Note: Descriptions are shown in the official language in which they were submitted.
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LINEAR MEDIA HANDLING SYSTEM AND DEVICES PRODUCED
USING THE SAME
[0001] This PCT application claims the benefit of U.S. Patent Application
Serial No. 17/159,047,
filed January 26, 2021, published as U.S. Patent Application Publication No.
2021/0229946,
which is a continuation-in-part of U.S. Patent Application Serial No.
15/927,877, filed March 21,
2018, now U.S. Patent No. 10,899,575, issued January 26, 2021, which is a
continuation-in-part
of PCT/US2016/053174, filed September 22, 2016, and published as W02017/053611
on March
30, 2017, the entire disclosures of which are incorporated by reference
herein.
PCT/US2016/053174 claims the benefit of U.S. Provisional Patent Application
Serial Nos.
62/221,910, filed September 22, 2015, U.S. Provisional Patent Application
Serial No. 62/242,393,
filed October 16, 2015, and U.S. Provisional Patent Application Serial No.
62/243,966, filed
October 20, 2015, entitled the entire disclosures of which are incorporated by
reference herein.
[0002] This application is related to U.S. Patent Application Serial No.
14/569,314, filed
December 12, 2014, now U.S. Patent No. 9,624,068, issued April 18, 2017, which
is a
continuation-in-part of U.S. Patent Application Serial No. 13/269,549, filed
October 7, 2011, now
U.S. Patent No. 8,936,209, issued January 20, 2015, which is a continuation-in-
part of abandoned
U.S. Patent Application Serial No. 13/114,012, filed May 23, 2011, which
claims the benefit of
expired U.S. Provisional Patent Application Serial No. 61/347,374, filed May
21, 2010, the entire
disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention are generally related to devices
and apparatus that
handle and manipulate delicate linear media, particularly to an apparatus and
method for winding
linear media such as superconducting linear media. Other embodiments of the
present invention
are the output of this apparatus, particularly products and devices made from
winding
superconductors into magnets, cables, and/or cable magnets.
BACKGROUND OF THE INVENTION
[0004] Superconductors (sometimes referred to herein as "SC") have the promise
of bringing pure
efficiency (i.e., 100% efficiency), which would allow for the manufacture of
innovative devices
that can accommodate increased energy and power requirements in a compact
package and
through HTS use provide for lessened cryogenic requirements via LN2 use.
Current
commercially-available advanced SC products, such as magnets, cables, and
cable magnets, are
virtually non-existent because superconductors, including those that can
tolerate higher
temperatures, are fragile. Accordingly, the winding process must consider the
fragile SC media
during handling, winding, and final operation.
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[0005] HTS machines are desired across industries from individual device to
enabling electric
system solutions. Conventional copper (Cu) and permanent magnet (PM) machines
are limited by
air gap magnetic flux density (B), torque, thermal, and power output. Cu
cooling needs are also
great and add to system weight. Conventional machines use iron (Fe) to
increase their air gap B
but at the expense of weight. An HTS direct drive machine has no thermal loss
and over 6x a
conventional machine torque limit due to the B output. The air gap is the non-
magnetic space
between the primary and secondary of any electromagnetic device.
[0006] After decades no HTS or MTS device, including electric machines
(particularly motors &
generator), have moved beyond laboratory-based demonstration levels. Due to
winding
limitations, other HTS winding machine attempts focus on making a pancake
stack machine field
coil with only limited protection from HTS winding and operational stress.
Pancake stacks
increase harmonic content, move the coils further from the air gap, which
lowers the air gap B,
and thus cannot be used for complex winds such as armature coils. Further,
pancake stacks are not
curved to protect the HTS tape from quenching due to high B locations. There
have been no
attempts to create a fully HTS via a fully cold, cryogenically cooled on both
the armature and
rotor, machine due to the difficulty in winding HTS armature coils, which
leads to a machine that
gains less than half of SC operational benefits. Other MTS solutions have
lower material cost but
when reacted are even more fragile and have a higher cryostat cost and
complexity given a lower
operating temperature and potentially more dangerous cryogen.
[0007] Those of ordinary skill in the art will appreciate that manufacturing
for HTS applications
requires complex geometric materials to experience low winding stress which in
turn allows
increased operating values. This requirement is exacerbated when manufacturing
complex
geometric magnets categorized by their primary mounting and rotation needs,
which include
solenoid (often mounted on a common central turning platform), planar (such as
a racetrack coil
or a curved plane cos-theta magnet and often mounted on cylindrical tooling),
and spherical (such
as a baseball or yin -yang magnets). Advances in HTS operational values, their
performance, the
reliability of cryogenic systems, connections, etc., and the understanding
that HTS material costs
drop during production have collectively targeted SC manufacturing as the
remaining issue for
commercial SC applications.
SUMMARY OF THE INVENTION
[0008] It is one aspect of embodiments to provide a revolutionary
manufacturing method for
producing high temperature superconducting (HTS) and medium temperature
superconducting
(MTS) commercial applications and devices across all relevant industries,
including enabling
fieldable superconducting devices and enabling electric systems that are not
possible without
being able to use HTS. The disclosed manufacturing process reduces stress,
allowing complex
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magnet, cable, and cable magnet configurations. For example, the method of one
embodiment
produces a robust magnet configuration configured for use in the first fully
cold (liquid cryogen)
HTS linear, rotary, curved, etc. electric machine (motor/generator). This
contemplated method
also may allow for the manufacture of a reliable and robust power-dense HTS
cable core operating
from DC to transient, including AC and pulsed power with negligible reactance
and acceptable
power loss compared to existing practice. The cable, magnet, cable core, cable
magnet, etc.
produced by the methods described herein are designed to function at liquid
nitrogen (LN2)
temperatures using existing HTS. Accordingly, the disclosed magnet, cable, and
cable magnet
superconductor winding capabilities disclosed herein allow for the most power-
dense, specific
power, energy-dense, and specific energy electrical and magnet-based products
ever created,
especially embodiments that utilize HIS.
[0009] The winding machines of some embodiments of the present invention
provide the ability
to directly monitor and actively control the location, tension, and bend of
every conductor and
insulator being used to create the magnet, cable, and/or cable magnet at every
moment of
production. This aspect is often key to generating the optimum magnet, cable,
and/or cable magnet
from fragile media. The use of sensors and control algorithms are also often
key to the most
complex part of the disclosed winding solution. Independent but electronically
geared active
control for each conductor and insulation winding spool for a single product
provides the
functionality required.
[0010] Degrees of Freedom (DoF) Controls. As used herein, the term "DoF" will
be used to
describe the control of the routing elements and structures to adjust the
orientation of the elements
and structures to provide linear and/or rotational degrees of freedom to
facilitate the handling of
the delicate media without causing damage.
100111 It is thus one embodiment of the present invention to provide a winding
machine that may
be capable of twenty DoF, comprising: a frame having an upper portion and a
base portion; a
wind-off spool subassembly, comprising: a first linear actuator interconnected
to the base, a first
rotary actuator interconnected to the first linear actuator, a second linear
actuator interconnected
to the first rotary linear actuator, a wind-off frame interconnected to the
second linear actuator,
and a rotatable wind-off spool, which is adapted to carry linear media,
operatively interconnected
to the wind-off frame; a follower subassembly, comprising: a third linear
actuator interconnected
to a cross member of the upper portion of the frame, the third linear actuator
being substantially
oriented with the first linear actuator, a second rotary actuator
interconnected to the third linear
actuator, a plate interconnected to the second rotary actuator, at least one
riser interconnected to
the plate, at least one beam interconnected to at least one riser, a
tensiometer operatively associated
with the at least one beam, a transverse beam interconnected to at least one
beam and spaced from
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the tensiometer, a turning fork rotatably interconnected to the transverse
beam, the turning fork
ending in parallel guides adapted to receive the linear matter, a fourth
linear actuator
interconnected to a frame member associated with the plate, wherein the fourth
linear actuator is
configured to urge a first arm in a direction non-parallel to the third linear
actuator, a fifth linear
actuator interconnected to a frame member associated with the plate, wherein
the fifth linear
actuator is configured to urge a second arm in a direction non-parallel to the
third linear actuator,
a sixth linear actuator interconnected to the fourth linear actuator, wherein
the sixth linear actuator
is configured to urge a third arm in a direction orthogonal to the fourth
linear actuator, a seventh
linear actuator interconnected to the fifth linear actuator, wherein the
seventh linear actuator is
configured to urge a fourth arm in a direction orthogonal to the fifth linear
actuator, a third rotary
actuator interconnected to the sixth linear actuator, a fourth rotary actuator
interconnected to the
seventh linear actuator, an eighth linear actuator interconnected to the third
rotary actuator,
wherein the eighth linear actuator is configured to urge a fifth arm in a
direction towards the linear
media, a ninth linear actuator interconnected to the fourth rotary actuator,
wherein the ninth linear
actuator is configured to urge a sixth arm in a direction towards the linear
media, a first wind-on
guide interconnected to an end of the fifth arm, and a second wind-on guide
interconnected to an
end of the sixth arm; a former subassembly, comprising: at least one tenth
linear actuator
interconnected to the base portion, at least one eleventh linear actuator
interconnected to the base
portion, a twelfth linear actuator interconnected to the tenth and twelfth
linear actuators, a fifth
rotary actuator interconnected to the twelfth linear actuator, a wind-on frame
interconnected to the
fifth rotary actuator, a sixth winding arc rotation interconnected to the
fifth rotary actuator, and a
wind-on spool operatively interconnected to the wind-on frame, the wind-on
spool configured to
rotate and adapted to receive the linear media, and wherein the linear media
is taken from the
wind-off spool, transitioned about the tensiometer, and wound onto the wind-on
spool to form a
magnet, and wherein the turning fork, the first wind-on guide, and the second
wind-on guide along
with selective movement of at least one of the first linear actuator, second
linear actuator, third
linear actuator, fourth linear actuator, fifth linear actuator, sixth linear
actuator, seventh linear
actuator, eighth linear actuator, ninth linear actuator, tenth linear
actuator, eleventh linear actuator,
twelfth linear actuator, first rotary actuator, second rotary actuator, third
rotary actuator, fourth
rotary actuator, fifth rotary actuator, or sixth winding arc rotation control
the position of the linear
media. The wind-on spool associated with a sixth rotary device at the spool
location provides
winding arc rotation, thereby allowing the wind-on spool to selectively tilt
which include
embodiments such as a goniometer or a rack and pinion arc mechanism.
[0012] Material Handling. It is yet another aspect of embodiments of the
present invention to
provide enhanced material handling capabilities. More specifically, current SC
winding methods
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produce various stress/strain points that lead to material failure and lower
critical SC values, which
lowers operational performance. The stress/strain points will often survive
winding and
subsequent quality assurance processes but will lead to failure during the
worst-case scenario of
the highest system power or energy operation.
[0013] Tensioner and Guide. It is another aspect of some embodiments of the
present invention
to provide a linear media tensioner and guide. More specifically, the LMHS may
manual or
automatically guide and hold tension for both wind-off and wind-on portions of
the cable, magnet,
or cable magnet wind while allowing individual SC operations, such as SC
critical value testing,
splicing operations, and wind-off spool swapping, to occur.
[0014] Winding Arc Rotation. Automated and/or manual rotation of the wind-on
former allowing
a key wind-on DoF ability. The purpose is to allow simple to very complex
magnet, cable, and
cable magnet wind abilities equivalent to human wind interaction and to a
level not possible with
other semi to fully automated winding machines. Embodiments include a
goniometer or rack and
pinion arc mechanized system such as for a complex solenoid, planar, and/or
spherical magnet
wind.
[0015] No Reverse Bends Linear Media Routing Design. Some embodiments of the
present
invention use a routing design that follows strict design rules in
transferring linear media from a
storage/reacting, wind-off spool to the desired wind-on spool (or bobbin or
former). It is highly
desirable that the media routing path, particulaiy HTS and reacted MTS, have
no reverse bends
whatsoever.
[0016] Bend Radius Control. As media is routed through the winding machine, it
is also highly
preferable that each bend, including wind-off and wind-on spools and any
pulleys over which
media passes, should maintain a minimum bend radius. This minimum radius,
which can also be
expressed as a minimum radius of curvature, is determined by the nature of the
media material
being processed.
[0017] Dynamic Surfaces. To minimize media stress and strain through friction
and rubbing,
which not only increases axial tension on the media but also tends to damage
any wire insulation,
all of the surfaces touched by the wire during the winding process will
preferably provide a
dynamic routing surface moving in the direction of the media motion (i.e.,
pulleys or wheels) or
low friction surfaces with no sharp edges.
[0018] Direct Closed Loop Axial Control. According to some embodiments of the
present
invention, axial tension is measured and used as input data for the primary
control loop affecting
system operation. Preferably, closed-loop control is used whereby the winding
process is initiated
by motors that turn either the wind-off spool or the wind-on spool (or both).
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[0019] Direct Closed Loop Lateral Control. Lateral bending and stress should
also be controlled
in some embodiments of the present invention. Superconductor wire should
unwind from the
wind-off spool, pass around the tension sensor wheel (preferably wrapped
around approximately
180 degrees circumferentially to ensure accurate measurement of the tension),
and wind onto the
wind-on spool while staying in substantially the same plane
[0020] Lateral sensors at the wind-on guides are placed orthogonal, or close
to it, to the wind-on
direction. This sense guides the level of guide force on the media which is
then compared to other
sensors, such as machine vision, to adjust the controls.
