Winding machine for winding solenoid shaped coils having band-shaped conductors

Abstract

A winding machine (1) for winding solenoid-shaped coils (21) with band-shaped conductors (6), comprising a winding means (3) which holds a circular-cylindrical coil core (2) of a coil (21) to be wound, and a winding drive which rotates a coil core (2), which is held in the winding means (3), about a winding axis W, wherein the winding means (3) can be moved in a first direction A by an axial drive, the direction A preferably extending approximately parallel to the winding axis W, is characterized in that the winding means (3) can be rotated about a pivot axis S by a pivot drive, wherein the pivot axis S extends perpendicularly to the direction A. The winding machine winds a solenoid-shaped coil with several layers of a band-shaped conductor without damaging the band-shaped conductor, in particular, when the band-shaped conductor contains brittle superconducting material.

Description

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a schematic side view of an embodiment of an inventive winding machine;

FIG. 2 a shows a schematic view of an embodiment of an inventive winding machine, wherein the winding means and the pivoting means are disposed on an axial carriage;

FIG. 2 b shows the winding machine of FIG. 2a after displacement of the axial carriage;

FIG. 2 c shows the winding machine of FIG. 2b after pivoting the winding means;

FIG. 2 d shows the winding machine of FIG. 2c after further displacement of the axial carriage;

FIG. 2 e shows an embodiment of an inventive winding machine, wherein the winding means can be displaced on a pivotable rail;

FIG. 2 f shows the winding machine of FIG. 2e after displacement of the winding means along a pivotable rail;

FIG. 2 g shows the winding machine of FIG. 2f after pivoting the winding means;

FIG. 2 h shows the winding machine of FIG. 2g after further displacement of the winding means along the pivotable rail;

FIG. 3 shows a schematic view of a coil onto which a band-shaped conductor is wound in accordance with the invention;

FIG. 4 shows a schematic cross-sectional view of a coil onto which a band-shaped conductor is wound in accordance with the invention;

FIG. 5 a shows a schematic view of bending a band-shaped conductor through the short side;

FIG. 5 b shows a schematic view of bending a band-shaped conductor through the long side;

FIG. 6 shows a stack of band-shaped conductors for use in accordance with the invention;

FIG. 7 a shows a schematic view of a band-shaped conductor with insulation, which can be used in the present invention;

FIG. 7 b shows a schematic view of a stack of band-shaped conductors, which can be used in the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a schematic side view of an embodiment of an inventive winding machine 1. A coil core 2 is held in a winding means 3. The winding means 3 has a winding drive (not shown) for turning the coil core 2 about a winding axis W. The winding axis W extends approximately perpendicularly to the plane of the drawing.

The winding machine 1 has several supply coils 4 for band-shaped conductors 6. The supply coils 4 are designed as flat coils. The flat coils have only one winding per layer, similar to a sound recording tape. The supply coils 4 are disposed in unwinding means 5 which turn the supply coils 4 via a motor to unwind the band-shaped conductor (band conductor) 6. The band-shaped conductors 6 advantageously comprise superconducting material, in particular, brittle HTS material. The band-shaped conductors 6 are combined into a conductor strand or conductor stack 8 of band-shaped conductors 6 using guiding means 7a-7d, in the present case guiding rollers, and guided to the winding means 3 or the coil core 2. The conductor strand 8 is thereby wound onto the coil core 2, thereby producing a coil.

After combination of all band-shaped conductors 6 into a conductor strand 8 at the guiding means 7c, the conductor strand 8 is supplied to an insulation station 9, in which the conductor strand 8 is wound with an insulation material, e.g. a band-shaped plastic foil, approximately perpendicularly (δ=90°) to the local direction of movement F. The insulation station can be turned about an axis of rotation D perpendicularly to the direction of motion F, such that the insulation material is ideally applied at an angle 6, wherein arctan δ=(insulating tape width overlap width)/(2*HS+2*BR). The overlapping area may thereby be adjusted via the relationship between the speed of the conductor in the direction of movement F and the winding speed. The axis D extends e.g. in a vertical direction.

