Study On Design Of A New Type Of Rolling Collector Ring

The rolling collector ring is a new type of collector ring,it has a rolling electrical contact instead of traditional sliding contact to transmit current and signal.It provides benefits such as long life,maintenance-free and reliable performance.At present,the manufacturing cost of the rolling collector ring is high,and thus is limited in its engineering application.Therefore,on the basis of research from domestic and overseas,it is necessary to design a new type of rolling collector ring with low cost,easy to install,and excellent performance.This paper introduces the overall structure and operation principle of the new rolling collector ring first,and expounds the design of each part,including the material,structure and function.Since the long life and the low contact resistance performance advantages of the rolling collector ring depend on the bending stress and the electrical contact state,the corresponding theoretical mechanical model of bending stress and Hertz contact are constructed.According to the material mechanics method,the bending stress formula of the flexible outer ring and the cantilever support is derived,and the relationship between the maximum bending stress of the flexible outer ring and the number of rollers is revealed.The contact stress and contact area of the rolling collector ring are obtained by Hertz contact theory.The finite element model of bending deformation and Hertz contact of the rolling collector ring are established by using ANSYS finite element software.The results show that the differences between the finite element simulation results and the theoretical calculation results are very small,and the correctness of the theoretical model of the rolling collector ring is verified.Based on the bending stress and the Hertz contact model of the rolling collector ring,combined with the fatigue mechanics and electrical contact theory,the theoretical calculation model of the fatigue life and contact resistance of the rolling collector ring is constructed.And calculate the design example,the theoretical fatigue life and contact resistance will be obtained as a reference for subsequent tests.By analyzing the theoretical calculation model,the relationship between material properties,bending stress,part size,number of rollers and fatigue life and contact resistance of rolling collector ring is obtained.The performance parameter design flow of the new rolling collector ring is summarized.According to the design example,the rolling collector ring prototype was fabricated,and running-in were carried out on a special rolling collector ring test bench.The variation of the contact resistance of the rolling collector ring with time was studied,by comparing the surface micro-morphology of the rolling contact ring contact parts before and after the test,the main wear mechanism was studied according to the wear condition to evaluate the working life of the rolling collector ring.This paper provides a new idea for the design of rolling collector ring,which has some reference for the analysis of fatigue life and contact resistance.