[0021] Non-Contact Sensor. It is yet another aspect of the present invention
to provide a non-
contact precision sensors, such as machine vision including optical including
3D vision, laser
including 3D laser profiling, and/or proximity sensors. For example, some LMHS
embodiments
employ a non-contact media position or wind pattern sensor system such as a
vision or laser or a
non-contact tension sense electromagnetic, resistance, or inductance
measurement sensor from
one to multiple sense directions.
[0022] Angle On/Off Wind. Active control loops based on the axial tension
value as one
embodiment of being the global control master and a hierarchy of master/slave
relationships
provide the means of varying the pitch angle and accurately keeping the
desired performance such
as constant axial tension.
[0023] End of Layer Sense. A critical transition in windings occurs when the
edge of a wind-on
spool is encountered. In multilayer windings, a change in direction must be
negotiated at this
transition.
[0024] Proof of Performance. Some embodiments of the present invention provide
proof of post
winding performance integrity. More specifically, values such as tension and
dropout occurrences
are recorded throughout each SC strand's length and, therefore, in the final
cable and magnet.
[0025] Turn-by-Turn Tension Control. It is another aspect of some embodiments
of the present
invention to provide turn-by-turn tension control or by continually varying
tension control
throughout the wind-on process. For example, some LMHS allow the operator to
set winding
tension values for each layer and even each turn per layer in the wind.
[0026] Reverse Direction Wind. Winding operation onto a bobbin commonly
involves a single
bobbin rotation direction. It is another aspect of some embodiments of the
present invention to
provide an LMHS that performs a reverse direction wind onto a bobbin.
[0027] Splice Mitigation. LMHS of one embodiment provides the ability to lower
the number of
and, in some cases, remove splices required for any linear media such as SC
wire or tape due to
the large number of controllable degrees of freedom (DoF).
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[0028] Cryostat Cladding and Cable Jacket The LMHS of one embodiment of the
present
invention provides an inline cryostat cladding station, cable jacket station,
etc. that facilitates the
development of large commercial cable magnets and commercial power cables by
completing the
cable former core.
[0029] Integrated Wound Components. It is yet another aspect of some
embodiments of the
present invention to provide a winding machine configured to integrate energy
storage system
(ESS), power electronics, sensors, etc., into a cable, magnet, or cable
magnet. The cable
embodiment can wrapped for a finite, intermittent, or complete cable length
and/or when used in
a cryogen environment. One of skill in the art will appreciate that a common
energy storage system
that could be incorporated by winding into or onto or placed into or onto a
cable, magnet, or cable
magnet, for example, is an ultracapacitor (same as a supercapacitor),
capacitor, battery, or similar
device. Further, "power electronics- are understood to often be solid-state,
non-solid-state, such
as linear based, etc., electronics that selectively control and convert
electric power. Sensors
provide ESS, power electronics, cable, magnet, cable magnet, etc. sensing
which can then be
recorded and/or used in a controlled response. Integrated ESS, power
electronics, sensors, etc.,
are lighter, smaller, and safer than a conventional ESS pack/box that employ
ESS housings,
busbars, nuts and bolts, etc. The ESS and power electronics may be wound
separately or together
as a combined solution at an automated and/or manual station.
[0030] One cable embodiment component is periodically wrapped around a cable
core either in a
spiral wrap process or formed into long strips to separately spiral wrap in
one embodiment. In a
further example, ultracapacitors (UCs) passively protect the remainder of the
ESS, such as
batteries, from stress that would otherwise require heavy and costly power
electronics. This
functionality provides a Distributed Grid solution, and for an electric
aircraft embodiment, a
Distributed Electric Propulsion (DEP) solution. In a separate or combined
embodiment example,
a wound battery will often be used to provide long-lasting energy to power
capabilities and the
UC will be used to provide peak power capabilities where either or both may
include power
electronics and sensors.
[0031] In one UC embodiment, cable wrapped chemical UCs are placed in a non-
cryogen region.
Another UC, e.g., nanowhiskers (nw), is placed in the cryogen resulting in a
more efficient and
thinner LTC, allowing the transmission of AC/DC/pulsed power. Placing the LTC
into the cryogen
removes the need to regularly break through the cryostat to connect the UC to
the superconductor,
which is important for thermal management and increased reliability. The
cryogen will also
provide added electromagnetic (EM) shielding external to the SC device.
Further, cryogenic
temperatures increase copper (Cu) electrodes' conductivity, further supporting
a more efficient
and thinner UC. Specifically, placing the UC into the cryogen should result in
a lower equivalent
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series resistance (ESR), which improves a lirs ability to deliver large
amounts of power as ESR
is inversely proportional to peak power. Power electronics and sensor
embodiments provide active
sense and control of any elements wrapped onto the cables, magnets, and/or
cable magnets
contemplated herein.
[0032] Adjustable Winding Guides. Adjustable Winding Guides, such as
independent follower
guides or wind-to guides, are utilized by some embodiments of the present
invention to allow
wind-on equivalent to a human operator. The contemplated guides provide an
automated and/or
manual ability to control the wound media. Wind-to guides can be low friction
surfaces, rollers,
rods, or guides located on one or multiple sides of the media in space. In one
embodiment, wind-
on guides are set to the linear media width and hold the media in place. The
guides are either
directly or via a separate pusher used for added side alignment force needs.
hi certain
embodiments, the software can code a spline or equivalent from computer-aided
design (CAD),
computer-aided manufacturing (CAM), or equivalent for multiple DoF to follow
to create a more
precise and winding contour. All adjustable winding guide embodiments can
connect to any
winding machine sensor and control to automatically control their motion.
Human interaction via
a control panel may also be used.
[0033] The guides are intended to provide a machine equivalent solution for
human interaction to
control delicate media. Accordingly, one benefit of some embodiments is that
the media is
properly handled. In addition, by providing machine-calculated variable
tension control at some
to all wind layup points, mechanical stress in the radial and angular
direction is controlled. Using
these techniques, system-neutral stress axis stress is also located, which can
be leveraged to negate
eventual operational stresses. Typically, a negative radial or inward wind
stress is chosen, thereby
reducing the entire wind stress from mechanical wound stress, such as magnet
hoop and radial
stress. Finally, more DoF provides a greater ability to actively minimize the
stress and bends and
achieve a more complex final geometry.
[0034] One embodiment is designed to fabricate a classic magnet armature wind
or any angled,
curved, or concave section wind. An added "push" is used for a zone equivalent
to a human pusher
tool. For applications that require a curved armature magnet, a single to
multi-positioned pusher
setup is employed on top of the linear media to hold media layers located in a
contoured slot to
achieve a curved stack instead of a linear pancake coil. In another process,
optional axial tension
is generated between the spool and bobbin/former to "pull" the media taught.
In another
embodiment, independent follower guide arms are used with multiple DoF such as
linear and
rotary motion of the follower providing motion relative to the former.
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[0035] In another embodiment, one pusher could be configured to push one or
both sides of the
linear media with the proper tooling, whereas the other pusher could be used
for other operations
such as pushing down on the linear media to hold in place or wrap around a
difficult corner.
[0036] In all embodiments, adjustable winding guides could help acquire a
tighter packing factor
and stop any wind fouling. Adjustable winding guides could also help control
winding
emplacement zones.
[0037] Winding Sections. In a hybrid to air core design, particularly for
superconductors, the
necessity of using continuous iron to direct the magnetic flux density is
removed which allows
winding to assembly sections. Embodiments include any electrical winding such
as electric
machines, transformers, fault current limiters, NMR/MRI, and SMES. In the
electric machine
embodiment both the stator and rotor can then be built to wind, 3D print, or
otherwise created and
assemble in winding sections to connect when forming the final device. These
sections are created
external from the final device for winding and/or ease of assembly including
providing line
replaceable units and/or a means of activating TFMs outside of the final
machine.
[0038] Multiple Wind Magnets. Wind multiple, separate magnets at once provides
the ability to
wind multiple magnets with no splice between magnets. Embodiments include
multiple magnets
such as multiple electric machine primary and/or secondary windings such as
for the same phase.
Other embodiments include concentric rings for the embodiments of a
transformer or fault current
limiter or SMES. Other embodiments include multiple cylindrical coils for use
in high energy
physics particle accelerators or NMR/MRI.
[0039] 3D Printing of Superconducting Winding to Application Parts. It is one
aspect to provide
3D print parts specific to superconducting, particularly HTS and MTS,
application. That is, 3D
print parts could be used in electric machines, MRIs and NMRs, regular to high-
frequency
transformers, fault current limiters, SMES, common to specialty magnetic
device cores, winding
formers and tooling, etc. Due to the extremely high superconductor current and
magnetic field
capable needs and benefits, use of 3D printing for final applications and
products can be of
extreme benefit, such as assisting the development and operation of fully
cryogenically cold and
power-dense devices, rotary electric machines with high structural capability
at high-speeds,
thermal conductive paths, specialty materials such as Titanium (Ti) for SC
use, and lower mass
devices and systems. A linear, rotary, arc and all other electric machine
embodiments include
elements to complete electric machine rotor and stator to hold the field and
armature windings
including winding support to final operational formers, including hybrid to
fully air core formers,
as well as other magnetic elements such as trapped field magnet (TFM) and
permanent magnets,
as well as non-magnetic elements. Any magnet, cable, and/or cable magnet
device includes 3D
printing for magnetic paths, cryostats and cryogenic cooling and conductive
paths, gas paths (e.g.,
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cryogenic liquid to gas expansion paths), electromagnetic (EM) shields and
shield mounts,
supporting and controlling EM and mechanical effects such as via mechanical
and/or electrical
high-speed and frequency induced EM effects, conductive cooling and quench
support, structural
support, allows increased manufacturability of components to systems, means of
minimizing part
counts and cost, increasing reliability, etc.
[0040] All electric machine or similar inventions described herein apply to a
rotary, linear, arc,
etc. type of motional AC or DC device. In a rotary or arc electric machine the
stator is the
stationary part and the rotor is the moving part. A rotor is commonly the
radially inside, but either
can be on the radially inside or outside. Portions of this disclosure refer to
"primary" and
-secondary" portions of an electric machines. The -primary" is the active
prime moving part of
the electric machine that is the location of the armature, i.e., the component
of an electic machine
that carries AC current in an AC machine. The "secondary- responds to the
primary of the electric
machine. In an AC machine the secondary comprises magnetic field producing
elements
(magnetic coils, permanent magnets, trap field magnets, etc. or some
combination) used in an AC
synchronous machine and passive conductors used in an AC induction machine,
which will be
described in more detail below.
[0041] Winding HTS and MTS generally requires very large bend radii and the
tensiometer (e.g.,
a tension measuring device) and tensiometer wheel that holds and senses the
linear media must be
large in diameter for HTS, and particularly reacted MTS, and well balanced in
all directions to
provide a part of a Newton level of tension continuous measurement. Such a
wheel does not exist
in industry.
[0042] Winding Injector. Some versions of the contemplated winding machine
employ an
automated and/or manual winding injector for placement of an adhesive, UV
adhesive, thermal
compound, spot, linear, pattern, etc. in the wind. In one embodiment, the
winding injector is used
for a concave, complex, or open on one or both ends wind. In another
embodiment, the winding
injector is used in conjunction with the follower guide(s) or pusher(s) to
hold for a brief dry and
then wind continuation or slow wind. Full transposition provides the option of
an embodiment for
better cooling paths which provides better quench and fault current protection
where each layer
thermally shields the layer below versus the more common Cu or equivalent
thermal stabilizer
usage. These cooling paths comprise HTS to HTS winding voids that accommodate
wound-in
thermally conductive material or injected cryogenics. In either case, voids
could be wound in
alignment to allow cryogen direct cooling to all layers. By orienting the
internally wound
thermally conductive material, the wound cooling paths can be connected to an
outer conductive
cooling path at repeated lengths down a cable, such as 0.5meter contacts or a
mesh contact, while
allowing cryogen flow. In all cases the voids or any magnet, cable, cable
magnet location can be
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epoxy or similarly filled also for other needs such as improved structural
support, magnetic path
support, etc.
100431 Wind Form Filler. Another aspect of some embodiments of the present
invention provides
an LMHS that incorporates a wound former filler or bridge that prevents sharp
bend points to
occur in the wind-on material, particularly during flexure, operation, or
other induced movement
in a wound magnet, cable, cable magnet. Applied filler can be solid or liquid.
[0044] Magnet Station. One embodiment of the present invention provides an
inline magnet and
cable magnet station that facilitates the development of commercial magnets
and cable magnets.
This magnet station improves capability, reliability, cost, and production
rate of complex magnet
and cable magnet configurations while incorporating partial to full
transposition and braiding of
modern SC magnets and cable magnets. Embodiments of industry use include high
energy physics
(HEP), fusion, NMR/MRI, transformers, fault current limiters, superconducting
energy storage
rings (SMES), motor/generator magnets, and cable magnets.
[0045] Advanced Sense and Control. The LMHS of one embodiment employs advanced
control
processes, techniques, algorithms, and supporting sensor, type, placement, and
use beyond what
winding systems use to date. A primary embodiment is the uniquely developed
and used axial
tension sensor as a basis for all wind feed rates and tension control.
[0046] Variable Media. Reviewers of this application and the applications
described above will
appreciate that in some respects the media type being wound or transferred is
not relevant. More
specifically, the wound media can be any type of delicate material (e.g.,
superconducting wire,
tape, cable, thermal to electrical insulation, etc.) wound or transferred from
one location to
another. Those of ordinary skill in the art will also recognize that the
apparatus and methods
described in these applications can be used to create cables, magnets, cable
magnets, or any other
device known in the art that incorporates wires or cables or linear media.
