generating high magnetic fields from SC materials for the purposes of TFM activation, high-B enhancement control, and high-B fields in desired output configurations. 1. A superconducting (SC) wire coil and an SC trapped field magnet (TFM) bulk material are used in combination to complement each other's SC magnetic field. a. The TFM can be positioned at the magnetic lower or higher point of the SC coil to intensify or enhance the generated DC, AC, or pulsed magnetic field. b. The use of both SC types in operation and TFM location in the typical void between the SC coil sides allows for much higher B capabilities than using either the TFM or the SC coils separately. 2. SC wire coils are used to enhance the TFM magnetic field, a. Easily vary the magnetic flux density B on the SC wire with various static DC field changes or even AC to transients depending on the desired output B. b. Enhanced field machines offer superior machine control techniques. The enhancement of uniquely high B is currently unprecedented in practice. 3. SC wire coil is used to provide high TFM material activation energy. a. TFM requires high activation energy to obtain high B. Such activation is extremely difficult to achieve. Difficulties arise from the ability to obtain high B for TFM when attempting activation outside the SC cryostat due to reasons such as magnetic strays and inductive paths to the conductive shield. By placing the SC wire inside the same cryostat with the TFM bulk, one can take advantage of not only the high B capability of the SC wire coil, but also the close proximity of the SC wire generated B and the TFM activated trapped B. b. By utilizing SC wire, unlike traditional conductors such as copper, SC wire can handle extreme currents for short periods of time in the absence of a pinning center and typically generates orders of magnitude less heat energy than pure conductors. Minimizing heat generation is extremely beneficial for any SC coil. c. The wires are automatically located inside the cryostat, whether around the entire SC bulk pack or next to an individual TFM. In the case of an individual TFM, the coils may be physically located around the TFM or over the TFM center. In this case, multiple SC coils may be connected in series and / or parallel to achieve activation. d. Once TFM is activated, or when using an SC DC magnet without TFM, the SC DC magnet can be configured for steady state mode, such as a motor or generator exciter field or an NMR or MRI field magnet, and will theoretically never lose DC steady state charge, with only SC losses resulting from any nearly negligible joint resistance. e. Use secondary and primary magnet windings in the appropriate orientation to achieve increased levels of TFM activation and / or deactivation energy, time, and TFM B orientation. 4. SC wire coil is used to provide high TFM material deactivation energy.

[0146] The same coil embodiment of the present invention may also be used to deactivate TFM bulk materials, where the SC coil is intentionally placed in a quench condition through means such as, but not limited to, forcing the SC coil to quench through an external power supply, or by suddenly opening a potential-permanent switch for reasons such as inducing a localized heating zone.

[0147] Although SC wire can be formed in many shapes, from pure solenoids to saddle coils, this form always has a magnetic field distribution such as high B points in the coil windings due to the strong interaction of the multiple coil legs in that area. The TFM is a small entity that provides a high magnetic field with a high flux density up to the TFM saturation level in the central area of ​​the TFM itself, where the B distribution approximates an ice cream cone shape. This combination allows the desired output magnetic field to be best generated from a uniform B using the inherent B distribution of both material forms, with a possible smoothed ingress and egress pole area that enters the machine air gap to reduce non-fundamental harmonic content. Such effects aid magnet design for dipole or quadrupole particle accelerator magnets, where the B is very high, but uniform B is crucial. For the machine case, the installation of the TFM in the typical void between the SC coil sides and the use of both SC coils and TFM in parallel during operation allows for a higher output B than either the independent SC coils or TFMs. This allows for a much higher power density machine than either the SC coils or TFMs alone.

