Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “coil design”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2

High-Power Polyphase PCB-Type Inductive Coupler for Wireless Electric Vehicle Charging

The cost and manufacturing difficulty of traditionally wound coils for wireless charging of electric vehicles has led to the exploration of alternative manufacturing for scalable deployment at a range of rated powers. A rotating-field polyphase wireless coupler is developed with balanced fully pitched coils which are not possible with conventional Litz wire. The usage of printed circuit board (PCB) technology is proposed for the innovative construction at large dimensions due to reduced cost, increased ease of manufacturability, and potential geometric customization compared to would coils. Design considerations specific to PCBs are detailed for wireless power transfer coils including advantages such as the potential for many turns and transposition with planar interconnections. A design procedure is developed which may be used to investigate the frequency to power to dimension correlation and limits associated with PCB coils. Designs are simulated in 3D electromagnetic finite element analysis (FEA) for the polyphase coil to evaluate the coupling between coils with varying geometric parameters at 100mm and 500mm outer diameters. A discussion is included on methods to increase PCB power ratings through a mixture of layer stacking, connections, and material selection.

Lewis, Donovin D.↗

Current potential patches

A novel form of the current potential, a mathematical tool for the design of stellarators and stellarator coils, is developed. Specifically, these are current potentials with a finite-element basis, called current potential patches. Current potential patches leverage the relationship between distributions of magnetic dipoles and current potentials to explore limits of the access properties of stellarator coil sets. An example calculation is shown using the Helically Symmetric Experiment (HSX) equilibrium, demonstrating the method's use in coil design and understanding the limits of the access properties of coil sets. Current potential patches have additional desirable properties such as of promoting sparse current sheet solutions and identifying crucial locations of shaping current placement. A result is found for the HSX equilibrium that shaping currents covering only 22% of the winding surface are sufficient to produce the equilibrium to a good accuracy, provided a toroidal field is generated by an exterior coil set.

Elder, Todd↗

Physics basis for design of 3D coils in tokamaks

Recent progress in 3D tokamak modeling is now leveraged to create a conceptual design of new external 3D field coils for the DIII-D tokamak. In this work generalized perturbed equilibrium code is used to determine optimally efficient spectrum for driving total, core, and edge neoclassical toroidal viscosity torque. These fundamental modes of 3D control are shown to have consistent outboard structures across a wide variety of plasma scenarios and machines. Given these target spectra, the currents and 3D geometry of multiple coils can be optimized to increase efficient drive for the physics of interest without undesired secondary effects. Here, this nonlinear optimization is demonstrated using the flexible optimized coils using space-curves code. The optimized coils are individually distorted in space, creating toroidal 'arrays' containing a variety of shapes that often wrap around a significant poloidal extent of the machine. Importantly, efficient coupling can be maintained even when enforcing large distances between coils and the plasma during the geometric optimization of coil designs. Finally, the physics-driven optimization presented here thus provides a practical path to utilizing coils built on the exterior of the vacuum chamber in future reactors to obtain the powerful 3D field benefits demonstrated on current machines with close, internal coils.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Quench Performance of a Large-Aperture Nb 3 Sn Cos-Theta Coil With Stress Management in Dipole Mirror Configurations

A 123-mm-aperture Nb 3 Sn cos-theta (CT) dipole coil with stress management (SM) has been developed at Fermilab to demonstrate and test the SM concept, including coil design, fabrication technology, and performance. The first SMCT1 coil has been fabricated and assembled together with a 60-mm-aperture Nb 3 Sn coil inside a dipole mirror structure and tested separately and in series with the inner coil. This article summarizes the design, parameters, and quench performance of the SMCT1 coil in a dipole mirror configuration.

