A fully automated adaptive conductive slip ring current-carrying tribological wear testing system and method

Abstract

This invention provides a fully automated adaptive conductive slip ring current-carrying friction and wear testing system and method. The system includes: a test bench, and a first test main body mounted on the test bench, comprising a first driving unit and a transmission unit interconnected thereto. The transmission unit is used to mount the conductive slip ring to be tested and drive the conductive slip ring to rotate. A second test main body includes a clamping unit and an automatic compensation unit interconnected thereto. The clamping unit is used to mount brush bristles, and the automatic compensation unit is used to drive the clamping unit to move so that the brush bristles on it contact the rotating conductive slip ring to be tested. The brush bristles are externally powered. The second driving unit is used to receive mechanical parameters collected by each mechanical sensor and adjust the contact position between the brush bristles and the conductive slip ring to maintain constant loading conditions. The system provided by this invention solves the problem that current friction and wear performance testing cannot achieve adaptive adjustment of the outer diameter of the conductive slip ring and automatic compensation of wear.

Description

Technical Field

[0001] This application relates to the field of material performance testing technology, and in particular to a fully automated adaptive conductive slip ring current-carrying friction and wear testing system and method. Background Technology

[0002] With the development of advanced aerospace and marine electronic equipment, the demand for high-power transmission, high-throughput, low-noise, and long-life electrical conduction is increasing. Conductive slip rings are key components that determine the overall performance of such equipment. Conductive slip rings (or "electric slip rings") are high-precision power transmission devices used to transmit electrical signals and current between stationary and rotating mechanisms. They are suitable for scenarios requiring unrestricted, continuous, or intermittent rotation while simultaneously transmitting power or data signals from a stationary region to a rotating region. They are widely used in aerospace equipment, radar and communication equipment, medical equipment, and automated processing equipment.

[0003] Designing slip rings is highly complex, requiring consideration of factors such as rated current, rated voltage, and operating speed. These intricate design standards make the performance testing of conductive slip rings crucial. To ensure that the performance of conductive slip rings meets practical requirements and does not fail prematurely due to mechanical or electrical wear during actual use, a comprehensive evaluation of the current-carrying capacity and tribological properties of the manufactured conductive slip ring materials is necessary. Developing current-carrying tribological testing equipment and methods can drive the design and development of high-performance conductive slip rings.

[0004] The testing of the tribological performance of conductive slip rings is a lengthy process with complex parameters. However, existing conductive slip ring test benches are mostly designed for slip ring assemblies / components, lacking experimental evaluation devices for individual parts such as brush filaments and slip rings. This restricts the development cycle and experimental costs. Furthermore, test benches require different tooling designs for different slip rings, making it impossible to achieve adaptive adjustment of the slip ring's outer diameter and real-time compensation for wear. Summary of the Invention

[0005] To address the aforementioned problems, one objective of this invention is to provide a fully automated adaptive conductive slip ring current-carrying friction and wear testing system, thereby solving the current limitations in friction and wear performance testing where adaptive adjustment of the conductive slip ring's outer diameter and automatic compensation for wear are not feasible. A second objective of this invention is to propose a fully automated adaptive conductive slip ring current-carrying friction and wear testing method.

[0006] To achieve one of the objectives, the first aspect of this invention provides a fully automated adaptive conductive slip ring current-carrying friction and wear testing system, the technical solution of which is:

[0007] A fully automated adaptive conductive slip ring current-carrying tribological wear testing system, comprising: a test bench, and a device mounted on the test bench:

[0008] The first test body includes a first drive unit and a transmission unit connected to each other. The transmission unit is used to install the conductive slip ring to be tested and drive the conductive slip ring to be tested to rotate.

[0009] The second test body includes a clamping part and an automatic compensation part connected to each other. The clamping part is used to install brush bristles, and the automatic compensation part is used to drive the clamping part to move until the brush bristles on it come into contact with the rotating conductive slip ring under test. The brush bristles are connected to an external power source.

[0010] The automatic compensation unit includes a second drive unit and multiple force sensors;

[0011] The second drive unit is used to receive the mechanical parameters collected by each of the mechanical sensors and adjust the contact position between the brush bristles and the conductive slip ring under test to maintain constant loading conditions.

[0012] Optionally, the automatic compensation unit further includes a motion mechanism, which is connected to the second drive unit and the clamping unit respectively, to convert the torque output by the second drive unit into linear motion of the clamping unit.

[0013] Optionally, the motion mechanism includes any one of a lead screw and nut structure, a crank and slider structure, and a worm gear structure.

[0014] Optionally, the moving end of the motion mechanism is connected to the clamping part via an elastic element.

[0015] Optionally, the transmission unit includes:

[0016] The bearing housing is mounted on the test bench;

[0017] The main shaft passes axially through the bearing housing, and its bottom axial end is connected to the first drive unit;

[0018] A transmission connector is disposed at the axial top end of the main shaft and is tightly connected to the conductive slip ring to be tested;

[0019] The test bench is equipped with multiple telescopic legs.

[0020] Optionally, the transmission connector includes a sleeve and an end cap, the end cap being configured to slide axially relative to the main shaft.

[0021] Optionally, both the clamping part and the transmission connector include insulating material.

[0022] Optionally, the clamping part has a corresponding opening in the area where the brush bristles are installed, a threaded sleeve is installed in the opening, and the gap between the threaded sleeve and the opening is filled with cured adhesive; and fasteners are provided on opposite sides of the brush bristles.

