A high-power rolling collector ring precision forming method

Abstract

The application discloses a high-power rolling-type collector ring precision forming method, which comprises the following steps: processing a plurality of groups of conductive ring parts, insulating plate parts and adhesive film parts according to product requirements; preparing a plurality of layers of outer conductive ring group blanks and inner conductive ring group blanks by adopting a conductive ring group blank laminating process; performing rolling track precision machining on the outer conductive ring group blank and the inner conductive ring group blank after pairing; precisely assembling the paired outer conductive ring group, the inner conductive ring group, a plurality of elastic rings and related accessory structural parts and cables, measuring and adjusting the relative positions, and completing the preparation of the high-power rolling collector ring. The application adopts the method of forming based on the conductive ring layer group compression forming process and the pairing multi-layer rolling track integrated machining forming, effectively controls the conductive ring group rolling track forming precision and the size consistency, and meets the high-current high-reliability long-life transmission requirements.

Description

Technical Field

[0001] This invention belongs to the field of bus rings, and particularly relates to a method for precision molding of a high-power rolling bus ring. Background Technology

[0002] Bus rings are key components for transmitting electrical signals and power between stationary and rotating equipment, and are widely used in military radar, communication navigation, satellite communication, precision instruments, and many other fields. Based on their contact type, bus rings can be divided into sliding bus rings and rolling bus rings. Compared to sliding bus rings, rolling bus rings avoid the friction and wear problems of carbon brushes and conductive ring contact surfaces, offering advantages such as high reliability, long lifespan, and maintenance-free operation, making them very promising for applications. A common architecture for rolling bus rings is a planetary gear mechanism consisting of inner and outer conductive ring assemblies and multiple flexible rings. The elastic rings rotate / revolve within the conductive ring raceways to achieve rotational transmission. To ensure stable power and signal transmission over long periods, extremely stringent requirements are placed on the machining, assembly precision, and consistency of the inner and outer conductive ring assemblies in the rolling bus ring.

[0003] Current public reports on rolling bus rings mainly focus on structural improvements. For multi-channel high-power transmission rolling bus rings, the process typically involves first machining individual conductive rings and insulating rings, then assembling them into a component with rotational transmission capabilities. Utility model patent CN 204992218U provides a rolling bus ring device suitable for power transmission, using rolling flexible rings and inner and outer conductive channels to replace brushes and conductive channels. It improves service life by replacing sliding contact with rolling contact and flexibly configures the number of channels in the rolling bus ring unit to increase conductive power. However, it does not describe the control of the fit accuracy between multiple sets of conductive rings and flexible rings. Invention patent CN 104779504B provides a high-power rolling bus ring device, where conductive rings and rolling blocks, as well as rolling contacts between rolling blocks and flexible rings, make rolling contact. High-power transmission is achieved by evenly distributing multiple rolling block assemblies radially and axially on a fixed support to form multiple conductive loops. However, it lacks effective measures for controlling the fit accuracy between multiple sets of conductive rings and flexible rings. Utility model patent CN 212304146 discloses a stacked ultra-micro precision conductive slip ring mandrel. An insulating sleeve is fitted onto a support shaft with several elongated grooves, followed by the alternating insertion of insulating rings and conductive rings. Finally, the cavity is filled with glue and cured to achieve ring core assembly. The ring core manufacturing method provided by this utility model involves independently processing multiple sets of insulating and conductive rings before assembly. The parts prepared through multiple clamping and positioning processes have dimensional errors, and inconsistent tightness between layers also affects assembly accuracy.

[0004] In summary, the method of separately processing and then assembling the conductive rings and insulating rings of each channel has problems such as height deviation and radial concentricity difference between the inner and outer conductive ring raceways due to processing and assembly errors. This leads to unstable signal transmission and damage to the raceways and flexible rings during long-term rotation of the bus ring, seriously affecting its service life. At the same time, uneven operation of the elastomer has generated excess material, posing a risk of short circuit in the equipment. It is necessary to further develop a better molding process and technical route to meet the high-reliability transmission requirements of high-power rolling bus rings. Summary of the Invention

[0005] To address the above problems, this invention proposes a precision forming method for high-power rolling bus rings, comprising the following steps:

[0006] Step 1: Prepare conductive metal raw materials, non-metallic raw materials and adhesive film raw materials. Process several sets of conductive ring parts, insulating board parts and adhesive film parts according to the finished product requirements. The conductive ring parts, insulating board parts and adhesive film parts are divided into two sets of specifications: inner ring and outer ring. The dimensional accuracy of each part in the same set is consistent.

