Multi-directional High Current Slip Ring with Free-Rotating Brush
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Solution Overview
Problem
Current slip ring technologies face limitations in achieving mega-amp current requirements while maintaining bi-directionality, as high-current designs either suffer from excessive friction and wear due to lack of lead-in angles or are economically infeasible with tangential contact configurations.
Innovation Solution
An independent brush ring assembly is used, comprising a rotor, stator, and a brush ring that rotates freely between the rotor and stator, allowing bi-directional motion with brushes arranged to maintain contact in a mechanically favorable orientation, enabling high current transfer capability in both directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If terminal-end spring fingers are arranged in a bank array perpendicular to the axis of rotation to increase contact surface area for high current loads, then current transfer capability is improved, but bi-directional capability is lost due to single lead-in angle configuration
Solution Approach 1:
The brush elements are configured with asymmetric lead-in angles relative to the direction of rotation. One set of brush elements has a lead-in angle optimized for clockwise rotation, while another set has a lead-in angle optimized for counter-clockwise rotation. This asymmetric configuration allows each brush element to maintain optimal contact geometry in its designated direction while enabling bi-directional operation of the slip ring assembly.
Solution Approach 2:
The brush bank array is segmented into multiple groups, with each group containing brush elements oriented at different angles. Specifically, the brushes are divided into sets with different lead-in angles (e.g., 30 degrees, 45 degrees, 60 degrees), allowing the system to provide optimal contact geometry for various rotation directions and speeds, thereby achieving both high current capacity and bi-directional capability.
2Quantity of substance
If brush elements are oriented perpendicular to the axis of rotation to maximize contact surface area, then current transfer capability is improved, but friction and wear increase due to lack of lead-in angle
Solution Approach 1:
The lead-in angle parameter of the brush elements is optimized to balance contact surface area with friction reduction. By configuring brush elements at specific angles (30, 45, or 60 degrees) relative to the direction of rotation rather than perpendicular to the axis, the system achieves adequate contact area for high current while reducing sliding friction and wear through the inclined contact geometry that allows smoother engagement and disengagement during rotation.
3Adaptability or versatility
If tangential contact configuration is used to enable bi-directional rotation, then bi-directional capability is improved, but contact surface area is limited due to point or line contact geometry
Solution Approach 1:
The brush elements are arranged in a three-dimensional bank array configuration rather than a single planar tangential contact arrangement. Multiple brush elements are stacked and oriented at different angles in space, transforming the contact geometry from two-dimensional point or line contact to a more complex three-dimensional distributed contact pattern. This dimensional expansion provides both bi-directional capability and increased effective contact surface area for high current loads.
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
The independent brush slip ring design reduces torque and wear at sliding interfaces, allowing efficient bi-directional operation with reduced mechanical stress and increased lifespan, while accommodating high current demands.
Implementation Method 1
the slip ring provides electric current conduction to and from the machine's rotor as required to induce electromotive force to cause rotation of the rotor
Implementation Method 2
cantilevered metallic 'spring fingers' made from precious metals
Data Source
AI summary
The present invention is an electrical slip ring device comprised of a stator, a rotor and an independent rotationally free brush ring. The brush ring may include a multitude of slipping fingers, chevrons or other current carrying structures that extend between the rotor and the stator. These current carrying structures have a directional bias or “lay”. The rotational freedom of the brush ring enables bi-directional movement of the rotor with reduced torque and wear at the sliding interfaces because sliding always occurs in the direction of the lay.