What is a Slip Ring?

Measured on size alone, a slip ring is a relatively small piece of a larger engineering puzzle, but
looks as they say can be deceiving. Slip rings are actually a vital electromechanical device
that youll find as a commonplace component in many of todays industrial, military and even
everyday equipment, where they play a crucial role in answering one of engineerings most
difficult questions:

How do you efficiently and effectively transfer power and other electrical signals from a
stationary device, component or power source to a rotating object?

Slip rings ensure engineering and design teams no longer require timely and often costly
workarounds in order to power rotating devices, whether they be motors, military devices or
rotating electrical assemblies. Playing a major role in improving mechanical performance, as
well as simplifying operations, they have further further eliminated the threat of damaged and
hazardous wiring and cable connections in moving joints.

Slip rings handle either power, data or both across a number of rings on which a spring or other
loaded contact finger, ring or brush is held in place to pass power as the rings rotate.

Power levels range from milliwatts to hundreds of kilowatts dependent on application. In all
applications, frictional wear is the main determinant of the lifecycle of the slip ring.

Many of these systems have migrated to using precious metals like gold and silver to increase
lifecycle. Dependent on speed, power level and environmental condition, the number of expected
rotations before replacement is needed ranges from a few million to 10s of millions.

With the advent of contactless, wireless power technologies, slip rings are once again taking their
next evolutionary step to fulfill the growing needs of modern designs, just as current slip ring
varieties have done so in the past. With these wireless slip rings, power and signals are able to be
delivered to rotating devices more efficiently and cost effectively than ever before.

How Does A Slip Ring Work?

So we know that Slip Rings are able to transfer power or signals across a rotating surface. But
how, exactly, do they do this? At a very elementary level, a slip ring is comprised of two major
components a metal brush, and a metal ring. The brush (or brushes) are in contact with the
metal ring as it rotates. The resulting friction then causes an electrical signal which delivers the
power.
The ring itself is a band of electrically conductive material, mounted on a shaft. Although its
insulated from the shaft itself, the slip ring is connected to the rotor or rotating assembly through
wingdings or other electrical connections.

The outer part of this slip ring remains in continuous sliding contact with the stationary brushes
or other stationary conductors which provides either intermittent or continuous rotating devices
with unbroken contact between the rotating assembly and external circuit. This ensures power
and data are able to be transmitted at all times.

Both this ring and the brush are contained within a single housing, designed to protect the
working parts from harmful environmental factors such as dust and moisture.

The Components Of A Standard Mechanical Slip Ring

Slip rings may appear to be complicated devices, yet most all standard mechanical slip rings can
be easily broken down into two major components, as already mentioned:

1. The Brush
The brush is a stationary contact made of either graphite or metal, which then rubs
against the outside of the rotating metal ring. Made from metal fibers, this brush can look
like any regular brush, though more often than not its usually a single wire or a spring
 with a pad of material attached to the end that makes physical contact with the ring.

2. The Ring
The ring is constantly rotating, and as it does so it conducts electrical currents or signals
via the stationary brush.
The number of rings found in any given slip ring can vary depending on the needs of the
device, with additional assemblies a combination of both brush and ring stacked
along the main rotating axis or shaft if more electrical circuits are required. The
insulation between the shaft and ring is generally made of any number of synthetic
materials, including nylon and phenolic plastic.
For the effective use of a slip ring, the ring itself needs to be properly matched with the
right brush, which is why theyre often sold as a set, known as a slip ring Assembly.
These sets usually serve most component replacement requirements, or alternatively can
be used as parts for custom assembly designers with a little mechanical engineering
know-how.

Where Are Slip Rings Most Commonly Found?

