HTS Cable Integrated Coil Form Helical Channel Design
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Solution Overview
Problem
Current high-temperature superconductor (HTS) cables are expensive to fabricate and degrade during the winding process, with limited bend diameters and increased inductance, leading to higher charging times and quench voltage, making them unsuitable for high-field solenoids.
Innovation Solution
The development of an integrated coil form (ICF) technology that uses a helical channel on the exterior surface of the coil form to house HTS tape layers, allowing for layer-wound cables with reduced strain and inductance, eliminating the need for separate cabling processes and minimizing joint resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If HTS cables are fabricated using the cable-then-wind coil process, then current carrying capacity is improved, but manufacturing cost increases and cable degradation occurs during winding
Solution Approach 1:
The coil form is prepared with pre-formed helical channels before the HTS cable winding process. These channels serve as predetermined pathways that guide and support the HTS cable layers during winding, preventing cable degradation while maintaining manufacturing efficiency. The support structure is established in advance rather than added after cable fabrication.
Solution Approach 2:
The helical channels act as an intermediary structure between the coil form and the HTS cable. These channels provide mechanical support and guidance to the cable during the winding process, eliminating direct contact between the cable and the coil form surface, thereby preventing cable degradation without requiring expensive specialized manufacturing processes.
2Reliability
If HTS cables are twisted or transposed for AC performance, then AC performance is improved, but inductance increases leading to higher charging times
Solution Approach 1:
The helical channels are designed with specific local geometric properties including optimized pitch, depth, and width variations along the axial length. These localized geometric modifications allow the cable to achieve desired AC performance characteristics without requiring extensive twisting or transposition, thereby reducing overall inductance and charging time.
3Quantity of substance
If HTS single tapes are used for coils, then inductance is high, but this leads to increased charging times and quench voltage
Solution Approach 1:
Multiple HTS cable layers are nested within the helical channels of the coil form, with each layer precisely positioned in its own designated channel. This nested arrangement allows for optimized current density distribution while maintaining manageable inductance levels, as the layered structure within confined channels reduces overall coil inductance compared to single-tape configurations.
Data Source
AI summary
A high temperature superconductor (HTS) cable comprising at least one coil form comprising a helical channel formed on an exterior surface of the coil form and the helical channel extending at least partially along an axial length of the coil form and a plurality of high temperature superconductor (HTS) tape layers positioned within the helical channel of the coil form. A method for operating a winding machine to produce a high temperature superconductor (HTS) cable comprising a plurality of coil forms comprising a helical channel formed on an exterior surface of the coil form.