Fluid-Cooled Electromagnet Pancake Coil Design
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Solution Overview
Problem
Conventional pre-polarization magnetic field coils face limitations in generating strong magnetic fields due to small volume, ineffective cooling methods, and thermal noise, which restrict their ability to maintain a stable and intense magnetic field for extended periods.
Innovation Solution
A fluid-cooled electromagnet design featuring pancake coils with a washer shape, spacers for coolant flow, and a Litz wire winding to enhance cooling efficiency and reduce thermal noise, allowing for continuous operation and improved magnetic field generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a small solenoid-type air-cooled coil is used, then the structure is simple and easy to manufacture, but the volume capable of applying pre-polarization magnetic field is very small and the generatable pre-polarization magnetic field is limited
Solution Approach 1:
The coil is divided into multiple pancake coils stacked in series, where each pancake coil is a flat circular winding. This segmentation allows the magnetic field to be generated across a larger volume while maintaining the simplicity of individual pancake coil structures that are easy to manufacture.
2Device complexity
If a small solenoid-type air-cooled coil is used, then the structure is simple, but the generatable pre-polarization magnetic field is limited to about 10 milliteslas
Solution Approach 1:
Multiple pancake coils are merged by stacking them in series along the vertical axis, creating a composite magnetic field system. This combination maintains the structural simplicity of individual pancake coils while achieving stronger pre-polarization magnetic fields through cumulative effect of multiple coils working together.
3Temperature
If a liquid nitrogen cooled coil is used, then the electrical resistance is reduced and cooling is fast and effective, but the device complexity increases and the volume capable of applying pre-polarization magnetic field is reduced
Solution Approach 1:
Instead of using liquid nitrogen (pneumatic approach), the patent employs water circulation through channels formed in the pancake coils (hydraulic approach). This allows effective cooling through fluid flow while avoiding the complexity of vacuum insulation and liquid nitrogen containment systems.
4Temperature
If a water-cooled coil with Litz wire is used, then cooling is effective, but the winding becomes complex and effective current density is reduced
Solution Approach 1:
The water cooling function is segmented from the winding process. Water channels are formed directly in the pancake coil structure itself rather than requiring complex winding patterns to create cooling passages. This segmentation allows simple circular winding while integrating cooling channels, maintaining both manufacturing ease and effective cooling.
5Device complexity
If a copper pipe allowing coolant flow is used as conducting wire, then the circulation structure is simplified, but the bulk of the conducting wire causes significant thermal noise
Solution Approach 1:
The pancake coil is designed with porous or channelled structure that allows water to flow through the coil body itself. This eliminates the need for separate copper pipes while maintaining simple circulation structure. The water channels are integrated into the coil structure, avoiding the thermal noise problem of bulky copper piping.
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 fluid-cooled electromagnet effectively generates and maintains a strong pre-polarization magnetic field with reduced thermal noise, enabling prolonged operation and efficient cooling, addressing the limitations of conventional designs.
Implementation Method 1
A coolant is introduced through the first vertical coolant flowing space and is discharged through the second vertical coolant flowing space after rotating once along the coolant flowing space
Implementation Method 2
a plurality of pancake coils disposed between the upper housing and the lower housing to be spaced apart from each other and sequentially stacked to have a washer shape
Data Source
AI summary
A fluid-cooled electromagnet includes an upper housing, a lower housing vertically aligned with the upper housing, a plurality of pancake coils disposed between the upper housing and the lower housing to be spaced apart from each other and sequentially stacked to have a washer shape, and at least one spacer, disposed between the upper housing and the lower housing, accommodating the pancake coils at regular intervals.