Slip ring module

Abstract

A method for manufacturing a slipring module comprising a plurality of sliding tracks and an insulating body. The method includes: making a monolithic sliding track component preferably by a 3D printing process. The monolithic sliding track component comprises a plurality of sliding tracks, multiple connector for electrically connecting the sliding tracks, and at least one strut for mechanically interconnecting the sliding tracks and the connector to form a monolithic sliding track component; inserting the monolithic sliding track component into a mold; filling the mold with an insulating material such as a plastic material, and curing the plastic material; removing the molded product forming a slipring module from the mold, and removing the at least one strut from the slipring module.

Claims

1. A monolithic sliding track component comprising: a plurality of sliding tracks, each shaped as a hollow cylinder having an outer side, an inner side, and a center axis, a plurality of struts, each strut of said plurality of struts corresponding to a different sliding track of the plurality of sliding tracks and attached to an inner side of said different corresponding sliding track, and comprising at least one fracture element between at least one of (1a) a first strut and a second strut, (1b) a strut of the plurality of struts and a sliding track of the plurality of sliding tracks; and (1c) a strut of the plurality of struts and at least one connector that in electrical contact and in monolithic mechanical contact with at least one of the sliding tracks of the plurality of sliding tracks, wherein the first strut corresponding to a first sliding track and the second strut corresponding to a second sliding track are monolithically connected with one another such that said first and second sliding tracks of the plurality of sliding tracks are monolithically interconnected through and with said first and second struts to be held in a fixed spatial relation, wherein the monolithic sliding track component includes a metal or an electrically conductive material.

2. The monolithic sliding track component according to claim 1, comprising a plurality of layers that have been molded, sintered, or thermally connected together.

3. The monolithic sliding track component according to claim 1, comprising at least one connector that is in electrical contact and in monolithic mechanical contact with at least one of the sliding tracks, the at least one connector extending parallel to the center axis aside from the center axis.

4. The monolithic sliding track component according to claim 1, wherein struts from said plurality of struts form multiple groups of struts, each group of struts containing multiple struts and respectively corresponding to a different sliding track of the plurality of sliding tracks, a first group of struts containing said first strut, a second group of struts containing said second strut.

5. The monolithic sliding track component according to claim 4, wherein each of the first strut and the second strut comprises a respectively-corresponding fracture element at a respectively-corresponding end of each of the first and second strut that is distal to the respectively-corresponding sliding track from the plurality of sliding tracks.

6. The monolithic sliding track component according to claim 1, wherein at least one of the sliding tracks of the plurality of sliding tracks comprises at least one holding structure that includes at least one of a recess formed on a surface of said at least one of the sliding track that faces a neighboring sliding track, and a protrusion formed on a radially inner surface of said at least one of the sliding tracks.

7. The monolithic sliding track component according to claim 1, wherein at least one of the sliding tracks of the plurality of siding tracks comprises a sliding surface that is coated or plated or bare.

8. The monolithic sliding track component according to claim 1, wherein at least one of the sliding tracks of the plurality of sliding tracks comprises at least one V-groove formed in a sliding surface of said sliding track from the plurality of sliding tracks.

9. The monolithic sliding track component according to claim 1, further comprising a main support component extending co-axially with the center axis, wherein each of said first and second struts directly and monolithically radially connects a respectively corresponding sliding track from the plurality of sliding tracks to the main support component.

10. The monolithic sliding track component according to claim 9, wherein the main support component is a rod oriented along the center axis.

11. A slipring module comprising an insulating body and the monolithic sliding track component according to claim 1, wherein the monolithic sliding track component is at least partially embedded into the insulating body.

12. A method for manufacturing the slipring module according to claim 11, the method comprising the steps of: fabricating said monolithic sliding track component; inserting said monolithic sliding track component into a mold; filling the mold with an electrically-insulating material, and curing the electrically-insulating material to form a molded product; removing the molded product from the mold; removing at least one strut from the molded product to procure the slipring module.

13. The method according to claim 12, wherein the fabricating the monolithic sliding track component includes 3D-printing said monolithic sliding track component.

14. The method according to claim 12, wherein said fabricating includes fabricating a main support component configured to mechanically connect struts from the plurality of struts, the method further comprising the step of: removing the main support from the molded product after the molded product has been removed from the mold.

