Slip ring and manufacturing process

Abstract

The present invention relates to the technical field of slip rings. Provided are a slip ring and a manufacturing process. The slip ring comprises several shaft rings, which are concentrically stacked to form a multi-layer structure, wherein a plurality of electrically-conductive-sheet holes are arranged in an annular array in and penetrate each shaft ring, the number of the electrically-conductive-sheet holes is not less than the total number of the shaft rings, and the electrically-conductive-sheet holes in the shaft rings are aligned with each other on a one-to-one basis; an opening is formed in the side wall of each shaft ring, and is in communication with any electrically-conductive-sheet hole in the shaft ring; an electrically conductive ring is sleeved outside each shaft ring, and completely covers the corresponding opening, and the electrically conductive rings are not in contact with each other; and electrically conductive sheets are welded onto an inner ring of each electrically conductive ring, and the electrically conductive sheets extend into the electrically-conductive-sheet holes through the openings, and penetrate beyond the shaft rings along the electrically-conductive-sheet holes. In the present invention, by means of improving the structural design of the slip ring, optimizing the welding process of the electrically conductive sheets, improving the heat dissipation effect, and simplifying the assembly process, the overall performance and the service life of the slip ring are comprehensively improved.

Description

Slip ring and manufacturing process TECHNICAL FIELD

[0001] The present application relates to the technical field of slip rings, in particular to an improved slip ring and manufacturing process. BACKGROUND

[0002] As a key power transmission component, slip rings are widely used in situations that require unrestricted rotation while transmitting large-capacity data and signals. However, traditional slip rings have a series of significant problems in design and assembly process, which directly affect their assembly efficiency and final performance stability.

[0003] Firstly, there is significant inconsistency in the welding quality of the traditional slip ring. Since the welding process is mostly manual operation, and the solder distribution around the welding points is often uneven, this leads to problems such as low mechanical strength of the welding points, weakened electrical conductivity, and thermal stress concentration. These problems not only affect the transmission efficiency of the slip ring, but also severely restrict its service life and reliability.

[0004] Secondly, the heat dissipation effect of the traditional slip ring is not satisfactory. During long-term operation, due to poor heat dissipation, the slip ring is prone to generate excessive temperature, which affects its performance and stability. This not only reduces the working efficiency of the slip ring, but also may cause a series of safety hazards.

[0005] In addition, the structural design of the traditional slip ring is relatively complex, and the assembly process is tedious and time-consuming. This not only increases the production cost, but also reduces the production efficiency, which cannot meet the demand of modern industrial production for efficient and low-cost manufacturing.

[0006] Therefore, there is a need for a new slip ring structure and manufacturing process to solve the above-mentioned problems. SUMMARY

[0007] The present application proposes a new slip ring structure and manufacturing process. The core purpose of the present application is to improve the overall performance and service life of the slip ring by improving the structural design of the slip ring, optimizing the welding process of the blades, improving the heat dissipation effect, and simplifying the assembly process.

[0008] The above technical purpose of the present application is achieved by the following technical scheme: a slip ring comprising a plurality of shaft rings stacked concentrically in a multi-layer structure, each shaft ring having a plurality of blade holes arranged in a ring array, the number of blade holes being not less than the total number of shaft rings, and the blade holes on each shaft ring being aligned one by one.

[0009] An opening is formed in the side wall of each shaft ring, and the opening is in communication with any blade hole on the shaft ring.

[0010] Each of the shaft rings is sleeved with a guide ring, the guide ring completely covers the opening, the guide rings are not in contact with each other, and the inner ring of each guide ring is welded with a guide sheet;

[0011] The guide sheet extends into the guide sheet hole through the opening and penetrates out of each layer of the shaft ring along the guide sheet hole;

[0012] Each layer of the shaft ring and the guide ring are fixed together by a fixing member;

[0013] The lengths of the guide sheets welded on each layer of the guide ring are different, and the lower the layer, the longer the length of the guide sheet.

[0014] Further, the guide sheet hole includes a mounting hole and an expansion hole which are in communication with each other, the mounting hole is matched with the shape of the guide sheet, the guide sheet can freely penetrate the mounting hole but cannot extend into the expansion hole, and the mounting hole and the expansion hole together constitute a guide sheet hole with a T-shaped cross section.