[0007] Step 2: Clean the conductive ring parts and insulating board parts. Using the conductive ring assembly blank lamination process, refer to the finished product structure and stack them in the order of "insulating board → adhesive film → conductive ring → adhesive film → insulating board..." until the specified number of layers are reached. Use pins for positioning to prepare several layers of outer conductive ring assembly blanks and inner conductive ring assembly blanks.

[0008] Step 3: After pairing the blanks of the outer conductive ring group and the inner conductive ring group, the raceway is precision machined; one end face is selected and precision machined and flattened as the axial reference surface; after one clamping, the raceway features of all channels are precision machined to form the outer conductive ring group and the inner conductive ring group, which together constitute the corresponding conductive ring group; the raceway features include the outer ring raceway features and the inner ring raceway features, which match the external structure of the elastic ring 2;

[0009] Step 4: Precision assemble the paired outer conductive ring group, inner conductive ring group, several elastic rings and related auxiliary structural parts and cables, measure and adjust their relative positions to complete the preparation of the high-power rolling bus ring.

[0010] Specifically, the conductive ring parts, insulating plate parts, and adhesive film parts retain a margin of 1-2mm according to the subsequent processing requirements of the conductive ring assembly; the raw material of the adhesive film is epoxy glass cloth semi-cured sheet, and the thickness of the cured adhesive film layer is 0.2-0.25mm. The number of semi-cured sheets required for the adhesive film is determined according to the design thickness.

[0011] Specifically, the lamination process of the conductive ring assembly blank requires the preparation of a corresponding hot press mold, and lamination is carried out by a TMP vacuum press. Under high temperature and high pressure conditions, the adhesive film is melted, has fluidity, and can be quickly cured and the bonding process is completed. The adhesive film and the insulating ring together form an insulating layer, and the outer conductive ring assembly blank and the inner conductive ring assembly blank are prepared.

[0012] Specifically, step 2 further includes the following steps: performing performance tests on the conductive ring assembly blank and the inner conductive ring assembly blank, requiring that the insulation resistance of each conductive ring component at room temperature and 85°C be >500MΩ and the breakdown voltage be >220V.

[0013] Specifically, the flatness of the axial reference surface in step 3 is better than 0.02mm; the coaxiality of the inner and outer concentric rings of the outer conductive ring assembly blank and the inner conductive ring assembly blank after clamping is better than φ0.03mm, and the surface finish of the raceway feature is better than Ra0.8;

[0014] All raceway features are precision machined in a single clamping process, ensuring that the accuracy of each raceway feature in a single conductive ring assembly is better than ±0.02mm, and the dimensional accuracy between the raceway features of the paired conductive ring assembly and the inner ring raceway features is better than ±0.03mm.

[0015] Specifically, the elastic ring in step 4 is designed with a pre-compression of 0.5 mm to ensure effective contact between the outer conductive ring group and the inner conductive ring group;

[0016] Specifically, each group of conductive rings in the single channel of the high-power rolling bus ring described in step 4 contains 6 conductive rings, and each channel transmits current through 8 evenly distributed elastic rings, with a single channel transmitting current. The dynamic contact resistance is less than 2mΩ.

[0017] Specifically, after precision machining, the conductive ring assembly undergoes a high wear-resistant conductive coating on its surface, the outer ring raceway features and the inner ring raceway features are plated with a wear-resistant precious metal coating, and the remaining positions are flash-plated with gold; then it is precisely assembled with the elastic ring.

[0018] Compared with the prior art, the advantages of this invention are as follows:

[0019] 1. Using a semi-cured sheet lamination process, the conductive rings and insulating rings of each layer are cured into a whole by hot pressing with adhesive film. The interlayer bonding is strong, the dimensions are stable during use, no additional fasteners are required, and the product integration and weight reduction are improved.

[0020] 2. After the conductive ring assembly is bonded and cured into a whole, it is precision machined. The inner and outer raceway features of each layer are based on a unified benchmark. All processing is completed in one clamping. Compared with the method of processing / assembling parts separately, the forming accuracy of the raceway and the dimensional consistency between each channel are greatly improved, thus improving the technical performance.

