Linear Media Winding With Closed-Loop Tension and Large-Radius Routing
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Solution Overview
Problem
Existing winding machines are inadequate for handling delicate linear media such as advanced superconducting wires and tapes, as they often damage the materials due to harsh tension control and inaccurate measurement, leading to poor quality and high manufacturing costs.
Innovation Solution
A Linear Media Handling System (LMHS) that employs direct closed-loop control and media routing design to carefully manage axial and lateral forces, eliminating small radius bends and reverse bends, and using non-contact sensors for precise tension measurement and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art winding machines are used to wind delicate superconducting media, then the winding process can be performed, but the delicate media such as reacted MgB2 and Nb3Sn are damaged due to harsh tension control and small radius bends
Solution Approach 1:
The patent changes the critical parameter of bend radius from small to large (minimum radius of curvature of at least 6 inches) to reduce stress on the superconducting media. This parameter change transforms the winding process from one that damages delicate media to one that preserves media integrity while still achieving the winding objective.
Solution Approach 2:
The patent introduces an intermediary guidance system with guide rollers and routing elements that mediate between the winding machine and the delicate superconducting media. This intermediary system provides smooth transitions and eliminates sharp bends, allowing the media to be wound without direct exposure to harsh mechanical forces.
2Manufacturing precision
If conventional tension control methods are used, then the winding process can proceed, but measurement accuracy is poor leading to inadequate tension control
Solution Approach 1:
The patent replaces conventional mechanical tension measurement methods with non-contact optical sensors. This substitution eliminates the mechanical interference that degraded measurement accuracy while providing precise, real-time tension data for closed-loop control of the winding process.
Solution Approach 2:
The patent implements closed-loop feedback control where non-contact sensors continuously measure tension and feed this information back to the control system, which adjusts winding parameters in real-time. This feedback mechanism transforms open-loop approximate control to closed-loop precise control, significantly improving manufacturing precision.
3Productivity
If small radius bends are allowed in the winding path, then the winding process is faster, but the superconducting media suffers from stress and damage
Solution Approach 1:
The patent changes the geometric parameter of the winding path from small radius to large radius (minimum 6 inches), which reduces stress on the media. While this may slightly reduce winding speed, it preserves media strength and prevents damage, ultimately improving overall productivity by reducing defects and rework.
Solution Approach 2:
The patent employs smooth curved paths with large radii of curvature throughout the winding system, eliminating sharp angles and small radius bends. This curvilinear design allows media to transition smoothly through the winding process, maintaining strength while achieving efficient winding through optimized path geometry.
Data Source
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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 optical fibers onto a spool. 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.