43 PARTICLE ACCELERATORS↗

Radio-Frequency Rapid Thermal Processing Enabling Spatial Phase Transformation and Nanocrystallization of Soft Magnetic Amorphous Alloys

Thermal processing of soft magnetic amorphous and nanocrystalline alloys is explored under the influence of radio-frequency induction-heating techniques. Direct induction-heating concepts based on longitudinal and transverse flux heating are examined and the details of electromagnetic fields interaction with metallic strips are discussed by analytical calculations as well as finite element analysis. Initial experimental results confirming spatial control of phase transformations and nanocrystallization within a single strip of Finemet Fe-based amorphous ribbons are reported. Here, the degree to which primary and secondary crystallization temperature are achieved depends on the spacing between the ribbon relative to the induction coil as well as the coil design and configuration. For transverse coil configurations, the local temperature and therefore microstructural evolution is different across the lateral dimension of processed ribbons, with reduced gap sizes producing enhanced peak temperatures and larger temperature distributions with greater spatial variation in microstructure. In addition, indirect susceptor-based induction heating under tension is performed and the impact of microstructure is demonstrated. Herein, potential for exploiting spatially optimized phase transformations is illustrated through electromagnetic field–assisted processing in a scalable manufacturing process with amorphous and nanocrystalline soft magnetic alloys.

36 MATERIALS SCIENCE↗

Optimized finite-build stellarator coils using automatic differentiation

A new stellarator coil design code is introduced that optimizes the position and winding pack orientation of finite-build coils. The new code, called flexible optimized curves in space using automatic differentiation (AD) and finite build (FOCUSADD), performs gradient-based optimization in a high-dimensional, non-convex space. The derivatives with respect to parameters of finite-build coils are easily and efficiently computed using AD. FOCUSADD parametrizes coil positions in free space using a Fourier series and uses a multi-filament approximation to the coil winding pack. The orientation of the winding pack is parametrized with a Fourier series and can be optimized as well. Optimized finite-build coils for a Wendelstein 7-X (W7-X)-like stellarator are found, and compared with filamentary coil results. The final positions of optimized finite-build W7-X-like coils are shifted, on average, by approximately 2.5 mm relative to optimized filamentary coils. These results suggest that finite-build effects should be accounted for in the optimization of stellarators with low coil tolerances.

43 PARTICLE ACCELERATORS↗

Development and test of a large-aperture Nb3Sn cos-theta dipole coil with stress management

The stress-managed cos-theta (SMCT) coil is a new concept which was proposed and is being developed at Fermilab in the framework of US Magnet Development Program (US-MDP) for high-field and/or large-aperture accelerator magnets based on low-temperature and high-temperature superconductors. A 120-mm aperture two-layer Nb3Sn SMCT dipole coil has been developed at Fermilab to demonstrate and test the SMCT concept including coil design, fabrication technology and performance. The first SMCT demo coil was fabricated and assembled with 60-mm aperture Nb3Sn coil inside a dipole mirror configuration and tested separately and in series with the insert coil. This paper summarizes the design, parameters, and quench performance of the 120-mm aperture SMCT coil in a dipole mirror configuration.

43 PARTICLE ACCELERATORS↗

Designing stellarators using perpendicular permanent magnets

We have developed a fast method to design perpendicular permanent magnets for simplifying stellarator coils based on existing codes. Coil complexity is one of the main challenges for stellarators. To date, only electromagnetic coils have been used to generate 3D fields for stellarators. Permanent magnets provide an alternative way to produce the desired magnetic field for optimized stellarators. In this paper, we revisit the concept of representing surface current using magnetic dipoles and carry out numerical validations. A surface magnetization is proven to be equivalent to the surface current that can be linearly solved by existing coil design codes. An incremental multi-layer method has been developed to obtain a practical solution that is attainable with present permanent magnets. With this method, we can reproduce a half-Tesla NCSX configuration using specially designed neodymium magnets together with simple planar coils. It shows that stellarator coils could be substantially simplified by adopting permanent magnets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Low Temperature CO2 Capture from an NGCC Flue Gas Using a Magnetically Stabilized, Inductively Heated Fluidized Bed Reactor

The lab sorbent testing finalized the sorbent composition and operating conditions for the integrated unit. The bench unit design included COMSOL simulation to finalize the coil design and select initial operating conditions of the power supply system. Fluidized bed testing with the induction heating verified that a heating efficiency of up to 90% can be achieved. The integrated bench unit operations provided valuable data confirming the feasibility of using induction heating for the desorption of CO2. Major challenge observed was the limited working capacity of the sorbent, requiring additional development in future projects. In addition, a large-scale reactor demonstration is required to mitigate the risk of uniform temperature distribution and heating efficiency over a large cross-sectional area when using induction heating.

