Analysis of Forming Characteristics of Conductive Slip Ring Brush Wire by Finite Element Method

The performance of the conductive slip ring brush wires has a vital impact on the lifespan of the satellite in orbit and the overall energy safety. In order to ensure the real-time transmission of signal and current, the brush wire angle needs to be controlled. This study established a three-dimensional model of the brush plate and the brush wire based on the theoretical analysis of the finite element method. The best way for producing the brush wire’s angles was identified by combining the explicit dynamics and implicit statics finite element simulation techniques. The brush wire angle forming and rebound were then fully simulated with these techniques. This paper presented a measurement method based on the rebound process of the brush wire angle, and compared the simulation value with the theoretical value of the brush wire rebound angle. The findings demonstrate that compared to the single-sided deflector plate and the double-sided short clamping plate, the double-sided long clamping plate performs at its finest when forming the brush wire’s angle; the brush wire’s rebound angle is positively correlated to the forming angle; the larger the forming angle of the brush wire, the larger the rebound deformation value of the brush wire after forming; when the brush wire is formed at an angle of 120° or more, the brush wire material is likely to be damaged due to excessive residual stresses. In order to prevent the destruction of the left root of the brush wire during elastic-plastic deformation, the left clamping surface of the clamping plate should be placed as close as possible to the left root of the brush wire to increase the constraints on the root of the brush wire, so as to ensure the quality of the angle forming of the brush wire; the maximum relative error in the angle of rebound of the brush wire is about 2°, but the average rebound inaccuracy is about 1°; the overall rebound trend is generally consistent, so the proposed method can well indicate the variation law of the rebound angle of the brush wire.