[0148] Activation and deactivation of the TFM is a crucial but to date unsolved problem for large machines. Activation techniques address controlled B and cryogenic temperatures, which can be complicated and further accompanied by controlled cryogenic pressures. It is easily possible to take advantage of placing both SCs in the same cryostat to use the fact that both the SC wire and the SC TFM bulk must be in the SC critical state with the cryogenic material. Using the present SC coil for activation has the enormous benefit of not pushing the B pulse through the conductive cryostat walls and other supporting materials, and that the SC wire generates orders of magnitude less heat than using a typical conductor for activation. In addition, by placing the TFM activation and deactivation as close as possible to the TFM, less overall energy is required for either TFM activation or deactivation. Examples of TFM bundles with a single SC wound coil around the stack are provided in Figures 3, 4, and 11, with a removable field pole 1767 for general purpose and TFM activation having a field coil 1778 applied around the TFM stack 1774 and a magnetic field focusing cover 1189 (not shown for the TFM pole, shown here for the PM pole). An example of a single TFM with a dedicated single SC wound coil per TFM, whether around the outside of the TFM or centered on the physical center of the TFM, is provided in Figure 12. In this second example, the dedicated TFM coils are connected to an external power supply in either parallel and / or series connection. In both the SC coil and TFM cases, the SC coil and TFM material are likely in the same cryostat, but this is not necessarily the case as there are also advantages to separating the SC bulk and the SC wire coil for reasons such as utilizing magnetic dampers. In both the SC coil and TFM cases, the SC persistent switch may or may not be used.

[0149] 13-18 show an LMHS, i.e., a magnet winding machine 1300 of one embodiment of the present invention capable of at least 20 degrees of freedom. The winding machine 1300 consists of a frame 1304 that supports an unwinding subassembly 1308, a follower subassembly 1312, and a take-up subassembly 1316. The unwinding subassembly 1308 and the take-up subassembly 1316 are interconnected to a base 1318 of the frame. In operation, linear media 1320 travels from the unwinding spool 1324 to the follower subassembly 1312 where it engages with a tensiometer 1328. The linear media 1320 then travels to the take-up spool 1332 of the take-up subassembly 1316. As in the embodiments described above, the handling of the linear media 1320 from the unwinding spool 1324 to the take-up spool 1332 is carefully monitored by sensors and controlled by multiple linear and rotary actuators. The actuators, which will be explained in more detail below, allow multiple solutions for the desired motion. The desired motion may be achieved by simultaneously moving more than one actuator in complementary directions, which allows the footprint of the winding machine to be reduced. Thus, windings that are usually associated with much larger machines are possible, since motion density in the horizontal and vertical directions can be achieved.

[0150] FIG. 15 details the unwinding subassembly 1308, which includes a frame 1340 that rotatably supports the unwinding spool 1324. In other embodiments, the unwinding spool 1324 is fixed vertically. The frame 1340 is interconnected to a linear actuator 1344 that allows movement in the direction of arrow B. The linear actuator 1344 is interconnected to a rotary actuator 1348 that allows the frame 1340 and the interconnected unwinding spool 1324 to rotate in the direction of arrow C. Finally, the rotary actuator 1348 is interconnected to a stationary linear actuator 1352 that allows the frame and the interconnected unwinding spool to advance in the direction of arrow D. In some embodiments, the unwinding spool can also move along the unwinding frame 1340, and / or the unwinding frame 1340 can be selectively tilted to provide even more Dof. The combination of linear and rotary actuators allows for precise control of the position of the unwind spool 1324, which dictates the position and orientation of the winding of the linear media from a point. The actuators therefore maintain the linear media in the winding angle plane, which will be described in more detail below.

[0151] FIG. 16 shows a follower subassembly 1312 that operatively supports a tensiometer 1328. The follower subassembly 1312 employs a stationary linear actuator 1356 that is interconnected on its end to a cross beam 1360 provided on the main frame 1304 (see FIG. 13). In one embodiment, the stationary linear actuator 1356 is generally oriented parallel to the stationary linear actuator 1352 of the unwinding subassembly 1308. The stationary linear actuator 1356 therefore also provides movement of the interconnected rotary actuator 1364 in the direction of arrow D. The rotary actuator 1364 is interconnected via a plate 1368 to at least one riser 1372 that supports a beam 1376. The beam 1376 is therefore rotatable in the direction of arrow C' when biased by the rotary actuator 1364. The tensiometer 1328 is also connected to the at least one beam 1376 via a support beam 1380. Various sensors may also be associated with the tensiometer and interconnected to the follower subassembly 1312 to ensure proper tensioning of the media and to provide a means for selective adjustment of the tensiometer position. The follower subassembly 1312 supports a pivot fork sensor 1382, which rotates in a direction consistent with arrow E. The pivot fork is comprised of parallel guides 1383 configured to operatively receive the linear media 1320. Input from the pivot fork sensor 1382 is used to guide control of a linear actuator 1344 in the unwind subassembly 1308.