Tong, Andrew↗

Direct computation of magnetic surfaces in Boozer coordinates and coil optimization for quasisymmetry

We propose a new method to compute magnetic surfaces that are parametrized in Boozer coordinates for vacuum magnetic fields. We also propose a measure for quasisymmetry on the computed surfaces and use it to design coils that generate a magnetic field that is quasisymmetric on those surfaces. The rotational transform of the field and complexity measures for the coils are also controlled in the design problem. Using an adjoint approach, we are able to obtain analytic derivatives for this optimization problem, yielding an efficient gradient-based algorithm. Starting from an initial coil set that presents nested magnetic surfaces for a large fraction of the volume, our method converges rapidly to coil systems generating fields with excellent quasisymmetry and low particle losses. In particular for low complexity coils, we are able to significantly improve the performance compared with coils obtained from the standard two-stage approach, e.g. reduce losses of fusion-produced alpha particles born at half-radius from $17.7\,\%$ to $6.6\,\%$ . We also demonstrate 16-coil configurations with alpha loss ${<}1\,\%$ and neoclassical transport magnitude $\epsilon _{\text {eff}}^{3/2}$ less than approximately $5\times 10^{-9}$ .

Physics↗

Genetic Fusion of Thermoresponsive Polypeptides with UCST‐type Behavior Mediates 1D Assembly of Coiled‐Coil Bundlemers

Abstract Thermoresponsive resilin‐like polypeptides (RLPs) of various lengths were genetically fused to two different computationally designed coiled coil‐forming peptides with distinct thermal stability, to develop new strategies to assemble coiled coil peptides via temperature‐triggered phase separation of the RLP units. Their successful production in bacterial expression hosts was verified via gel electrophoresis, mass spectrometry, and amino acid analysis. Circular dichroism (CD) spectroscopy, ultraviolet‐visible (UV/Vis) turbidimetry, and dynamic light scattering (DLS) measurements confirmed the stability of the coiled coils and showed that the thermosensitive phase behavior of the RLPs was preserved in the genetically fused hybrid polypeptides. Cryogenic‐transmission electron microscopy and coarse‐grained modeling revealed that functionalizing the coiled coils with thermoresponsive RLPs leads to their thermally triggered noncovalent assembly into nanofibrillar assemblies.

Patkar, Sai S.↗

Genetic Fusion of Thermoresponsive Polypeptides with UCST–type Behavior Mediates 1D Assembly of Coiled–Coil Bundlemers

Thermoresponsive resilin-like polypeptides (RLPs) of various lengths were genetically fused to two different computationally designed coiled coil-forming peptides with distinct thermal stability, to develop new strategies to assemble coiled coil peptides via temperature-triggered phase separation of the RLP units. Furthermore, their successful production in bacterial expression hosts was verified via gel electrophoresis, mass spectrometry, and amino acid analysis. Circular dichroism (CD) spectroscopy, ultraviolet-visible (UV/Vis) turbidimetry, and dynamic light scattering (DLS) measurements confirmed the stability of the coiled coils and showed that the thermosensitive phase behavior of the RLPs was preserved in the genetically fused hybrid polypeptides. Cryogenic-transmission electron microscopy and coarse-grained modeling revealed that functionalizing the coiled coils with thermoresponsive RLPs leads to their thermally triggered noncovalent assembly into nanofibrillar assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A Field Enhancement Integration Design Featuring Misalignment Tolerance for Wireless EV Charging Using LCL Topology