15. The method according to claim 12, further comprising: processing a sliding track of the plurality of sliding tracks by performing at least one of a) coating; b) plating: and c) machining said sliding track of the plurality of sliding tracks to finish a sliding surface of the sliding track, said processing being performed either before said inserting the monolithic sliding track component into the mold or after said removing the molded product from the mold.

16. A monolithic sliding track component comprising: a plurality of sliding tracks, each shaped as a hollow cylinder having an outer side, an inner side, and a center axis, a plurality of struts, each strut of said plurality of struts corresponding to a different sliding track of the plurality of sliding tracks and attached to an inner side of said different corresponding sliding track, wherein a first strut corresponding to a first sliding track and a second strut corresponding to a second sliding track are monolithically connected with one another such that said first and second sliding tracks of the plurality of sliding tracks are monolithically interconnected through and with said first and second struts to be held in a fixed spatial relation, wherein struts of said plurality of struts form multiple groups of struts, each group of struts containing multiple struts and respectively corresponding to a different sliding track of the plurality of sliding tracks, a first group of struts containing said first strut, a second group of struts containing said second strut, wherein each of the first strut and the second strut comprises a respectively-corresponding fracture element at a respectively-corresponding end of each of the first and second strut that is distal to the respectively-corresponding sliding track from the plurality of sliding tracks, wherein the monolithic sliding track component includes a metal or an electrically conductive material.

17. The monolithic sliding track component according to claim 16, comprising at least one connector that is in electrical contact and in monolithic mechanical contact with at least one of the sliding tracks, the at least one connector extending parallel to the center axis aside from the center axis.

18. The monolithic sliding track component according to claim 16, wherein at least one of the sliding tracks of the plurality of sliding tracks comprises at least one holding structure that includes at least one of a recess formed on a surface of said at least one of the sliding tracks that faces a neighboring sliding track, and a protrusion formed on a radially inner surface of said at least one of the sliding tracks.

19. A slipring module comprising an insulating body and the monolithic sliding track component according to claim 16, wherein the monolithic sliding track component is at least partially embedded into the insulating body.

20. A method for manufacturing the slipring module according to claim 19, the method comprising the steps of: fabricating said monolithic sliding track component; inserting said monolithic sliding track component into a mold; filling the mold with an electrically-insulating material, and curing the electrically-insulating material to form a molded product; removing the molded product from the mold; removing the at least one strut from the molded product to procure the slipring module.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, the invention is described with the use of non-limiting examples of embodiments and with reference to the drawings, of which:

(2) FIG. 1 is a sectional view of a slipring module configured according to a first embodiment.

(3) FIG. 2 shows a side view of the first embodiment.

(4) FIG. 3 shows a monolithic sliding track component.

(5) FIG. 4 shows a sectional side view of the monolithic sliding track component.

(6) FIG. 5 shows a front view of the monolithic sliding track component.

(7) FIG. 6 illustrates the slipring module after it has been removed from the mold.

(8) FIG. 7 shows a side view of the monolithic sliding track component.

(9) FIG. 8 shows a related embodiment of the invention.

(10) FIG. 9 shows a sectional front view through a section of the sliding track.

(11) FIG. 10 shows a side view of the molding.

(12) FIG. 11 depicts a specific embodiment of a sliding track.

(13) FIG. 12 illustrates sliding tracks with holding protrusions.

(14) FIG. 13 presents a brush block.

(15) Embodiments of the invention can be variously modified and assume alternative forms. It should be understood that the drawings and the corresponding detailed description are not intended to limit the invention to the any particular disclosed forms but to the contrary, the scope of the intention is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

