Methods of manufacturing a molded, formerless multi-coil cylindrical superconducting magnet structure, and a structure as may be manufactured by such methods
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing cylindrical superconducting magnets are complex, expensive, and potentially unreliable, particularly for formerless designs, which are unsuitable for high-volume production due to manufacturing tolerances and increased coil diameter, leading to higher costs and wire usage.
Innovation Solution
A method involving a mandrel with parallel walls or slight taper, combined with friable tabs or retractable pins, allows for the assembly of parallel SBM magnets with constant inner diameter, using glass fiber cloth to adjust coil diameter and reduce material costs, and a resin-impregnation process to enhance precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If formers are used to manufacture cylindrical superconducting magnets, then manufacturing precision and coil geometry control are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the former from the magnet structure entirely, creating a formerless design where coils are supported only by internal structural elements and external sleeves. This extraction eliminates the complexity of former manufacturing, assembly, and removal while maintaining coil precision through alternative support mechanisms.
Solution Approach 2:
The patent introduces internal structural elements (such as ribs or support structures integrated into the coil form) and external sleeves as intermediary components that provide the necessary support and positioning functions previously performed by formers, but without requiring complex former assembly and disassembly processes.
2Manufacturing precision
If formers are used to support superconducting coils, then coil positioning precision is improved, but the required diameter of coils increases and wire cost increases
Solution Approach 1:
By removing the former entirely, the patent eliminates the radial space occupation that previously increased coil diameter. The coils are positioned and supported directly by integrated structural elements and external sleeves, achieving precise positioning without the additional diameter required by former structures.
3Strength
If externally machined sleeves are used to constrain solenoids, then hoop stress reduction is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs composite material sleeves (such as carbon fiber reinforced polymers or other high-strength-to-weight composite materials) that provide superior hoop stress resistance compared to traditional machined metal sleeves, while being more cost-effective to manufacture through processes like filament winding or resin transfer molding rather than expensive precision machining.
4Adaptability or versatility
If serially bonded magnets with individual coils stacked and annular spacers are used, then assembly flexibility is improved, but manufacturing time increases and manufacturing tolerances stack up
Solution Approach 1:
The patent merges multiple individual coil assemblies into a single integrated structure where coils are wound continuously or pre-positioned as integrated units on the mandrel before impregnation. This combining approach maintains the flexibility of individual coil design while eliminating the cumulative tolerance problems and lengthy assembly processes associated with stacking multiple separate coils with spacers.
Solution Approach 2:
The patent performs preliminary positioning and integration of all coil structures on the mandrel before the impregnation process. By establishing precise coil positions and relationships in advance during the winding stage, the patent eliminates subsequent assembly steps and prevents tolerance stacking that would occur with post-manufacturing assembly of individual coils.
5Device complexity
If mandrel extraction is performed after coil winding, then formerless structure is achieved, but manufacturing reliability decreases
Solution Approach 1:
The patent employs a disposable mandrel design where the mandrel is intentionally made from inexpensive, easily breakable materials (such as friable tabs or brittle ceramic coatings) that are designed to fracture and detach cleanly after serving their temporary purpose during coil winding. This approach maintains manufacturing reliability by ensuring predictable mandrel failure at predetermined weak points without compromising coil integrity.
Solution Approach 2:
The patent incorporates predetermined weak points, fracture planes, or release mechanisms in the mandrel structure before winding begins. These pre-engineered features ensure that mandrel extraction occurs cleanly and predictably at specific locations, preventing unexpected failures or damage to the coil structure during the extraction process and thereby maintaining high manufacturing reliability.
Data Source
AI summary
A method for the manufacture of a formerless, multi-coil cylindrical superconducting magnet structure is disclosed. The structure comprises superconducting coils and annular spacers of composite filler material. The disclosure also provides a formerless, multi-coil cylindrical superconducting magnet structure as may be manufactured by such a method.