[0015] Further, a plurality of bolt holes are arranged in an annular array on each of the shaft rings, and the bolt holes on each of the shaft rings are in one-to-one alignment.

[0016] The fixing member includes a bolt and a nut which are used in cooperation with the bolt hole.

[0017] Further, a gasket is arranged between the contact surfaces of the shaft ring and the guide ring.

[0018] Further, the gasket is provided with a mold frame made of elastic material at the position where the guide sheet and the guide ring are welded, the mold frame can completely surround the welding points of the guide sheet and the guide ring, the mold frame is a hollow structure, and the gasket is provided with an air inlet hole on the outer ring side, the air inlet hole is in communication with the internal space of the mold frame.

[0019] Further, hard support blocks are arranged on both sides of the air inlet hole.

[0020] Further, the gasket and the mold frame are made of soft magnetic composite material.

[0021] Further, a plurality of annular grooves are formed on the outer side wall of the guide ring.

[0022] A manufacturing process of a slip ring, comprising the following steps:

[0023] a) sheet making: taking a copper sheet, cutting it into a plurality of guide sheets according to design requirements, and preparing for subsequent welding work;

[0024] b) tin immersion: immersing the cut end of the guide sheet into molten solder, so that the end of the guide sheet is uniformly wrapped with a layer of solder, in order to facilitate subsequent welding and ensure welding quality;

[0025] c) welding the tinned tabs to the prepared copper guide rings;

[0026] d) preparing the gaskets and the mold frame: drilling air inlet holes on the gaskets and setting up the mold frame made of elastic material at the position where the tabs and the guide rings are welded, so that the mold frame can completely surround the welding points of the tabs and the guide rings;

[0027] e) assembling the rings: placing the gaskets between the shaft rings and the guide rings, then according to the design requirements, sequentially putting the guide rings with welded tabs into the corresponding shaft rings, and ensuring that the tabs on each guide ring accurately pass through the tab holes on the shaft rings, and then assembling layer by layer until all the shaft rings and the guide rings are stacked;

[0028] f) optimizing the welding points: heating the mold frame to the melting point of tin by introducing high-temperature gas or inserting electric heating wires into the mold frame, so that the solder around the welding points is redistributed and shaped, and then introducing cold air to accelerate the solidification of the tin paste, completing the optimization of the welding points;

[0029] g) detection: comprehensively detecting the assembled slip ring, including appearance inspection, electrical performance test and environmental adaptability test, to ensure that the product meets the design requirements and has no defects and hidden dangers;

[0030] h) packaging: cleaning the slip ring that has passed the detection, removing the stains and impurities on the surface, then putting it into a special packaging box, and doing the last inspection work before leaving the factory, to ensure that the product is correct before leaving the factory.

[0031] In summary, the present application has the following beneficial effects:

[0032] 1. Significantly improve the assembly efficiency:

[0033] By adopting the method of layer-by-layer assembly from bottom to top, and combining with the design of pre-welding the tabs and the guide rings together, the assembly process of the slip ring is more orderly and efficient.

[0034] The repeated debugging and correction work caused by the damage of the welding relationship and the improper control of the length and direction of the tabs is reduced, thereby greatly shortening the assembly time.

[0035] 2. Ensure stable performance:

[0036] The design of the opening on the shaft ring makes the combination of the guide ring and the shaft ring not damage the welding relationship of the tabs and the guide rings, effectively avoiding the problems of electrical performance decline and unstable signal transmission quality caused by the assembly process.

[0037] By accurately controlling the length and direction of the tabs, it is ensured that all the tabs can be stretched out in the same direction to the outside of the shaft ring for external connection, further improving the performance stability of the slip ring.

[0038] 3. Optimized solder joint quality:

[0039] During the assembly process, the mold frame is heated by passing high-temperature gas into the air inlet hole or inserting an electric heating wire, causing the solder around the solder joint to redistribute and set, thereby improving the mechanical strength, electrical conductivity, and thermal stress distribution of the solder joint.