DETAILED DESCRIPTION

(16) In FIG. 1, a slipring module according to a first embodiment is shown in a sectional view. At least one sliding track 110, 120, 130 is at least partially embedded into an insulating body 200. (Although this embodiment shows three sliding tracks, there is no limitation on the number of sliding tracks. A simple module may include only one sliding track, whereas complex modules may include a large number of sliding tracks.) The sliding tracks shown here are of the same size, but sliding tracks of different sizes may be combined in a single module. The sliding tracks may have different widths, different thicknesses, or even different diameters. There may be present at least one connector 134 that is connected to at least one sliding track (130, as shown). Most preferably, the connector is embedded into the insulating material 200. There may be additional connectors cooperated with the other sliding tracks. (In this implementation, such additional connectors may be provided for sliding tracks 110 and 120, but they are not shown in this sectional view, as they are embedded into the insulating body 200.) The slipring module has a rotation axis 300, which most preferably is the same axis as the center axis of the individual sliding tracks 110, 120, 130. In other words, in the preferred implementation the sliding tracks are co-axial with the rotation axis of the slipring module.) Preferably, the sliding tracks and connectors shown herein are monolithic, single-piece components. The monolithic structure of the sliding track components is preferably made via 3D printing with the use of a 3D printer. Such a 3D printing process may be a process of dissipating multiple layers of a material to generate a predetermined three-dimensional structure. Such process may include at least one of the EBM, LEMS, SLM, SLS.

(17) In FIG. 2, a sectional side view of the first embodiment of FIG. 1 is shown. Here, the front ends of connectors 114, 124, and 134 (corresponding, respectively, to the sliding tracks 110, 120, 130) can be seen extending through the insulating body 200.

(18) In FIG. 3, a monolithic sliding track component 100 according to a first embodiment is shown. The first 110, second 120 and third 130 sliding tracks (having first sliding surface 115, second sliding surface 125 and third sliding surface 135, respectively) are held in a fixed spatial relationship with the first and second struts 111, 112 of the first sliding track 110, first and second struts 121, 122 of the second sliding track 120, and first and second struts 131, 132 of the third sliding track 130. These struts are further held with a main support 140 (which may for example be configured as a rod extending along the rotation axis 300). Furthermore, there is at least first, second and/or third connectors 114, 124, 134 configured to electrically connect the sliding tracks. In one embodiment, at least one fracture point or element or feature 150 is formed at least one of the struts, to allow for separation of the struts from the sliding tracks at the location of the fracture element, to avoid electrical short circuiting. The connectors 114, 124, 134 may be connected to a given sliding track at any point, as long as such connection(s) provide good electrical contact. For example, as shown the connector 134 is connected to the sliding track 130 at an upper section of the first strut 131. In another example, the connectors 114 and 124 are connected directly to the corresponding sliding tracks to provide a spatial offset(s) from the connector 134. In one embodiment, at least one of the sliding tracks (and most preferably all sliding tracks) is equipped with a holding structure 160, preferably at the side of the corresponding sliding track. In one embodiment, there is a symmetrical arrangement of the holding structures at the sliding tracks to evenly distribute the holding forces. In reference to FIGS. 1 and 12, and depending on the specifics of a particular implementation, such holding structure 160 may include recesses 201 and/or protrusions 161. In the example of FIG. 3, the holding structure 160 includes a V-shaped recess (groove). During the molding process, the insulating material (e.g. a plastic material) flows into this V-shaped recess or any other holding structure, and forms a form-fit to hold the sliding track in place.

(19) In FIG. 4, a sectional side view of the monolithic sliding track component is shown in a mold after the mold has been filled with an insulating material (e.g. a plastic material) forming the insulating body 200. Preferably, the mold is a two-sectioned cylindrically-shaped body having a first section 510 and a second section 520.

(20) In FIG. 5, a front view of the monolithic sliding track component is shown, with a cross-section through the center of the third sliding track 130. FIG. 5 also clearly shows the arrangement of the struts 131 and 132. The other struts 111, 121, 112, 122 are not visible in this view because they are hidden (blocked from view) by the struts 131 and 132.

(21) In FIG. 6, an embodiment of the slipring module is shown in a sectional view after it has been removed from the mold 500. Now, an insulating body 200 is formed by the insulating material, e.g. a cured plastic material. Before using the slipring module, the struts and the main support 140 have to be removed to avoid short-circuiting of the sliding tracks. This may easily be done by moving the main support 140 into the direction of the rotation axis 300. Such movement, when implemented, would bend the struts and cause the struts to break at the fracture points 150 of the main support 140 and the sliding tracks. The appropriate movement may easily be carried out by pushing or knocking a bolt against the main support 140 or by pushing the slipring module with its main support 140 on a flat surface) with the main support extending over one side of the slipring module as shown).

