Inter-layer Transition Forming for Superconducting Coils
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Solution Overview
Problem
There is a lack of high-precision, compact, and easy-to-operate forming devices in China for manufacturing large-sized superconducting coils, particularly for the inter-layer transition of double-pancake structures used in tokamak superconducting magnets, which are crucial for thermonuclear fusion applications.
Innovation Solution
An inter-layer transition forming machine is designed with a fixing plate, vertically and horizontally movable forming mechanisms, and wedge clamping mechanisms, utilizing a double-acting hydraulic cylinder to ensure accurate and reliable inter-layer transitions in superconducting coil winding, featuring a broken-line fixing plate for structural stiffness and online tolerance detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high-precision forming device is designed for inter-layer transition, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The forming device is divided into two independent forming mechanisms: a vertically movable forming mechanism and a horizontally movable forming mechanism. Each mechanism has its own linear guide rail, forming mold, and wedge clamping mechanism, allowing them to operate independently and simplifying the overall control while achieving high precision in both directions
Solution Approach 2:
The patent replaces traditional complex mechanical transmission systems with a hydraulic cylinder-driven system. The double-acting hydraulic cylinder directly drives the vertical movement, eliminating the need for complex gear trains or linkages, thereby reducing mechanical complexity while maintaining high precision through the linear guide rail and wedge clamping mechanisms
2Device complexity
If a compact forming device is designed, then device complexity is reduced, but manufacturing precision may deteriorate
Solution Approach 1:
A double-acting hydraulic cylinder is used to drive the vertical movement of the forming mechanism. The hydraulic system provides precise, controlled motion with high stiffness, achieving accurate inter-layer transition formation without requiring complex mechanical positioning systems. The hydraulic drive compactly integrates power transmission and positioning functions
Solution Approach 2:
The wedge clamping mechanism with right- and left-handed threads automatically maintains constant clamping force on the conductor during forming. As the forming mold moves, the wedge nuts self-adjust to maintain optimal clamping pressure, ensuring precision without requiring external force control systems or complex feedback mechanisms
3Device complexity
If conventional forming methods are used, then device simplicity is maintained, but ease of operation deteriorates
Solution Approach 1:
The patent incorporates reference lines for inter-layer transition positioning that provide visual feedback during the forming operation. The operator can align the conductor with the reference lines on the fixing plate and forming molds, ensuring accurate positioning. This simple visual feedback system greatly improves ease of operation without adding complex electronic control systems
Solution Approach 2:
The forming device features movable fixing plates that can slide along linear guide rails in both vertical and horizontal directions. This dynamic capability allows the operator to easily adjust and reposition the forming mechanisms for different coil configurations and sizes, significantly improving operational flexibility and convenience while maintaining structural simplicity
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 machine enables smooth and reliable formation of inter-layer transitions in large-sized superconducting coils, ensuring precise alignment and meeting tolerance requirements, thus supporting the production of large-scale superconducting coils for fusion reactors.
Implementation Method 1
a first wedge nut with right- and left-handed threads is mounted at each of two ends of the first screw with right- and left-handed threads; a slot is formed respectively at an end of the first forming mold and an end of the first conductor clamping plate which are in the same direction, and the slots form a first wedge slot which allows the first wedge nut with right- and left-handed threads in a corresponding direction to be embedded
Implementation Method 2
a double-acting hydraulic cylinder is mounted on a portion of the fixing plate above the first linear guide rail in the Y-direction, and a piston rod of the double-acting hydraulic cylinder is fixed to the hydraulic cylinder connection plate in the Y-direction
Data Source
AI summary
The present invention discloses an inter-layer transition forming machine for winding of a large-sized superconducting coil. A vertically movable forming mechanism and a horizontally movable forming mechanism are mounted on a fixing plate. When the winding of a large-sized superconducting coil performs inter-layer transition, an armored superconducting conductor is clamped by wedge clamping mechanisms with right- and left-handed threads on the vertically movable forming mechanism and the horizontally movable forming mechanism, and a reference line on the conductor is ensured to be aligned with a reference line on a forming mold. The vertically movable forming mechanism is pressed down, under the drive of a double-acting hydraulic cylinder, in a vertical direction to form inter-layer transition, and the horizontally movable forming mechanism moves in a horizontal direction according to the reduction of the vertically movable forming mechanism.