This article proposes a magnetic integration design for EV wireless power transfer (WPT) systems, where the compensation and transmitting coils overlap one on top of the other to share the ferrite layer without any decoupling consideration. The magnetic field generated by both the compensation and transmitting coils are exploited to transfer power. To this end, a compensation method is proposed to enable magnetic field enhancement without any reactive power flow between the compensation and the transmitting coils, and to achieve input zero phase angle and constant current output. In addition, an efficient finite element analysis-based coil optimization algorithm is proposed to improve the coil misalignment tolerance on the horizontal plane, in which a reversely connected inner coil is used to stabilize the system output under misalignment conditions. Analytical and simulation results confirm transmission flux density enhancement and reduced leakage field characteristics of the proposed coil design. Finally, a scaled-down WPT prototype is built and tested to verify the performance and effectiveness of the design. The proposed design achieves 91.17% efficiency and misalignment tolerance up to 200 mm in any XY-direction while maintaining the power transfer and its efficiency. The results of this work provide insights into magnetic integration design of high-order compensation topologies featuring higher compactness, less ferrite usage, magnetic field enhancement, and misalignment tolerance for WPT systems.

42 ENGINEERING↗

Engineering Design of D1/D3 Dipole Magnets for the Electron-Ion Collider (EIC)

Here, the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) is designed to deliver a peak luminosity of 10 34 cm −2 s −1 . An electron storage ring (ESR) will be installed in the existing Relativistic Heavy Ion Collider (RHIC) tunnel and will store polarized electron beams from 5 to 18 GeV. The ESR will have 750 dipole magnets with varying field requirements, including 576 super-bend triplets consisting of two magnets D1/D3 and D2. This paper presents on the engineering design of the D1/D3 dipole magnets within the arcs, with special focus on the coil design that allows the magnet to be configured for variable ampere-turns per energy.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

The CLAS12 superconducting magnets

As part of the Jefferson Lab 12 GeV upgrade, the Hall B CLAS12 system requires two superconducting iron-free magnets — a torus and a solenoid. The physics requirements to maximize space for the detectors guided engineers toward particular coil designs for each of the magnets which, in turn, led to the choice of using conduction cooling. The torus consists of 6 trapezoidal NbTi coils connected in series with an operating current of 3770 A. The solenoid is an actively shielded 5 T magnet consisting of 5 NbTi coils connected in series operating at 2416 A. Within the hall, the two magnets are located in close proximity to each other and are completely covered both inside and outside by particle detectors. Stringent size limitations were imposed for both magnets and introduced particular design and fabrication challenges. This paper describes the design, construction, installation, commissioning, and operation of the two magnets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Cooling Design and Thermal Analysis for Thermal Shields of a Cryocooler-Cooled Superconducting ECR Ion Source MARS-D Magnet

Here, a demonstrative NbTi based Mixed Axial and Radial field System (MARS-D) is being developed for a next-Generation Electron Cyclotron Resonance Ion Source (ECRIS) at Lawrence Berkeley National Laboratory (LBL), which employs a novel closed-loop coil design scheme that more efficiently utilizes conductor fields and extend the application of NbTi for high frequency (up to 45 GHz) ECR operation. The NbTi MARS-D magnet consists of a single hexagonally shaped closed-loop coil and a set of auxiliary solenoids. A cryostat for cooling the MARS-D magnet is under design at LBL. The MARS-D magnet working around 4.2 K will be bath-cooled in liquid helium using multiple two-stage cryocoolers. An intermediate temperature thermal radiation shield is adopted to reduce the heat leakage imposed on 4.2 K coil cold mass from room temperature. The thermal shield is conduction-cooled by the first-stage cold heads of four two-stage cryocoolers and the cold head of a single-stage cryocooler shared with nine binary leads. The temperature in the area of the shield that warm ends of HTS leads are mounted on is expected no higher than 60 K, which is limited by maximum allowable working temperature of HTS leads. The paper presents thermal analysis on the thermal radiation shield including heat loads and effects of eddy current induced during quench on its material selection.