[0047] Superconducting Electric Machine of any Flux Type. It is yet another
aspect of some
embodiments of the present invention to provide radial, axial, transverse, and
any other type of
flux type device that employs HTS, wherein the motor's stator and/or rotor
portions are
cryogenically cooled. The transverse flux motor components can also be partial
or half cold. In
one contemplated AC induction machine a field coil side can be replaced with
conductive material,
such as short circuited, passive HTS tapes perhaps in the form of coils, a
squirrel cage, or sheet
equivalent.
[0048] One embodiment of the contemplated invention is an air core AC or DC
superconducting
machine with HTS EM armature coils and HTS EM and trapped field magnet (TFM)
field poles,
which maximizes rotational speed, removes all possible losses, provides the
most efficient, power-
dense, and specific power machine possible with today's technology. A fully
HTS electric
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machine including complex curve multi-turn per layer HTS field and armature
coils increases
efficiency and power for the very low mass and volume, especially for a
smaller sized machine
electric machine, beyond any other currently possible within the same rotor
velocity range. Fully
cold HTS electric machine with curved HTS coil transformational benefits
include: 1) highest
efficiency (>99.0%); 2) highest power and power density; 3) lightest weight;
4) smallest size; 5)
highest torque; 6) highest air gap B; 7) no internal heat generation; 8) no
resistive losses
(particularly beneficial for short axial length machines such as most
circumferential machines);
9) safely wound HTS commercial production magnets; 10) first ever complex
curve multi-turn
per layer HTS field and armature coils; 11) fully cold machine; 12) TFMs
incorporated with EM
coils into the field poles; 13) TFM activation inside of the machine due to
combined field and
armature EM coil activation method; 14) least amount of conductor tape/wire
required; and 15)
manufacturing ease from winding to modular stockable/swappable subassemblies
for all frame
sizes. In this example, HTS primary losses are 85% removed. Machine
performance increase is
related to the number of magnets converted to HTS, starting with the removal
of all magnet
resistive losses.
[0049] Tape Curvature and Alignment for B Path. Complex wind and curve the
linear media for
the best B path operation which is especially important for HTS tapes. Iron,
which controls the B
path (including a normal B into the air gap), is absent in an air core device.
Accordingly, a curved
winding pattern is used to accommodate B path needs. Properly designed complex
3D shaped SC
magnets allow compact and lighter sizing for high efficiency and B without
exceeding HTS
critical values. Multi-layer magnets, such as an electric machine field coil,
incorporates radii at
their corners to curve the B path and minimize placement of HTS in the highest
B regions, like
electric machine Fe tooth curves for limiting motor saturation. The highest
HTS induced current
occurs when the external B is perpendicular to the tape width, so in another
unique design step,
each HTS tape is placed and oriented to set the HTS width parallel to the
highest B. When this
configuration is not possible, such as certain armature configurations, HTS EM
shields deflect the
highest B from the tape width.
[0050] Flat Fan Magnetic Coil. The winding ability described herein turns the
considered
negatives of HTS tape geometry to an advantage. Flat Fan compact coil
embodiments range from
common EM-based devices to any EM specialty devices, such as radial, linear,
arc, and
circumferential electric machines (examples include a motor for an aircraft
turbofan and a
generator for a wind turbine), transformers, fault current limiters,
superconducting energy storage
rings (SMES), NMR/MRI, cable magnets, thrust tubes such as for exoatmospheric
satellite ion
propulsion, fusion reactors, and high energy physics particle accelerator beam
compression/recompression and focusing to deflection magnets. For an electric
machine
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embodiment, this increases electric machine performance far beyond any other
machine attempt
with an electrical machine as close to an ideal sinewave machine as current
technology allows for
a discrete, multi-turned winding. In an electric machine, any stator or rotor
coils [both primary
(armature) and secondary (field, passive secondary, etc.) coil sides] can
assume the flat fan
configuration and certain field pole configurations can include TFMs and the
stator or rotor can
be on the inside radius and either can include the armature or field coils.
[0051] An extremely high power, compact device of any type is also possible
because HTS has
no internal heat generation at any non-critical current level, excluding
minute solder joint and EM
transient conductor heating. No heat generation means there are no current
thermal limits, no EM
shielded winding cooling beyond cryo cool down, no parallel winds needed for
internal current
heating, etc. Given no large heat generation concerns, specialized complex HIS
winding
placement turns the very thin nature of HTS to an advantage, allowing a new
"Flat Fan- coil to be
built and placed into a new configuration. The flat fan coil uses a thin tape
profile such as an HTS
(often 0.1mm with lmicrometer for HTS) by placing the HTS tape width (often 2
to 12mm) facing
width along the straight length, like a shallow saddle coil that is densely
packed and curved. B
acts in a direction across the surface current, which is highest parallel to
the longest length, so
orienting the tape width perpendicular or close to perpendicular to the air
gap gives the highest B
across the air gap. Long wind depths are no longer required versus a single
(pancake), double, or,
as expected, at most only a few layers winding, also allowed with max. B into
the airgap due to
flux exclusion as the B travels from the furthest (e.g., outer) layer tapes to
the airgap with the thin
HTS maintaining their path. When compacted into a pancake coil that curves to
the air gap, this
configuration places the thickness of all armature and secondary coil turns at
the surface next to
the air gap with no layers moving the HTS away from the air gap but with 100's
to 1000's of turns
with all at high currents. This configuration maximizes the air gap B while
minimizing losses.
When superimposing the B for many parallel, discrete turns aligned together,
an extremely high
B is attained. The limit is then defined by the maximum B for each HTS tape
group region where
discrete B loops are separated across the circumference versus the
superposition of many turns
into a deep tooth for the embodiment of a common radial machine.
[0052] A Flat Fan HTS magnet design allows the removal to minimization of
slots and harmonic
losses with a small air gap and support for magnetic and mechanical forces,
main issues with
slotless winds. The HTS provided high air gap B allows an air core machine
which, along with no
PM use, removes all hysteretic losses. An evacuated or non-air air gap removes
all windage loss.
Cryogenic cooling loss is equivalent to conventional cooling loss. A slotless
armature allows a
high rpm, removal of slot losses, construction ease, and good armature back
plane cooling,
including removing the need to separate coil turns and coil groups for cooling
purposes. The
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armature phases and field coils can then be placed next to one another, with
or without a phase-
to-phase HTS shielding layer, and then structurally bind all HTS phases into
single armature
and/or field coil rings. Without slots and only shallow surface coils, the
diameter, the best machine
dimension to decrease for sizing and weight reduction needs, is minimized with
only structural
support and cooling beyond the radially outermost coils.
[0053] Secondary coils such as field coils follow a similar structure of
winding to thermal support
as the armature. If operations including a quench do not structurally or
thermally allow a slotless
wind, then short, thin teeth or equivalent can also be incorporated. Harmonics
are minimized in
this highly distributed armature and secondary wind with each turn (of
possibly 100's of turns for
a small sized electric rotary, linear, arc, etc. machine and only increasing
for larger sized
machines) next to the air gap providing a slight B electromotive force (emf)
step versus slot
generated emf from concentrated windings with most turns far from the air gap.
A coil is then a
compact series of either vertical or angled HTS turns. In the individual HTS
angle case each turn
can be wound to partially overlap one another to further remove harmonics,
further decrease any
unwanted induced B in the tape width while providing the highest air gap B,
and this V-pattern
assists with creating coil end turns by always rotating the HTS thickness side
into the turn. For
this case the HTS of the armature and/or secondary coil halves are angled into
an overlapping V-
pattern with respect to the B path. The contemplated angle may be slight due
to the aspect ratio
common to HTS ¨ long length and relatively thin width.
[0054] The armature phase half turns in one embodiment turn inwards with
respect to the
secondary to accommodate the secondary B moving past the armature. To provide
the highest
induced B in the secondary, the secondary turns are expected to turn inwards
with respect to the
secondary pole to accommodate any B moving past the pole. The addition of a
skew angle is also
possible. A fractional pitch wind can further remove any harmonics remaining.
Without
harmonics, mostly due to the highly distributed wind, all non-leakage B goes
into the power
producing fundamental frequency and thus greatly approximates a pure
sinusoidal machine.
[0055] If the stray B is minimized, critical HTS current is not approached,
and if the B across the
tape width is acceptable, then any tape width desired can be used for either
the armature or field
coils embodiment. For a high current machine, larger HTS widths provide a
higher current output
with a faster response time. On the lower end, smaller HTS widths allow many
ampere-turns for
a multi-layer coil or a high power, highly compact HTS single layer machine.
Electrically, more
turns give a higher emf with a natural current filter where HTS is already a
high current output.
More layers provide a higher power density within B and current critical
limits.
[0056] Flat Fan End Turns. Conventional device end turns often experience
leakage flux and Cu
loss due to no back-iron and geometries that move the end turns away from the
air gap and not
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orthogonal to the secondary. To use end turns as part of the magnetic length,
orient end turns in
an electric machine where poles can overlap end turns on one or both sides
making them part of
the magnetic length due to: 1) the flat, fan geometry of the HTS end turns; 2)
the short end turns
air gap; 3) 45-degree or smaller end turn angle with respect to the straight
armature length; and 4)
no end turn resistive losses. Mainly for an air core and compact and/or short
axial machine where
the end turns are a large axial length percentage, this adds power density and
efficiency by
increasing useable axial length and removing leakage inductance for the end
turns and nearby
straight magnetic length. If the phase power is not smooth due to no phase
transition region such
as chording, phase overlaps, enough inductive lag, end turn magnet lengths
smooth phase power
by automatically overlapping.
100571 Curved Flat Fan Coils and TFMs. In one electric machine embodiment, the
field coils are
common coils or flat fan with multi-dimensional curved sides to control the B
path and further
accommodate trapped field magnets (TFM), such as but not limited to HTS TFMs,
to further
increase the air gap B and output performance. The TFMs can be activated into
different pole
orientations, which is of great benefit for changing the output from the same
electric machine
without having to rebuild the electric machine such as changing out the
secondary. In a further
electric machine embodiment of an HTS electric machine, the EM coil outsides
curve to enclose
all TFMs while maximizing the B for a small air gap pole area that overlaps
multiple armature
phases. The HTS EM field pole: 1) activates the TFMs in the machine; 2)
maximizes the field B;
3) augments and controls the B for a higher and more efficient fundamental B
for each rpm; and
4) waveform shapes power generation when in a self-excitation mode with the
armature. Because
the TFM B forms the shape of an equilateral triangle with the maximum at the
puck middle
surface, in one embodiment TFMs are placed side to side facing and angled with
the air gap to
provide the maximum averaged air gap B. The entire pole is then curved to
decrease the curved
air gap to allow the highest B without quench while providing a variable air
gap length at each
pole end to further lower harmonics. Field coil TFMs are epoxied into place,
which protects the
TFM and for ease of rotor manufacturing. Sensors and heaters placed with the
TFMs control
deactivation. Rotor poles are connected to form a cylinder for structural
support.
[0058] TFM activation in a conventional or half HTS EM wound machine is a
large concern due
to the limitations of Cu winds and the maximum B they can hold across the TFM
as well as Fe
limitations. This concern is removed for a superconducting, such as HTS and
MTS, EM due to
the high B with no heat generation and further with hybrid to air core
benefits. In one embodiment,
TFM activation is achieved by aligning the field pole to a specific armature
phase location and
applying a same direction DC B across both the armature and field HTS coils.
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[0059] EM Shields. In an electric machine embodiment, electromagnetic (EM)
shields of an SC
such as HTS or conventional conductor and the option to cryogen cool, both
options allowing a
high conductivity which greatly increases the EM shielding, are employed over
the field poles,
between armature phases, and over non-magnetic length end turns. These unique
EM shield
windings, with HTS being one embodiment: 1) lower quench issues; 2) support a
higher B in a
tight and contained path, especially in smaller magnets; 3) lowers mass by
removing Fe and HTS
turn needs; 4) optimize efficiency by minimizing stray and hysteretic B loss
while allowing more
current per HTS strand. For an embodiment of an armature magnetic length and
end turn EM
shielding, one to multiple single strips of parallel HTS with possibly
soldered ends is used. In the
armature length, the HTS strips and/or amortisseur bars are placed between the
phases. End turns
will use shorted HIS strip EM shields between phases to protect against high
frequency losses
such as power conditioning system (PCS) switching, a larger concern when
resistance is removed.
In some embodiments, a field pole EM shield for armature transients is
required to minimize
transient EM losses. In such cases if a field cryostat is required, then the
stainless steel or
aluminum or titanium or equivalent conductive metal cryostat wall will be
considered for the EM
shield, or shorted HTS strips are placed over the field poles. Due to the high
conductivities and
skin depth of all metals at cryogenic temperature, any high frequency metal EM
shield is very
thin. Cryogenic cooling paths for all EM shields can provide an excellent
inductively generated
heat removal mechanism.
[0060] Induction SC Electric Machine. Use wound secondary SC coils and/or
squirrel cage
configuration to obtain an high induced B and/or use HTS, such as many turns
stacked or similarly
in parallel, to provide an induced current path for starting torques and/or
oscillation damping. An
SC machine does not have the inherent resistive damping of a conventional
machine which can
lead to rotor oscillations. Embodiments to remove damping include embedding Cu
or aluminum
(Al) amortisseur bars, variable external resistors, and/or the power
electronics drive where any
listed device can include cryogen cooling to increase performance. These
solutions also help
control the speed/torque characteristics of an induction machine. For example,
wound secondary
motors with equivalent poles as the armature can be started with the highest
torque and a low
inrush current by inserting high resistance into the rotor circuit. As the
motor accelerates, the
secondary resistance can be decreased, coils shorted at maximum speed, to
maintain maximum
power. In all operational modes the benefits of an SC are achieved due to the
extremely high
induced emf. An embodiment is an HTS flat flan wound secondary with LN2 cooled
damping
bars between the winds and a potential skew opposite the armature coil or in
place of an armature
skew achieves a high performance output.