(22) Before removing the struts and the main support from the mold, any tests or modification may be done which require an electrical connection of the sliding tracks. For example, a common electrical test may be performed, or the sliding tracks may be galvanized or anodized, for which the main support may be a common electrode connection.

(23) In FIG. 7, a side view of an embodiment of the monolithic sliding track component is shown, with a cross-section through the center of the third sliding track 130. FIG. 7 also clearly shows the arrangement of the struts 131 and 132. The other struts 111, 121, 112, 122 are not visible because they are hidden (blocked from view) by the struts 131 and 132.

(24) In FIG. 8, a related embodiment of the monolithic sliding track component 101 is shown. In this embodiment, the struts have a different design than in the previous embodiment. Whereas in the previous embodiment only two struts were used to hold/affix a sliding track to the main support, in the embodiment of FIG. 8 three struts are used for the same purpose. Structural details of the struts can be appreciated from the following FIG. 9, which shows a front cross-sectional view drawn through the sliding track 130. In this embodiment, first sliding track 110 is held by the first strut 111, second strut 112, and third strut 113, which are only shown in FIG. 9. There is connector 114 configured to electrically connect the first sliding track 110 to another component. A second sliding track 120 is held by the first strut 121, second strut 122, and third strut 123, which is also shown in FIG. 9. Furthermore, a connector 124 is provided and configured to connect the second sliding track 120. Third sliding track 130 is held by a first strut 131, a second strut 132, and a third strut 133, which is shown in FIG. 9. A connector 134 is provided and configured to connect the first sliding track 130.

(25) In FIG. 9, a cross-sectional front view through a section of the sliding track 130 is presented. FIG. 9 shows all the struts configured to hold the sliding tracks. In this embodiment, there exist three struts per sliding track, each strut extending along an axis at 120 degrees with relation to that of the neighboring strut.

(26) In FIG. 10, a side view of the molded module is shown. Here, portions of the struts are shown embedded into the insulating material 200.

(27) In FIG. 11, a specific embodiment of a sliding track is shown with a V-groove 170 at its sliding surface.

(28) FIG. 12 illustrates sliding tracks with holding protrusions 161 extending from the inner side of the sliding tracks. Such holding protrusions are later (during the fabrication process) embedded into the insulating body material 200 to firmly hold the sliding tracks in place.

(29) In FIG. 13, a brush holder 600 is shown as a monolithic, single-piece component, which most preferably is made by a 3D printing process by a 3D printer as mentioned above. The brush holder 600 includes a brush holder body 601 that has at least a first brush contact 602 and a second brush contact 603. The brush contacts establish contact(s) with and/or hold at least a first brush wire 610 and/or a second brush wire 611. Generally, there may be any number of brush contacts and/or brush wires. Preferably, the brush contacts are oriented such, that the brush wire extends the brush holder body at a certain angle that is different from 90° to provide desired pressure to a sliding track, in operation. Electrical contact between the brush wires and the brush holder body may be established by crimping, soldiering, welding or any other suitable method. There may be a threaded hole 608 or any other means configured to mount and/or electrically contact the brush holder. Multiple brush holders may be assembled to a brush block. This embodiment may be combined with at least one of the embodiments mentioned above.

(30) It will be appreciated to those skilled in the art having the benefit of this disclosure that this invention is believed to provide slipring modules. Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is provided for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be re-versed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.

LIST OF REFERENCE NUMERALS

(31) 100 monolithic sliding track component 101 monolithic sliding track component 110 first sliding track 111 first strut 112 second strut 113 third strut 114 first connector 115 first sliding surface 120 second sliding track 121 first strut 122 second strut 123 third strut 124 second connector 125 second sliding surface 130 third sliding track 131 first strut 132 second strut 133 third strut 134 third connector 135 third sliding surface 140 main support 150 fracture point 160 holding structure 161 holding protrusion 170 V-groove 200 insulating body 201 recess 300 rotation axis 500 mold 510 first mold section 520 second mold section 600 brush holder 601 brush holder body 602 first brush contact 603 second brush contact 608 threaded hole 610 first brush wire 611 second brush wire