| Considering the main technical challenges of the China Fusion Engineering Test Reactor(CFETR)prototype Toroidal Field(TF)coil,such as the gigantic overall dimension,the huge mass,the strict winding requirements,and the complicated winding process,the key technology research of CFETR prototype TF coil winding has been carried out,laying a foundation for constructing the CFETR prototype TF coil winding line and continuous winding the coil.The main research work includes the following.The characteristics of the TF coil winding pack are analyzed,and the mathematical model of the winding motion of the D-shape TF coil is established for the first time.Using MATLAB,the simulation of the winding motion trajectory is completed,and the trajectory curve of the winding motion,as well as the motion parameters of each axis including the speed,acceleration,and displacement of the rotary platform,are obtained,laying a theoretical foundation for the precision winding of the D-shape TF coil.Furthermore,a calculation program for the winding motion trajectory of the D-shape TF coil is designed and developed,greatly simplifying the calculation process of similar TF coil winding motion data.The motion simulation and overall layout of the CFETR prototype TF coil winding line are carried out.A method relying on gravity to achieve constant-height spiral cable laying is proposed for the first time.The mechanical model of the conductor delivery process is established,and the mechanical simulation analysis and experimental testing of key components of the conductor delivery system are completed,verifying the feasibility of the method.Combined with the results of the TF coil winding motion data calculation,the design and simulation analysis of the multi-axis winding table are carried out.The development of the winding table is completed,and the no-load and 50 t load tests are conducted.The reliability of the multi-axis winding table is jointly verified by simulation analysis and experimental testing.Using a research method combining finite element analysis and trials,stress conditions of the TF conductor during precision straightening,bending forming,interlayer transition "S" bend forming,and outlet "R" bend forming are established for tension-free winding of the largest cross-section CICC in the world.Through finite element simulation,stress,strain,and bending forming force parameters of the TF conductor during the coil winding process are obtained,and the stress of the TF conductor during precision straightening,bending forming,and special positions(interlayer transition "S" bend,outlet "R" bend)forming process are predicted.A method using a fixed-length transition section to smoothly connect circular arcs is proposed for the first time,reducing the impact of the discontinuity of the transition between circular arcs on the winding forming contour.Combined with the results of finite element simulation,the development and testing of precision straightening equipment,bending forming equipment,and special position forming equipment for the conductor are completed,further verifying the accuracy of the TF conductor stress simulation and the reliability of the equipment development.The overall requirements for the automatic control system of the TF coil winding line are formulated.Combined with the mathematical model of the permanent magnet synchronous motor(PMSM),the double-closed-loop proportional-integral(PI)control method of the speed loop and current loop is used,and the space vector pulse width modulation(SVPWM)algorithm is applied to establish the decoupled closed-loop position control model of the PMSM.MATLAB Simulink is used for motor motion control simulation,and the speed characteristics of PMSM are optimized.Research on the software construction technology of the automatic control system is conducted.The lower machine program of the control system is written using SIMOTION SCOUT software,and the upper machine human-machine interface is built using SIMATIC WinCC development tools.Local control,remote control,jog control,and multi-axis synchronous control functions of the automatic control system are established,which can meet the single-machine debugging and linkage operation requirements of the TF coil winding line equipment.The reliability of the multi-axis linkage automatic control system is verified through the commissioning test of the TF coil winding line.The winding forming and testing of one double pancake dummy coil are completed,and the prototype TF dummy coil winding process is studied,further verifying the reliability of the TF coil winding line related equipment,automatic control system,and coil winding process,laying a technical foundation for the batch winding of TF coils. |
