CN110911160A - 一种三维线圈制造方法 - Google Patents
一种三维线圈制造方法 Download PDFInfo
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/098—Mandrels; Formers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/122—Insulating between turns or between winding layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Abstract
本发明涉及一种三维线圈制造方法,包括以下步骤:1)设计与所需磁场对应的线圈形状,根据线圈形状选择适当的芯轴;2)在所述芯轴上敷设增材,形成复合材料骨架;3)对所述复合材料骨架进行开槽加工,所述槽的形状与所述线圈形状相对应;4)将电磁线嵌入所述槽中;5)对布好电磁线的所述复合材料骨架浇注环氧树脂;6)重复步骤2)‑步骤5),直至得到预定层数的三维线圈。将增材制造过程结合减材加工及槽内镶线过程,实现了电磁线按指定路径精准布线的过程,同时多层组合线圈的激磁效率大大增加,线圈整体结构更加紧凑。
Description
技术领域
本发明是关于一种三维线圈制造方法,属于线圈加工领域。
背景技术
电磁线圈广泛用于核磁共振,靶向给药,磁热疗,粒子加速器等领域中。但随着科学技术发展,需要设计的三维磁场结构越来越复杂,相应的电磁线圈也要绕制成复杂三维结构,如Cos(nθ)型线圈,斜螺线管型线圈、蛇型线圈等。特别是在粒子加速器中,需要多种复杂的三维场型来控制和约束带电粒子,例如粒子加速器中需要设置二极、四极和六极磁场,这就需要设置如马鞍型等形状的线圈。对于复杂结构的线圈,目前通用的方法还是人工绕制电磁线圈,生产效率低,费时费力,且电磁线圈绕制质量依赖于工人的经验和责任心,故不能很好的满足核磁共振,靶向给药,磁热疗,粒子加速器等精密装置的需要。
发明内容
针对上述问题,本发明的目的是提供一种三维线圈制造方法,其基于复合材料制造技术和开槽镶线技术,将电磁线的高精度布线过程设计成循环作业形式,从而实现复杂三维电磁线圈的高效规范布线加工。
为实现上述目的,本发明采取以下技术方案:本发明提供了一种三维线圈制造方法,包括以下步骤:1)设计与所需磁场对应的线圈形状,根据线圈形状选择适当的芯轴;2)在所述芯轴上敷设增材,形成复合材料骨架;3)对所述复合材料骨架进行开槽加工,所述槽的形状与所述线圈形状相对应;4)将电磁线嵌入所述槽中;5)对布好电磁线的所述复合材料骨架浇注环氧树脂;6)重复步骤2)-步骤5),直至得到预定层数的三维线圈。
进一步,所述芯轴为直管或弯管。
进一步,所述芯轴为直管时,所述步骤2)中,通过纤维复合材料预浸料热压罐成型、树脂传递模塑成型、真空树脂注入成型或多股复合材料缠绕在所述芯轴上敷设增材。
进一步,所述芯轴为弯管时,所述步骤2)中,通过多股复合材料缠绕或纤维材料干绕浇注工艺在所述芯轴上敷设增材。
进一步,所述增材为纤维预浸渍环氧树脂材料,所述纤维为碳纤维或玻璃纤维。
进一步,复合材料骨架的表面粗糙度不得大于开槽后剩余复合材料骨架厚度;若达不到要求,还需对槽的侧壁进行表面平整度加工。
进一步,所述步骤4)中,将电磁线嵌入所述槽中时,采用胶带对所述电磁线进行预固定。
本发明由于采取以上技术方案,其具有以下优点:碳纤维或玻璃纤维预浸渍环氧树脂材料的机械性能及低温性能都很优秀,后期可加工性好,精度可控,特别适合用作在具有任意圆形、椭圆等截面的直管或弯管模具表面沿任意指定路径布线的电磁线圈的骨架。碳纤维或玻璃纤维预浸渍环氧树脂材料制造过程结合减材加工及槽内镶线过程,实现了电磁线按指定路径精准布线的过程,同时此类多层组合线圈的激磁效率大大增加,使线圈整体结构更加紧凑。在超导磁体领域,依据磁体优化的电流密度分层思路,合理规划每层电磁线的线规布置,可实现超导磁体的最优工作点设计,有效提高超导线材的性价比。
附图说明
图1为本发明一实施例中三维线圈制造方法的流程图。
具体实施方式
以下结合附图来对本发明进行详细的描绘。然而应当理解,附图的提供仅为了更好地理解本发明,它们不应该理解成对本发明的限制。在本发明的描述中,需要理解的是,术语仅仅是用于描述的目的,而不能理解为指示或暗示相对重要性。