[0023] Optionally, multiple automatic compensation units are provided, and the multiple automatic compensation units are interconnected to jointly drive the clamping unit to move in multiple directions.

[0024] To achieve the second objective, the second aspect of this invention provides a fully automated adaptive conductive slip ring current-carrying friction and wear test method, the technical solution of which is:

[0025] A fully automated adaptive conductive slip ring current-carrying friction and wear test method, relying on the fully automated adaptive conductive slip ring current-carrying friction and wear test system provided in the first aspect of the present invention, includes the following test method:

[0026] The conductive slip ring to be tested is installed on the transmission part of the first test body;

[0027] The brush bristles are mounted on the clamping part of the second test body and energized.

[0028] The first drive unit of the first test body is activated, and the conductive slip ring under test is driven to rotate through the transmission unit;

[0029] The second drive unit of the automatic compensation unit of the second test body is activated, which drives the clamping part to move to the brush bristles on it, and the brush bristles are in contact with the rotating conductive slip ring under test, and form a current path with the conductive slip ring under test.

[0030] The second drive unit receives mechanical parameters collected by each mechanical sensor and adjusts the contact position between the brush bristles and the conductive slip ring under test to maintain constant loading conditions.

[0031] Compared with the prior art, this application has the following significant advancements:

[0032] The testing system provided in this invention can fully simulate the actual use of conductive slip rings under complex operating conditions, especially in tests under complex conditions such as high current carrying capacity, variable speed, and variable current. This significantly improves the reliability of experimental data and the ability to simulate actual operating conditions, thereby more realistically predicting the performance of conductive slip rings in long-term use and obtaining more accurate and practically meaningful test data. Furthermore, it can dynamically compensate based on wear amount or slip ring model, overcoming the problems of poor adaptability and inability to dynamically compensate for wear in traditional tests. The fully automated adaptive system not only greatly improves testing efficiency and reduces errors during the testing process, but also improves the accuracy and stability of the test, possessing significant technical and market value. Moreover, this design can adapt to various outer diameters, speeds, and current conditions, improving the versatility and adaptability of the test, and meeting the long-cycle automatic testing needs of different models of high-precision conductive slip rings. Attached Figure Description

[0033] To more clearly illustrate the technical solution of this application, the accompanying drawings used in the description of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0034] Figure 1 This is a schematic diagram of the working state of an existing conductive slip ring;

[0035] Figure 2 This is a structural diagram of an existing conductive slip ring;

[0036] Figure 3 This is a schematic diagram of the main structure of the fully automatic adaptive conductive slip ring current-carrying friction and wear test system according to an embodiment of this application;

[0037] Figure 4 This is a front view of the fully automated adaptive conductive slip ring current-carrying friction and wear test system according to an embodiment of this application;

[0038] Figure 5 This is a schematic diagram of the installation of the threaded sleeve according to an embodiment of this application;

[0039] Figure 6 This is a schematic diagram of the second main structure of the fully automatic adaptive conductive slip ring current-carrying friction and wear test system according to an embodiment of this application;

[0040] Figure 7 This is a flowchart of the steps of the fully automated adaptive conductive slip ring current-carrying friction and wear test method according to an embodiment of this application.

[0041] Explanation of reference numerals in the attached figures:

[0042] 1. Test bench; 2. Second drive unit; 3. Automatic compensation unit; 31. Lead screw; 32. Nut; 4. First drive unit; 5. Conductive slip ring to be tested; 6. Brush bristles; 7. Clamping unit; 8. Elastic element; 9. Mechanical sensor; 10. Connecting block; 11. Fixture support; 12. Bearing seat; 13. Coupling; 14. Main shaft; 15. Telescopic support leg; 16. Sleeve; 17. End cap. Detailed Implementation

[0043] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0044] like Figure 1 and Figure 2 As shown, Figure 1 and Figure 2 The working principle and overall structure of existing conductive slip rings are illustrated. It can be seen that a conductive slip ring mainly consists of key components such as the slip ring itself, brushes, bearings, stator, rotor, stator end wires, and rotor end wires. The filamentary brushes are fixed to the stator by a brush holder or other structure and are held under a certain contact pressure to form electrical contact with the slip ring. The wires are connected to external circuits or equipment to transmit current or signals. The slip ring is mounted on the rotating part; when the rotor rotates, the slip ring itself also rotates, while the fixed brushes are always in contact with the rotating slip ring surface. Through these contact points, electrical signals or current are transmitted from the fixed part to the rotating part.

[0045] Therefore, frictional contact between the slip ring and the brush inevitably causes wear. Wear directly affects the performance, reliability, and service life of the slip ring. Due to its wide range of applications and its often critical position in industrial instruments, conductive slip rings have been the subject of considerable theoretical and experimental research both domestically and internationally. This research covers the causes of frictional wear in conductive slip rings, the impact of frictional wear on their performance, and how to improve their performance through the selection of more suitable materials, improved manufacturing processes, or better usage methods.

[0046] In scientific research, researchers focus more on the impact of various experimental conditions on the properties of the materials themselves. However, due to the complexity of actual conductive slip rings and the numerous influencing factors, there are very few comprehensive experiments directly targeting actual conductive slip rings. From the perspective of experimental instruments, currently commercially available conductive slip ring testing instruments measure the dynamic contact resistance, insulation resistance, and service life of conductive slip rings, but there are no instruments directly targeting their friction and wear performance.

[0047] Currently, the testing instruments for through-hole conductive slip rings used in laboratories to test friction and wear performance are also directly geared towards material properties. The testing conditions are not exactly the same as the actual working conditions of conductive slip rings. Therefore, the experimental data cannot fully reflect the overall performance of conductive slip rings in actual use.

