Non-Planar Coil Plates for Precise HTS Cable Alignment
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Solution Overview
Problem
The challenge in manufacturing non-planar magnetic field coils for stellarators lies in achieving precise alignment of high temperature superconductor (HTS) cables with complex geometries, which are sensitive to magnetic field alignment, and requires a solution that simplifies the manufacturing process while reducing errors during assembly.
Innovation Solution
The use of plates with non-planar geometries and recesses that allow for precise alignment of HTS cables by defining changing orientations along the path, enabling the cables to be split into parts for easier assembly and winding, and incorporating fixing members for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If HTS cables are used in non-planar magnetic field coils, then strong magnetic fields and positive energy balance are achieved, but alignment precision requirements increase due to field alignment sensitivity
Solution Approach 1:
The patent applies preliminary action by pre-defining the cable path and orientation through the recess geometry before cable installation. The recess is manufactured with precise non-planar geometry that predetermines the cable's spatial configuration, eliminating the need for complex alignment operations during assembly. This pre-established geometric constraint ensures the cable maintains the required alignment precision throughout the coil structure.
Solution Approach 2:
The recess acts as an intermediary element between the cable and the coil structure. It provides a geometric mediator that translates the complex alignment requirements into simple mechanical constraints, allowing the cable to be positioned accurately through the recess geometry rather than requiring direct precision alignment between multiple components.
2Reliability
If complex non-planar geometries are used for magnetic field coils, then improved magnetic confinement is achieved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent applies segmentation by dividing the complex non-planar coil into modular sections, each with its own recess defining a specific cable path segment. This allows the complex geometry to be constructed from simpler, repeatable modular units, reducing manufacturing complexity while maintaining the overall non-planar configuration required for effective magnetic confinement.
Solution Approach 2:
The patent utilizes parameter changes by varying the recess geometry parameters (cross-sectional shape, orientation, position) along the cable path to achieve the desired non-planar coil configuration. By changing these geometric parameters systematically, the complex three-dimensional shape is created through controlled variations of the recess characteristics rather than requiring entirely unique manufacturing for each section.
3Loss of substance
If cable alignment accuracy is improved along the winding path, then material usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies self-service by designing the recess to automatically guide and align the cable through its geometric features alone, without requiring external alignment tools or complex winding procedures. The recess geometry itself performs the alignment function, allowing the cable to be positioned accurately through simple insertion and mechanical constraint rather than complex manipulation procedures.
Data Source
Figure 1~2a
Figure 2b
Figure 2c
AI summary
A stellarator with a non-planar magnetic field coil with a first plate as well as a method of winding a non-planar magnetic field coil for a stellarator is presented. The first plate (100) comprises a first surface (110) with a non-planar geometry and a first recess (120). The first recess (120) extends along a first path (130) along the first surface (110). The first recess (120) has a first cross-section (140) with a first orientation (150). The first orientation (150) changes along the first path (130) with respect to the first surface (110).