[0152] The follower subassembly 1312 also supports linear actuators 1384 (which in one embodiment are electric cylinders) that impart selective movement of interconnected guide rods 1388 in the direction of arrow A. These linear actuators 1384 are attached to linear actuator 1386, which selectively imparts motion in the direction of arrow G. Using a combination of actuators in the follower subassembly 1312, the guide rods 1388 are moved to maintain position on either side of a take-up point 1390 shown in FIG. 13 and are designed to guide the linear media onto the take-up spool.

[0153] A winding injector can be used for placement of adhesive, UV adhesive, thermal compound, spot, linear, pattern, etc. on the windings. In one embodiment, the winding injector is mounted on the follower 1312 and used in conjunction with a follower guide or pusher, such as the follower arm 1386 and / or guide rod 1388 of Figures 16 and 17, to hold for a short drying period and then continuously wind or slowly wind. A drying element, such as a UV lamp for UV adhesives, may be used.

[0154] As highlighted in FIG. 17, precise articulation is accomplished by the take-up guide subassembly, which provides many degrees of freedom (DoF) to affect automated movement of the guide rod tip, simulating human interaction and enabling a wide range of control approaching complete control of the linear media as it is taken up by the take-up spool 1332. More specifically, the take-up guide subassembly 2000 is interconnected to the end of a linear actuator 1384, and thus can move in the directions of arrows A and G and rotate in the direction of arrow C'. A guide rod rotation actuator is provided that is configured to impart selective rotation in the direction of arrow H. The guide rod rotation actuator is interconnected to a guide rod linear actuator, which selectively articulates the guide rod 1388 in the direction of arrow J. Those skilled in the art will appreciate that linear / rotation actuators may be added / removed or employed / disabled (if present) to hold, tilt, and extend the guide rod to provide for achieving the desired linear media control.

[0155] Although referred to herein as guide "rods," one of ordinary skill in the art would understand that these components may be formed in a variety of shapes. Additionally, some embodiments employ a single guide while other embodiments employ two or more guides. The guide rod 1388 may terminate in a wheel, cone, arcuate member, or similar device. In one embodiment, one guide contains the linear media and the other guide urges the linear media onto the take-up spool.

[0156] Here, the tensiometer 1328 and pivoting fork 1382 are located above the take-up and unwind spools and connect the rotary motion to the linear motion. By operating around a stationary linear actuator 1356, the follower subassembly 1312 minimizes the vertical distance required to connect the motion and sensor elements, thereby achieving high motion density in the vertical direction. The motion density minimizes machine frame size and vibration amplitude and allows the assembly to be made from lightweight aluminum extrusions instead of steel. This aspect is a key feature of one embodiment of the present invention (MMP) that supports modular design of the subassembly and simplified accessory attachment.

[0157] 18 generally illustrates the wind-up subassembly 1316, which is comprised of a stationary linear actuator 1394 interconnected to a frame base and supporting another linear actuator 1402. In this embodiment, the stationary linear actuator 1394 is orthogonal to the stationary linear actuator 1352 of the unwind subassembly 1308. Thus, the stationary linear actuator 1394 enables the rotary actuator 1406 interconnected to the linear actuator 1402 to selectively move in the directions of arrows D and F. The rotary actuator 1406 is configured to rotate the take-up spool about an axis parallel to the axis defined by arrows C or C', along the arc indicated by arrow C". A frame 1410, here a rotating former, supporting the take-up spool 1332, is interconnected to the rotary actuator 1406. In some embodiments of the invention, the angle between the frame 1410 and the linear actuator 1402 can be selectively altered to change the orientation of the take-up spool 1332. Some embodiments of the invention include a goniometer 1412 associated with the rotary actuator 1406 adapted to precisely guide the angular orientation of the frame.