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[0061] Combined Induction and Synchronous SC Electric Machine. A fully HTS
electric machine
with no resistance losses, high currents, and a high number of turns in a
small packing factor has
the benefit of combining the two AC machine types, induction and synchronous.
Operate the same
electrical machine as an induction, secondary is an induced passive B, or
synchronous, secondary
is active B, machine. This allows an extreme coupled B for both inductance and
synchronous
machine modes and hence high power and efficiency across all speeds. This HTS
machine
embodiment has a higher HTS cost and machine to power conditioning system
(PCS) control
complexity, but the benefits from this first ever machine can be critical for
certain applications
from industrial to electric vehicles (EV). An HTS wound induction solution
provides a high self-
starting torque to torque frequency range and efficiency due to the high
induced currents with no
loss. High starting torques and higher efficiency and power across speed
ranges allow better total
lifetime cost (TLC) for high torque motion and start/stop EVs (off-road
construction, buses, A/C
ascent, and tugboats). An HTS synchronous solution allows extreme efficiency
and power at
optimal speeds where the secondary B is varied to maximize torque at the
desired speed.
Optionally, TFMs can be incorporated and activated for synchronous mode to
greatly increase the
power and/or close circuit the secondary in a passive mode with respect to
external circuitry else
do not activate the TFMs for inductive mode operation.
[0062] Combined Induction and Synchronous SC Electric Machine Mode and
Operation
Damping. Secondary coils are shorted for an induction machine response and
coils are active with
or without TFMs or permanent magnets (PM) for a synchronous machine response.
Precise control
is required to achieve the optimal torque-velocity when moving between
induction (for variable
speeds and/or slower speeds with higher torques) and synchronous (for
optimized constant speeds)
modes. An induction machine mirrors the armature poles, so in one embodiment a
wound
induction secondary can go into a common induction machine mode with external
resistances or
shorted coils or move into a synchronous mode by DC powering different pole
configurations as
set via connections for different pole numbers. The synchronous poles of
choice are DC powered
to lock from an inductive slip into a synchronous mode with limited hunting
oscillations. An SC
machine does not have the inherent resistive damping of a conventional machine
which can lead
to rotor oscillations. In another embodiment the external resistors including
conductive cryo
cooling are an extra rotor damping option but are not expected to be required
due to the extreme
air gap B stiffness and damping versus typically far lower motor output power
pull leaving only
high frequency, low power oscillations that the HTS and HTS coating should
accommodate.
Another embodiment includes variable pole options for how rotor based
persistent switches close
as passive inductive or active field coils.
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[0063] Compact Advanced Superconducting Devices. It is another aspect of some
embodiments
of the present invention to provide advanced, compact devices made of
superconductors. The
superconductors may be made or processed using the techniques described
herein. Contemplated
compact SC devices include but are not limited to: motor and generator
machines, magnetic
resonance imagining (MRI), nuclear magnetic resonance (NMR), surface NMR
(SNMR) [which
includes surface MRI (SMRI) in this document], fault current limiters (FCL),
and any device that
includes or uses a high EM field and/or current partly to fully created by an
advanced SC.
Advanced SCs contain materials that allow superconducting operation at higher
temperatures and
are generally more to significantly more mechanically fragile. The disclosed
devices can be used
for motors and generators, medical applications, geoscience applications, wind
energy generators,
hydro-electric generators, hybrid or all-electric vehicles, oil and gas
applications, magnetic
containment, high energy physics (HEP) and fusion applications, including high
B magnets,
greater than 16Tesla (T) magnets, power systems, aeronautical and aerospace
applications, EM
propulsion (magprop), EM levitation (maglev), space EM shielding, ship
systems, ground
transportation, military, utility, agricultural, construction, mining,
environmental, resource
management, disaster relief, archeology, and any industry using an EM system.
Although some
of the instant disclosure is focused on compact systems, those of skill in the
art will appreciate SC
devices of any size can be manufactured.
[0064] Compact Superconducting Device. The compact advanced SC of one
embodiment is a
high output and/or resolution device compact in size and weight. Some compact
SC devices may
be personnel portable employing power, energy storage, controls, data
acquisition (DAQ),
operator interface, and cryogenic systems.
[0065] Component Based Superconducting Device. Another embodiment of the
invention
includes the SC magnet set and other elements being swappable components or
line replaceable
units (LRUs).
[0066] Hybrid Superconducting Magnetics. The magnetics include hybrid
embodiments with
conventional electromagnet (EM) conductors and/or permanent magnets to
complete wound SC
and/or bulk TFM type SC. Embodiments include using magnetics of one type of
source, such
controlled and wound SC, to control and shape the magnetics of another type of
source, such as a
TFM or permanent magnet, whether part of the same magnet or pole or not.
[0067] Combined Superconducting Magnetics and Speed. Another embodiment of the
invention
is the combination of increasing speed of a partial to complete SC device to
further increase energy
density and specific energy while not losing efficiency due to speed induced
transient losses. In
an electric machine embodiment, maximizing B with a fully HTS device and high
(5,000 rpm and
above) to extreme speeds (10,000 rpm and above) supports highest power and
size savings,
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leading to an ultra-high power and compact size through improved specific
power/energy and
power/energy density.
100681 Superconducting Magnetic Prime Mover Power System Approach. The
magnetic prime
mover power system focus is atypical for an SC machine. Large scale efficiency
and performance
increase for any electrical machine is commonly achieved through the energy
system means of
increased relative motion of the magnetic reference frame, for example, the
armature and exciter
field coil in a synchronous motor and/or generator machine, and/or by
maximizing the magnetic
air gap magnetic flux density (B) for a particular operational temperature
(T). This energy system
approach is the future of SC machines once SC materials allow further
increases. This common
approach is not the direct focus of this embodiment. Instead, this embodiment
incorporates a
power system approach from the benefits of increased current density (J) from
a system mindset.
[0069] Magprop. The winding to application descriptions herein, such as all
electric machine
descriptions, as applied to electromagnetic propulsion (magprop) including the
embodiment of an
HTS and MTS applied to any and all SC linear or curved electric machines of
any type for
terrestrial to extraterrestrial use including magnetic levitation (maglev)
train propulsion and
vehicle launchers including space launch systems.
[0070] Superconducting Inertial Propulsion. The winding to application
descriptions herein, such
as all electric machine descriptions, as applied to electromagnetic inertial
propulsion including the
embodiment of an HTS and MTS applied to any and all SC inertial propulsion of
any type for
terrestrial to extraterrestrial, including space, use including ion propulsion
systems.
[0071] Maglev. The winding to application descriptions herein, such as all
electric machine
descriptions, as applied to magnetic levitation (maglev) including the
embodiment of an HTS and
MTS applied to any and all SC linear curved electric machines of any type for
terrestrial to
extraterrestrial use including magnetic levitation (maglev) train levitation
and vehicle launchers
including space launch systems.
[0072] Superconducting Transformer. The winding to application descriptions
herein as applied
to a transformer including the embodiment of an HTS and MTS regular to high
frequency
transformer. One embodiment of such a transformer may include a 3D printed
core to support
more advanced needs such as high frequency switching operations.
[0073] Superconducting Fault Cun-ent Limiters. The winding to application
descriptions herein
as applied to a superconducting fault current limiters (FCL) including the
embodiment of an HTS
and MTS regular to high transient and power FCL.
[0074] Superconducting Magnetic Energy Storage. The winding to application
descriptions
herein as applied to superconducting magnetic energy storage (SMES) including
the embodiment
of an HTS and MTS SMES.
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[0075] Superconducting Flywheel Energy Storage. The winding to application
descriptions herein
as applied to a superconducting flywheel energy storage including the
embodiment of an HTS and
MTS regular to high speed and power flywheel.
[0076] Superconducting High Field Magnets. The winding to application
descriptions herein as
applied to superconducting high field magnets including the embodiment of an
HTS and MTS
high field magnets for high energy physics (HEP) and fusion applications
greater than three Tesla
(T) magnets.
[0077] Superconducting Space EM Shielding. The winding to application
descriptions herein as
applied to superconducting electromagnetic (EM) shielding magnets including
the embodiment
of HTS and MTS EM shielding magnets.
[0078] It is thus one aspect of embodiments of the present invention an
electric machine,
comprising: a primary component comprising at least one coil; and a secondary
component having
at least one coil formed of a layer of superconducting tape having a
rectangular cross section, the
secondary component positioned adjacent to the primary component and separated
from the
primary component by an air gap, the primary component configured to create an
electromagnetic
force that interacts with the secondary component to move the secondary
component.
[0079] It is another aspect of some embodiments of the present invention to
provide an electric
machine, comprising: a primary component comprising at least one coil; a
secondary component
having at least one coil formed of a layer of superconducting tape having a
rectangular cross
section, the secondary component positioned adjacent to the primary component
and separated
from the primary component by an air gap, the primary component configured to
create an
electromagnetic force that interacts with the secondary component to move the
secondary
component; and wherein the rectangular cross section is defined by a long edge
and a short edge,
the short edge positioned adjacent to the air gap, and wherein the long edge
is associated with
lateral side surfaces of the superconducting tape that extends away from the
air gap.
[0080] It is another aspect of some embodiments of the present invention to
provide an electric
machine, comprising: a primary component comprising at least one coil; a
secondary component
having at least one coil formed of a layer of superconducting tape having a
rectangular cross
section, the secondary component positioned adjacent to the primary component
and separated
from the primary component by an air gap, the primary component configured to
create an
electromagnetic force that interacts with the secondary component to move the
secondary
component; wherein the rectangular cross section is defined by a long edge and
a short edge, the
short edge positioned adjacent to the air gap, and wherein the long edge is
associated with lateral
side surfaces of the superconducting tape that extends away from the air gap,
and wherein the
lateral side surfaces are not normal to the curvature of the air gap.
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[0081] It is yet another aspect of some embodiments of the present invention
to provide an electric
machine, comprising: a primary component comprising at least one coil; a
secondary component
having at least one coil formed of a layer of superconducting tape having a
rectangular cross
section, the secondary component positioned adjacent to the primary component
and separated
from the primary component by an air gap, the primary component configured to
create an
electromagnetic force that interacts with the secondary component to move the
secondary
component; and wherein the at least one coil of the primary component is
comprised of a layer of
superconducting tape having a rectangular profile.
[0082] It is still yet another aspect of some embodiments of the present
invention to provide an
electric machine, comprising: a primary component comprising at least one
coil; a secondary
component having at least one coil formed of a layer of superconducting tape
having a rectangular
cross section, the secondary component positioned adjacent to the primary
component and
separated from the primary component by an air gap, the primary component
configured to create
an electromagnetic force that interacts with the secondary component to move
the secondary
component; wherein the at least one coil of the primary component is comprised
of a layer of
superconducting tape having a rectangular profile; and wherein the layers of
superconducting tape
of the primary or secondary component are comprised of a plurality of magnets
wound together
with a continuous connection of wire or tape.
[0083] It is another aspect of some embodiments of the present invention to
provide an electric
machine, comprising: a primary component comprising at least one coil; a
secondary component
having at least one coil formed of a layer of superconducting tape having a
rectangular cross
section, the secondary component positioned adjacent to the primary component
and separated
from the primary component by an air gap, the primary component configured to
create an
electromagnetic force that interacts with the secondary component to move the
secondary
component; wherein the at least one coil of the primary component is comprised
of a layer of
superconducting tape having a rectangular profile; and wherein the rectangular
cross section is
defined by a long edge and a short edge, the short edge positioned adjacent to
the air gap, and
wherein the long edge is associated with lateral side surfaces of the
superconducting tape that
extends away from the air gap.
[0084] It is another aspect of some embodiments of the present invention to
provide an electric
machine, comprising: a primary component comprising a plurality
superconducting coils a
secondary component positioned adjacent to the primary component, the
secondary component
separated from the primary component by an air gap, the primary component
configured to create
an electromagnetic force that interacts with the secondary component to move
the secondary
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component; and wherein the superconducting coils are formed of a layer of
superconducting tape
having a rectangular cross section.
100851 It is another aspect of some embodiments of the present invention to
provide an electric
machine, comprising: a primary component comprising a plurality
superconducting coils a
secondary component positioned adjacent to the primary component, the
secondary component
separated from the primary component by an air gap, the primary component
configured to create
an electromagnetic force that interacts with the secondary component to move
the secondary
component; wherein the superconducting coils are formed of a layer of
superconducting tape
having a rectangular cross section; and wherein the rectangular cross section
is defined by a long
edge and a short edge, the short edge positioned adjacent to the air gap, and
wherein the long edge
is associated with lateral side surfaces of the superconducting tape that
extends away from the air
gap.
[0086] It is yet another aspect of some embodiments of the present invention
to provide a method
of controlling an electric machine comprising a primary component and a
secondary component
separated from the primary component by an air gap, the secondary component
comprising a
superconducting coil formed of a layer of superconducting tape having a
rectangular cross section,
comprising: initially energizing the primary component to create a magnetic
field that interacts
with the superconducting coil to begin rotation of the secondary component;
and energizing the
at least one superconducting coil to selectively alter the rotation of the
secondary component.