ECRIS↗

36 Hz integral linewidth laser based on a photonic integrated 4.0 m coil resonator

Laser stabilization sits at the heart of many precision scientific experiments and applications, including quantum information science, metrology, and atomic timekeeping. Many of these systems narrow the laser linewidth and stabilize the carrier by use of Pound–Drever–Hall (PDH) locking to a table-scale, ultrahigh quality factor (Q), vacuum spaced Fabry–Perot reference cavity. Integrating these cavities to bring characteristics of PDH stabilization to the chip scale is critical to reducing their size, cost, and weight, and enabling a wide range of portable and system-on-chip applications. We report a significant advance in integrated laser linewidth narrowing, stabilization, and noise reduction by use of a photonic integrated 4.0 m long coil resonator to stabilize a semiconductor laser. We achieve a 36 Hz 1 / π <#comment/> -integral linewidth, Allan deviation of 1.8 × <#comment/> 10 − <#comment/> 13 at 10 ms measurement time, and a 2.3 kHz/s drift—to the best of our knowledge, the lowest integral linewidth and highest stability demonstrated for an integrated waveguide reference cavity. This performance represents over an order of magnitude improvement in integral linewidth and frequency noise over previous integrated waveguide PDH stabilized reference cavities and bulk-optic and integrated injection locked approaches, and over two orders of magnitude improvement in frequency and phase noise than integrated injection locked approaches. Two different wavelength coil designs are demonstrated, stabilizing lasers at 1550 nm and 1319 nm. The resonator is bus-coupled to a 4.0 m long coil, with a 49 MHz free spectral range, mode volume of 1.0 × <#comment/> 10 10 µ <#comment/> m 3 , and 142 million intrinsic Q , fabricated in a CMOS compatible, ultralow loss silicon nitride waveguide platform. Our measurements and simulations show that the thermorefractive noise floor for this particular cavity is reached for frequencies down to 20 Hz in an ambient environment with simple passive vibration isolation and without vacuum or thermal isolation. The thermorefractive noise limited performance is estimated to yield an 8 Hz 1 / π <#comment/> -integral linewidth and Allan deviation of 5 × <#comment/> 10 − <#comment/> 14 at 10 ms, opening a stability regime that heretofore has been available only in fundamentally non-integrated systems. These results demonstrate the potential to bring the characteristics of laboratory-scale stabilized lasers to the integrated, wafer-scale compatible chip scale, and are of interest for a number of applications in quantum technologies and atomic, molecular, and optical physics, and with further developments below 10 Hz linewidth, can be highly relevant to ultralow noise microwave generation.

Liu, Kaikai (ORCID:0000000213609646)↗

The magnetic gradient scale length explains why certain plasmas require close external magnetic coils

Abstract The separation between the last closed flux surface of a plasma and the external coils that magnetically confine it is a limiting factor in the construction of fusion-capable plasma devices. This plasma-coil separation must be large enough so that components such as a breeding blanket and neutron shielding can fit between the plasma and the coils. Plasma-coil separation affects reactor size, engineering complexity, and particle loss due to field ripple. For some plasmas it can be difficult to produce the desired flux surface shaping with distant coils, and for other plasmas it is infeasible altogether. Here, we seek to understand the underlying physics that limits plasma-coil separation and explain why some configurations require close external coils. In this paper, we explore the hypothesis that the limiting plasma-coil separation is set by the shortest scale length of the magnetic field as expressed by the ∇ B tensor. We tested this hypothesis on a database of > 40 stellarator and tokamak configurations. Within this database, the coil-to-plasma distance compared to the minor radius varies by over an order of magnitude. The magnetic scale length is well correlated to the coil-to-plasma distance of actual coil designs generated using the REGCOIL method (Landreman 2017 Nucl. Fusion 57 046003). Additionally, this correlation reveals a general trend that larger plasma-coil separation is possible with a small number of field periods.

Physics↗