本实施例提供了一种三维线圈制造方法,包括以下步骤:1)设计与所需磁场对应的线圈形状,根据线圈形状选择适当的芯轴;2)在芯轴上敷设增材,形成复合材料骨架;3)对复合材料骨架进行开槽加工,槽的形状与线圈形状相对应;4)将电磁线嵌入槽中;5)对布好电磁线的复合材料骨架浇注环氧树脂;6)重复步骤2)-步骤5),直至得到预定厚度的三维线圈。本实施例将增材制造与减材加工及槽内镶线过程结合,实现了电磁线按指定路径精准布线的过程,同时此类多层组合线圈的激磁效率大大增加,使线圈整体结构更加紧凑。在超导磁体领域,依据磁体优化的电流密度分层思路,合理规划每层电磁线的线规布置,可实现超导磁体的最优工作点设计,有效提高超导线材的性价比。
依据设定的三维线圈的形状,选择合适尺寸和材质的芯轴。其中芯轴的材质为金属,优选为铜、铁等导电性较好的金属。依据芯轴的外形,即芯轴是直管或者弯管选择合适的增材制造方式,具体选择方式如下:
芯轴为直管时,步骤2)中,通过纤维复合材料预浸料热压罐成型、树脂传递模塑成型、真空树脂注入成型或多股复合材料缠绕等方式在芯轴上敷设增材。
芯轴为弯管时,步骤2)中,通过多股复合材料缠绕或纤维材料干绕浇注工艺等方式在芯轴上敷设增材。
步骤2)中的增材是一种有机材料,可以是有机聚合物也可以是混合物。优选的,该增材为具有一定拉伸强度的纤维预浸渍环氧树脂材料。用于浸渍环氧树脂的纤维为玻璃纤维或碳纤维。此处的环氧树脂可以根据不同的需求和工作环境确定其具体配方,以实现高传导、高强度、高绝缘等特殊要求。
待步骤2)完成后,开始进行步骤3)中复合材料骨架开槽加工,即减材制造过程。增材的厚度根据开槽深度确定,既要保证开槽过程不会穿透复合材料骨架,又要保证剩余复合材料骨架的强度。剩余复合材料骨架是指槽底与芯轴之间的复合材料骨架。开槽形状及深度与线圈设计形状相对应,槽间剩余复材最薄壁厚依据对复合材料骨架机械性能做相关结构分析后决定。复合材料骨架进行了开槽加工前,该复合材料骨架外壁的表面粗糙度不得大于开槽后剩余复合材料骨架厚度;若达不到要求,还需对槽的侧壁进行表面平整度加工。
步骤4)中,将电磁线嵌入开好槽的骨架,为防止镶线过程电磁线易翘起的问题发生,可使用胶带事先将电磁线的关键点固定。
步骤5)中,对布好电磁线的复材骨架进行环氧树脂浇注,主要作用是将复合材料骨架与电磁线间的空隙占满,防止电磁线发生位移动作。至此单层电磁线布线功已完成。
以绕制了单层电磁线的骨架为芯轴,重复上述步骤2)-步骤5),直至得到预定层数和预定厚度的三维线圈。
上述各实施例仅用于说明本发明,其中各部件的结构、连接方式和制作工艺等都是可以有所变化的,凡是在本发明技术方案的基础上进行的等同变换和改进,均不应排除在本发明的保护范围之外。
Claims (7)
1.一种三维线圈制造方法,其特征在于,包括以下步骤:
1)设计与所需磁场对应的线圈形状,根据线圈形状选择适当的芯轴;
2)在所述芯轴上敷设增材,形成复合材料骨架;
3)对所述复合材料骨架进行开槽加工,所述槽的形状与所述线圈形状相对应;
4)将电磁线嵌入所述槽中;
5)对布好电磁线的所述复合材料骨架浇注环氧树脂;
6)重复步骤2)-步骤5),直至得到预定层数的三维线圈。
2.如权利要求1所述的三维线圈制造方法,其特征在于,所述芯轴为直管或弯管。
3.如权利要求2所述的三维线圈制造方法,其特征在于,所述芯轴为直管时,所述步骤2)中,通过纤维复合材料预浸料热压罐成型、树脂传递模塑成型、真空树脂注入成型或多股复合材料缠绕在所述芯轴上敷设增材。
4.如权利要求2所述的三维线圈制造方法,其特征在于,所述芯轴为弯管时,所述步骤2)中,通过多股复合材料缠绕或纤维材料干绕浇注工艺在所述芯轴上敷设增材。
5.如权利要求1-4任一项所述的三维线圈制造方法,其特征在于,所述增材为纤维预浸渍环氧树脂材料,所述纤维为碳纤维或玻璃纤维。
6.如权利要求1所述的三维线圈制造方法,其特征在于,所述复合材料骨架的表面粗糙度不得大于开槽后剩余复合材料骨架厚度;若达不到要求,还需对槽的侧壁进行表面平整度加工。
7.如权利要求1所述的三维线圈制造方法,其特征在于,所述步骤4)中,将电磁线嵌入所述槽中时,采用胶带对所述电磁线进行预固定。
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