[0087] It is yet another aspect of some embodiments of the present invention
to provide a method
of controlling an electric machine comprising a primary component and a
secondary component
separated from the primary component by an air gap, the secondary component
comprising a
superconducting coil formed of a layer of superconducting tape having a
rectangular cross section,
comprising: initially energizing the primary component to create a magnetic
field that interacts
with the superconducting coil to begin rotation of the secondary component;
energizing the at
least one superconducting coil to selectively alter the rotation of the
secondary component; and
wherein the secondary component further comprises at least one of a conductor
of a coil or bar,
superconducting tape, a permanent magnet, and a trapped field magnet.
[0088] It is another aspect of some embodiments of the present invention to
provide a method of
controlling an electric machine comprising a primary component and a secondary
component
separated from the primary component by an air gap, the secondary component
comprising a
superconducting coil formed of a layer of superconducting tape having a
rectangular cross section,
comprising: initially energizing the primary component to create a magnetic
field that interacts
with the superconducting coil to begin rotation of the secondary component;
energizing the at
least one superconducting coil to selectively alter the rotation of the
secondary component; and
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wherein energizing the superconducting coil occurs when the rotation speed of
the secondary
component approaches a predetermined rate.
100891 It is another aspect of some embodiments of the present invention to
provide a method of
controlling an electric machine comprising a primary component and a secondary
component
separated from the primary component by an air gap, the secondary component
comprising a
superconducting coil formed of a layer of superconducting tape having a
rectangular cross section,
comprising: initially energizing the primary component to create a magnetic
field that interacts
with the superconducting coil to begin rotation of the secondary component;
energizing the at
least one superconducting coil to selectively alter the rotation of the
secondary component; and
wherein the rectangular cross section is defined by a long edge and a short
edge, the short edge
positioned adjacent to the air gap, and wherein the long edge is associated
with lateral side surfaces
of the superconducting tape that extend away from the air gap.
[0090] It is another aspect of some embodiments of the present invention to
provide a method of
controlling an electric machine comprising a primary component and a secondary
component
separated from the primary component by an air gap, the secondary component
comprising a
superconducting coil formed of a layer of superconducting tape having a
rectangular cross section,
comprising: initially energizing the primary component to create a magnetic
field that interacts
with the superconducting coil to begin rotation of the secondary component;
energizing the at
least one superconducting coil to selectively alter the rotation of the
secondary component; and
wherein the superconducting coil of the secondary component has a passive mode
of use and an
active mode of use where current passes therethrough, and wherein the
superconducting coil is in
the passive mode of use when the primary component is initially energized.
[0091] It is another aspect of some embodiments of the present invention to
provide a winding
machine that may be capable of twenty DoF, comprising: a frame having an upper
portion and a
base portion; a wind-off spool subassembly, comprising: a first linear
actuator interconnected to
the base, a first rotary actuator interconnected to the first linear actuator,
a second linear actuator
interconnected to the first rotary linear actuator, a wind-off frame
interconnected to the second
linear actuator, and a rotatable wind-off spool, which is adapted to carry
linear media, operatively
interconnected to the wind-off frame; a follower subassembly, comprising: a
third linear actuator
interconnected to a cross member of the upper portion of the frame, the third
linear actuator being
substantially oriented with the first linear actuator, a second rotary
actuator interconnected to the
third linear actuator, a plate interconnected to the second rotary actuator,
at least one riser
interconnected to the plate, at least one beam interconnected to at least one
riser, a tensiometer
operatively associated with the at least one beam, a transverse beam
interconnected to at least one
beam and spaced from the tensiometer, a turning fork rotatably interconnected
to the transverse
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beam, the turning fork ending in parallel guides adapted to receive the linear
matter, a fourth linear
actuator interconnected to a frame member associated with the plate, wherein
the fourth linear
actuator is configured to urge a first arm in a direction non-parallel to the
third linear actuator, a
fifth linear actuator interconnected to a frame member associated with the
plate, wherein the fifth
linear actuator is configured to urge a second arm in a direction non-parallel
to the third linear
actuator, a sixth linear actuator interconnected to the fourth linear
actuator, wherein the sixth linear
actuator is configured to urge a third arm in a direction orthogonal to the
fourth linear actuator, a
seventh linear actuator interconnected to the fifth linear actuator, wherein
the seventh linear
actuator is configured to urge a fourth arm in a direction orthogonal to the
fifth linear actuator, a
third rotary actuator interconnected to the sixth linear actuator, a fourth
rotary actuator
interconnected to the seventh linear actuator, an eighth linear actuator
interconnected to the third
rotary actuator, wherein the eighth linear actuator is configured to urge a
fifth arm in a direction
towards the linear media, a ninth linear actuator interconnected to the fourth
rotary actuator,
wherein the ninth linear actuator is configured to urge a sixth arm in a
direction towards the linear
media, a first wind-on guide interconnected to an end of the fifth arm, and a
second wind-on guide
interconnected to an end of the sixth arm; a former subassembly, comprising:
at least one tenth
linear actuator interconnected to the base portion, at least one eleventh
linear actuator
interconnected to the base portion, a twelfth linear actuator interconnected
to the tenth and twelfth
linear actuators, a fifth rotary actuator interconnected to the twelfth linear
actuator, a wind-on
frame interconnected to the fifth rotary actuator, a sixth winding arc
rotation interconnected to the
fifth rotary actuator, and a wind-on spool operatively interconnected to the
wind-on frame, the
wind-on spool configured to rotate and adapted to receive the linear media;
and wherein the linear
media is taken from the wind-off spool, transitioned about the tensiometer,
and wound onto the
wind-on spool to form a magnet, and wherein the turning fork, the first wind-
on guide, and the
second wind-on guide along with selective movement of at least one of the
first linear actuator,
second linear actuator, third linear actuator, fourth linear actuator, fifth
linear actuator, sixth linear
actuator, seventh linear actuator, eighth linear actuator, ninth linear
actuator, tenth linear actuator,
eleventh linear actuator, twelfth linear actuator, first rotary actuator,
second rotary actuator, third
rotary actuator, fourth rotary actuator, fifth rotary actuator, or sixth
winding arc rotation control
the position of the linear media The wind-on spool associated with a sixth
rotary device at the
spool location provides winding arc rotation, thereby allowing the wind-on
spool to selectively
tilt which include embodiments such as a goniometer or a rack and pinion arc
mechanism.
[0092] It is yet another aspect of some embodiments to provide a winding
machine, comprising:
a wind-off spool adapted to carry linear media; a wind-on spool adapted to
receive the linear
media; a follower subassembly positioned between the wind-off spool and the
wind-on spool,
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comprising: at least one actuator associated with at least one wind-on guide
subassembly, the at
least one actuator configured to selectively impart lateral motion, transverse
motion, or a
combination thereof relative to the wind-on spool onto the at least one wind-
on guide
subassembly, the at least one wind-on guide subassembly comprising: a rotary
guide actuator, a
linear guide actuator operably interconnected to the rotary guide actuator, a
wind-on guide
operably interconnected to the linear guide actuator, wherein the linear guide
actuator provides at
least selective movement of an end of the wind-on guide towards or away from
the wind-on spool,
wherein the rotary guide actuator provides selective arcuate translation of
the end of the wind-on
guide; and wherein the linear media is taken from the wind-off spool and wound
onto the wind-
on spool to form a magnet, cable, or cable magnet, and wherein selective
movement of the linear
guide actuator or the rotary guide actuator controls the position of the
linear media as it is placed
on the wind-on spool.
[0093] It is still yet another aspect of some embodiments to provide a winding
machine for use
with linear media, comprising: a linear media supply spool adapted to store
the linear media and
from which linear media is removed; a cable core, magnet, or cable magnet
associated with a
wind-off spool; at least one motor that translates the cable core, magnet, or
cable magnet, thereby
transferring the cable core, magnet, or cable magnet onto a wind-on spool, a
wrapping station
configured to wrap linear media strands from the linear media supply spool
onto the cable core,
magnet, or cable magnet; and a component integration station that adds a
component to the cable
core, magnet, or cable magnet before, during, or after the cable core, magnet,
or cable magnet is
wound onto the wind-on spool or a former.
[0094] The Summary of the Invention is neither intended nor should it be
construed as being
representative of the full extent and scope of the present invention. That is,
these and other aspects
and advantages will be apparent from the disclosure of the invention(s)
described herein. Further,
the above-described embodiments, aspects, objectives, and configurations are
neither complete
nor exhaustive. As will be appreciated, other embodiments of the invention are
possible using,
alone or in combination, one or more of the features set forth above or
described below. Moreover,
references made herein to "the present invention" or aspects thereof should be
understood to mean
certain embodiments of the present invention and should not necessarily be
construed as limiting
all embodiments to a particular description. The present invention is set
forth in various levels of
detail in the Summary of the Invention as well as in the attached drawings and
the Detailed
Description and no limitation as to the scope of the present invention is
intended by either the
inclusion or non-inclusion of elements, components, etc. in this Summary of
the Invention.
Additional aspects of the present invention will become more readily apparent
from the Detailed
Description, particularly when taken together with the drawings.
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[0095] The above-described benefits, embodiments, and/or characterizations are
not necessarily
complete or exhaustive, and in particular, as to the patentable subject matter
disclosed herein.
Other benefits, embodiments, and/or characterizations of the present invention
are possible
utilizing, alone or in combination, as set forth above and/or described in the
accompanying figures
and/or in the description herein below.
[0096] The phrases -at least one," -one or more," and -and/or," as used
herein, are open-ended
expressions that are both conjunctive and disjunctive in operation. For
example, each of the
expressions "at least one of A, B and C," "at least one of A, B, or C," -one
or more of A, B, and
C," "one or more of A, B, or C," and "A, B, and/or C" means A alone, B alone,
C alone, A and B
together, A and C together, B and C together, or A, B and C together.
[0097] Unless otherwise indicated, all numbers expressing quantities,
dimensions, conditions, and
so forth used in the specification and drawing figures are to be understood as
being approximations
which may be modified in all instances as required for a particular
application of the novel
assembly and method described herein.
[0098] The term -a" or -an" entity, as used herein, refers to one or more of
that entity. As such,
the terms "a- (or "an-), "one or more- and "at least one- can be used
interchangeably herein.
[0099] The use of -including," -comprising," or -having" and variations
thereof herein is meant
to encompass the items listed thereafter and equivalents thereof as well as
additional items.
Accordingly, the terms -including," -comprising," or -having" and variations
thereof can be used
interchangeably.
[0100] It shall be understood that the term "means" as used herein shall be
given its broadest
possible interpretation in accordance with 35 U.S.C., Section 112(0.
Accordingly, a claim
incorporating the term -means" shall cover all structures, materials, or acts
set forth herein, and
all of the equivalents thereof Further, the structures, materials, or acts and
the equivalents thereof
shall include all those described in the Summary, Brief Description of the
Drawings, Detailed
Description and in the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0101] The accompanying drawings, which are incorporated in and constitute a
part of the
specification, illustrate embodiments of the invention and together with the
general description of
the invention given above and the detailed description of the drawings given
below, serve to
explain the principles of these inventions.
[0102] Fig. 1 is a perspective view of a solid core SC cable of one embodiment
of the present
invention showing the internal components thereof
[0103] Fig. 2 is a perspective view of a hollow core SC cable of one
embodiment of the present
invention.
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[0104] Fig. 3 is a perspective view of an a compact superconducting
motor/generator of one
embodiment of the present invention.
101051 Fig. 4 is an exploded view of Fig. 3.
[0106] Fig. 5 is an exploded perspective view of magnets that can be used in a
compact
superconducting motor/generator of one embodiment of the present invention.
[0107] Fig. 6 is a perspective view of a fully HIS and fully cryogenically
cold electric machine
(motor/generator) of one embodiment of the present invention, wherein portions
have been
removed.
[0108] Fig. 7 is a perspective view of a rotor employed by the electric
machine shown in Fig. 6.
[0109] Fig. 8 is a perspective view a stator that employs high temperature
superconducting
elements in the form of flat fans employed by the electric machine shown in
Fig. 6.
101101 Fig. 8A is a cross-sectional representation of a HIS winding of one
embodiment and the
associated air gap.
[0111] Fig. 9 is a detailed view of Fig. 8.
[0112] Fig. 10 shows an perspective view of a an electric machine of another
embodiment of the
present invention that employs high temperature superconducting elements in
the form of flat fans.
[0113] Fig. 11 shows the embodiment of an SC wound magnet around a grouping of
SC bulk
trapped field magnets (TFM).
[0114] Fig. 12 shows the embodiment of an SC wound magnet around and on top of
a single SC
bulk trapped field magnets (TFM).
[0115] Fig. 13 is a perspective view of a winding machine of one embodiment of
the present
invention.
[0116] Fig. 14 is a top plan view of the winding machine shown in Fig. 13.
101171 Fig. 15 is a wind-off spool subassembly of the winding machine shown in
Fig. 13.
[0118] Fig. 16 is a follower subassembly of the winding machine shown in Fig.
13.
[0119] Fig. 17 is a detailed view of Fig. 16.
[0120] Fig. 18 is a wind-on subassembly of the winding machine shown in Fig.
13.