[0021] 3. The bus ring assembly uses elastic rings for rolling transmission, with a compact structure and strong current carrying capacity. The number of elastic rings can be reasonably arranged according to the size of the transmitted current, making it suitable for high current transmission applications. Attached Figure Description

[0022] Figure 1 This is a flowchart of a high-power rolling busbar precision forming method according to an embodiment of the present invention.

[0023] Figure 2 This is a schematic diagram of the multi-channel raceway manifold structure according to an embodiment of the present invention.

[0024] Figure 3 This is a schematic diagram of the hot-pressed outer conductive ring assembly blank according to an embodiment of the present invention.

[0025] Figure 4 This is a cross-sectional view of the hot-pressed outer conductive ring assembly blank according to an embodiment of the present invention.

[0026] Figure 5 This is a schematic diagram of the blank of the inner conductive ring assembly formed by hot pressing according to an embodiment of the present invention.

[0027] Figure 6 This is a cross-sectional view of the inner conductive ring assembly blank formed by hot pressing according to an embodiment of the present invention.

[0028] Figure 7 This is a cross-sectional view of the inner and outer conductive ring assembly blanks before processing, according to an embodiment of the present invention.

[0029] Figure 8 This is a cross-sectional view of the inner and outer conductive ring assembly blanks after processing according to an embodiment of the present invention.

[0030] The markings in the diagram represent the following meanings:

[0031] Outer conductive ring assembly 1, outer ring raceway feature 101, elastic ring 2, inner conductive ring assembly 3, inner ring raceway feature 301, outer conductive ring assembly blank 4, outer ring insulating plate 401, outer conductive ring 402, outer ring adhesive film 403, inner conductive ring assembly blank 5, inner ring insulating plate 501, inner conductive ring 502, inner ring adhesive film 503. Detailed Implementation

[0032] To address the requirements of complex electronic equipment such as radar for high-power, long-life, and highly reliable rotary transmission of electrical signals, this invention aims to provide a precision molding method for high-power rolling bus rings. Based on conductive ring lamination molding technology and multi-layer raceway integrated processing, this method controls the molding accuracy and dimensional consistency of the conductive ring assembly's raceways, achieving precise manufacturing of high-power rolling bus rings. According to the research requirements, this rolling bus ring consists of several layers of outer conductive ring assemblies, several layers of inner conductive ring assemblies, several layers of insulating assemblies, and multiple elastic rings. It features a compact structure and improved current transmission capacity. By combining the conductive ring lamination molding technology and the multi-layer raceway integrated processing method, the inner and outer conductive ring assembly raceways are based on a unified benchmark and formed in a single clamping process, ensuring accuracy and dimensional consistency to meet the requirements of smooth rolling of the elastic rings, achieving high-current, highly reliable, and long-life transmission.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application.

[0034] This invention provides a high-power rolling busbar precision forming method, based on conductive ring lamination forming process and multi-layer raceway integrated processing forming method, to ensure the forming accuracy and dimensional consistency of the conductive ring group raceway, meet the long-cycle stable operation requirements of the rolling busbar planetary gear structure, and realize high-power, high-reliability, and long-life rotational transmission.

[0035] This embodiment provides a method for precision molding of a high-power rolling bus ring, such as... Figure 1 As shown, it includes the following steps:

[0036] Step S1: Prepare conductive metal raw materials, non-metallic raw materials, and adhesive film raw materials. Process 6 sets of conductive ring parts (outer conductive ring 402, inner conductive ring 502), 7 sets of insulating plate parts (outer ring insulating plate 401, inner ring insulating plate 501), and adhesive film parts (outer ring adhesive film 403, inner ring adhesive film 503) according to the finished product requirements. These are divided into inner and outer ring specifications. The dimensional accuracy of each part in the same group should be kept as consistent as possible, controlling the flatness and parallelism of the upper and lower end faces of the parts. The raceway features (outer ring raceway feature 101, inner ring raceway feature 301) are not processed initially. The conductive ring parts, insulating plate parts, and adhesive film parts should retain a 1-2mm allowance based on the subsequent processing requirements of the conductive ring groups to meet the precision machining requirements of the raceway features. The adhesive film raw material is epoxy glass cloth prepreg (PP sheet). The cured adhesive film layer thickness is 0.2-0.25mm. The number of prepreg sheets required for the adhesive film depends on the design thickness, generally not less than 2 sheets.

