Superconducting Coil Corner Turn Design for Low-Pole Rotor
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Solution Overview
Problem
The production of superconducting coil windings is challenging due to their sensitivity to mechanical loads, particularly when forming three-dimensional geometries, which often requires space-consuming winding overhangs, leading to increased weight and material consumption in applications like low-pole rotor electrical machines.
Innovation Solution
A superconducting coil device with a three-dimensional winding shape that incorporates a 'corner turn' design, where the strip conductor changes direction and orientation with a distinct bend radius between 1 cm and 25 cm, minimizing axial space requirements and avoiding damage from mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If three-dimensional coil windings are produced using conventional methods, then the coil geometry is improved for low-pole rotor applications, but the winding overhangs increase in length and space consumption
Solution Approach 1:
The patent applies dimensionality change by transitioning from planar coil windings to three-dimensional saddle-shaped coil windings. The strip conductor is bent in multiple directions to form longitudinal limbs extending in the axial direction and transverse limbs in the radial direction, creating a spatial configuration that optimizes the magnetic field distribution for low-pole rotors while controlling overhang dimensions
Solution Approach 2:
The patent utilizes curvature principles by forming the strip conductor into curved paths with specific bend radii. The corner turns connecting longitudinal and transverse limbs are designed with controlled curvature to minimize the winding overhang length while maintaining the three-dimensional saddle shape necessary for low-pole rotor applications
2Shape
If the strip conductor is bent to form three-dimensional coil windings, then the coil shape is improved, but the mechanical stress on the superconducting layer increases causing damage
Solution Approach 1:
The patent applies parameter changes by carefully controlling the bend radius of the strip conductor during winding. The minimum bend radius is specified to be sufficiently large to prevent delamination and degradation of the superconducting layer, while still achieving the desired three-dimensional saddle shape. The winding tension and other process parameters are also optimized to minimize mechanical stress
Solution Approach 2:
The patent applies local quality by differentiating the bending characteristics in different regions of the coil winding. The corner turns connecting longitudinal and transverse limbs are designed with specific bend radii that are larger than what would be used in non-critical areas, locally adapting the geometry to protect the superconducting layer in high-stress regions while maintaining overall three-dimensional shape
3Object-affected harmful factors
If flat coil windings are used, then the mechanical stress on the superconducting layer is minimized, but the coil cannot be adapted to low-pole rotor geometries requiring longitudinal limbs close to the equatorial plane
Solution Approach 1:
The patent resolves this contradiction by introducing three-dimensionality through saddle-shaped coil windings. The longitudinal limbs extend in the axial direction and can be positioned close to the equatorial plane, while the transverse limbs connect them in the radial direction. This spatial configuration provides the geometric adaptability needed for low-pole rotors while controlling mechanical stress through appropriate bend radius selection
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
This design allows for compact, three-dimensionally shaped coil windings that can be adapted to low-pole rotor geometries, enabling closer placement of longitudinal limbs to the equatorial plane while maintaining the superconducting layer's integrity, reducing material usage and weight.
Implementation Method 1
at a temperature below the transition temperature of the superconductor, a current can flow almost loss-free
Data Source
AI summary
Various embodiments include a superconducting coil device comprising: a coil winding with at least one turn of a superconducting strip conductor; wherein the strip conductor has a first main face and a second main face. The coil winding includes a turning region wherein the strip conductor is bent such that, in the turning region, the strip conductor has a distinct change of direction in a longitudinal direction and simultaneously changes the orientation of both the first main face and the second main face with respect to a central axis of the coil device.