[0121] The following component list and associated numbering found in the
drawings is provided
to assist in the understanding of one embodiment of the present invention:
ft Component Component
2 Cable core 1360 Crossbeams
6 Cladding and insulation 1364 Rotary actuator
Jacket and outer wall 1368 Mounting/rotating plate
14 Superconducting material 1372 Riser
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Component Component
20 Cable 1376 Beam
24 HTS Layer 1380 Support beam
28 Conductive stabilizer and insulating layer 1384 Linear
actuator
32 Cryogen path (hollow core) 1388 Follower wind-on guides
36 Cryogen path 1390 Wind-on point
504 Magnets 1394 Stationary linear
actuators
508 Connecting wire/tape between magnets 1402 Linear
actuator
1100 Motor/generator 1406 Rotary actuator
1180 Housing 1410 Rotating former frame
1181 Stator 1412 Goniometer
1182 Rotor 1750 Electric machine
1183 Non-metal shaft portion 1754 Air core
1185 Stator coils 1758 Armature flat fan end
turn
1186 Hollow shaft 1759 Armature flat fan coil
1187 Field pole 1760 Magnetic coil
1188 Field coil 1762 Magnetic coil end turns
1189 Cover with EM shield 1764 Secondary flat fan coil
1190 Permanent magnets 1765 Secondary flat fan coil
end turn
bend
1300 Magnet winding machine 1766 Field poles
1304 Frame 1767 Rotor
1308 Wind-off subassembly 1770 Field pole spacer
1312 Follower subassembly 1774 Trapped field magnets
1316 Wind-on subassembly 1778 Field coils
1318 Base 1782 Reservoir
1320 Linear media 1786 Hollow shaft
1324 Wind-off spool 1790 Non-metal shaft portion
1328 Tensiometer 1794 Rotor hollow portion
1332 Wind-on spool/former 1800 HTS Tape Member
1340 Frame 1802 Superconducting
material
1344 Linear actuator 1806 Air gap
1348 Rotary actuator 1808 Gap
1352 Stationary linear actuator 1810 Second layer
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Component Component
1356 Stationary linear actuator 1812 First layer
[0122] It should be understood that the drawings are not necessarily to scale.
In certain instances,
details that are not necessary for an understanding of the invention or that
render other details
difficult to perceive may have been omitted. It should be understood, of
course, that the invention
is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0123] Embodiments of the present invention are directed to a Linear Media
Handling System
(LMHS) (one example of which is shown in Figs. 13-18). The contemplated LMHS
my include a
partial to fully automated inline cryostat station allowing the entire LMHS to
be deployed into the
field for continuous length use similar as the splicing concept described
herein. A primary example
is using LMHS for cable production at the cable installation site. In this
example one or more
LMHS developed SC cables can be wound to include any desired cable twisting or
weaving by
using a further embodiment of LMHS placed downline in the SC cable winding
system, and then
inserting or cladding into a cable cryogen container or cryostat inline, which
is then fed into the
installation. Fig. 1 shows a cable with cable core 2 where cryostat cladding
and insulation 6 and
jacker and outer wall of 10 are placed around the superconductor core 14. One
of ordinary skill in
the art will appreciate that EM shielding can be located outside the
superconductor and insulation.
In some embodiments, power elements are inserted into areas 6 and 14 such as
the Integrated
Wound Component of a spiral wrapped ultracapacitor as a nanowhisker form of
energy storage
system embodiment.
[0124] Fig. 2 shows further embodiments of the invention that functions as an
HIS cable as also
shown in Fig. 1. The device shown here is a Field Operable Superconducting
Device and can
function as a primary element of a Field Operable Superconducting System. Fig.
2 shows one
embodiment of a 3-phase, hollow core superconducting cable 20. The cable 20
has three HTS
layers 24 separated by conductive stabilizer and/or insulating layers 28. In
some embodiments,
cryogen flows in areas 32 and 36. In some embodiments, power elements are
inserted into area 36
such as the Integrated Wound Component of a spiral wrapped ultracapacitor as a
nanowhisker
form of energy storage system embodiment
[0125] Figs. 3-5 show a compact superconducting motor/generator 1100. The
motor generator
may be used in field-operable SC personal, portable devices. The machine may
be half or fully
HIS and, hence, half or fully cryogen cold of an electric machine
(motor/generator) of any
armature winding. Cryogenic cooling may be achieved by conductive cooling or a
partial bath
cool, where any stator cryostat is currently not shown. For simplicity of
drawings, many
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cryogenic, armature core, etc elements are removed or simplified. The
motor/generator 1100
comprises a housing 1180 that supports a stator coils 1185, which may be of
the construction of a
armature coil group shown in Fig. 5 to limit splices. That is, Fig. 5 shows a
plurality of magnets
504 wound together without a continuous connection of wire or tape 508 to
remove or limit the
number of splices. A rotor 1182 is positioned within the stator 1185. The
rotor is comprised of the
shaft 1186 that supports a plurality of field poles 1187.
[0126] Trapped field magnets (TFM) 1774 or permanent magnets 1190 are placed
in the field
poles 1767 or 1187 in groups and surrounded by the field coils 1778 or 1188.
Magnetic field
focusing cover 1189 provides a transient electromagnetic (EM) shield option
for all field TFMs
and coils. The entire field pole 1187, even if fully HTS, can be built
separately and assembled as
a unit into the electric machine including the option for superconducting TFM
activation outside
of the machine. This case of a totally cold, cryogenic, motor or generator is
possible through a
non-thermal conducting hollow shaft 1186, which may have a non-metal section
such as the rotor
bearing optional location 1183, with a rotating cryogenic coupling with
embedded slip ring-based
power and data cables.
[0127] A motor and/or generator type machine embodiment includes units such as
any motor
and/or generator use. A motor and/or generator embodiment which is personnel
portable if
compact enough is shown in Figs. 3-5 where certain cryostat elements are
removed to show SC
coils 1185. Motor and generator embodiments range across all types of rotary
and linear AC, such
as synchronous and induction machines, as well as DC machines for both a
hybrid to complete
SC armature and/or a hybrid to complete SC active and/or passive exciter
secondary or field coils
where the magnetic poles range from one or a combination of individual
component, wound,
TFM, PM, solid pole, etc. Embodiments also include back iron or in particular
a hybrid core and/or
air core motor where removal of back iron allows a lighter machine and lowered
frequency losses
given the SC magnetics allowing a compact machine. The superconducting machine
air gap
includes an evacuated or non-air air gap to remove icing of water from the air
but also removes
all windage loss. The air gap is the non-magnetic space between the primary
and secondary of any
electromagnetic device. Motor and generator machine embodiments are across an
extensive
number of industries and applications which is too exhaustive to readily list.
One embodiment is
a wind or hydro turbine generator. Another embodiment is a hybrid or all
electric air, land, sea, or
space vehicle motor and generator including the embodiment of a partial to
complete SC type
motor or generator. The embodiment of hybrid to all electric aircraft of all
types and sizes are
expected to make great use of this invention by itself and in particular
embodiments involving the
Combined Superconducting Magnetics and Speed invention disclosure and
potentially the Hybrid
Superconducting Magnetics invention disclosure.
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[0128] Figs. 6-8A and 10 show an electric machine of another embodiment having
hybrid or fully
air core formers, and other magnetic elements placement, location, support,
and operational
assistance such as common to flat fan invention disclosure magnet coils,
trapped field magnet
(TFM) and permanent magnets, magnetic flux paths, cryostats and cryogenic
cooling and
conductive paths, gas paths (e.g., cryogenic liquid to gas expansion paths),
electromagnetic (EM)
shields and shield mounts. The electric machine 1750 is a compact advanced
superconducting
device that can function as a field operable superconducting device and can
function as a primary
element of a field operable superconducting system. The high magnetic flux
density (B) provided
by the machine 1750 allows a combined induction and synchronous machine. The
contemplated
machine is also a hybrid to air core electric machine where tape curvature and
alignment for B
path is provided in all armature and field coils. Here, the air core 1754 is
provided on the rotor
core back area, but for any air core section non-magnetic material is used to
be considered air core
with respect to the magnetic flux density.
[0129] The armature coils 1759 are comprised of a flat fan magnetic coil with
end turns 1758,
where in this embodiment the armature is associated with the stator. Secondary
coils, such as the
embodiment of field coils or wound induction, may be formed as an overlapping
flat fan magnetic
coil such as the secondary coils 1760. Fig. 10 shows a such a magnetic coil
1764 where the rotor
coils 1760 with a rotor diameter 1764 larger than that of the stator thus
placing the armature on
the inside of the rotor. Of course, the magnetic coil may be inverted where
the field coils are
located on a smaller diameter rotor positioned within a larger diameter
stator, a more common
electric machine configuration as shown in Figs. 3 and 6. The inversion of the
primary on the
outside radius and secondary on the inside radius, or vice versa, to make an
electromagnetic device
such as an electric machine, similarly for swapping sides of an arc or linear
device, will occur to
those skilled in the art. As shown in Fig. 9, the flat fan end includes a turn
1765 on the primary
and (Fig. 10 shows turns 1762 on the secondary) that can be set to add to the
electric machine
magnetic length, 1759 and 1764, respectively. This configuration also curves
the B path and
minimizes placement of HTS in the highest B regions. Complex, 3D-shaped SC
magnets allow
compact and lighter sizing for high efficiency and B without exceeding HTS
critical values.
Further, as seen in Fig. 6, the end turns are oriented such that poles can
overlap end turns on one
or both sides making them part of the magnetic length and, hence, part of the
prime mover of the
electric machine.
[0130] In this embodiment the curved flat fan coils and TFMs are both used to
comprise the field
poles 1766 on the rotor 1767. More specifically, the contemplated field coils
may be common
coils or flat fan with multi-dimensional curved sides to control the B path
and further
accommodate trapped field magnets (TFM), such as but not limited to HTS TFMs,
to further
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increase the air gap B and output performance. The TFMs can be activated into
different pole
orientations. Specialized HTS EM shields 1189 are provided over the field
poles 1766 with field
pole spacers 1770, between armature phases, and over non-magnetic length end
turns. In this
hybrid superconducting magnetic configuration, the Trapped Field Magnets (TFM)
1774 or
permanent magnets are placed in the field coils in groups with surrounding
field coils 1778. The
entire field pole 1766, even if fully HTS, can be built separately and
assembled as a unit into the
electric machine including the option for superconducting TFM activation
outside of the machine.
In one embodiment the field pole 1766 has a cryogen reservoir 1782 below
conductive cooling
regions to support cryo-cooling needs. Here, a totally cold, cryogenic, motor
or generator is
possible through the non-thermal conducting hollow shaft 1786, which may
include a non-metal
section 1790, with a rotating cryogenic coupling with embedded slip ring-based
power and data
cable connection. An evacuated or non-air (e.g., a non-water-based gas
replacement such as a
nobel gas, nitirogen, cyogen cooling system gas, etc.) air gap, which could
include evacuating
other machine areas such as the back areas 1794, embodiment supports a fully
cold electric
machine by removing icing concerns while also removing windage.
[0131] Fig. 6-8A and 10, show the application of winding sections where
separately built winding
sections are 3D printed, or otherwise created, separately wound, and then
assembled and
connected to form each magnet or each phase group of an armature core 1759. 3D
printing, flat
fan windings, TFM activation needs as a separate pole outside the device as
well as when
activating inside the device, and hybrid to air core machines separately and
together make great
use of this ability, such as the removal of magnetic material continuity
needs.
[0132] 3D printing further provides benefits include structural, magnetic
paths, EM shields,
electrical paths, cooling paths, and gas to fluid paths for any purpose such
as Fig. 4 and 6. A 3D
printing component embodiment is shown in Fig. 13, 1328 for a tensiometer
wheel with extreme
precision needs.
[0133] The contemplated flat fan coils, 1760 in Fig. 10 for a secondary
embodiment and 1759 in
Fig. 8 for an armature embodiment, uses a thin tape profile such as an HTS
(often, 0.1mm with 1
micrometer for HTS) by placing the HTS tape width (often, 2 to 12mm) facing
width along the
straight length, like a shallow saddle coil that is densely packed and curved.
B acts in a direction
across the surface current, which is highest parallel to the longest length,
so orienting the tape
width perpendicular or close to perpendicular to the air gap gives an
extremely distributed winding
with the highest B across the air gap and the lowest losses. Long wind depths
are no longer
required versus a single (pancake), double, or, as expected, at most only a
few layers winding.
This is different than a common radial flux machine (i.e., the most common
electric machine)
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where the B generation source is further into the slot of a machine and hence
away from the air
gap which then increases losses such as stray loss.
101341 Embodiments of the present invention such as an induction SC electric
machine employ
wound secondary SC coils and/or squirrel cage configuration to obtain an high
induced B and/or
use HTS, such as many turns stacked or similarly in parallel, which provide an
induced current
path for starting torques and/or oscillation damping. Some embodiments remove
damping by
embedding Cu or aluminum (Al) amortisseur bars, variable external resistors,
and/or the power
electronics drive where any listed device can include cryogen cooling to
increase performance.
An embodiment of an electric machine primary is Fig. 8 with an inverted Fig.
10 orientation as
the secondary if the secondary is short circuited.
101351 Fig. 8A is a cross-sectional representation of a HIS winding of one
embodiment of the
present invention that generally illustrates the concepts of enhanced magnetic
flux density (B)
mentioned above. The HTS tape member 1800 shown includes a flat strip of
superconducting
material 1802, which is commonly a few im thick. The HTS winding is shown as a
plurality of
HTS tape members 1800 placed such that the smallest tape dimension is directed
towards an air
gap 1806 provided between the primary and secondary components of an electric
motor, for
example. The tape members could be separated by a small gap 1808 to assist
desired B flow
outside of the tapes. One of skill in the art will appreciate that lateral
surfaces of adjacent tape
members may abut.
