Insulating Encoder Shaft Holder for Slip Ring Assembly
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Solution Overview
Problem
Existing slip ring assemblies face challenges in maintaining the outside diameter tolerance of the encoder shaft, leading to inaccurate counting of rotor turns and potential damage from unintentional electricity transfer, which affects the control of the magnetic field and the reliability of wind turbines.
Innovation Solution
The slip ring assembly features an encoder shaft holder made from electrically insulating materials like plastic, ceramics, or composite, allowing for precise dimensioning and insulation, eliminating the need for a separate insulation part and reducing thermal expansion issues, thus ensuring stable connections and accurate turn counting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate insulation part is used to protect the encoder from electricity, then the encoder is protected from damage, but the manufacturing complexity increases and the encoder shaft dimension tolerance becomes difficult to control
Solution Approach 1:
The patent combines the insulation function and the encoder shaft holder function into a single integrated component. The holder is made from electrically insulating material (such as plastic or ceramic) and simultaneously provides mechanical support for the encoder shaft and electrical insulation protection. This eliminates the need for separate insulation parts while maintaining encoder protection.
Solution Approach 2:
The encoder shaft holder is designed to perform multiple functions: it mechanically holds the encoder shaft, provides electrical insulation to protect the encoder from unintentional electricity transfer, and maintains dimensional stability for accurate encoder positioning. This multi-functional design simplifies the overall structure while achieving all necessary protection and support functions.
2Reliability
If the encoder shaft holder is made from metal, then the ground connection is improved, but the thermal expansion causes dimension tolerance deviations affecting encoder accuracy
Solution Approach 1:
The patent changes the material parameter of the encoder shaft holder from metal to electrically insulating material (plastic or ceramic). This material substitution eliminates thermal expansion issues that cause dimension tolerance deviations, while the ground connection is alternatively established through the slip ring unit structure itself, maintaining electrical grounding without requiring thermal stability from the holder material.
3Ease of manufacture
If the encoder shaft outside diameter is not precisely controlled, then the manufacturing becomes easier, but the encoder cannot accurately count the rotor turns
Solution Approach 1:
The patent extracts the dimensional precision requirement from the encoder shaft itself and transfers it to the encoder shaft holder. The holder, made from insulating material, provides a stable reference framework that maintains precise dimensional relationships. The encoder shaft can be manufactured more easily without critical dimension tolerances, while the holder ensures the overall positioning accuracy needed for precise turn counting.
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 solution enables accurate control of the magnetic field, prevents encoder damage from electricity, and simplifies production by allowing for easier manufacturing and assembly, ensuring reliable operation over a long production period.
Implementation Method 1
the holder is made from an electrically insulating material... so that the encoder is not destroyed by electricity unintentionally transferred from the slip ring unit
Implementation Method 2
eliminating the need for a separate insulation part and reducing thermal expansion issues, thus ensuring stable connections and accurate turn counting
Data Source
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AI summary
The present invention relates to a slip ring assembly 1 for providing electricity to a rotor which is able to rotate in relation to a stator in a generator or an electrical motor, the slip ring assembly being in connection with an encoder 4. The slip ring assembly 1 comprises a slip ring unit 2 having at least one first slip ring 3, and an encoder shaft holder 6 connected to the slip ring unit and in which holder an encoder shaft 5 is situated. The encoder shaft holder 6 is made from an electrically insulating material for providing an electrical insulation between the slip ring unit 2 and the encoder 4.