Continuous Brazing System for Armored Superconductor Wire
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Superconductor wires, such as those made of magnesium diboride, lose their superconducting properties at elevated temperatures, potentially causing damage due to thermal energy, and existing solutions like coupling with copper wires for protection are not efficiently manufactured in a continuous process.
Innovation Solution
A continuous brazing system comprising feeders for superconductor and conductor wires, a brazing alloy layer, an aligning device, a furnace for melting, and a collimator with rotatable rolls and cooling means to align and solidify the wires, ensuring perfect coupling and stabilization of the armored wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If superconductor wire is used, then superconducting properties are achieved at low temperatures, but the wire loses superconducting properties and generates thermal energy when temperature increases, causing damage
Solution Approach 1:
A copper conductor wire is introduced as an intermediary protective element coupled in parallel with the superconductor wire. When the superconductor loses its superconducting properties due to temperature increase, the copper wire acts as a mediator to conduct the electric current, preventing thermal energy generation and damage to the superconductor wire.
Solution Approach 2:
The copper conductor wire is pre-coupled to the superconductor wire before operation to provide preventive protection. This prior cushioning ensures that if superconducting properties are lost, the protective copper wire is already in place to immediately conduct current and prevent damage.
2Reliability
If copper conductor wire is coupled to superconductor wire for protection, then reliability is improved, but continuous manufacturing process is not achieved
Solution Approach 1:
The brazing system enables continuous manufacturing by continuously feeding superconductor and conductor wires through the system, melting brazing alloy along the entire length of the wires in a furnace, and cooling the assembly to solidify the joint, producing a continuous armored superconductor wire without interruption.
Solution Approach 2:
Traditional discrete mechanical coupling methods are replaced with a thermal brazing process. The brazing alloy is melted thermally to create a metallurgical bond between the superconductor and conductor wires, enabling continuous production rather than discrete assembly operations.
3Manufacturing precision
If brazing alloy is melted and cooled to solidify, then coupling between wires is achieved, but alignment precision and structural stability must be maintained
Solution Approach 1:
Rolls are arranged in multiple dimensions around the wire assembly - some rolls compress in the radial direction while other rolls compress in the axial direction. This multi-dimensional compression ensures uniform alignment and stable coupling of the wires during brazing alloy solidification.
Solution Approach 2:
The physical state of the brazing alloy is changed from liquid to solid through controlled cooling. The brazing alloy is melted at high temperature to enable flow and bonding, then cooled to solidify and stabilize the coupling between wires, maintaining alignment precision throughout the process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the continuous production of armored superconductor wires with excellent alignment and stabilization, preventing damage from temperature increases by ensuring the brazing alloy solidifies correctly, resulting in a stable and effectively protected superconductor conductor.
Implementation Method 1
a furnace for melting said brazing alloy layer
Implementation Method 2
cooling means downstream of said plurality of rolls to remove heat from said superconductor and conductor wire assembly and said molten brazing alloy layer to obtain the solidification of said brazing alloy layer
Implementation Method 3
to obtain the solidification of said brazing alloy layer
Implementation Method 4
at least one first plurality of rolls rotatable about respective first rotation axes orthogonal to said axial direction to compress said superconductor and conductor wire assembly and said layer of molten brazing alloy
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A brazing system (1) for manufacturing an armored superconductor wire (10, 10a) comprises: - a first feeder (5) of a superconductor wire (11), - a second feeder (6) of a conductor wire (12), a layer (13) of brazing alloy being applied to a first face (12a) of the conductor wire (12), - an aligning device (8) for approaching the superconductor wire (11) to said first face (12a), - a furnace for melting the brazing alloy layer (13), - a collimator (15), comprising: - at least one first plurality of rolls (17) rotatable about respective first rotation axes (Y) orthogonal to said axial direction (X) to compress said assembly in direction orthogonal to said first face (12a), - at least one second plurality of rolls (18) rotatable about respective second rotation axes (Z) orthogonal to the axial direction (X) and to the first rotation axes (Y) to compress the sides of the assembly, - cooling means (25) downstream of the rolls (17, 18) to solidify the brazing alloy layer (13).