101361 In one embodiment, the flat fan HTS winding includes a second layer
1810 over wrapping
a first layer 1812 position adjacent to the air gap 1806. The first layer 1812
and second layer 1810
produce magnetic flux B' and B". As magnetic flux B" from the second layer
1810 cannot pass
through the HTS within the tape of the first layer 1812 when it is
superconducting, it must pass
through gaps 1806 provided between HTS tape members as well as non-
superconducting elements
of the HTS tape member 1800. Accordingly, flux B" from the second layer 1810
is added to the
flux B' from the first layer 1812 to define the aggregate flux B provided by
the flat fan winding,
which maximizes flux within the air gap 1806. Although two winding layers are
shown, one of
ordinary skill in the art will appreciate that additional layers may be added
to increase the
aggregate flux B or a single layer could also be used. Accordingly, the flat
fan winding
configuration contemplated herein, allows for the production of increased flux
in a reduced sized
component that does not suffer the drawbacks of conventional windings, e.g.,
flux crosstalk,
magnetic field irregularities, highly separated slot or otherwise windings and
all associated issues,
etc. In one embodiment, current being directed to the first and second layers
are controllable such
that the magnetic flux provided by each layer and groups of tapes can be
selectively modified.
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[0137] One embodiment of the present invention is a combined induction and
synchronous SC
electric machine. The machine is similar to the induction Sc electric machines
described above
with secondary SC coils to form an induced passive B (inductive) or active B
(synchronous) type
electric machine where configurations such as switching vary machine types
operationally. The
secondary SC coils may be shorted for an induction machine response and coils
are active with or
without TFMs or permanent magnets (PM) for a synchronous machine response.
Oscillation
damping can be controlled with embodiments such as a high B locking rotor,
introduced
inductance effects, external resistance with optional cryo cooling effects.
Another embodiment
includes variable pole options for how rotor based electrical switches close
as passive inductive
or active field coils.
[0138] A further embodiment that is not a compact system in the strict sense
of personnel portable
but is compact regarding how all elements must be as light as possible is
exemplified in a
spacecraft EM shield. In this case a set of large SC coils are arranged around
a spacecraft providing
a B shield to protect the spaceship and occupants from harmful EM radiation
and ions. Although
the coils are very large they assume many of the properties of compact coils
such as the need to
increase specific power and power density to allow a launch into and then use
in space as well as
long term robustness without failure. Hence all appropriate embodiments apply
to this larger
system.
[0139] One embodiment allows a large B in the air gap that in turn allows a
higher power system
including a higher speed and torque propulsion system as well as a higher
energy levitation system
for the combined use of maglev and magprop. One embodiment is an SC based
linear motor for
vehicle launch purposes such as aeronautical and aerospace. Another embodiment
is an advanced
SC such as HTS based superconducting maglev and/or magprop including
commercial train
speeds to high-speed vehicles beyond commercial train limits including Mach 1
or greater test
sleds.
[0140] Embodiments of these hybrid magnetics include conventional magnetics to
a hybrid motor
and generator. In the motor and generator embodiments, SC to complete SC
armature, exciter field
coil, and AC induction machine passive conductor. Such embodiments of various
magnetics
options, in particular combining SC wound and TFM, allow not only a proper
magnetic solution
for a given task but in particular allow for a very compact machine.
[0141] In a motor and/or generator embodiment any magnetic type including SC
combination
units are held down via epoxy and/or mechanical bolts and/or dovetails and/or
banding/retaining
rings which increases stray losses through a larger air gap and then a
different banding option is
often employed such as for high-speed machines.
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[0142] Historically SC bulk and wire materials are used separately across
applications. The
combined benefits of both are not utilized in a single unit to date.
101431 In one embodiment a system for combining SC wire and trapped field bulk
material is
presented. This combination provides the ability to capture the greatest
benefits of both SC
formats at a common cryogenic state. Benefits include magnetic field forming
to bulk material
activation.
[0144] A key embodiment for any Sc device is a wound SC such as a magnetic
coil wound around
a single or group of TFM magnets and used to both activate and then modify the
field of a TFM.
As a further embodiment these combined SC type poles can be created as
separate units to include
into the machine for ease of assembly as well as activation of the TFM outside
of the SC device
or in place in part or whole in the final SC device. This embodiment also
allows line replaceable
unit (LRU) solution.
[0145] This invention relates to methods of generating high magnetic fields
from SC material for
the purposes of TFM activation, high B augmentation control, and high B fields
in a desired output
fonn.
1. Superconducting (SC) wire coil and SC trapped field magnet (TFM) bulk
materials
are used in combination to supplement one another's SC magnetic field.
a. The TFM can be positioned at the magnetic lower or higher points of an
SC coil for enhancing or augmenting DC, AC, or pulsed field generated.
b. TFMs places in the typical void between the SC coil sides and using both
SC types in operation allows for a much higher B capability than using either
a TFM
or SC coil separately.
2. Sc wire coil is used to augment the TFM magnetic field
a. Readily change the magnetic flux density, B, on the SC wire with a
varying
static DC field change or even an AC to transient depending on the output B
desired.
b. Augmented field machines provide a wonderful machine control technique.
Augmenting a uniquely high B is currently unheard of in practice.
3. Use SC wire coil to provide a high TFM material ACTIVATION energy.
a. TFMs require high activation energies to acquire a
high B. Such activation
is extremely difficult to achieve. Difficulties arise from the ability to get
a high B to
the TFM due to reasons such as inductance path to magnetic stray and
conductive
shields when trying to activate external to the SC cryostat. By placing the SC
wire
inside of the same cryostat with the TFM bulk then one can make use of not
only the
high B capability of the SC wire coil but also the close proximity of the SC
wire
generated B to the TFM activated captured B.
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b. Utilizing an SC wire, unlike conventional a conventional conductor such
as
copper, the SC wire can handle an extreme current for a short period of time
when
devoid of pinning centers and typically generates orders of magnitudes less
thermal
energy than a pure conductor. Minimizing heal generation is extremely
beneficial for
any SC coil.
c. The wire is automatically located inside of the cryostat whether around
the
entire SC bulk pack or next to individual TFMs. In the individual TFM case the
coil
may be located physically around the TFM or on top of the TFM center. In this
case
multiple SC coils may be connected in series and/or in parallel to achieve
activation.
d. Once the TFMs are activated, or when using an SC DC magnet without
TFMs, the SC DC magnet can set for a steady state mode, such as a motor or
generator
exciter field or NMR or MRI field magnet, will theoretically never lose the DC
steady
state charge with the only SC loss occurring from any mostly negligible splice
resistance.
c. Use secondary and primary magnet windings in an
appropriate orientation
to achieve increased levels of TFM activation and/or deactivation energies,
times, and
TFM B orientations.
4. Use SC wire coil to provide a high TFM material
DEACTIVATION energy.
101461 The same coil case of this invention may be used to also deactivate the
TFM bulk materials.
In this case the SC coil is purposely placed into a quench situation through
means such as but not
limited to forcing the SC coil(s) to quench through the external power supply
or as sudden opening
of a potential persistent switch for reasons such as inducing a localized
heating zone.
101471 An SC wire is able to be formed in many shapes from pure solenoids to
saddle coils, yet
this form always has magnetic field distributions such as high B points at the
coil turns due the
multiple coil legs interacting strongly in that region. A TFM is a small
entity that provides a
magnetically flux dense field up to the TFM saturation levels in the center
areas of the TFM itself
where the B distribution approximates an ice cream cone shape. This
combination allows one to
use the B distributions inherent to both material forms to best create a
desired output field from a
uniform B with a possible smoothed entering and exit pole region entering a
machine air gap to
lower the non-fundamental harmonic content Such affects assist machine design
to a dipole or
quadrupole particle accelerator magnet where a very high but uniform B is
crucial. As for a
machine case the placement of TFMs into the typical void between the SC coil
sides and using
both the SC Coil and TFMs in parallel while in operation allows for a higher
output B than either
the independent SC Coil or TFM. This allows a much higher power dense machine
than either an
SC Coil or TFM alone.
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[0148] Activation and deactivation of a TFM is of extreme importance yet to
date not a solved
problem for a large machine. Activation techniques are complex and work on
controlled B and
cryogenic temperatures which may even involve controlled cryogenic pressures.
To use the fact
that both SC wires and SC TFM bulks must exist within an SC critical state
that includes
cryogenics, then one is able to readily make use of placing both SCs into the
same cryostat. Using
this SC coil for activation has the extreme benefit of not forcing a B pulse
through a conductive
cryostat wall and other supporting material as well as the SC wire generates
orders of magnitudes
less heat than using a typical conductor for activation. To add, by placing
the TFM activation and
deactivation as close to the TFM as possible, then less overall energy is
required for either TFM
activation or deactivation. An example of a TFM bundle with a single SC Wound
Coil around the
stack is provided in Figs. 3, 4, and llwhere the removable field pole 1767,
for general purposes
and TFM activation, has field coil 1778 wrapping around the TFM stack 1774 and
magnetic field
focusing cover 1189 (not shown for TFM pole but for a PM pole here). An
example of a single
TFM with a dedicated and single SC Wound Coil per TFM whether around the
outside of the
TFM or centered on the TFM physical center is provided in Fig. 12. In this
second example the
dedicated TFM coils are connected in either a parallel and/or series
connection to an outside power
supply. In either SC coil and TFM case the SC coil and TFM materials are
likely in the same
cryostat but not necessarily since there are advantages to also separate the
SC bulk and SC wire
coils for reasons such as making use of magnetic dampers. In either SC coil
and TFM case a SC
persistent switch may or may not be used.
[0149] Figs. 13-18 show LMHS, i.e., a magnet winding machine 1300 of one
embodiment of the
present invention capable of at least 20 degrees of freedom. The winding
machine 1300 consists
of a frame 1304 that supports a wind-off subassembly 1308, a follower
subassembly 1312, and a
wind-on subassembly 1316. The wind-off subassembly 1308 and wind-on
subassembly 1316 are
interconnected to the frame's base 1318. In operation, linear media 1320
travels from a wind-off
spool 1324 to the follower subassembly 1312, where it engages with a
tensiometer 1328. The
linear media 1320 then travels to a wind-on spool 1332 of the wind-on
subassembly 1316. As in
the embodiments described above, handling of the linear media 1320 from the
wind-off spool
1324 to the wind-on spool 1332 is carefully monitored by sensors and
controlled by a plurality of
linear and rotary actuators. The actuators, which will be described in further
detail below, allow
multiple solutions for a desired motion. The desired motion may be achieved by
simultaneously
moving more than one actuator in complementary directions, which allows for
the winding
machine's footprint to be reduced. Thus, a winding normally associated with a
much larger
machine is possible as motion density in the horizontal and vertical
directions can be achieved.
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[0150] Fig. 15 shows the wind-off subassembly 1308 in detail, which comprises
a frame 1340
that rotatably supports the wind-off spool 1324. In other embodiments, the
wind-off spool 1324
is vertically fixed. The frame 1340 is interconnected to a linear actuator
1344 that allows
movement in the direction of Arrow B. The linear actuator 1344 is
interconnected to a rotary
actuator 1348 that allows for the frame 1340 and interconnected wind-off spool
1324 to rotate in
the direction of Arrow C. Finally, the rotary actuator 1348 is interconnected
to a stationary linear
actuator 1352 that allows for the frame and interconnected wind-off spool to
travel in the direction
of Arrow D. In some embodiments, the wind-off spool is also able to move along
the wind-off
frame 1340 and/or the wind-off frame 1340 can be selectively tilted to provide
even more Dof.
The combination of linear and rotary actuators allow for precise control of
wind-off spool 1324
position, which dictates the position and orientation of the linear media's
wind from point. The
actuators, thus, maintain the linear media in the wind angle plane, which will
be described in
further detail below.
[0151] Fig. 16 shows the follower subassembly 1312 that operatively supports
the tensiometer
1328. The follower subassembly 1312 employs a stationary linear actuator 1356
interconnected
on its ends to crossbeams 1360 provided on the primary frame 1304 (see Fig.
13). In one
embodiment, the stationary linear actuator 1356 is generally oriented parallel
to the stationary
linear actuator 1352 of the wind-off subassembly 1308. Thus, the stationary
linear actuator 1356
provides movement of an interconnected rotary actuator 1364 also in the
direction of Arrow D.
Rotary actuator 1364 is interconnected via a plate 1368 to at least one riser
1372 that supports
beams 1376. Thus, the beams 1376 are rotatable in the direction of Arrow C'
when urged by the
rotary actuator 1364. The tensiometer 1328 is also connected to at least one
beam 1376 via support
beam 1380. Various sensors may also be associated with the tensiometer and
interconnected to
the follower subassembly 1312 to ensure proper tensioning of the media and to
provide the means
for selective adjustment of tensiometer position. The follower subassembly
1312 supports a
turning fork sensor 1382 that rotates in the direction consistent with Arrow
E. The turning fork is
comprised of parallel guides 1383 configured to operatively receive the linear
media 1320. Input
from the turning fork sensor 1382 is used to guide control of linear actuator
1344 in wind-off
subassembly 1308.
[0152] The follower subassembly 1312 also supports linear actuators 1384
(which in one
embodiment are electric cylinders) that impart selective movement of
interconnected guide rods
1388 in the direction of Arrow A. These linear actuators 1384 are attached to
linear actuators 1386
that selectively impart motion in the direction of Arrow G. Using combinations
of actuators in
follower subassembly 1312, the guide rods 1388 are moved to maintain a
position on either side
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of a wind-on point 1390 shown in Fig. 13 and are designed to guide the linear
media onto the
wind-on spool.
101531 A winding injector can be used for placement of an adhesive, UV
adhesive, thermal
compound, spot, linear, pattern, etc. in the wind. In one embodiment, the
winding injector is
mounted on the follower 1312 and used in conjunction with the follower arms
1386 and/or
follower guide(s) or pusher(s), such as the guide rods 1388 of Figs. 16 and 17
to hold for a brief
dry and then wind continuation or slow wind. A drying elements such as a UV
lamp for UV
adhesize may be used.
