Slip Ring Contact Assembly for Dense Rotational Wiring
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Solution Overview
Problem
Conventional radar systems face challenges in maintaining reliable electrical connections between rotating components, such as complex cabling issues and expensive external rotating devices, especially when connecting a large number of wires.
Innovation Solution
A contact assembly using a stack of conducting and isolating rings with spring-loaded finger-shaped elements that provide sliding electrical contacts, allowing for continuous rotation and supporting a large number of electrical connections within a compact space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cabling systems are used for electrical connections, then the system can maintain electrical contact between rotating components, but the system becomes complex with kinks, tangling and space constraints
Solution Approach 1:
The patent divides the continuous cable into multiple discrete spring elements that make contact with conducting rings at different positions. Each spring element is independently mounted on the rotating component and contacts a specific conducting ring, segmenting the electrical connection path to eliminate cable entanglement while maintaining continuous electrical contact during rotation
Solution Approach 2:
The patent replaces the flexible cable-based mechanical connection system with an elastic spring-based contact system. The spring elements use elastic deformation to maintain constant contact pressure with the conducting rings, providing reliable electrical connection without the mechanical constraints of conventional cabling
2Reliability
If external rotating devices are used for electrical connections, then the system can support rotation, but the device becomes very expensive, very large and limited in the number of cables
Solution Approach 1:
The patent transitions from a planar cable arrangement to a three-dimensional stacked configuration of conducting rings and spring elements. Multiple conducting rings are stacked axially with corresponding spring elements arranged in layers, enabling numerous electrical connections to be packed into a compact cylindrical volume, thus supporting many more connections than conventional external rotating devices
Solution Approach 2:
The patent implements a nested structure where multiple conducting rings are stacked concentrically around the rotation axis, with spring elements nested between the rings. This nested arrangement allows multiple electrical connections to be integrated in a compact space, dramatically reducing the device size compared to external rotating devices while supporting a large number of simultaneous connections
3Quantity of substance
If a large number of wires are connected, then the electrical connection capacity increases, but the available space is exceeded with conventional systems
Solution Approach 1:
The patent utilizes the axial dimension by stacking conducting rings and spring elements in multiple layers along the rotation axis. This vertical stacking enables a large number of electrical connections to be arranged in three dimensions rather than spreading them out in a plane, significantly increasing connection density within a compact volume
Solution Approach 2:
The patent employs a composite structure combining conducting rings (for electrical conduction), isolating rings (for electrical insulation), and spring elements (for mechanical contact pressure). This composite material approach allows multiple functional requirements to be integrated into a compact multi-layer assembly, enabling high connection density without increasing volume
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 solution enables reliable and compact electrical connections for a large number of wires, overcoming the limitations of conventional systems by maintaining contact across various angles and preventing shorts, thus scaling with the number of lines without significant size increase.
Implementation Method 1
The spring elements of the plurality of spring elements are configured to provide multiple sliding electrical contacts to outer circles of the conducting rings while rotating the first terminal relative to the second terminal about the rotational axis
Data Source
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AI summary
A contact assembly for electrically connecting a first terminal (10) with a second terminal (20) that are rotatable relative to each other about a rotation axis (R) is disclosed. The assembly comprises: a plurality of conducting rings (110), each ring (110) of the plurality comprising a contact element (111) at its inner circle for contacting the first terminal (10); a plurality of isolating rings (120) alternatively stacked with the plurality of conducting rings (110) to form a stack of rings (110, 120), wherein the conducting rings (110) are electrically isolated from each other; a case (130) including a bearing (135, 136) for the stack of rings (110, 120), wherein the stack of rings (110, 120) is rotationally fixed relative to the first terminal (10); and a plurality of spring elements (140) electrically connected to the second terminal (20) and configured to provide multiple sliding electrical contacts to outer circles of the conducting rings (110) while rotating the first terminal (10) relative to the second terminal (20) about the rotational axis (R).