The conductor strand 8 passes through an intake measuring means 10, disposed between the last guiding means 7d and the coil core 2 or the partially wound coil, which measures the position of the strand 8 using optical sensors. The position of the strand 8 depends on the stationary guiding means 7d and the contact location or the contact line of the strand 8 on the coil core 2 or the partially wound coil. The contact location depends, in turn, on the position of the winding means 3. In an optimum position, the strand 8 extends in a rectilinear fashion behind the guiding means 7d as a continuation of the direction of movement F between the guiding means 7c and 7d. When the intake measuring means 10 determines a deviation from this optimum position (e.g. relative to the absolute position, or tilting), an electronic control means 11 instructs change in the position of the winding means 3, which also corrects the position of the strand 8 during further winding.

The winding means 3 can be pivoted about a perpendicular pivot axis S via a pivot drive (not shown). The winding means 3 can moreover be displaced by an axial drive (not shown) in a direction A which extends approximately perpendicularly to the plane of the drawing in the present case. These different possibilities of movement of the winding means 3 are shown very clearly in the following FIGS. 2a to 2h. The winding means 3 may finally also be vertically displaced in the direction T using a translation drive (not shown). When one winding layer has been completed, the winding means 3 (and thereby also the partially wound coil) is lowered by the height HS of one conductor strand 8, such that the strand 8 is also horizontally supplied to the coil in the next layer. The height HS of the conductor strand 8 is thereby the sum of the thicknesses of the stacked band-shaped conductors 6 and the thicknesses of the upper and lower insulation of the stack (compare FIG. 7b).

FIGS. 2 a-2d and 2e-2h show different views of embodiments of inventive winding machines 1 which differ only in view of type of motion of the winding means 3 (or coil 21). The schematic side view does not show the differences. For this reason there is only one side view of FIG. 1 for the two embodiments of FIGS. 2a-2d and 2e-2h.

The embodiment of FIG. 2a shows a coil 21, wherein winding of a new layer has just started. The coil 21 comprises the coil core onto which the conductor strand 8 has been wound with numerous windings 21a. The coil 21 is held by a winding means 3. A winding drive (not shown) is integrated in the winding means 3, for turning the coil 21 about its central axis, i.e. the winding axis W.

The winding means 3 is mounted to a pivot bar 22. The ends of the pivot bar 22 can slide along pivot holders 23 (in FIG. 2a to the right and left). The position of the ends of the pivot bar 22 is adjusted and controlled by a motorized pivot drive (not shown). The coil 21 can thereby be pivoted between different pivot positions (an alternative pivot position is shown in FIG. 2d). This corresponds to pivoting in (or opposite to) the direction of arrow 24 about a pivot axis S which extends perpendicularly to the plane of the drawing through the center of the coil 21.

The pivot holders 23 are rigidly mounted to an axial carriage 25. The axial carriage 25 may be moved along a straight, axial rail (not shown) in the direction A using a motorized axial drive (not shown). The axial rail is mounted to a Z carriage (not shown) which can be moved in the direction T, perpendicularly to the plane of the drawing, by a translation drive.

In the embodiment of FIG. 2a, the winding means 3 is consequently linearly moved together with the pivot drive by the axial drive. The pivot motion 24 is performed relative to the axial carriage 25.

The guiding means 7a-7d guide the band-shaped conductors or the conductor stack 8 exclusively in a straight line. During one rotation of the coil 21 about the winding axis W, the axial carriage 25 is moved by a conductor width BR (which is at the same time the width of a stack 8 of band conductors), wherein the value BR already includes twice the thickness of the insulation, such that the stack 8 of band-shaped conductors is also not bent through the short side of the band conductor between the guiding means 7d and the coil 21. The direction B in which the stack 8 is guided to the coil 21 remains the same. The possible travelling distance of the axis carriage 25 is sufficiently long to also guide the end areas of the coil 21 to the arriving stack 8.