[0154] As highlighted in Fig. 17, precise articulation is accomplished by a
wind-on guide
subassemblies that provide many degrees of freedom (DoF) that affect automated
movement of
the guide rod tips, which simulates human interaction and allows a wide range
of control that
approaches complete control of the linear media as it is taken up by the wind-
on spool 1332. More
specifically, the wind-on guide subassemblies 2000 are interconnected to the
ends of the linear
actuators 1384 and, thus, can move in the directions of Arrows A and G and
rotate in the direction
of Arrow C'. A guide rod rotary actuator, which is configured to impart
selective rotation in the
direction of Arrow H, is provided. The guide rod rotary actuator is
interconnected to a guide rod
linear actuator that selectively articulates the guide rod 1388 in the
direction of Arrow J. One of
skill in the art will appreciate that linear/rotary actuators may be
added/removed or
employed/disabled (if present) to hold, tilt, and extend the guide rods to
provide achieve the
desired linear media control.
[0155] Although referred to herein as guide "rods," those of ordinary skill in
the art should
appreciate that these components can be formed of various shapes. In addition,
some embodiments
employ a single guied, while other embodiemnts employ two or more guides. The
guides rods
1388 may terminate in a wheel, a cone, an arcuate member, or similar device.
In one embodiment,
one guide contains the linear media and the other guide urges the linear media
onto the wind-on
spool.
[0156] Here, the tensiometer 1328 and the turning fork 1382 are located above
the wind-on spool
and the wind-off spool, connecting rotary motion to linear motion. By
operating around the
stationary linear actuator 1356, the follower subassembly 1312 minimizes
vertical distance
required to connect motion and sensor elements, thereby achieving high motion
density in the
vertical direction, motion density minimizes machine frame size and vibration
amplitude,
allowing the assembly to be made of lightweight aluminum extrusions instead of
steel. This aspect
is an important feature of one embodiment of the present invention (MMP) that
supports module
design of subassemblies and simplified accessory attachment.
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[0157] Fig. 18 shows the wind-on subassembly 1316 generally comprised of
stationary linear
actuators 1394 that interconnect to the frame base and that support another
linear actuator 1402.
In this example, the stationary linear actuators 1394 are orthogonal to the
stationary linear actuator
1352 of the wind-off subassembly 1308. Accordingly, the stationary linear
actuators 1394 allow
for a rotary actuator 1406 interconnected to the linear actuator 1402 to
selectively move in the
directions of Arrows D and F. The rotary actuator 1406 is configured to rotate
the wind-on spool
along an arc indicated by Arrow C", about an axis parallel to an axis defined
by Arrow C or C'. A
frame 1410 such as the rotating former here that supports the wind-on spool
1332 is interconnected
to the rotary actuator 1406. In some embodiments of the present invention, the
angle between the
frame 1410 and the linear actuator 1402 can be selectively altered to change
the orientation of the
wind-on spool 1332. Some embodiments of the invention include a goniometer
1412 associated
with the rotary actuator 1406 adapted to precisely guide the frame's angular
orientation.
[0158] In operation, the wind-on spool 1332 is caused to move through a series
of orientations
conducive to producing desired wound output configuration. Operations within
the wind-off
subassembly and the follower subassembly support placement of the linear media
at the wind-on
point. Linear media 1320 is taken from the wind-off spool 1324 and directed
upwardly to the
tensiometer 1328. As mentioned above, the linear media 1320 is also positioned
between guides
1383 of the turning fork 1382. The linear media then travels downwardly and
contacts the wind-
on spool 1332 at the wind-on point 1390. The guide rods 1388 control the
position of the linear
media as it engages the wind-on spool 1332. System control of linear and
rotary actuators
maintains the linear media 1320 in a wind angle plane, which is generally
vertical, as shown in
the Figs. 29-32. The wind angle plane's angle is defined by the linear media's
path from the wind-
off spool 1324 to the wind-on spool 1332, and varies according to a desired
direction of the wind-
on point 1390. Again, the turning fork 1382 is aligned with the wind angle
plane, and the linear
media 1320 is held between the parallel guides 1383 of the turning fork 1382.
Feedback from the
turning fork sensor accommodates winding linear media off of a spool with
axial width greater
than the linear media width while maintaining the linear media path in the
wind angle plane. As
the wind-off point moves out of the wind angle plane, the linear media held
within the turning
fork guides causes it to turn and its sensor indication is used to command
linear actuator 1344 to
move the wind-off spool and therefore the wind-off point until the linear
media and turning fork
are again centered in the wind angle plane. Guiding the linear media in this
way and along this
path guarantees no reverse bends and allows only one bend of a minimum
diameter around the
tensiometer wheel 1328 before the linear media reaches the wind-on point 1390.
[0159] The linear media's formation onto the wind-on spool 1332 and all other
motion in the
winding machine 1300 precipitates from initially moving the wind-on spool
1332. The linear
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actuators 1394 and 1402 move the wind-on spool 1332 in orthogonal horizontal
directions while
the rotary actuator 1406 moves the wind-on spool 1332 about a vertical axis.
For more complex
outputs, simultaneous with other motions, winding arc rotation (i.e.,
selective tilting) of the wind-
on spool 1332 can be accomplished by the goniometer 1412. For cylindrical arc
rotation, the
goniometer 1412 can be exchanged with gearing.
[0160] Some of the LMHS contemplated herein removes high and non-uniform axial
tension,
makes all non-axial tension negligibly small, removes all reverse bends, keeps
all bends to a single
and large radius, and makes all side bends negligibly small, etc., during the
winding process. Side
bends are especially problematic for wires that are not round such as
rectangular cross sections of
wire, particularly very thin by very wide to then become a tape.
[0161] For any motorized single or combination of DoF, independent or
electronically geared
control of linear media motion is possible through automated, partially
automated, and fully
manual means. This multiple degree of freedom (DoF) system will have an
operator interface
equivalent to providing computer aided drafting (CAD) input to computer aided
manufacturing
(CAM) toolpaths for computer numeric control (CNC) production. Options include
a hardware
joystick, a software joystick, or partially automated motion controls that
allow turning on/off a
single to multiple DoF for a particular move. Such ability allows the user to
tune the motion for a
particular need. Preferably, automated, partially automated, and/or fully
manual control of any
motorized single or combination of multiple DoFs is accomplished to achieve
motion while
accurately maintaining desired performance values such as constant axial
tension. In examples
described below, for example, a motorized DoF provides a continuous or
changing winding pitch
angle. Active control loops based on the axial tension value as the global
control master and a
hierarchy of master slave relationships provide the means of varying the pitch
angle while
accurately maintaining desired performance values such as constant axial
tension. The routing
design and controlled DoF of the LMHS of one embodiment provide not only a no
bend situation
with minimized forces but for a tape also a line over point initial contact at
the wind-on location
in order to further minimize stresses and bends in the linear media. This is
achieved through
controlled design routing and DoF control. Single winding plane with limited
bends of material
as well as limited stress in any direction allows a limited strain final
product. The more bends and
stress introduced during the magnet and cable manufacturing process, then the
lower operational
values allowed.
[0162] Although the description of some embodiments of the present invention
above is mainly
directed at a superconductor wire, tape and cable, it should be recognized
that the invention could
be applicable to any linear media and in particular delicate linear media. As
used herein, the term
"delicate linear media" will include advanced superconducting wire and tape,
very fine
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conventional wire, filamentary linear materials, fiber optic wire, thin
strands of carbon-based
fiber, smart fabrics, and extremely dense fine fiber matrices. Further, the
present invention can be
applied not only to coil and cable winding but also to any other delicate
media handling process
including but not limited to media insulating, bending, braiding, forming,
splicing, heat or
chemical treatment such as reacting, encapsulation, inspecting, and any manual
or automated
process that requires handling the media safely. As used herein, the terms
"wire," -tape," "cable,"
and "media" are used interchangeably. Some embodiments of the present
invention can be applied
to allow an automatic winding (or other similar) process. Also, the term
"spool" is used herein to
refer to any object onto which the delicate liner media is wound, regardless
of the object's shape.
Industry language commonly refers to a wind-off spool as "spool" and wind-on
spool as "former"
or "bobbin," and those terms may also be used interchangeably herein. Whenever
the terms
"automatic," "automated," or similar terms are used herein, those terms will
be understood to
include manual initiation of the automatic or automated process or step.
[0163] It should also be recognized that embodiments of the present invention
can be
implemented via computer hardware or software, or a combination of both. The
methods can be
implemented in computer programs using standard programming techniques-
including a
computer-readable storage medium configured with a computer program, where the
storage
medium so configured causes a computer to operate in a specific and predefined
manner according
to the methods and figures described in this Specification. Each program may
be implemented in
a high level procedural or object-oriented programming language to communicate
with a computer
system. However, the programs can be implemented in assembly or machine
language, if desired.
In any case, the language can be a compiled or interpreted language. Moreover,
the program can
run on dedicated integrated circuits programmed for that purpose.
101641 Further, methodologies may be implemented in any type of computing
platform, including
but not limited to, personal computers, mini-computers, main-frames,
workstations, networked or
distributed computing environments, computer platforms separate, integral to,
or in
communication with charged particle tools or other imaging devices, and the
like. Aspects of the
present invention may be implemented in machine readable code stored on a
storage medium or
device, whether removable or integral to the computing platform, such as a
hard disc, optical read
and/or write storage mediums, RAM, ROM, and the like, so that it is readable
by a programmable
computer, for configuring and operating the computer when the storage media or
device is read
by the computer to perform the procedures described herein. The invention
described herein
includes these and other various types of computer-readable storage media when
such media
contain instructions or programs for implementing the steps described above in
conjunction with
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a microprocessor or other data processor. The invention also includes the
computer itself when
programmed according to the methods and techniques described herein.
101651 The invention has broad applicability and can provide many benefits as
described and
shown in the examples above. The embodiments will vary greatly depending upon
the specific
application, and not every embodiment will provide all the benefits and meet
all of the objectives
that are achievable by the invention. In the previous discussion and in the
claims, the terms
"including" and "comprising" are used in an open-ended fashion, and thus
should be interpreted
to mean "including, but not limited to .... 'To the extent that any term is
not specially defined in
this specification, the intent is that the term is to be given its plain and
ordinary meaning. The
accompanying drawings are intended to aid in understanding the present
invention and, unless
otherwise indicated, are not drawn to scale.
[0166] While various embodiments of the present invention have been described
in detail, it is
apparent that modifications and alterations of those embodiments will occur to
those skilled in the
art. It is to be expressly understood that such modifications and alterations
are within the scope
and spirit of the present invention, as set forth in the following claims.
Further, it is to be
understood that the invention(s) described herein is not limited in its
application to the details of
construction and the arrangement of components set forth in the preceding
description or
illustrated in the drawings. The invention is capable of other embodiments and
of being practiced
or of being carried out in various ways. Also, it is to be understood that the
phraseology and
terminology used herein is for the purpose of description and should not be
regarded as limiting.
The use of "including," "comprising," or "having" and variations thereof
herein is meant to
encompass the items listed thereafter and equivalents thereof as well as
additional items.
[0167] Exemplary characteristics of embodiments of the present invention have
been described.
However, to avoid unnecessarily obscuring embodiments of the present
invention, the preceding
description may omit several known apparatus, methods, systems, structures,
and/or devices one
of ordinary skill in the art would understand are commonly included with the
embodiments of the
present invention. Such omissions are not to be construed as a limitation of
the scope of the
claimed invention. Specific details are set forth to provide an understanding
of some embodiments
of the present invention. It should, however, be appreciated that embodiments
of the present
invention may be practiced in a variety of ways beyond the specific detail set
forth herein.
[0168] Modifications and alterations of the various embodiments of the present
invention
described herein will occur to those skilled in the art. It is to be expressly
understood that such
modifications and alterations are within the scope and spirit of the present
invention, as set forth
in the following claims. Further, it is to be understood that the invention(s)
described herein is not
limited in its application to the details of construction and the arrangement
of components set forth
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in the preceding description or illustrated in the drawings. That is, the
embodiments of the
invention described herein are capable of being practiced or of being carried
out in various ways.
The scope of the various embodiments described herein is indicated by the
following claims rather
than by the foregoing description. And all changes which come within the
meaning and range of
equivalency of the claims are to be embraced within their scope. It is
intended to obtain rights
which include alternative embodiments to the extent permitted, including
alternate,
interchangeable and/or equivalent structures, functions, ranges or steps to
those claimed, whether
or not such alternate, interchangeable and/or equivalent structures,
functions, ranges or steps are
disclosed herein, and without intending to publicly dedicate any patentable
subject matter.
101691 The foregoing disclosure is not intended to limit the invention to the
form or forms
disclosed herein. In the foregoing Detailed Description, for example, various
features of the
invention are grouped together in one or more embodiments for the purpose of
streamlining the
disclosure. This method of disclosure is not to be interpreted as reflecting
an intention that the
claimed inventions require more features than expressly recited. Rather, as
the following claims
reflect, inventive aspects lie in less than all features of a single foregoing
disclosed embodiment.
Thus, the following claims are hereby incorporated into this Detailed
Description, with each claim
standing on its own as a separate preferred embodiment of the invention.
Further, the embodiments
of the present invention described herein include components, methods,
processes, systems,
and/or apparatus substantially as depicted and described herein, including
various sub-
combinations and subsets thereof Accordingly, one of skill in the art will
appreciate that would
be possible to provide for some features of the embodiments of the present
invention without
providing others. Stated differently, any one or more of the aspects,
features, elements, means, or
embodiments as disclosed herein may be combined with any one or more other
aspects, features,
elements, means, or embodiments as disclosed herein.
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