[0158] In operation, the take-up spool 1332 is moved through a series of orientations that aid in producing the desired winding output configuration. Actions within the unwind subassembly and follower subassembly aid in placement of the linear media at the winding point. The linear media 1320 is taken from the unwind spool 1324 and directed upwardly to the tensiometer 1328. As mentioned above, the linear media 1320 is also positioned between the guides 1383 of the pivot fork 1382. The linear media then travels downwardly and contacts the take-up spool 1332 at the winding point 1390. The guide rod 1388 controls the position of the linear media as it engages the take-up spool 1332. System control of the linear and rotary actuators maintains the linear media 1320 in a winding angle plane that is approximately vertical, as shown in FIGS. 29-32. The angle of the wind angle plane is defined by the path of the linear media from the unwind spool 1324 to the take-up spool 1332 and varies according to the desired orientation of the winding point 1390. Again, the pivot fork 1382 is aligned with the wind angle plane and the linear media 1320 is held between the parallel guides 1383 of the pivot fork 1382. Feedback from the pivot fork sensor accommodates unwinding the linear media from a spool with an axial width greater than the linear media width while maintaining the linear media path in the wind angle plane. As the unwinding point moves out of the wind angle plane, the linear media held in the pivot fork guides will pivot and the sensor indication is used to command the linear actuator 1344 to move the unwinding spool and therefore the unwinding point until the linear media and pivot fork are again aligned in the wind angle plane. Guiding the linear media in this manner and along this path ensures that there are no reverse bends and allows only one bend of the minimum diameter around the tensiometer wheel 1328 before the linear media reaches the winding point 1390.

[0159] The formation of linear media on the take-up spool 1332 and all other motions in the winding machine 1300 are caused by first moving the take-up spool 1332. Linear actuators 1394 and 1402 move the take-up spool 1332 in orthogonal horizontal directions, while a rotary actuator 1406 moves the take-up spool 1332 about a vertical axis. For more complex outputs, a winding arc rotation (i.e., selective tilt) of the take-up spool 1332 can be accomplished by a goniometer 1412, simultaneously with the other motions. For a cylindrical arc rotation, the goniometer 1412 can be replaced with a gear transmission.

[0160] Some of the LMHS contemplated herein are to eliminate high and non-uniform axial tensions during the winding process, make all non-axial tensions negligible, eliminate all counter bends, keep all bends to a single and large radius, make all side bends negligible, etc. Side bends are particularly problematic for non-round wires, such as rectangular cross-section wires, especially for very thin, very wide wires that are then to be made into tapes.

[0161] For any motorized single DoF or combination of DoFs, independent or electronically coordinated control of the linear media motion is possible through automated, partially automated, and fully manual means. The present multiple degree of freedom (DoF) system would have an operator interface equivalent to providing computer-aided drafting (CAD) input to computer-aided manufacturing (CAM) tool paths for computer numerical control (CNC) production. Options include hardware joystick, software joystick, or partially automated motion control that allows turning on / off single to multiple DoFs for specific movements. Such capabilities allow the user to tailor the motion for specific needs. Preferably, automated, partially automated, and / or fully manual control of any motorized single DoF or combination of multiple DoFs is accomplished to achieve motion while precisely maintaining a desired performance value, such as constant axial tension. In the embodiments described below, for example, the motorized DoFs provide a continuous or variable winding pitch angle. An active control loop based on the axial tension value provides a means to vary the pitch angle while precisely maintaining a desired performance value such as constant axial tension as a global control master and a hierarchy of master / slave relationships. The routing design and controlled DoF of the LMHS of one embodiment provides not only a no-bend situation with minimized forces, but also initial line contact over a point at the winding location to further minimize stress and bending on the tape and in the linear media. This is achieved through controlled design routing and DoF control. A single winding plane with limited bending of the material and limited stress in any direction allows for a final product with limited distortion. The more bending and stress introduced during the magnet and cable manufacturing process, the lower the operating values ​​allowed.