FIGS. 2 b to 2d illustrate the winding sequence of subsequent layers in the winding machine 1 of FIG. 2a. Starting from the position of FIG. 2a, the just started layer is wound by turning the coil 21 about its winding axis W, and synchronously moving the axial carriages 25 along the direction of arrow 28. In FIG. 2b, this layer is finished. The coil 21 must then be prepared for the next layer. Towards this end, the coil 21 (or the winding device 3 with pivot rod 22) is pivoted about the pivot axis S in the direction of arrow 24a (compare FIG. 2c). The next layer can then be wound. Towards this end, the coil 21 is turned again about the winding axis W, and the axial carriage 25 including the coil 21 are synchronously displaced in the direction of arrow 28a (compare FIG. 2d). After pivoting in the direction of arrow 24, the next layer can be started (see FIG. 2a).

In the slightly modified embodiment of the winding machine 1 of FIG. 2e, the winding means 3, in which the coil 21 is held and can be turned through a winding drive, is disposed on a straight, pivotable rail 27. The winding means 3 can be moved along the pivotable rail 27 in the direction A. Direction A extends parallel to the winding axis W about which the coil 21 can be turned.

The ends of the pivotable rail 27 can, in turn, slide along pivot holders 23. The position of the ends of the pivotable rail 27 are controlled by a pivot drive (not shown). The coil 21 can thereby again be pivoted about the pivot axis S, wherein the pivot axis S is perpendicular to the plane of the drawing, and extends through the center of the pivotable rail 27. This means that the direction A changes during pivoting. The pivot axis S is stationary in this case. The position of the pivot axis S relative to the coil 21 depends on its axial displacement position along the pivotable rail 27. The pivot holders 23 are mounted to a Z-carriage which can be moved (not shown) perpendicularly to the plane of the drawing by means of the translation drive.

In the embodiment of FIG. 2e, the pivot drive pivots the winding means 3 together with the axial drive. The axial motion of the winding means 3 in the direction A is relative to the pivot drive.

During one rotation of the coil 21 about the winding axis W, the winding means 3 moves along the pivotable rail 27 by a slightly larger distance than one conductor width BR, namely by BR/cos(β), with β: pitch angle (see FIG. 3).

FIGS. 2 f through 2h show, in turn, the winding sequence of successive layers in the winding machine 1 of FIG. 2e. Starting from the position of FIG. 2e, the just started layer is wound by turning the coil 21 about its winding axis W and moving the winding means 3 or the coil 21 synchronously along the direction of arrow 29 on the pivotable rail 27. In FIG. 2f, the layer is finished. The coil 21 must then be prepared for the next layer. Towards this end, the coil 21 or the winding means 3 is pivoted about the pivot axis S in the direction of arrow 24a (compare FIG. 2g). The next layer can then be wound. Towards this end, the coil 21 is turned again about the winding axis W and the coil 21 is synchronously displaced in the direction of arrow 29a (compare FIG. 2h). After pivoting in the direction of arrow 24, the next layer can be started (FIG. 2e) again.

FIG. 3 schematically shows in more detail the geometric relationships on the coil, e.g. the coil of FIG. 2a in a more advanced winding state of the layer.

A conductor stack 8 or in accordance with the invention, one single band-shaped conductor) is wound onto a coil 21. The stack 8 is thereby supplied to the coil 21 in a direction B. The stack 8 thereby extends in a tangential plane E parallel to the plane of the drawing (neglecting its thickness). The tangential plane E contains the contact line 31 of stack 8 and coil 21 and tangentially contacts the coil 21 or its uppermost layer 32.

The coil 21 has a central axis, i.e. the winding axis W, about which the coil 21 can be turned. The layer 32 is just being wound on the coil, which is supported on a layer disposed underneath.

