Rotary Conductor Rolling Contact Pressure Design
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Solution Overview
Problem
Existing rotary conductors face issues with wear, corrosion, sensitivity to vibrations, and limited suitability for high-speed signal transfer and high-current transmission due to low contact pressures, corrosion in harsh environments, and complexity in design, leading to inefficiencies and reduced operational life.
Innovation Solution
A rotary conductor with metal contact surfaces of predetermined hardness and yield pressure, engaging in rolling contact at pressures greater than or equal to 10% of the yield pressure to ensure frictional engagement and prevent slipping, smoothing the surfaces through plastic deformation, and using conductive metals like silver, gold, copper, or aluminum alloys, with optional meshing teeth and conductive oil to reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If sliding contacts are used with low contact pressures, then wear is reduced, but reliability decreases due to spark forming and sensitivity to vibrations
Solution Approach 1:
The patent changes the contact pressure parameter from low (conventional) to high (at least 10% of yield pressure), and changes the contact mode from sliding to rolling. This resolves the contradiction by achieving both low wear (through rolling contact) and high reliability (through sufficient frictional engagement that prevents sparking and vibration sensitivity)
Solution Approach 2:
The patent replaces the sliding mechanical contact system with a rolling mechanical contact system. By substituting sliding motion with rolling motion, the system achieves reduced wear while simultaneously improving reliability through better contact stability and reduced sparking
2Reliability
If high contact pressures are used to prevent slipping, then reliability improves, but wear increases due to surface degradation
Solution Approach 1:
The patent replaces sliding contact with rolling contact, allowing high contact pressures to be applied without the severe wear associated with sliding. The rolling mechanism distributes pressure more evenly and reduces surface degradation while maintaining the reliability benefits of high contact pressure
3Duration of action of stationary object
If expensive metal alloys are used to counteract wear, then durability improves, but cost increases
Solution Approach 1:
The patent replaces sliding contact with rolling contact, which inherently reduces wear rates. This allows the use of less expensive metal alloys while achieving the same durability, or extends the service life of expensive alloys significantly, thereby reducing overall cost
4Loss of substance
If carbon brushes with oil lubrication are used, then wear is reduced, but contamination and maintenance requirements increase
Solution Approach 1:
The patent replaces sliding contact with rolling contact, which reduces wear without requiring external lubrication. This eliminates the need for oil lubrication systems, reducing contamination risks and maintenance requirements while maintaining low wear rates
5Reliability
If liquid metal (mercury) is used for current transfer, then conductivity improves, but toxicity and safety hazards increase
Solution Approach 1:
The patent replaces liquid metal contact with solid rolling contact between metal surfaces. This achieves reliable electrical conductivity through the rolling contact interface without using toxic mercury, eliminating associated safety hazards and environmental concerns
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 stable and efficient high-current and high-speed signal transfer with reduced wear and corrosion, improved reliability under vibrations, and extended operational life, achieving low voltage loss and high contact pressures without sparking, suitable for applications like wind turbines and offshore installations.
Implementation Method 1
a contact pressure between the contact surfaces being greater or equal to at least 10%, preferably at least 15% of the yield pressure of the contact surface metal having the lowest hardness such that the contact surfaces are smoothed by plastic deformation
Implementation Method 2
said pressure ensures that sufficient frictional engagement between the contact surfaces is present to avoid slipping and to ensure a pure rolling motion
Data Source
Figure 1~3
Figure 2a~2c
Figure 4
AI summary
The invention relates to Rotary conductor (1,20) comprising a first and second circular bodies (3,22,23) with metal contact surfaces that engage in rolling contact. The metals of the contact surfaces have a predetermined hardness and a corresponding yield pressure, a contact pressure between the contact surfaces being greater or equal to at least 10%, preferably at least 15% of the yield pressure of the contact surface metal having the lowest hardness. High currents can be transferred between the rolling conductors as well as electrical signals at rates above 1Gb/s.