[0037] Step S2: Clean the conductive ring parts (outer conductive ring 402, inner conductive ring 502) and insulating plate parts (outer ring insulating plate 401, inner ring insulating plate 501). Using the conductive ring assembly blank lamination process, refer to the finished product structure and stack them sequentially in the order of "insulating plate → adhesive film → conductive ring → adhesive film → insulating plate..." until the specified number of layers are reached. Pins are used for positioning to prepare several layers of outer conductive ring assembly blank 4 and inner conductive ring assembly blank 5. The conductive ring assembly blank lamination process requires the preparation of a corresponding hot press mold. Lamination is carried out using a TMP vacuum press. Under high temperature and high pressure conditions, the prepreg melts, becomes fluid, and can quickly solidify and complete the bonding process. The prepreg and the insulating ring together form an insulating layer, thus preparing the outer conductive ring assembly blank 4 and inner conductive ring assembly blank 5.

[0038] The cured adhesive film layer has a thickness of 0.2 to 0.25 mm. A 1080 type semi-cured sheet with a thickness of 0.06 mm is selected, and 4 semi-cured sheets are laid at each bonding interface.

[0039] like Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, the performance of the blank is tested, requiring that the insulation resistance of each conductive ring part be >500MΩ and the breakdown voltage be >220V at room temperature and 85℃.

[0040] Step S3: Number the outer conductive ring blank 4 and the inner conductive ring blank 5, and pair them for raceway finishing; select one end face for finishing and flattening as the axial reference surface, with a reference surface flatness better than 0.02mm; complete the precision machining of all channel outer ring raceway features 101 and inner ring raceway features 301 in one clamping, forming outer conductive ring group 1 and inner conductive ring group 3, ensuring dimensional and positional accuracy between paired raceways; outer conductive ring group 1 and inner conductive ring group 3 constitute corresponding conductive ring groups; the conductive ring blanks are paired and precision machined for raceway features, and a special concentric positioning clamping fixture is prepared, with the coaxiality of the inner and outer concentric rings better than φ0.03mm, and after one clamping, CNC turning and grinding are performed to form the raceway feature surface finish better than Ra0.8. Figure 7 , Figure 8 As shown, all raceway features are precision machined in one clamping process, ensuring that the accuracy of each raceway feature in a single conductive ring group is better than ±0.02mm, and the dimensional accuracy between the paired ring group raceway feature 101 and the inner ring raceway feature 301 is better than ±0.03mm.

[0041] Step S4: Precision assemble the paired outer conductive ring group 1, inner conductive ring group 3, several elastic rings 2, and related auxiliary structural parts, cables, etc., measure and adjust their relative positions to complete the preparation of the high-power rolling bus ring;

[0042] The outer conductive ring group 1, inner conductive ring group 3, elastic ring 2 and related auxiliary structural parts, cables, etc. are precision assembled. The elastic ring 2 is designed with a pre-compression amount of 0.5mm to ensure effective contact. The relative position is measured and adjusted to complete the preparation of the high-power rolling bus ring. The subsequent running-in test is carried out.

[0043] like Figure 2 As shown, each channel has 8 elastic rings 2 evenly distributed, and the 6-channel rolling bus ring contains a total of 48 elastic rings 2, which meets the high-current transmission requirements of 200A and above per channel.

[0044] The rolling bus ring with 6 channels prepared by the above method has 6 conductive rings in each group of conductive rings, and each channel transmits current through 8 evenly distributed elastic rings. The measured single-channel transmission current is [data missing]. The dynamic contact resistance is less than 2mΩ, which meets the requirements for high-power and high-reliability transmission.

[0045] After precision machining, the conductive ring assembly is coated with a high wear-resistant conductive coating. The outer ring raceway feature 101 and the inner ring raceway feature 301 are plated with a wear-resistant precious metal coating, and the remaining positions are flash-plated with gold. Then, it is precisely assembled with the elastic ring 2, and a rolling busbar running-in test is carried out.

[0046] Compared with the prior art, the present invention has the following advantages:

[0047] 1. Using a semi-cured sheet lamination process, the conductive rings and insulating rings of each layer are cured into a whole by hot pressing with adhesive film. The interlayer bonding is strong, the dimensions are stable during use, no additional fasteners are required, and the product integration and weight reduction are improved.

[0048] 2. After the conductive ring assembly is bonded and cured into a whole, it is precision machined. The inner and outer raceway features of each layer are based on a unified benchmark. All processing is completed in one clamping. Compared with the method of processing / assembling parts separately, the forming accuracy of the raceway and the dimensional consistency between each channel are greatly improved, thus improving the technical performance.