[0162] Although the description of some embodiments of the present invention above is directed primarily to superconductor wires, tapes, and cables, it should be recognized that the present invention may be applicable to any linear media, particularly sensitive linear media. As used herein, the term "sensitive linear media" would include advanced superconducting wires and tapes, very fine conventional wires, filamentous linear materials, fiber optic wires, thin strands of carbon-based fibers, smart fabrics, and extremely dense fine fiber matrices. Furthermore, the present invention can be applied not only to coil and cable winding, but also to any other sensitive media handling process, including, but not limited to, media insulation, bending, braiding, forming, splicing, thermal or chemical treatment such as reacting, encapsulation, inspection, and any manual or automated process that requires safe handling of the media. As used herein, the terms "wire," "tape," "cable," and "media" are used interchangeably. Some embodiments of the present invention can be applied to enable automated winding (or other similar) processes. Also, the term "spool" is used herein to refer to any object on which a sensitive linear media is wound, regardless of the shape of the object. Industry language commonly refers to the unwinding spool as a "spool" and the take-up spool as a "form" or "bobbin," and these terms may also be used interchangeably herein. Whenever the terms "automatic," "automated," or similar terms are used herein, they will be understood to include manual initiation of an automatic or automated process or step.

[0163] It should also be appreciated that embodiments of the present invention may be implemented via computer hardware or software, or a combination of both. The methods may be implemented in a computer program using standard programming techniques, including a computer-readable storage medium configured with a computer program, which causes the computer to operate in a specific and predetermined manner according to the methods and figures described herein. Each program may be implemented in a high-level procedural or object-oriented programming language to communicate with a computer system. However, the programs may be implemented in assembly or machine language, if desired. In either case, the language may be a compiled or interpreted language. The programs may also be executed on dedicated integrated circuits programmed for that purpose.

[0164] Furthermore, the methodology may be implemented in any type of computing platform, including, but not limited to, a personal computer, a minicomputer, a mainframe, a workstation, a networked or distributed computing environment, a computing platform separate from, integral with, or in communication with a charged particle tool or other imaging device, and the like. Aspects of the invention may be implemented in machine-readable code stored on a storage medium or device, whether removable or integral with a computing platform, such as a hard disk, an optical read and / or write storage medium, RAM, ROM, and the like, such that when the storage medium or device is read by a computer to perform the procedures described herein, it is readable by a programmable computer to configure and operate the computer. The invention described herein includes these and other various types of computer-readable storage media, when such media contains instructions or programs for implementing the steps described above in conjunction with a microprocessor or other data processor. The invention also includes the computer itself when programmed according to the methods and techniques described herein.

[0165] The present invention has broad applicability and can provide many benefits as described and illustrated in the above examples. The embodiments may vary widely depending on the specific application, and not all embodiments will provide all benefits and meet all of the objectives achievable by the present invention. In the foregoing discussion and claims, the terms "including" and "comprising" are used in a non-limiting manner and should therefore be interpreted to mean "including, but not limited to." To the extent that any term is not specifically defined herein, it is intended that the term be given its plain and ordinary meaning. The accompanying drawings are intended to aid in understanding the invention and are not drawn to scale unless otherwise indicated.

[0166] Although various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations to those embodiments will occur to those skilled in the art. It is to be clearly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. It is further to be understood that the invention described herein is not limited in its application to the details of construction and the arrangement of components set forth in the foregoing description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including", "comprising", or "having" and variations thereof herein is meant to encompass the items listed thereafter and their equivalents and additional items.

[0167] Exemplary characteristics of embodiments of the present invention have been described. However, to avoid unnecessarily obscuring the embodiments of the present invention, the foregoing description may omit some known apparatus, methods, systems, structures, and / or devices that a person skilled in the art would understand to be generally included with the embodiments of the present invention. Such omissions are not to be construed as limitations on the scope of the invention as claimed. Specific details are described to provide an understanding of some embodiments of the present invention. However, it should be understood that the embodiments of the present invention may be practiced in various ways other than the specific details described herein.

[0168] Modifications and alterations of the various embodiments of the invention described herein will occur to those skilled in the art. It is to be clearly understood that such modifications and alterations are within the scope and spirit of the invention, as set forth in the following claims. It is further to be understood that the invention described herein is not limited in its application to the details of construction and the arrangement of components set forth in the foregoing description or illustrated in the drawings. That is, the embodiments of the invention described herein can be practiced or carried out in various ways. The scope of the various embodiments described herein is indicated by the following claims, rather than by the foregoing description. Moreover, all changes that fall within the meaning and range of equivalence of the claims are intended to be embraced within their scope. It is intended to acquire the right to include alternative embodiments, including alternative, interchangeable, and / or equivalent structures, functions, scopes, or steps to those claimed, to the extent permitted, whether or not such alternative, interchangeable, and / or equivalent structures, functions, scopes, or steps are disclosed herein, and without any intention to publicly dedicate any patentable subject matter.