[0048] In related technologies, reciprocating friction and wear testing instruments for conductive slip rings are only applicable to conductive slip rings with specific outer diameters, and cannot achieve adaptive and fully automated measurement of the friction coefficient and wear rate, severely affecting their versatility. Conductive slip ring electrical contact wear test benches cannot adjust the measurement diameter, nor can they compensate for the wear generated during the experiment. High-speed, high-current sliding current-carrying friction and wear testing machines are only suitable for high-speed, high-current research conditions. Furthermore, the excessively large and heavy front section of the measurement segment causes deflection due to gravity, resulting in vibration driven by the motor. This vibration displacement severely interferes with the measurement process. These shortcomings significantly affect the application and control of contact stress at the current-carrying friction interface, limiting the accuracy and reliability of current-carrying friction tests.

[0049] It is evident that there is a wide demand for fundamental research on the friction and wear of electric slip rings. However, existing testing instruments suffer from shortcomings such as complex operation, low loading accuracy, and insufficient model adaptability, making it difficult to fully meet research and development needs. Therefore, there is an urgent need to develop a component-level current-carrying friction testing device for brush filaments and slip rings, achieving adaptive matching of outer diameter and high-precision feedback control of contact stress. This would overcome the limitations of existing experimental devices, such as tooling dependence and lack of wear compensation, thereby improving the agility and reliability of current-carrying friction materials in research and development.

[0050] Based on this, such as Figure 3 and Figure 4 As shown, Figure 3 A schematic diagram of the main structure of the fully automated adaptive conductive slip ring current-carrying friction and wear testing system of the present invention is shown. Figure 4 A front view structural schematic diagram of the fully automatic adaptive conductive slip ring current-carrying friction and wear testing system of the present invention is shown. The first aspect of the present invention provides a fully automatic adaptive conductive slip ring current-carrying friction and wear testing system, the system comprising: a test bench 1, and mounted on the test bench 1: a first test main body, including a first drive unit 4 and a transmission unit interconnected thereto, the transmission unit being used to mount a conductive slip ring 5 to be tested and drive the conductive slip ring 5 to be tested to rotate; a second test main body, including a clamping unit 7 and an automatic compensation unit 3 interconnected thereto, the clamping unit 7 being used to mount brush bristles 6, the automatic compensation unit 3 being used to drive the clamping unit 7 to move so that the brush bristles 6 thereon contact the rotating conductive slip ring 5 to be tested; wherein the brush bristles 6 are externally powered; wherein the automatic compensation unit 3 includes a second drive unit 2 and a plurality of mechanical sensors 9; the second drive unit 2 is used to receive mechanical parameters collected by each of the mechanical sensors 9 and adjust the contact position between the brush bristles 6 and the conductive slip ring 5 to be tested to maintain constant loading conditions.

[0051] Specifically, the test bench 1 is the supporting structure of the entire system, serving as the testing platform. The test bench 1 can be a frame or support plate, designed to mount all components, such as the first and second test main bodies and their corresponding mounting parts. In this embodiment, the first test main body is vertically positioned relative to the test bench 1, and the second test main body is horizontally positioned on the test bench 1. The portion of the vertically positioned first test main body on which the conductive slip ring 5 to be tested is mounted is on the table surface, directly opposite the portion of the second test main body on the table surface on which the brush filaments 6 are mounted, while the remaining portion is located below the table surface.

[0052] It is understandable that the conductive slip ring 5 under test can be a simplified structure of a common conductive slip ring, retaining the main structure, such as the conductive contact surface and supporting parts of the slip ring. The geometry, material, and other properties of this slip ring are consistent with those of a conventional slip ring, and it is used to cooperate with the assembled brush bristles 6 and carry current. By installing the conductive slip ring 5 under test on the transmission part, the overall friction and wear performance of the conductive slip ring sample can be evaluated.

[0053] The conductive slip ring 5 under test is mounted on the transmission unit, which is connected to the first drive unit 4 and is responsible for transmitting the power of the first drive unit 4 to the conductive slip ring to make it rotate, so as to simulate the working state of the conductive slip ring in actual working conditions.

[0054] In some embodiments, the first drive unit 4 may include a DC motor, an AC motor, a servo motor, a stepper motor, a hydraulic drive motor, or a pneumatic drive motor, etc. Preferably, a DC motor is used to drive the transmission unit to rotate.

[0055] In some embodiments, the transmission unit can transmit the torque of the first drive unit 4 to the slip ring under test via gear transmission, coupling 13, belt transmission, chain, etc. Preferably, coupling 13 is used to drive the slip ring under test to rotate.

[0056] In some embodiments, the first drive unit 4 may be equipped with a frequency converter to adjust the speed to simulate different operating conditions.

[0057] Specifically, the clamping part 7 fixes the brush bristles 6 and drives them to contact the conductive slip ring 5 under test. In practical applications, current needs to be transmitted between the slip ring and the brush bristles 6. When the conductive slip ring operates under current-carrying conditions, the current directly affects the wear performance of the conductive slip ring. Therefore, in this embodiment, the brush bristles 6 are energized by an external power supply connected by a cable, transmitting current to the conductive slip ring 5 under test to simulate the working conditions of the conductive slip ring under current-carrying conditions, ensuring the coupling of electrical and mechanical performance. By measuring under current-carrying conditions, the friction and wear characteristics of the conductive slip ring in the actual working environment can be truly reflected, allowing the test results to better match the actual application situation.