Slip rings are utilised in a variety of devices across a broad range of industries. Some of these
include:

TRUCKS & MANLIFT EQUIPMENT:

o Aerial Work Platforms
o Bridge Cranes
o Platform Cranes
INDUSTRIAL/COMMERCIAL IN-PLANT EQUIPMENT:
o Automated Welding Equipment
o Centrifuges
o Conveyor Systems
o Custom Machinery
o Fabrication Equipment
DRILLING & OTHER BORING EQUIPMENT:
o Off-Shore Drilling Rigs
o Down hole Drill and Geotechnical Testing
o Horizontal Earth Boring & Drilling
 SIGNAGE RELATED EQUIPMENT:
o Advertising Displays
o Exhibits and Displays
MISC. OFF-HIGHWAY HEAVY EQUIPMENT:
o Forklifts
o Utility Trucks
o Truck Body / Service Cranes
OTHER:
o Amusement Rides
o Arcade Machines
o Car Wash Equipment
o Wind Turbines

Types Of Slip Rings

Contactless, Wireless Slip Rings

Contactless, wireless slip rings are the next generation in inductive power transfer solutions,
specifically designed to replace existing, aging mechanical slip ring technology. Moving on from
a reliance on friction based metal and carbon brush contact to enable the transfer of power and
data, wireless slip rings utilise IPT to transfer power via an electromagnetic field created by coils
placed in the stationary transmitter and rotating receiver.
By removing the inherent need for friction or contact to generate an electrical current, wireless
slip rings significantly reduce the maintenance costs associated with worn mechanical slip rings,
while also offering a simple, clean design thats easily integrated into any application or device.

Miniature & Capsule Slip Rings

As the name suggests, miniature and capsule slip rings are the smaller, more compact counterpart
of their regular sized cousin, yet despite this downsizing they still feature many of the same
features and capabilities.

Often used in small and medium sized equipment particularly the security industry where
theyre often found in CCTV equipment and other small rotating systems, such as revolving
stage lights miniature and capsule slip rings generally measure 22mm in diameter, and
facilitate the transfer of video, control, sensor, power and ethernet.

Mercury Wetted Slip Rings

While they may share the name, Mercury Wetted slip rings differ in a number of crucial ways.
Their major point of difference is that they replace the regular metal or graphite sliding brush
contact of a standard, mechanical slip ring with a pool of liquid metal, which is molecularly
bonded to the contact.

This change affects the fundamental operation of this variety of slip ring: as they rotate, the
liquid metal maintains the electrical connection between both the stationary and rotating
contacts, much like a brush would in a regular slip ring.

Mercury Wetted slip rings do suffer from one major flaw: safety. The use of mercury presents
numerous safety concerns, as mercury is, after all, a toxic substance. This inherent safety risk has
seen mercury wetted slip rings prohibited from use in a number of environments and industries,
including:

Food manufacturing and processing

Pharmaceutical equipment
Other uses where contamination could present a serious health and safety threat.

Pancake Slip Rings

As the name implies, the conductors of a Pancake slip ring are arranged on a flat disc much
like a pancake as concentric rings centered on the rotating shaft. Insulating material is then
used between these concentric rings, while the brushes are distributed on the top.

The form factor provides Pancake Slip Rings with major advantages, making them a perfect fit
for electrical conduction in narrow, smaller spaces where regular slip rings just wouldnt work.
However the unique configuration does have its drawbacks. Namely, pancake slip rings are often
much heavier in both weight and volume for the same capacity circuit of a regular slip ring,
while also exhibiting greater capacitance and crosstalk, as well as increased brush wear which
more readily collects on its vertical axis. This propensity for wear and tear means pancake slip
rings often suffer from an increased need for maintenance and repairs over their lifetime,
resulting in a higher maintenance cost.

Leading Causes Of Slip Ring Failure

Its common knowledge that standard mechanical slip rings are prone to failure, particularly in
dirty, dusty or outdoor environments where machinery and equipment is exposed to debris, water
and other environmental factors. The most common cause of failure is often attributed to sticking
brushes, however there are numerous issues that can lead to the need for maintenance and at
times outright replacement of mechanical slip rings.