[0169] The foregoing disclosure is not intended to limit the invention to the form or forms disclosed herein. In the foregoing detailed description, for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited. Rather, as the following claims reflect, aspects of the invention lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are incorporated herein into this detailed description, with each claim standing on its own as a separate preferred embodiment of the invention. Furthermore, the embodiments of the invention described herein include components, methods, processes, systems, and / or devices substantially as depicted and described herein, including various subcombinations and subsets thereof. Thus, one skilled in the art will appreciate that it may be conceivable to provide some features of the embodiments of the invention without providing others. In other words, any one or more of the aspects, features, elements, means, or embodiments as disclosed herein may be combined with any one or more other aspects, features, elements, means, or embodiments as disclosed herein.

Claims

1. 1. An electric machine comprising: a primary component comprising at least one coil; a secondary component having at least one coil formed from layers of superconducting tape having a rectangular cross-section, the secondary component positioned adjacent to the primary component and separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component; An electric machine comprising:

2. 2. The machine of claim 1, wherein the rectangular cross-section is defined by a long edge and a short edge, the short edge being positioned adjacent the gap and the long edge being associated with a lateral side of the superconducting tape that extends away from the gap.

3. The machine of claim 2 , wherein the lateral sides are not normal to the curvature of the gap.

4. 2. The machine of claim 1, wherein the layer of superconducting tape is a first layer and further comprises a second layer located outside the first layer, the first layer being located between the gap and the second layer, and lateral surfaces of the superconducting tape of the first layer and the second layer being separated by a gap.

5. The machine of claim 1 , wherein at least one coil of the secondary component includes embedded copper or aluminum, a damper winding bar, a variable external resistor, and / or power electronics.

6. The machine of claim 1 , wherein the secondary component is positioned within the primary component.

7. The machine of claim 1 , wherein the primary component and the secondary component comprise linear portions positioned side-by-side.

8. The machine of claim 1 , wherein the secondary component further employs a plurality of permanent magnets or trapped field magnets that interact with the magnetic field generated by the primary component.

9. 9. The machine of claim 8, wherein the magnetic flux provided by the trapping field magnet and / or the magnetic flux generated by the secondary and / or primary components can be selectively modified.

10. 10. The machine of claim 1, wherein at least one coil of the primary component is comprised of a layer of superconducting tape having a rectangular profile.

11. 11. The machine of claim 10, wherein the layer of superconducting tape of the primary or secondary components consists of a plurality of magnets wound with a continuous connection of wire or tape.

12. 11. The machine of claim 10, wherein the rectangular cross-section is defined by a long edge and a short edge, the short edge being positioned adjacent the void and the long edge being associated with a lateral side of the superconducting tape that extends away from the void.

13. 11. The machine of claim 10, wherein at least one coil of the primary component is comprised of a first layer and a second layer, the second layer being located outside of the first layer, and the first layer being located between the air gap and the second layer.

14. 14. The machine of claim 13, wherein the magnetic flux produced by the primary component consists of a portion of the magnetic flux generated by the first layer and a portion of the magnetic flux generated by the second layer.

15. The machine of claim 1 , wherein the secondary component is a rotor comprising a shaft supporting a plurality of field poles comprising trapped field magnets, permanent magnets, and / or the at least one coil.

16. The machine of claim 15 further comprising an electromagnetic shield covering the trapping field magnet, permanent magnet, and / or the at least one coil.

17. 17. The machine of claim 16, wherein the electromagnetic shield is an HTS tape in any orientation.

18. 16. The machine of claim 15, wherein the shaft is at least partially hollow and includes a rotor bearing and a rotary cryogenic coupler with embedded slip rings that house power and data cables.

19. The machine of claim 1 , wherein the gap is evacuated of air or the air is replaced with a non-aqueous gas.

20. 2. The machine of claim 1, wherein the secondary component is a rotor that spins rapidly up to at least 100 rpm when urged by a magnetic field generated by the primary component or by an external mechanical force.