[0058] Among them, the brush filament 6 can also be a voltage and current sensor, used to detect the current and voltage during the current carrying process.

[0059] In some embodiments, different operating conditions can be simulated by adjusting the current magnitude.

[0060] In some embodiments, the clamping part 7 may include a rigid clamp, a flexible clamp, or an adjustable clamp, etc.

[0061] For example, the clamping part 7 can be a horizontally arranged U-shaped plate with its opening facing the conductive slip ring 5 to be tested on the table. Two holes are opened on each of the parallel sides of the U-shaped plate for two brush filaments 6 to pass through, and the brush filaments 6 are assembled onto the clamp. When the two brush filaments 6 are in contact with the conductive slip ring 5 to be tested, when energized, the current flows in from the first bundle of brush filaments 6, flows out from the second bundle of brush filaments 6 after passing through the conductive slip ring 5 to be tested, and ensures the current transmission characteristics of the conductive slip ring 5 under current-carrying conditions.

[0062] In some embodiments, a portion may be extended along both sides of the U-shaped plate to serve as a baffle. The baffle can isolate the charged brush bristles 6 from electrical contact with other components and can also serve as a support for mounting the force sensor 9.

[0063] In some embodiments, a connector may be provided to connect the clamping part 7 to the automatic compensation part 3. In this embodiment, the connector may be a flexible connection structure, preferably an elastic element 8.

[0064] In some embodiments, a connecting block 10 may also be provided to connect the clamp, the force sensor 9 and the automatic compensation unit 3 in a preset shape through the baffle, the connector and the connecting block 10.

[0065] During the tribological testing of the slip ring, different mechanical parameters can be tested. In this embodiment, the mechanical parameters may include one or a combination of several of the following: normal force, frictional force, and contact surface morphology data. By combining the electrical performance of the slip ring under actual current-carrying conditions, the tribological performance of the slip ring can be evaluated.

[0066] Correspondingly, the force sensor 9 can be a one-dimensional force sensor, a two-dimensional force sensor, a three-dimensional force sensor, etc.

[0067] In some embodiments, multiple force sensors 9 can be provided and installed at different locations to measure different force parameters. For example, two or more force sensors 9 can be provided.

[0068] As a specific explanation of this embodiment, measuring the normal force and frictional force are key factors in evaluating the frictional wear performance of the conductive slip ring. These two factors respectively reflect the contact state, frictional behavior, and wear condition between the conductive slip ring 5 and the brush bristles 6. The normal force is the vertical force exerted by the brush bristles 6 on the slip ring when the slip ring 5 contacts the brush bristles 6. The frictional force is the horizontal force between the brush bristles 6 and the conductive slip ring 5. Therefore, by recording and measuring the frictional force in real time using the mechanical sensor 9, the contact quality between the slip ring and the brush bristles 6, the change in the coefficient of friction, and their impact on frictional wear can be directly reflected.

[0069] The magnitude of the normal force directly affects the magnitude of the frictional force. Therefore, in friction and wear experiments, the normal force needs to be kept constant; otherwise, the frictional force will be uneven, and the repeatability and reliability of the test data will be affected.

[0070] In one embodiment, during a friction and wear test, as the test progresses, wear occurs at the contact portion between the conductive slip ring 5 and the brush bristles 6, leading to a change in the morphology of the contact surface and thus affecting the mechanical parameters. The automatic compensation unit 3 provided in this embodiment acquires the mechanical parameters in real time and dynamically adjusts the position of the clamping unit 7 via the second driving unit 2, thereby changing the contact position between the brush bristles 6 and the conductive slip ring 5. This dynamic position adjustment compensates for the wear, compensating for the parameter changes caused by wear and maintaining constant test conditions.

[0071] Preferably, when the conductive slip ring 5 and the brush bristles 6 wear down during friction, the normal pressure changes. The sensor monitors the normal pressure data between the brush bristles 6 and the conductive slip ring 5 in real time. The second drive unit 2 adjusts the position of the clamping unit 7 according to the change in normal pressure. By increasing or decreasing the contact force between the brush bristles 6 and the conductive slip ring 5, the wear generated in the experiment can be compensated, and the load can be kept constant, thereby ensuring the accuracy of the test results.

[0072] In another implementation scheme, based on the same principle, in addition to compensating for the wear generated during the friction and wear test, the adjustable measurable radius of the conductive slip ring can also be achieved. When the conductive slip ring 5 under test has different sizes, the compensation mechanism of the automatic compensation unit 3 can adjust the contact position with the conductive slip ring 5 as needed, realizing adaptive loading of conductive slip rings with different outer diameters, ensuring that the test conditions remain constant, and thus automatically adjusting the loading force and method according to different slip ring models and test conditions to adapt to different test requirements. At the same time, it realizes one-button fully automated measurement, reduces manual operation, and improves test efficiency.

[0073] As a specific explanation of the above embodiments, the second drive unit 2, the clamping unit 7, and multiple force sensors 9 combine to form an automatic compensation system based on the negative feedback control principle. The force sensors 9 monitor in real time the positive pressure (vertical direction) and frictional force (horizontal direction) applied by the brush bristles 6 to the conductive slip ring 5 under test, and transmit the positive pressure data to the second drive unit 2. The second drive unit 2 compares the real-time measured positive pressure data with a set value. If a difference exists (e.g., pressure changes due to wear or radius adjustment), the second drive unit 2 controls the movement of the motion mechanism connected to the clamping unit 7 to adjust the clamp position, thereby compensating for the positive pressure between the contact surfaces in real time and maintaining a constant pressure.

