Conical Roller Contact Rings for High-Current Transfer at Standstill
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Solution Overview
Problem
Existing electrical contact arrangements face challenges in efficiently transmitting high currents and maintaining reliable contact at both low and high speeds, especially when stationary, due to issues with wear, precision requirements, and speed-dependent contact forces.
Innovation Solution
The contact arrangement features cone-shaped contact surfaces on primary and secondary contact rings with rollers having conical surfaces, where the rollers are biased by spring elements acting parallel to the longitudinal axis, ensuring consistent contact pressure independent of speed, and includes a ball contact unit for low-current signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If carbon brush systems are used to transmit direct current to rotating parts, then high currents can be transmitted, but maintenance costs increase and energy transmission is poor when the machine is at a standstill
Solution Approach 1:
The patent replaces the traditional carbon brush mechanical contact system with a magnetic coupling system that uses magnetic fields to transmit rotational motion and power. The magnetic drive unit creates a magnetic field between the drive rotor and driven rotor, eliminating physical contact and carbon brushes, thereby solving the problems of maintenance and standstill energy transmission while maintaining high current capability
2Reliability
If contactless transmitters are used, then low power and alternating current can be transmitted, but high currents cannot be transmitted
Solution Approach 1:
The patent changes the operational parameters of the magnetic coupling system by using direct current excitation coils instead of alternating current, and by designing the magnetic circuit with high-permeability materials and optimized geometry. This enables the contactless magnetic drive to transmit high direct currents while maintaining reliable contactless operation
3Reliability
If manufacturing precision is increased to ensure line contacts are formed, then contact reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses conical contact surfaces on the rollers instead of requiring precise cylindrical or flat surfaces for line contact. The conical geometry naturally guides the rollers into proper alignment and maintains contact through self-centering action, reducing manufacturing precision requirements while ensuring reliable contact formation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables reliable high-current transmission at various speeds and stationary conditions without slip, reducing maintenance costs and wear, while also accommodating fluid transfer through a rotary feedthrough.
Implementation Method 1
at least one spring element, by which the contact surface of the roller is pressed against the contact surfaces of the primary and secondary contact rings, wherein the spring force of the at least one spring element acts parallel to the longitudinal central axis
Implementation Method 2
at least one roller rolling between the primary and secondary contact rings of a respective contact pair, which is rotatably mounted about an axis of rotation perpendicular to the longitudinal central axis
Data Source
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AI summary
An electrical contact arrangement comprising at least one pair of contacts which is formed by a primary and a secondary contact ring (11, 12) which can be rotated in relation to one another about a longitudinal centre axis (16) and each have a conical shell-like contact face (11d, 12d) which surrounds the longitudinal centre axis (16), and at least one roller (27) which rolls between the primary and the secondary contact ring (11, 12) and is rotatably mounted about a rotation axis (28) which is at a right angle to the longitudinal centre axis (16). The roller (27) has a conical shell-like contact face (27a) which surrounds the rotation axis (28) and respectively forms a line contact, which runs along a respective contact line (31, 32), with the contact faces (11d, 12d) of the primary and secondary contact rings (11, 12).