Threading Of Brushes

The initial signs of brush threading can often be found on the commutator or ring itself, where
fine grooves begin to form. These are usually created by high levels of friction causing small
particles of copper to wear away from the commutator, which then becomes embedded in the
brush face resulting in scratches on the commutator.

Atmospheric contamination including dirt and dust is also known to cause threading, with
particles gathering on the slip ring and brushes gradually wearing away at the commutator during
operation.

Grooving

As with any device or component, uniform wear around the circumference of the rings known
as Grooving is commonplace. However higher levels of wear requiring regular maintenance
demands further investigation as this can often point to more serious, ongoing issues.

Polarity Wear

In scenarios where slip ring polarities are separate, including the likes of synchronous motors or
generators, one ring may suffer from more wear than the other. This is often referred to as
Polarity Wear.

Selectivity

Uneven currents in parallel paths affects the wear rates of slip ring brushes, with no two brushes
ever wearing at the same rate. Though as with any mechanical component, brushes operating at
higher temperatures and currents generally wear faster than those operating under less extreme
conditions.
Loss Of Brush Contact

The loss of contact between brush and ring can result in a shortened brush lifespan, and cause
damage to the ring surface. This is often a result of weak brush springs, but can also be attributed
to abnormal vibrations, brushes becoming hung up in holders, as well as brushes wearing too
short over time.

Ring Corrosion

Steel slip rings that operate in damp or wet environments are susceptible to rust, while copper
bearing materials are also prone to reacting to acids as well as various sulfur compounds found in
the air.

Its these scenarios where hermetically sealed & waterproof wireless slip rings have a distinct
advantage as there no direct contact and no friction causing the breakdown in power delivery.

How Does A Wireless Slip Ring Work?

Wireless slip rings are based on fundamental Inductive Power Transfer technology whereby
specially tuned copper coils transfer AC power via an electromagnetic field.

The diagram below highlights the basic technology:

Click image to enlarge

The Advantages Of Wireless Slip Rings

Contactless, brushless and providing complete freedom of movement, they offer countless
advantages over their aging, mechanical counterparts.
 Provides highly efficient transfer of power and data across short distances through
inductive power transfer
Eliminates friction or heating between rotating and stationary circuit contacts, with a
fully brushless, contactless design
Complete freedom of movement, high RPM and no need for lubrication and cooling
Cost-effective, maintenance-free alternative to traditional mechanical slip rings
Solves the issue of continuity of power & data delivery
Specially manufactured for an easy hassle free, seamless, plug-and-play replacement for
existing mechanical slip ring components

The History Of Slip Ring Design

Today, slip rings are commonly manufactured from any number of conductive materials, though
youll typically find that this is a combination of copper or gold alloy contacts, though silver and
coin silver are also used in some cases. However, this wasnt always the case.

Until the late 1970s, slip rings commonly used copper rings, in combination with graphite
brushes. The thinking here was sound: copper is smooth and conductive, while graphite is soft,
conducts well and does not abrade or deteriorate the copper rings that they come into contact
with in order to transfer the electrical signal or data.

These old copper and graphite brushes soon found their limitations, as fast-advancing industries
including complex aerospace and military applications required more of their slip rings for
mission critical systems. These older designs were unable to cope with the wear, tear and design
requirements, which resulted in a flurry of research and innovation that delivered a more robust
and viable alternative solution that addressed the emerging needs at the time.

Through this process, an advanced gold-on-gold alloy system was produced, which employed a
silver alloy ring in combination with brush tips made of a silver and graphite mixture.

Today, youll find both of these systems in active use in various slip ring products, depending on
the device and its intended use. Gold-on-gold is often found in lower current signal circuits,
thanks to its compact size. While silver and silver graphite slip rings are used in higher-current
power circuits, as they are at one more economical and boast a longer service life.