[0074] In some embodiments, the second drive unit 2 can compensate for the wear generated in the experiment in addition to the change of positive pressure, as well as other factors such as changes in surface morphology, so as to more comprehensively simulate the actual working conditions and ensure the reliability and accuracy of the experimental data.

[0075] For example, the second drive unit 2 can adjust the position of the clamping unit 7 according to changes in surface morphology. As the conductive slip ring 5 and the brush bristles 6 rub against each other, the surface will experience wear, resulting in changes in surface morphology (such as wear marks, roughness changes, local deformation, etc.). Surface morphology sensors, laser scanners, or micro sensors can be used to monitor the wear condition of the conductive slip ring surface. The second drive unit 2 adjusts the clamping position, force direction, or contact angle according to the wear condition. If the contact surface between the conductive slip ring and the brush bristles 6 becomes uneven, the position adjustment compensates for local wear, ensuring good contact quality.

[0076] As a further explanation of this embodiment, the position of the clamping part 7 can be adjusted in multiple directions through a combination design of multiple automatic compensation units 3. In some embodiments, the contact angle of the clamping part 7 can also be changed by a corresponding angle adjustment device or the like.

[0077] In some embodiments, the parameters that can be compensated may also include temperature, contact location, and other environmental conditions.

[0078] In some embodiments, under more complex experimental conditions, the change in contact area caused by wear can be compensated by a variety of mechanical parameters, and the loading method can be adjusted in real time according to the friction and wear generated during the test to maintain constant test conditions and ensure the accuracy and continuity of test results.

[0079] In some embodiments, the amount of wear caused by wear can be compensated by any mechanical parameter.

[0080] In summary, the testing system provided by this invention can simulate the actual use of conductive slip rings under complex operating conditions, especially under complex conditions such as current carrying capacity, rotational speed, and current variations. This significantly improves the reliability of experimental data and the ability to simulate actual operating conditions, thereby more realistically predicting the performance of conductive slip rings in long-term use and obtaining more accurate and practically meaningful test data. Furthermore, it can dynamically compensate based on wear amount or slip ring model, overcoming the problems of poor adaptability and inability to dynamically compensate for wear in traditional tests. The automated adaptive system not only greatly improves testing efficiency and reduces errors during the testing process but also enhances the accuracy and stability of the test, possessing significant technical and market value, and is particularly suitable for long-term testing of high-precision equipment such as conductive slip rings. Moreover, this design can adapt to various outer diameters, rotational speeds, and current conditions, improving the versatility and adaptability of the test and meeting the automatic testing needs of different models of conductive slip rings.

[0081] As a further explanation of this embodiment, in order to accurately measure the normal force and frictional force, the installation of multiple force sensors 9 is rationally designed according to the direction of the force and the measurement target. Therefore, for the force sensor 9 measuring the normal force, it is preferable to install the force sensor 9 in the direction perpendicular to the contact surface between the brush bristles 6 and the conductive slip ring 5 to be measured, so as to accurately sense the normal force applied by the brush bristles 6 to the surface of the conductive slip ring 5. For the force sensor 9 measuring the frictional force, it is installed on the side of the brush bristles 6 to accurately sense the horizontal frictional force generated when the brush bristles 6 slides on the surface of the conductive slip ring 5 to be measured.

[0082] In actual installation, the force sensor 9 can be directly installed at the corresponding position of the brush bristles 6 or installed on the bracket that contacts the brush bristles 6.

[0083] For example, two first mechanical sensors 9 for measuring friction force are fixed to the two side baffles of the U-shaped plate by bolts. The two first mechanical sensors 9 are connected to two second mechanical sensors 9 for measuring normal force by connecting block 10, respectively. The two second mechanical sensors 9 are then mounted on the elastic element 8 by connecting block 10. The elastic element 8 is connected to the second drive unit 2 by a motion mechanism.

[0084] In this embodiment, to control the cost of the overall prototype's mechanical structure, four one-dimensional force sensors are decoupled to achieve synchronous, real-time, high-precision measurement of normal force and friction. The measurement range is 0-100g, with a theoretical maximum resolution of 0.01g and a sampling frequency of 10Hz, which meets the testing requirements. To control the influence of factors such as torque and bending moment on the measurement results, the design aims to ensure that the axis of forces outside the measured direction passes through the center of the force sensor 9 to avoid interference. Before final use, the force sensor values ​​are calibrated to ensure the accuracy of the measurement data.

[0085] Furthermore, the automatic compensation unit 3 also includes a motion mechanism, which is connected to both the second drive unit 2 and the clamping unit 7 to convert the torque output by the second drive unit 2 into linear motion of the clamping unit 7. In this embodiment, the second drive unit 2, such as a stepper motor, generates rotational motion, and the motion mechanism uses a threaded or geared motion mechanism to convert the rotational motion into horizontal movement of the clamping unit 7, thereby adjusting the measuring distance between the brush bristles 6 and the conductive slip ring. If the force sensor 9 detects a change in positive pressure, the second drive unit 2 starts rotating, driving the motion mechanism to adjust the vertical distance between the brush bristles 6 and the slip ring, and reapplies the set positive pressure.

[0086] In some embodiments, the second drive unit 2 may be a DC motor, AC motor, servo motor, stepper motor, hydraulic drive motor or pneumatic drive motor, or other linear, closed-loop motion components, such as piezoelectric displacement stage, pneumatic displacement stage, linear motor, etc.