The pitch angle β of the layer 32 just being wound and partially already wound is determined substantially by the actual diameter D of the coil 21 and the width BR of the stack 8 (or the identical width BR of the band-shaped conductors forming the stack 8) including twice the thickness of insulation. D depends on the number of wound layers underneath. The pitch within one winding must be one width BR (corresponding to one turning of the coil). For tight winding β=arctan[BR/(τD)]. For large coil diameters D compared to the height HS of a conductor stack 8 and a small overall number of layers, the height of already wound layers can be neglected. The pitch angle β can be read as the angle between the direction 35 of extension of the stack 8 and the peripheral direction 36 of the coil at that place, at any location on the layer 32.

The coil 21 can be pivoted about the pivot axis S, which extends perpendicularly to the winding axis W and also perpendicularly to the direction B. The pivot angle α of the coil 21 is measured between the winding axis W and the direction OB. The direction OB extends parallel to the tangential plane E and perpendicularly to the direction B. In FIG. 2a, the direction OB is also parallel to direction A, in which the coil 21 can be moved by the axial drive.

The intake angle γ of the stack B is measured between the direction B and the peripheral direction 34 of the coil 21 in the area of the contact line 31. α=γ, since the direction OB is defined as being perpendicular to the direction B, and the peripheral direction 34 is perpendicular to the winding axis W.

In accordance with the invention, the coil 21 is wound in one orientation in which the pivot angle α of the coil 21 corresponds at any time to the desired pitch angle β, i.e. α=β. Consequently, the band-shaped conductors of the stack 8 are not bent through the short side during winding of the stack 8 (or of an individual band-shaped conductor) onto the coil 21.

Stationary guiding means generally determine the direction B, such that the direction B and the overall conductor intake are also fixed. The illustrated pivot position of the coil 21 is suited for winding the layer 32, but the pivot position is not suited for winding the layer 33. For winding the layer 33, the coil 21 can be turned in accordance with the invention through an angle of approximately 2β in a clockwise direction (to be more precise, the pitch angles β of successive layers differ slightly due to the larger diameter D in the radially outer layer and the coil 21 is rotated in accordance with the total amount of the respective pitch angles β of the two layers concerned). Pivoting of the coil 21 for changing the layers is also called a turning manoeuvre. In accordance with the invention, pivoting about the pivot axis S is performed slowly and synchronously with a turning motion of the coil 21 about the winding axis W in order to distribute the bending motion of the band-shaped conductors in the stack 8 through the short side over e.g. one winding, thereby minimizing the material strain.

Conventional winding machines cannot be pivoted about S. As a compromise for reciprocating layers, the band-shaped conductor is guided perpendicularly relative to the winding axis to the coil (intake angle=pivot angle=0°), wherein a certain amount of bending of the band-shaped conductor over the short side is accepted in the contact area during winding, corresponding to the pitch angle. This could damage the band-shaped conductor.

It should be noted that the angles α,β,γ in the figures are shown in an excessively large scale for clear illustration. In practice, the angles may e.g. be only a few tenth of a degree.

FIG. 4 shows a schematic cross-section through the coil 21 of FIG. 3. The coil 21 comprises a hollow, circular cylindrical coil core 2 onto which the conductor stack 8 is wound. The stack 8 contacts the coil 21 at the contact line 31. The contact line 31 penetrates the plane of the drawing and is therefore only shown as a point. The tangential plane E extends parallel to the direction B and contains the contact line 31.

The coil core 2 and thereby the entire coil 21 can be moved in the direction T to account for adjustment to the changing actual coil diameter during advanced winding.

FIGS. 5 a and 5b illustrate the potential mechanical stress of a band-shaped conductor 6.

A band-shaped conductor 6 has a short side 51 and a long side 52, as viewed in cross-section. The length of the short side 51 is designated as height HL of the band-shaped conductor. The length of the long side 52 is designated as the width BR of the band-shaped conductor. The band-shaped conductor 6 has no insulation in either case.

The band-shaped conductor 6 is bent through the short side by holding the front end of the band-shaped conductor 6 and moving the free end parallel to the long side 52 (FIG. 5a top). This bend (FIG. 5a bottom) is extremely detrimental to the band-shaped conductor 6. Radii of curvature of the outer edge 53 of less than 1 m are generally not tolerable for typical band-shaped conductors that contain brittle, ceramic superconducting material. In particular, the current carrying capacity that can be technically utilized is considerably reduced.