21. The machine of claim 1 , wherein ends of the primary and secondary components include turns that increase the effective magnetic length of the primary and secondary components.

22. 1. An electric machine comprising: a primary component comprising a plurality of superconducting coils; a secondary component positioned adjacent to the primary component, the secondary component separated from the primary component by an air gap, the primary component configured to generate an electromagnetic force that interacts with the secondary component to move the secondary component; Equipped with The electric machine wherein the superconducting coil is formed from layers of superconducting tape having a rectangular cross section.

23. 23. The machine of claim 22, wherein the rectangular cross-section is defined by a long edge and a short edge, the short edge being positioned adjacent the void and the long edge being associated with a lateral side of the superconducting tape that extends away from the void.

24. 24. The machine of claim 23, wherein the lateral sides are not normal to the curvature of the gap.

25. 23. The machine of claim 22, wherein the layer of superconducting tape is a first layer and further comprises a second layer located outside the first layer, the first layer being located between the gap and the second layer, and lateral surfaces of the superconducting tape of the first layer and the second layer being separated by a gap.

26. The machine of claim 22 , wherein the secondary component is positioned within the primary component.

27. The machine of claim 22 , wherein the primary component and the secondary component comprise linear portions positioned side-by-side.

28. 23. The machine of claim 22, wherein the secondary component employs a plurality of permanent magnets, trapped field magnets, superconducting tapes, or coils that interact with the magnetic field generated by the primary component.

29. 30. The machine of claim 28, wherein the magnetic flux provided by the trapping field magnet and / or the magnetic flux generated by the secondary and / or primary components can be selectively modified.

30. 23. The machine of claim 22, wherein the secondary component is a rotor comprising a shaft supporting a plurality of field poles comprising trapped field magnets, permanent magnets, and / or the at least one coil.

31. 31. The machine of claim 30, further comprising an electromagnetic shield covering the trapping field magnet, permanent magnet, and / or at least one coil.

32. 32. The machine of claim 31, wherein the electromagnetic shield is an HTS tape in any orientation.

33. 31. The machine of claim 30, wherein the shaft is at least partially hollow and includes a rotor bearing and a rotary cryogenic coupler with embedded slip rings that house power and data cables.

34. 23. The machine of claim 22, wherein the void is evacuated of air or the air is replaced with a non-aqueous gas.

35. 23. The machine of claim 22, wherein the secondary component is a rotor that spins up to at least 100 rpm when urged by a magnetic field generated by the primary component or by an external mechanical force.

36. 23. The machine of claim 22, wherein ends of the primary and secondary components include turns that increase the effective magnetic lengths of the primary and secondary components.

37. 1. A method of controlling an electric machine comprising a primary component and a secondary component separated from the primary component by an air gap, the secondary component comprising a superconducting coil formed from layers of superconducting tape having a rectangular cross section; first energizing the primary component to generate a magnetic field that interacts with the superconducting coil and initiates rotation of the secondary component; energizing the at least one superconducting coil to selectively alter the rotation of the secondary component; A method comprising:

38. 40. The method of claim 37, wherein the secondary component further comprises at least one of a coil or bar conductor, a superconducting tape, a permanent magnet, and a trapped field magnet.

39. 40. The method of claim 37, wherein energizing the superconducting coil occurs when the rotational speed of the secondary component approaches a predetermined rate.

40. 38. The method of claim 37, wherein the rectangular cross-section is defined by a long edge and a short edge, the short edge being positioned adjacent the void and the long edge being associated with a lateral side of the superconducting tape that extends away from the void.

41. 38. The method of claim 37, wherein the superconducting coil of the secondary component has a passive use mode and an active use mode in which current is passed therethrough, the superconducting coil being in the passive use mode when the primary component is initially energized.

42. 38. The method of claim 37, wherein the magnetic field density of the trapping field magnet is set by superconducting coils of the primary component and / or the secondary component.

43. The machine of claim 1 , wherein the secondary components are fabricated in sections external to the final device.

44. The machine of claim 10 , wherein the primary components are fabricated in sections external to an end device.

45. 20. The machine of claim 19, wherein the gas is a cryogen cooling system gas.

46. 35. The machine of claim 34, wherein the gas is a cryogen cooling system gas.