A Slip Ring By Any Other Name

While most commonly referred to as slip rings, these devices are also known by a variety of
other names, including:

Rotary Electrical Interface

Electrical Rotary Joint
Rotating Electrical Connectors
Collectors or Collector Rings
Swivels or Electrical Swivels
What Are Slip Rings Commonly Used To Transfer?
Slip rings arent used for just electrical purposes. They can also transfer analog and digital
signals such as data meaning theyre now commonly found in applications such as
aerodrome beacons, rotating tanks, radio telescopes and power shovels.

Video
Communications & Data
Serial Links
ESD Signals
Fibre Optic

How Slip Rings Are Rated

Slip rings are available in a number of standard and custom configurations, specifically designed
for a given device or the environment theyre operating in. These slip rings are often identified
and classified by the following attributes:

Speed
Current
Voltage
Insulation Resistance
Other Factors

Note: The speed of a slip ring is measured by the number of Rotations Per Minute, or RPM. This
RPM is then used in combination with the length of use to provide the estimated life span of the
slip ring. Where the length of use is multiplied by the speed at which it will operate.

Slip Ring Repair & Maintenance Why Its Important

Regular maintenance of slip ring hardware is paramount for both personal and operator safety, as
well as ensuring maximum service life of the slip ring in question. This maintenance and
servicing regime is usually provided by the slip ring manufacturer or a qualified engineer, who
supply ongoing maintenance, servicing, tests and repairs.

This maintenance usually runs on a schedule, with a yearly inspection followed by proper
maintenance once every 5-8 years. While it can be costly, regular maintenance can save the
operator from prolonged downtime and repairs in the long run as major malfunctions or failures
are avoided.

The maintenance required often varies depending on the current number of rotations performed
by the slip ring, as well as the environment it has been operating within. The more demanding
the environment, the more wear and tear it will exhibit. Though some, and in fact most, slip rings
very rarely require maintenance at all, as they never reach the required number of revolutions to
need maintenance.
Frequently Asked Slip Ring Questions
What Is The Difference Between A Slip Ring And Brush?

Rather than a separate device, a brush is actually a major component of a slip ring. These brushes
are blocks of either graphite or carbon material, with conductive mountings that are then
connected to the system outside of the rotating components. When operational, the ring makes
contact with these brushes as it rotates, effectively and continuously providing a transfer of
electrical power or data signals.

What Is The Difference Between A Slip Ring And Commutator?

Slip Rings and Commutators are often mistakenly referred to as the same device, however they
both fulfill very different needs. A commutator is a specialised slip ring, which youll find
primarily used in likes of direct current (DC) motors and electrical generators. Its here that they
transfer electrical power between stationary housing and the rotating armature with the added
purpose of reversing the electrical current direction.

Unlike the solid metal ring of a standard slip ring, commutators are made of insulated metal
segments, with electrical brushes (contacts) then rubbing on the ring as it rotates to make the
electrical connection.

The ring segments of a commutator have also been specially wired to act as a rotary switch in
order to reverse the electrical current. In a DC motor, this switching reverses the magnetic field
and keeps the motor turning. In a generator, for example, this switching changes alternating
current (AC) into current flowing in one direction (DC).

What Is The Difference Between A Slip Ring Commutator & Split Ring
Commutator?

While they may sound the same, a Slip Ring Commutator and Split Ring Commutator fulfill two
very different roles. A Slip Ring commutator maintains a connection between the moving rotor
and the stationary stator, providing AC current. While a Split Ring Commutator functions
differently, by changing the direction every half rotation, and is used to get a pulsating voltage
for example, in the case of a direct current (DC) motor.

Further Slip Ring Reading & Resources

YouTube | A Video Guide To Electrical Slip Rings
NASA | Space Mechanisms Lessons Learned Study incl Slip Rings
NASA | Environmental Study of Miniature Slip Rings
Research Gate | Friction, Wear, and Noise of Slip Ring and Brush Contacts for
Synchronous Satellite Use
Windpower Engineering & Development | Slip Ring Use In Wind Turbines
https://powerbyproxi.com/slip-ring/