When, in contrast thereto, the free end is moved parallel to the short side (FIG. 5b top), the band-shaped conductor 6 is bent through the long side (FIG. 5b bottom). Such a mechanical stress can, in general, be better tolerated by the band-shaped conductor.

FIG. 6 shows a stack or strand 8 of band-shaped conductors 6 which can be used within the scope of the invention. The illustrated stack 8 has no insulation. In this example, the stack 8 has a width BR which corresponds to the width BR of the band-shaped conductors 6 that form the stack 8. The stack 8 has also a height HS that corresponds to the product of the number of stacked band conductors 6 and the height HL of a band conductor 6. The stack 8 should not be bent through its short side 61 or the short sides of the band-shaped conductors 6 either, whereas bending over the long side 62 or the long sides of the band-shaped conductors 6 is relatively uncritical.

FIG. 7 a shows a band-shaped conductor 6 which is surrounded by an insulation 71. For the purpose of this invention, the height HL of the band conductor 6 is then measured including insulation 71 in this invention, such that the height HL contains the wire thickness and twice the thickness of the insulation 71. Twice the thickness of the insulation 71 is thereby also analogously included in the width BR of the band-shaped conductor 6.

When the insulation consists of overlapping layers of an insulating tape, the thickness of insulation on one side of the band-shaped conductor 6 is obtained from the product of the insulating tape thickness and the number of layers of the insulating tape lying on top of each other.

FIG. 7 b shows a stack 8 of band-shaped conductors 6, which is surrounded by a common insulation 72 for the whole stack 8. For the purpose of the invention, the stack height HS is then obtained from the wire thicknesses of the individual band-shaped conductors 6 and twice the thickness of the insulation 72. The dimension of the band-shaped conductors 6 and twice the thickness of insulation 72 are analogously included in the width BR of the stack 8.

The insulation 72 can, in turn, consist of partially overlapping layers of an insulating tape.

Claims

1. A winding machine for winding a solenoid-shaped coil with a band-shaped conductor by manipulating a circular-cylindrical coil core on which the coil is wound, the machine comprising: a winding drive for rotating the coil core about a winding axis W;an axial drive for moving the coil core in a first direction A; anda pivot drive for rotating the coil core about a pivot axis S which extends perpendicular to said first direction A.

2. The winding machine of claim 1, wherein said first direction extends approximately parallel to said winding axis W.

3. The winding machine of claim 2, further comprising a translation drive for moving the coil core in a second direction T, said second direction T extending perpendicularly to said first direction A and parallel to said pivot axis S.

4. The winding machine of claim 3, wherein the winding machine supplies the band-shaped conductor to the coil in a direction B and further comprising an additional pivot drive for turning the coil core about an additional pivot axis Z extending parallel to said direction B.

5. The winding machine of claim 4, further comprising at least one unwinding means holding a supply coil for the band-shaped conductor.

6. The winding machine of claim 5, further comprising guiding means or guiding rails for transferring the band-shaped conductor from said supply coil of said at least one unwinding means to the coil.

7. The winding machine of claim 6, wherein said guiding means are stationary relative to the winding machine, said guiding means being structured such that the band-shaped conductor is not bent or is only slightly bent through a short side thereof in a region extending from said supply coil to said guiding means or such that a radius of curvature of the band-shaped conductor through the short side at an outer side of the band-shaped conductor is always larger than or equal to 1 m or larger than or equal to 5 m.

8. The winding machine of claim 6, wherein said guiding means and/or said unwinding means have a conductor drive for supplying the band-shaped conductor from said supply coil of the at least one unwinding means via said guiding means to the coil, wherein said conductor drive is operated independently of said winding drive.