[0087] Furthermore, the motion mechanism includes any one of a lead screw and nut structure, a crank and slider structure, and a worm gear structure.

[0088] In the lead screw and nut structure, a stepper motor is connected to a threaded lead screw 31, and a nut 32 with threads matching those of the lead screw 31 is fixed to the lead screw 31. The nut 32 is also fixed to the clamping part 7. The stepper motor rotates to drive the lead screw 31. When the lead screw 31 rotates under the drive of the motor, the nut 32 moves axially relative to the lead screw 31, causing the clamping part 7 to achieve horizontal linear motion, thereby adjusting the position of the brush bristles 6.

[0089] In this structure, a guide rail or support structure can be installed on the test bench 1. The nut 32 moves along the guide rail during operation to ensure the stability and accuracy of its linear motion. For example... Figure 3 and Figure 4 As shown, nut 32 is connected to clamping part 7 via L-shaped clamp support 11. The clamp support 11 is fixed on nut 32, and the movement of the slide is controlled by a 28 stepper motor via lead screw 31 guide rail.

[0090] In the crank-slider structure, a stepper motor is connected to the crank, and the slider is connected to the crank via a connecting rod, allowing it to slide linearly along the guide rail. The slider is fixed to the clamping part 7. The crank rotates under the action of the stepper motor, and the connecting rod converts the rotational motion of the crank into the reciprocating linear motion of the slider. The linear motion of the slider is used to adjust the clamping part 7.

[0091] In the worm gear structure, the worm gear meshes with the worm, and the worm is a helical shaft connected to the clamping part 7. The worm gear rotates under the drive of the motor, driving the meshing worm to move, which is converted into linear motion of the clamping part 7.

[0092] In some embodiments, the motion mechanism may also include a gear and rack mechanism, a slide mechanism, etc., which can be selected or combined according to the specific needs of the system. This embodiment will not elaborate on this further.

[0093] Preferably, the moving end of the motion mechanism is connected to the elastic element 8 of the clamping part 7. For example, the nut 32 of the lead screw nut structure is connected to the elastic element 8, the slider of the crank slider structure is connected to the elastic element 8, and the worm of the worm gear structure is connected to the elastic element 8. Therefore, the stiffness of the loading system can be reduced, and the magnitude of the load applied per unit displacement of the moving end can be reduced.

[0094] The elastic element 8 can be a 65Mn double-layer spring steel sheet. Both ends of the double-layer spring steel sheet are connected to the second mechanical sensor 9 via connecting blocks 10, and the middle area is connected to the lead screw nut 32 via a clamp support 11. The double-layer spring steel sheet does not contact the table surface. The double-layer spring steel sheet provides a flexible element for the entire clamp structure, ensuring smooth adjustment of the positive pressure. Using spring steel or other elastic materials to provide a flexible element for the measuring device reduces stiffness and improves the accuracy of load application.

[0095] Alternatively, the elastic element 8 can also be made of other elastic materials, such as rubber and nylon.

[0096] Alternatively, the flexible element that reduces stiffness is not limited to cantilever and can be replaced with air springs and bellows, etc.

[0097] As a further explanation of this embodiment, the transmission unit includes: a bearing seat 12, which is disposed on the test bench 1; a main shaft 14, which passes through the bearing seat 12 axially and whose axial bottom end is connected to the first drive unit 4; and a transmission connector, which is disposed at the axial top end of the main shaft 14 and is tightly connected to the conductive slip ring 5 to be tested; wherein, the test bench 1 is equipped with a plurality of telescopic support legs 15.

[0098] In this embodiment, conventional slip ring testing machines place the slip ring's shaft system horizontally. While this saves vertical space, it easily leads to deflection and vibration due to gravity, which can interfere with test results. Therefore, in this design, the entire shaft system is placed vertically, driven by a DC motor, and connected to the main shaft 14 via coupling 13. The bearing housing 12 is bolted to the table, providing axial support and radial positioning for the main shaft 14. Axial positioning is achieved using the shaft shoulder and end retaining ring, ensuring the main shaft 14 can maintain flexible rotation while bearing radial and axial loads. The transmission connector transmits the rotational motion of the main shaft 14 to the conductive slip ring 5 under test. It typically uses mechanical snap-fit ​​or interference fit to provide a secure connection while preventing slippage.

[0099] For example, in order to support the entire device on the tabletop and prevent the DC motor from interfering with the tabletop, and at the same time, the height of the test bench 1 is adjustable to adapt to different installation environments, the telescopic support legs 15, with a telescopic range of 12-18 cm, can achieve the design goals while saving processing costs.

[0100] In this design, the telescopic support legs 15 are used to adjust the height and level of the test bench 1 and ensure precise alignment between the transmission unit and the experimental fixture. They can be mechanical screw-type legs or hydraulic / pneumatic legs, and four are positioned at the four opposite corners of the bottom surface of the test bench 1.

[0101] Therefore, from bottom to top along the axial direction, the components are a DC motor, coupling 13, main shaft 14, and transmission connector. Bearing housing 12 is fitted onto the outside of main shaft 14. The transmission unit has a vertical structure and compresses the axial distance to reduce the vertical height. This embodiment improves the structural design of the transmission unit, reducing external interference such as gravity and vibration, ensuring that the accuracy during testing is not affected.

