Linear Media Winding with Closed-Loop Tension and Bend Control
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Solution Overview
Problem
Current winding machines are inadequate for handling delicate high-temperature superconducting (HTS) and medium-temperature superconducting (MTS) materials, as they often damage the fragile media during the winding process due to excessive stress and lack of precise control, limiting the production of reliable and efficient SC devices such as magnets and cables.
Innovation Solution
A Linear Media Handling System (LMHS) with advanced tension control and non-linear closed-loop feedback systems that minimize stress and strain on the media, allowing for precise control of axial and lateral forces, and eliminating reverse and lateral bends, enabling the production of robust and efficient HTS and MTS devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding machines are used to wind HTS/MTS materials, then the winding process can be performed, but the fragile media is damaged due to excessive stress and lack of precise control
Solution Approach 1:
The system dynamically adjusts winding parameters including tension force, winding speed, and curvature radius to match the specific characteristics of HTS/MTS materials. The tension control system maintains force within a precise range (e.g., 0.1-10 Newtons) to prevent damage while ensuring proper winding, and the curvature radius is adjusted based on the material's minimum bend radius specifications
Solution Approach 2:
The system employs sensors (load cells, encoders, vision systems) to continuously monitor winding parameters and material state, feeding this information back to the control system. This closed-loop feedback enables real-time adjustment of tension, speed, and positioning to prevent media damage while maintaining manufacturing capability
2Manufacturing precision
If tension control is increased to improve winding precision, then manufacturing precision improves, but stress on the fragile media increases causing damage
Solution Approach 1:
The system transitions from static tension control to dynamic tension control, where the applied tension is continuously adjusted during the winding process based on real-time feedback. The tension profile changes throughout winding - higher tension during initial layers for positioning accuracy, then reduced tension for subsequent layers to prevent cumulative stress damage
Solution Approach 2:
The system pre-calculates and applies compensatory forces before critical winding events. For example, it anticipates tension spikes during layer transitions or direction changes and applies cushioning force in advance to prevent excessive stress on the fragile HTS/MTS media, thereby maintaining precision without damage
3Reliability
If reverse bends are eliminated to protect the media, then media integrity is maintained, but the winding process complexity increases
Solution Approach 1:
The winding process is divided into discrete segments or zones, each with specific bend radius requirements. The system segments the winding path into sections where reverse bends are explicitly prohibited, and uses intermediate positioning points to transition between winding directions without creating damaging reverse bends, managing complexity through structured segmentation
4Reliability
If advanced tension control systems are implemented to minimize stress, then media integrity improves, but device complexity and cost increase
Solution Approach 1:
The system introduces intermediary elements such as compliance mechanisms, elastic elements, or buffer zones between the winding mechanism and the HTS/MTS media. These intermediaries absorb and dampen stress variations, reducing the need for extremely complex active control systems while still protecting the fragile media from damage
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 LMHS enables the manufacture of reliable, power-dense HTS and MTS devices with negligible reactance and acceptable power loss, capable of operating at liquid nitrogen temperatures, achieving unprecedented levels of efficiency and reliability in SC applications.
Implementation Method 1
Axial tension applied to the linear media during the winding process may be closely controlled with a feedback control loop using tension measurements to control rotation speeds of each the wind-off spools, e.g., one or more source spools, and wind-on spool, e.g., coil or cable former
Implementation Method 2
Once extremely low impedance superconductor transients are settled, a superconductor (sometimes referred to herein as 'SC') will exhibit immeasurably low to 0 electrical resistance primarily inside a low-temperature operating range
Implementation Method 3
When coil temperature is reduced below a predetermined threshold, the conducting material will exist in a superconducting state
Data Source
AI summary
An improved system for handling delicate linear media and in particular to a method and apparatus for winding delicate linear media such as superconducting wire or tape or optical fibers onto a spool or former. A combination of direct closed loop control and media routing design facilitates the handling of the delicate media without causing damage. The axial tension in the linear media may be closely controlled during winding by means of feedback control loop using tension measurements to control the rotation speeds of the wind-from and wind-to spools. Further, during winding, the delicate linear media is only exposed to large radius bends with no reverse bending. Finally, output devices and features, commercial or otherwise, made possible by delicate linear media handling are revealed. This includes advanced SC devices and features.