9. The winding machine of claim 8, wherein said conductor drive comprises a crawler drive.

10. The winding machine of claim 6, further comprising a control means for automatically adjusting a position of the coil core in dependence on a pivot angle α of said pivot axis S and/or a position in said direction A and/or a position in said direction T and/or an angle of rotation of said additional pivot axis Z during winding of the coil, wherein a band-shaped conductor to be transferred to said coil core is not bent or is only minimally bent through a short side thereof in a region extending from said guiding means to the coil or such that a radius of curvature of the band-shaped conductor through a short side thereof at an outer side of the band-shaped conductor is larger than or equal to 1 m or larger than or equal to 5 m.

11. The winding machine of claim 6, wherein several said unwinding means and said guiding means are provided for stacking several band conductors from several unwinding means and for commonly guiding them to the coil.

12. The winding machine of claim 11, wherein each said unwinding means has one single individually regulated tensile force controller.

13. The winding machine of claim 1, further comprising an insulation station for winding the band-shaped conductor and/or a stacked band conductor together with an insulation material.

14. The winding machine of claim 13, wherein said insulation station is structured for turning about an axis D, said axis D extending perpendicularly to a direction of motion F of the band-shaped conductor or of the stack of band conductors.

15. The winding machine of claim 1, wherein the winding machine is structured to execute all winding functions in reverse order by pressing a button.

16. The winding machine of claim 1, further comprising an intake measuring means for monitoring conductor intake using non-contact distance measurement.

17. The winding machine of claim 1, wherein the winding machine is designed to separately stop said axial drive.

18. The winding machine of claim 1, wherein said axial drive moves said coil core together with said pivot drive and further comprising an axial rail along which an axial carriage can be displaced by said axial drive, said coil core being mounted to said axial carriage together with said pivot drive.

19. The winding machine of claim 1, wherein said pivot drive pivots said coil core together with said axial drive and further comprising a rail disposed for pivoting by said pivot drive and along which said coil core is moved by said axial drive.

20. A method for winding a solenoid-shaped coil with a band-shaped conductor, the band-shaped conductor being wound onto the coil having a circular-cylindrical coil core and with a winding axis W, the method comprising the step of supplying the band-shaped conducted to the coil in a direction B to contact the coil in a tangential plane E, wherein several layers of band-shaped conductor are wound onto the coil, the winding axis W having a time varying pivot angle α about a pivot axis S relative to a direction OB extending within the tangential plane E and perpendicular to the direction B, the pivot axis S extending perpendicularly to the tangential plane E, the pivot angle α being adjusted such that it always corresponds to a pitch angle β of windings of the band-shaped conductor on the coil, relative to the winding axis W.

21. The method of claim 20, wherein the direction B and the tangential plane E are constant during winding of the coil.

22. The method of claim 20, wherein, when layers are changed, the coil core is automatically moved through a height HL of the band conductor in a direction T which extends parallel to the pivot axis S.

23. The method of claim 20, wherein, during winding of the coil, the coil core is moved transversely in the direction OB, wherein one rotation of the coil involves a travelling distance of one conductor width BR.

24. The method of claim 20, wherein, during winding of the coil, the coil core is moved transversely in the direction of the winding axis W, wherein one rotation of the coil involves a travelling distance of BR/cos(β).

25. The method of claim 20, wherein a turning manoeuvre is performed on the coil during layer change, wherein the pivot angle α is automatically changed by a sum of the amounts of a pitch angle β of a most recently finished layer and a pitch angle β of a layer to be wound next.

26. The method of claim 25, wherein the pivot angle α is changed approximately uniformly over at least a quarter turning of the coil about the winding axis W or over at least one full rotation of the coil about the winding axis W.

27. The method of claim 20, wherein an insulating tape is wound as insulation about the band conductor and in a partially overlapping manner, wherein a turning angle δ of an insulation station is adjusted in dependence on the condition arctan(δ)=(insulating tape width−overlap width)/[2*(HL+BR)].

28. The method of claim 20, wherein several band-shaped conductors are stacked into a conductor strand and the conductor strand of band-shaped conductors is wound onto the coil, wherein a height HS of the conductor strand corresponds, in each case, to a height HL of the band-shaped conductor.

29. A method for winding a coil using the winding machine of claim 1.