[0040] The optimized solder joint quality not only enhances the electrical connection reliability of the slip ring, but also improves its environmental adaptability in terms of vibration resistance and impact resistance. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 is a overall structure diagram of the slip ring in embodiment one of the present application (view angle one);

[0042] Figure 2 is a overall structure diagram of the slip ring in embodiment one of the present application (view angle two);

[0043] Figure 3 is a split structure diagram of the slip ring in embodiment one of the present application;

[0044] Figure 4 is a split structure diagram of the collar, guide sheet and guide ring in embodiment one of the present application;

[0045] Figure 5 is a structure detail diagram of the collar in embodiment one or embodiment two of the present application;

[0046] Figure 6 is a cross-sectional view of the combination structure of the collar, guide sheet and guide ring in embodiment one of the present application;

[0047] Figure 7 is a split structure diagram of the collar, gasket, guide sheet and guide ring in embodiment two of the present application;

[0048] Figure 8 is a cross-sectional view of the combination structure of the collar, gasket, guide sheet and guide ring in embodiment two of the present application;

[0049] Figure 9 is a structure detail diagram of the gasket and mold frame in embodiment two of the present application;

[0050] Figure 10 is an enlarged view of A in figure 9;

[0051] Figure 11 is a preferred structure detail diagram of the guide ring in embodiment one or embodiment two of the present application.

[0052] In the figure: 1, collar; 101, guide sheet hole; 1011, mounting hole; 1012, expansion hole; 102, bolt hole; 103, opening; 2, guide sheet; 3, guide ring; 301, annular groove; 4, bolt; 5, nut; 6, gasket; 601, air inlet hole; 602, support block; 7, mold frame. DETAILED DESCRIPTION Embodiment one

[0053] As shown in FIGS. 1-6, the embodiment provides a slip ring, which includes a plurality of collaterally stacked shaft rings 1 in a multi-layer structure, a plurality of guide vane holes 101 are arranged in a ring array on each shaft ring 1, the number of guide vane holes 101 is not less than the total number of shaft rings 1, and the guide vane holes 101 on each shaft ring 1 are in one-to-one alignment;

[0054] An opening 103 is formed on the side wall of each shaft ring 1, and the opening 103 is in communication with any guide vane hole 101 on the shaft ring 1;

[0055] Each shaft ring 1 is sleeved with a guide ring 3, the guide ring 3 completely covers the opening 103, the guide rings 3 do not contact each other, and the inner circle of each guide ring 3 is welded with a guide vane 2;

[0056] The guide vane 2 extends into the guide vane hole 101 through the opening 103 and penetrates the guide vane hole 101 to the outside of each layer of shaft rings 1;

[0057] Each layer of shaft rings 1 and guide rings 3 are fixed together by a fixing member;

[0058] In order to ensure that each guide vane 2 can extend out of the shaft ring 1 in the same direction for external connection, the lengths of the guide vanes 2 welded on each layer of guide rings 3 are different, the lower the layer, the more shaft rings 1 the guide vane 2 needs to penetrate, and the longer the length required. Specifically, since the slip ring is stacked by a plurality of shaft rings 1, each shaft ring 1 has a guide vane hole 101, and the guide vane 2 needs to pass through these holes. Therefore, for guide rings 3 of different layers, the number of shaft rings 1 that the guide vanes 2 need to pass through is different. For guide rings 3 located in lower layers, the guide vanes 2 need to pass through more upper shaft rings 1 to extend to the outside. Therefore, the lengths of these guide vanes 2 need to be designed to be longer. Conversely, for guide rings 3 located in higher layers, the number of shaft rings 1 that the guide vanes 2 need to pass through is less. Therefore, the lengths of these guide vanes 2 can be relatively short. Through such a design, it can be ensured that all guide vanes 2 can maintain the same direction when extending out of the shaft ring 1, and the length is moderate, neither too long to cause waste or interference, nor too short to achieve the expected connection effect.