[0049] 3. The bus ring assembly uses elastic rings for rolling transmission, with a compact structure and strong current carrying capacity. The number of elastic rings can be reasonably arranged according to the size of the transmitted current, making it suitable for high current transmission applications.

[0050] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for precision molding of a high-power rolling bus ring, characterized in that, Includes the following steps: Step 1: Prepare conductive metal raw materials, non-metallic raw materials and adhesive film raw materials. Process several sets of conductive ring parts, insulating board parts and adhesive film parts according to the finished product requirements. The conductive ring parts, insulating board parts and adhesive film parts are divided into two sets of specifications: inner ring and outer ring. The dimensional accuracy of each part in the same set is consistent. Step 2: Clean the conductive ring parts and insulating board parts. Using the conductive ring assembly blank lamination process, refer to the finished product structure and stack them in the order of "insulating board → adhesive film → conductive ring → adhesive film → insulating board..." until the specified number of layers are reached. Position them with pins to prepare several layers of outer conductive ring assembly blank (4) and inner conductive ring assembly blank (5). Step 3: After pairing the outer conductive ring blank (4) and the inner conductive ring blank (5), the raceway is precision machined; one end face is selected and flattened as the axial reference surface; after clamping, the raceway features of all channels are precision machined to form the outer conductive ring group (1) and the inner conductive ring group (3), which constitute the corresponding conductive ring group; the raceway features include the outer ring raceway feature (101) and the inner ring raceway feature (301), which match the external structure of the elastic ring (2); Step 4: Precision assemble the paired outer conductive ring group (1), inner conductive ring group (3), several elastic rings (2), and related auxiliary structural parts and cables, measure and adjust their relative positions, and complete the preparation of the high-power rolling bus ring; The conductive ring parts, insulating plate parts, and adhesive film parts shall retain a margin of 1~2mm according to the subsequent processing requirements of the conductive ring assembly; the raw material of the adhesive film is epoxy glass cloth semi-cured sheet, and the thickness of the cured adhesive film layer is 0.2~0.25mm. The number of semi-cured sheets required for the adhesive film is determined according to the design thickness. The bonding process of the conductive ring assembly blank requires the preparation of a corresponding hot press mold. The bonding is carried out by a TMP vacuum press. Under high temperature and high pressure conditions, the adhesive film is melted, has fluidity, and can be quickly cured and bonded. The adhesive film and the insulating ring together form an insulating layer, and the outer conductive ring assembly blank (4) and the inner conductive ring assembly blank (5) are prepared. Step 2 further includes the following steps: to perform performance tests on the conductive ring assembly blank (4) and the inner conductive ring assembly blank (5), requiring that the insulation resistance of each conductive ring part at room temperature and 85℃ be >500MΩ and the breakdown voltage be >220V. The flatness of the axial reference surface mentioned in step 3 is better than 0.02mm; the coaxiality of the inner and outer concentric rings of the clamped outer conductive ring blank (4) and inner conductive ring blank (5) is better than φ0.03mm, and the surface finish of the raceway feature is better than Ra0.8; All raceway features are precision machined in one clamping process, ensuring that the accuracy of each raceway feature in a single conductive ring group is better than ±0.02mm, and the dimensional accuracy between the raceway feature (101) and the inner ring raceway feature (301) of the paired conductive ring group is better than ±0.03mm.

2. The high-power rolling busbar precision forming method according to claim 1, characterized in that, The elastic ring (2) in step 4 is designed with a pre-compression amount of 0.5 mm to ensure effective contact between the outer conductive ring group (1) and the inner conductive ring group (3).

3. The high-power rolling busbar precision forming method according to claim 1, characterized in that, Step 4 describes a high-power rolling bus ring. Each group of conductive rings in a single channel comprises 6 conductive rings. Each channel transmits current through 8 evenly distributed elastic rings, allowing for single-channel current transmission. 200A, dynamic contact resistance less than 2mΩ.

4. The high-power rolling busbar precision forming method according to claim 1, characterized in that, After the conductive ring assembly is precision machined, a high wear-resistant conductive coating is applied to the surface. The outer ring raceway feature (101) and the inner ring raceway feature (301) are plated with a wear-resistant precious metal coating, and the remaining positions are flash-plated with gold. Then, it is precisely assembled with the elastic ring (2).

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