[0102] Furthermore, the transmission connector includes a sleeve 16 and an end cap 17, the end cap 17 being configured to slide axially relative to the main shaft 14. The sleeve 16 and end cap 17, which are interference-fitted with the main shaft 14, provide circumferential positioning and torque transmission for the conductive slip ring 5 under test. By machining threads on the main shaft 14, the end cap 17 presses against the conductive slip ring 5 under test, preventing relative rotation between the conductive slip ring 5 under test and the main shaft 14.

[0103] In some embodiments, the insulating sleeve 16 and end cap 17 that fix the conductive slip ring 5 under test can be replaced with other components that can provide axial positioning and circumferential torque transmission, such as a combination of shaft end retaining rings and positioning screws.

[0104] Both the conductive slip ring 5 and the brush filaments 6 under test need to carry current, therefore materials with good electrical conductivity (such as metal or carbon brushes) must be used, and reliable electrical contact between the brush filament bundle 6 and the conductive slip ring 5 under test must be ensured. To ensure that the current only flows through the designated path, insulation treatment is required between the spindle 14 and the conductive slip ring 5 under test, as well as between the brush filaments 6 and the clamping part 7, to prevent current leakage. The clamping part 7 and the transmission connector both include insulating material, which can be polyoxymethylene, nylon, plastic, etc., preferably polyoxymethylene, which has good machinability and excellent insulation properties, meeting the design requirements.

[0105] Please see Figure 5The diagram shows the installation of the threaded sleeve. To prevent damage to the threads during repeated clamping of the brush bristles 6, this embodiment has a corresponding hole in the area of ​​the clamping part 7 where the brush bristles 6 are installed. A threaded sleeve is installed in the hole, and the gap between the threaded sleeve and the hole is filled with curing adhesive. Fasteners are provided on opposite sides of the brush bristles 6. After applying thread-locking adhesive to the threads of the clamping part 7, the threaded sleeve is screwed in and left to stand for a certain period of time to ensure complete tightening. Then, the brush bristles 6 are pressed together from top and bottom with a cylindrical pin, and finally, a screw is tightened from above to complete the tightening. Therefore, the added threaded sleeve can reduce the influence of contact resistance on the measurement, extend the service life of the brush bristle 6 clamp, and can also be combined with cold-pressed terminals to energize the brush bristles 6, enhancing the compactness of the structure.

[0106] Please see Figure 6 The diagram shows a second main structure of the fully automated adaptive conductive slip ring current-carrying friction and wear testing system. As an improvement to this embodiment, multiple automatic compensation units 3 are provided, and these multiple automatic compensation units 3 are interconnected to jointly drive the clamping unit 7 to move in multiple directions.

[0107] In this embodiment, the automatic compensation unit 3 can be referred to above, with one of the multiple automatic compensation units 3 connected to the clamping unit 7, and the others connected in pairs. Therefore, each automatic compensation unit 3 can drive the clamping unit 7 to move in one direction, and the multiple automatic compensation units 3 are connected in a linkage manner to form a multi-degree-of-freedom motion system, supporting precise adjustment of the position of the clamping unit 7 in multiple directions. Multi-directional adjustment can better simulate the multi-dimensional load and friction characteristics in the real environment, providing higher reliability and representativeness for experimental data.

[0108] For example, the multi-directional movement of multiple automatic compensation units 3 provides linear multi-dimensional motion adjustment capabilities, including but not limited to: X direction: adjusting the left-right position of the contact area between the brush bristles 6 and the conductive slip ring 5 under test; Y direction: adjusting the front-to-back distance of the contact area; Z direction: adjusting the vertical distance of the contact area. This can thus provide the system with additional stability or degrees of freedom.

[0109] For further explanation of this plan, please refer again. Figure 6 The system provides two axially stacked but mutually perpendicular automatic compensation units 3, each consisting of a second drive unit 2 and a lead screw and nut structure in a one-to-one correspondence. The upper lead screw and nut structure is positioned along the X-direction and connected to the clamping unit 7, while the lower lead screw and nut structure is positioned along the Y-direction and mounted on the table. Therefore, when the upper lead screw and nut structure moves along the X-direction under the drive of the second drive unit 2, it causes the clamping unit 7 to move left and right relative to the brush bristles 6; when the lower lead screw and nut structure moves along the Y-direction under the drive of the second drive unit 2, it causes the upper lead screw and nut structure to move, thereby causing the clamping unit 7 to move back and forth relative to the brush bristles 6.

[0110] In some embodiments, the two lead screw and nut structures can move simultaneously or sequentially.

[0111] In some embodiments, the arrangement direction of the two lead screw and nut structures can be interchanged.

[0112] Similarly, the lead screw and nut structure can be used for other motion mechanisms.

[0113] The upper lead screw and nut structure can be connected to the table through an additional guide rail slider mechanism to improve stability during movement.

[0114] Please see Figure 7 , Figure 7 A flowchart illustrating the steps of the fully automated adaptive conductive slip ring current-carrying friction and wear test method of the present invention is shown. This method relies on the fully automated adaptive conductive slip ring current-carrying friction and wear test system provided above in this invention. The test method includes the following steps:

[0115] S1. Install the conductive slip ring 5 to be tested on the transmission part of the first test body;

[0116] S2. Install the brush bristles 6 on the clamping part 7 of the second test body and energize the brush bristles 6;

[0117] S3. Activate the first drive unit 4 of the first test body part, and drive the conductive slip ring 5 under test to rotate through the transmission unit;

[0118] S4. Activate the second drive unit 2 of the automatic compensation unit 3 of the second test main body, drive the clamping unit 7 to move the brush 6 on it to contact the rotating conductive slip ring 5 under test, and form a current path with the conductive slip ring 5 under test.