[0059] The sliding ring can be assembled from bottom to top in layers, specifically as follows: first, the shaft ring 1 at the bottom is used as a starting point, the guide piece 2 part of the guide ring 3 that has been welded with the guide piece 2 is aligned with the guide piece hole 101 on the shaft ring 1. Then the shaft ring 1 is threaded on the guide piece 2 through the guide piece hole 101 until the shaft ring 1 reaches the lowest point and is in place. In this process, the opening 103 on the shaft ring 1 is used to allow the guide ring 3 to be smoothly fitted outside the shaft ring 1 without interfering with the welding relationship between the guide piece 2 and the guide ring 3. Then the above steps are repeated to assemble layer by layer from bottom to top, and each layer ensures that the guide piece 2 can smoothly pass through the guide piece hole 101 of the shaft ring 1 of the previous layer and the shaft ring 1 is threaded on the guide piece 2. During the assembly process, special attention should be paid to the length and direction of the guide piece 2 to ensure that they can extend out of the shaft ring 1 in the same direction.

[0060] The present application can ensure that the assembly process of the sliding ring is more orderly and efficient by using the method of assembling from bottom to top in layers and pre-welding the guide piece 2 and the guide ring 3 together. At the same time, due to the design of the opening 103 on the shaft ring 1, the combination of the guide ring 3 and the shaft ring 1 will not damage the welding relationship between the guide piece 2 and the guide ring 3, and the final sliding ring will have excellent performance and stable connection effect.

[0061] Preferably, the guide piece hole 101 includes a mounting hole 1011 and an expansion hole 1012 that are interconnected, wherein the mounting hole 1011 is adapted to the shape of the guide piece 2, the guide piece 2 can freely pass through the mounting hole 1011 but cannot extend into the expansion hole 1012, and the mounting hole 1011 and the expansion hole 1012 together constitute a T-shaped guide piece hole 101 in cross section. In the later use process, if a certain guide piece 2 appears to be broken, an insulating stick-shaped tool can be inserted into the expansion hole 1012 to press the welding part of the guide piece 2 and the guide ring 3 to determine whether the guide piece 2 and the guide ring 3 are in poor contact. In addition, the expansion hole 1012 also helps to dissipate heat from the guide piece 2, and the expansion hole 1012 also provides a certain accommodation space for the modification of the guide piece 2.

[0062] Preferably, a plurality of bolt holes 102 are arranged in a ring array on each shaft ring 1, and the bolt holes 102 on each shaft ring 1 are aligned one by one.

[0063] The fixing member includes a bolt 4 and a nut 5, which are used in cooperation with the bolt hole 102 to fix each layer of shaft ring 1 and guide ring 3. Embodiment two

[0064] As shown in Figures 7-10, unlike embodiment one, a gasket 6 is provided between the contact surfaces of the shaft ring 1 and the guide ring 3 in this embodiment, which is used to reduce wear between the shaft ring 1 and the guide ring 3 and can also enhance the sealing between the two to improve the assembly firmness.

[0065] Preferably, the gasket 6 is provided with a mold frame 7 of elastic material at the position where the guide sheet 2 is welded with the guide ring 3, the mold frame 7 can completely surround the welding spot where the guide sheet 2 is welded with the guide ring 3, the mold frame 7 is a hollow structure, and the gasket 6 is provided with an air inlet hole 601 on the outer ring side, the air inlet hole 601 is communicated with the internal space of the mold frame 7.

[0066] The welding between the guide sheet 2 and the guide ring 3 is mostly tin welding, and mostly manual welding, which often leads to uneven distribution of solder around the welding spot, which will bring a series of adverse consequences, such as low mechanical strength of the welding spot, weakened electrical conductivity, and concentrated thermal stress, etc. Therefore, for such a key conducting component as the slip ring, the welding quality of tin welding determines the quality of the entire slip ring. Therefore, in order to ensure the uniformity of the solder distribution around the welding spot between the guide sheet 2 and the guide ring 3, in the embodiment, high-temperature gas or an electric heating wire can be introduced into the air inlet hole 601 to realize the heating of the internal space of the mold frame 7, so as to realize the heating of the entire mold frame 7. When the temperature of the mold frame 7 reaches the melting point of tin, the solder around the welding spot will have a certain fluidity. At this time, the mold frame 7 will play the role of a mold, which can shape the part of the tin that is re-melted. Then, cold air can be introduced into the air inlet hole 601 to accelerate the solidification of the tin paste, so as to realize the re-distribution of the tin paste of the welding spot. The above process can realize the unified standardization of the welding spot between the guide sheet 2 and the guide ring 3, which is beneficial to improve the overall welding quality. And the entire process can be operated after the assembly of the slip ring, as a supplementary process to enhance the welding quality of the slip ring.

[0067] Preferably, hard support blocks 602 are arranged on both sides of the internal space of the air inlet hole 601, which are used to support the air inlet hole 601 to avoid being flattened.

[0068] Preferably, the gasket 6 and the mold frame 7 are made of soft magnetic composite material. The soft magnetic composite material is a material formed by the alternating distribution of magnetic material and non-magnetic material, which has good magnetic permeability and thermal conductivity, and very low magnetic resistance. At the same time, the soft magnetic composite material also has good flexibility and processability, which can maintain the heat conduction performance while meeting certain elastic requirements.

[0069] Preferably, as shown in FIG. 11, a plurality of annular grooves 301 are arranged on the outer side wall of the guide ring 3, which are processed by turning process for heat dissipation and pollution removal.

[0070] The embodiment also provides a manufacturing process of the slip ring, which comprises the following steps:

[0071] a) sheet making: a copper sheet is taken and cut into a plurality of guide sheets 2 according to the design requirements, for subsequent welding work;

[0072] b) Tin dipping: dip the ends of the cut lead 2 into molten solder to evenly coat the ends of the lead 2 with solder, facilitating subsequent soldering and ensuring soldering quality;

[0073] c) Soldering the lead ring 3: solder the lead 2 after tin dipping to the pre-prepared copper lead ring 3;

[0074] d) Preparing the gasket 6 and the mold frame 7: opening the air inlet hole 601 on the gasket 6 and setting the mold frame 7 made of elastic material at the position where the lead 2 and the lead ring 3 are soldered, which can completely surround the solder joint of the lead 2 and the lead ring 3;

[0075] e) Ring assembly: place the gasket 6 between the shaft ring 1 and the lead ring 3, then according to the design requirements, sequentially insert the lead ring 3 with the soldered lead 2 into the corresponding shaft ring 1, and ensure that the lead 2 on each lead ring 3 accurately passes through the lead hole 101 on the shaft ring 1, then assemble layer by layer until all the shaft rings 1 and the lead rings 3 are stacked;

[0076] f) Solder joint optimization: pass high-temperature gas or insert electric heating wire into the mold frame 7 through the air inlet hole 601 to heat the mold frame 7 to the melting point of tin, so that the solder around the solder joint is redistributed and shaped, then pass cold air to accelerate the solidification of the tin paste, complete the optimization of the solder joint;

[0077] g) Detection: conduct comprehensive detection on the assembled slip ring, including appearance inspection, electrical performance test and environmental adaptability test, to ensure that the product meets the design requirements and has no defects and hidden dangers;

[0078] h) Packaging: clean the slip ring that has passed the detection to remove surface stains and impurities, then put it into a special packaging box, and do the final inspection work before shipment to ensure that the product is correct before shipment.