[0119] The second drive unit 2 receives the mechanical parameters collected by each mechanical sensor 9 and adjusts the contact position between the brush bristles 6 and the conductive slip ring 5 under test to maintain constant loading conditions.

[0120] It should be noted that, for the sake of simplicity, the method embodiments are all described as a series of actions. However, those skilled in the art should understand that the embodiments of this application are not limited to the described order of actions, because according to the embodiments of this application, some steps can be performed in other orders or simultaneously. Secondly, those skilled in the art should also understand that the embodiments described in the specification are all preferred embodiments, and the actions involved are not necessarily required by the embodiments of this application.

[0121] As the method embodiments are basically similar to the system embodiments, the description is relatively simple, and relevant parts can be found in the description of the method embodiments.

[0122] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0123] It should also be noted that, in this document, the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations, nor should they be construed as indicating or implying relative importance. Moreover, the term "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements, but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device.

[0124] The above provides a detailed description of the fully automated adaptive conductive slip ring current-carrying friction and wear testing system and method provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand this application, and the content of this specification should not be construed as limiting this application. Furthermore, those skilled in the art will recognize that various modifications may be made to the specific implementation methods and application scope based on this application. It is neither necessary nor possible to exhaustively list all implementation methods here, but obvious variations or modifications derived therefrom are still within the protection scope of this application.

Claims

1. A full-automatic adaptive conductive slip ring current-carrying friction and wear test system, characterized in that, The system comprises: a test bench, and a first test main body part comprising a first driving part and a transmission part connected to each other, the transmission part being used for mounting a to-be-tested electrically conductive slip ring and driving the to-be-tested electrically conductive slip ring to rotate; the first driving part is provided with a frequency converter, which is used for adjusting the rotating speed to simulate different use conditions; a second test main body part comprising a clamping part and an automatic compensation part connected to each other, the clamping part being used for mounting a brush wire, and the automatic compensation part being used for driving the clamping part to move to a position where the brush wire contacts the to-be-tested electrically conductive slip ring in a rotating state; wherein the brush wire is connected with a power supply; a region of the clamping part where the brush wire is mounted corresponds to an opening, a threaded sleeve is mounted in the opening, and a gap between the threaded sleeve and the opening is filled with solidified glue; and fasteners are arranged on opposite sides of the brush wire; wherein the automatic compensation part comprises a second driving part and a plurality of mechanical sensors; the second driving part is used for receiving mechanical parameters collected by each of the mechanical sensors, adjusting a contact position between the brush wire and the to-be-tested electrically conductive slip ring; not only dynamically compensating wear generated between the brush wire and the to-be-tested electrically conductive slip ring to maintain a constant loading condition, but also achieving adaptive loading of the to-be-tested electrically conductive slip ring with different outer diameters; wherein the mechanical parameters include one or a combination of several of positive pressure, friction and contact surface morphology data; the plurality of mechanical sensors include: a surface morphology sensor, a laser scanner or a micro sensor, which is used for monitoring the contact surface morphology data; two first mechanical sensors which are used for measuring the friction and are symmetrical to each other, and are installed on the side surface of the brush wire; two second mechanical sensors which are used for measuring the positive pressure and are symmetrical to each other, and are installed in a vertical direction of a contact surface between the brush wire and the to-be-tested electrically conductive slip ring.

2. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 1, characterized in that, The automatic compensation part further comprises a movement mechanism, which is connected with the second driving part and the clamping part respectively, so as to convert the torque output by the second driving part into linear motion of the clamping part.

3. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 2, characterized in that, The movement mechanism comprises any one of a screw nut structure, a crank slider structure and a worm gear structure.

4. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 2, characterized in that, A moving end of the movement mechanism is connected with the clamping part through an elastic element.

5. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 1, characterized in that, The transmission part comprises: a bearing seat arranged on the test bench; a main shaft axially penetrating through the bearing seat, and an axial bottom end of the main shaft being connected with the first driving part; a transmission connecting piece arranged at an axial top end of the main shaft and being tightly connected with the to-be-tested electrically conductive slip ring; wherein the test bench is provided with a plurality of telescopic legs.

6. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 5, characterized in that, The transmission connecting piece comprises a sleeve and an end cover, and the end cover is configured to axially slide relative to the main shaft.

7. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 5, characterized in that, The clamping part and the transmission connecting piece both comprise an insulating material.

8. The full-automatic adaptive conductive slip ring current-carrying friction and wear test system according to claim 1, characterized in that, The automatic compensation part is provided with a plurality of automatic compensation parts, and the plurality of automatic compensation parts are connected with each other to jointly drive the clamping part to move in multiple directions.

9. A full-automatic adaptive conductive slip ring current-carrying friction and wear test method, characterized in that, The test method comprises: mounting the to-be-tested electrically conductive slip ring on the transmission part of the first test main body part; The brush wire is installed on the clamping part of the second test main body part, and the brush wire is powered on; The first driving part of the first test main body part is turned on, and the to-be-tested conductive slip ring is driven to rotate through the transmission part; The second driving part of the automatic compensation part of the second test main body part is turned on, the brush wire on the clamping part is driven to move to contact the to-be-tested conductive slip ring in a rotating state, and an electric current path is formed between the brush wire and the to-be-tested conductive slip ring. The second driving part receives the mechanical parameters collected by each mechanical sensor, adjusts the contact position between the brush wire and the to-be-tested conductive slip ring, and maintains a constant loading condition.

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