Claims

1. A slip ring characterized in that: a plurality of shaft rings (1) are concentrically stacked in a multi-layer structure, a plurality of conductor slot holes (101) are arranged in a ring array on each of the shaft rings (1), the number of the conductor slot holes (101) is not less than the total number of the shaft rings (1), and the conductor slot holes (101) on each of the shaft rings (1) are aligned one by one; an opening (103) is formed on the side wall of each of the shaft rings (1), and the opening (103) is communicated with any of the conductor slot holes (101) on the shaft ring (1); a conductor ring (3) is sleeved outside each of the shaft rings (1), the conductor ring (3) completely covers the opening (103), the conductor rings (3) are not in contact with each other, and a conductor (2) is welded to the inner ring of each of the conductor rings (3); the conductor (2) extends into the conductor slot hole (101) through the opening (103) and penetrates through the conductor slot hole (101) to outside of each of the shaft rings (1); each of the shaft rings (1) and the conductor ring (3) are fixed together by a fixing member; wherein the lengths of the conductors (2) welded to the conductor rings (3) of different layers are different, and the lower the layer, the longer the length of the conductor (2). The conductor slot hole (101) comprises a mounting hole (1011) and an expansion hole (1012) which are communicated with each other, the mounting hole (1011) is matched with the shape of the conductor (2), the conductor (2) can freely penetrate through the mounting hole (1011) but cannot extend into the expansion hole (1012), and the mounting hole (1011) and the expansion hole (1012) jointly form the conductor slot hole (101) with a T-shaped cross section. A plurality of bolt holes (102) are arranged in a ring array on each of the shaft rings (1), and the bolt holes (102) on each of the shaft rings (1) are aligned one by one; The fixing member comprises a bolt (4) and a nut (5) which are used in cooperation with the bolt hole (102). A gasket (6) is arranged between the contact surfaces of the shaft ring (1) and the conductor ring (3). The gasket (6) is provided with a mold frame (7) made of elastic material at the position where the conductor (2) and the conductor ring (3) are welded, the mold frame (7) can completely surround the welding point of the conductor (2) and the conductor ring (3), the mold frame (7) is a hollow structure, and an air inlet hole (601) is formed on the outer ring side of the gasket (6) and communicated with the internal space of the mold frame (7). Hard support blocks (602) are arranged on both sides of the air inlet hole (601).

2. A slip ring according to claim 1, characterised in that: The gasket (6) and the mold frame (7) are made of soft magnetic composite material.

3. A slip ring according to claim 1, characterized in that: A plurality of ring grooves (301) are formed on the outer side wall of the conductor ring (3). The method comprises the following steps:

4. A slip ring according to claim 1, characterized in that: a) sheet preparation: a copper sheet is cut into a plurality of conductors (2) according to design requirements, and subsequent welding work is prepared; 5. A slip ring according to claim 4, wherein: b) tin immersion: the end of the cut conductor (2) is immersed in molten solder, so that the end of the conductor (2) is uniformly wrapped with a layer of solder, in order to facilitate subsequent welding and ensure welding quality; 6. A slip ring according to claim 5, wherein: ​ 7. A slip ring according to claim 5, wherein: ​ 8. A slip ring according to claim 1, characterized in that: ​ 9. A process for the production of a slip ring, said process being based on a slip ring according to any one of claims 5-7, characterized in that, ​ ​ ​ c) Welding the guide ring (3): After the tin immersion, the guide sheet (2) is welded to the pre-prepared copper guide ring (3); d) Prepare the gasket (6) and the mold frame (7): Open the air inlet hole (601) on the gasket (6), and set the mold frame (7) made of elastic material at the position where the guide sheet (2) and the guide ring (3) are welded. The mold frame (7) can completely surround the welding point of the guide sheet (2) and the guide ring (3); e) Assembly: Place the gasket (6) between the shaft ring (1) and the guide ring (3), then according to the design requirements, the guide ring (3) welded with the guide sheet (2) is sequentially sleeved on the corresponding shaft ring (1), and it is ensured that the guide sheet (2) on each guide ring (3) accurately passes through the guide sheet hole (101) on the shaft ring (1), then assemble layer by layer upwards, until all the shaft rings (1) and the guide rings (3) are stacked; f) Welding point optimization: high-temperature gas is introduced into the mold frame (7) through the air inlet hole (601) or an electric heating wire is inserted, the mold frame (7) is heated to the melting point of tin, the solder around the welding point is redistributed and shaped, then cold air is introduced to accelerate the solidification of the tin paste, and the optimization of the welding point is completed; g) Detection: The assembled slip ring is comprehensively detected, including appearance inspection, electrical performance test and environmental adaptability test, to ensure that the product meets the design requirements, has no defects and hidden dangers; h) Packaging: The slip ring that has passed the detection is cleaned to remove the stains and impurities on the surface, then put into a special packaging box, and the last inspection work before shipment is done, to ensure that the product is error-free before shipment.

Images