CN113948929B - 1 hundred million-turn long-life multipoint end-face contact gold alloy fiber electric brush and preparation method thereof - Google Patents
1 hundred million-turn long-life multipoint end-face contact gold alloy fiber electric brush and preparation method thereof Download PDFInfo
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- CN113948929B CN113948929B CN202111210172.8A CN202111210172A CN113948929B CN 113948929 B CN113948929 B CN 113948929B CN 202111210172 A CN202111210172 A CN 202111210172A CN 113948929 B CN113948929 B CN 113948929B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R39/00—Rotary current collectors, distributors or interrupters
- H01R39/02—Details for dynamo electric machines
- H01R39/18—Contacts for co-operation with commutator or slip-ring, e.g. contact brush
- H01R39/20—Contacts for co-operation with commutator or slip-ring, e.g. contact brush characterised by the material thereof
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R39/00—Rotary current collectors, distributors or interrupters
- H01R39/02—Details for dynamo electric machines
- H01R39/18—Contacts for co-operation with commutator or slip-ring, e.g. contact brush
- H01R39/24—Laminated contacts; Wire contacts, e.g. metallic brush, carbon fibres
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/12—Manufacture of brushes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
The invention relates to a hollow cylinderA1 hundred million-degree-of-revolution long-life, high-rotating-speed and large-current-carrying gold alloy fiber brush material for conductive slip ring products in the intermediate field and a preparation method thereof. The material is in high vacuum and high rotating speed of more than or equal to 300rpm and more than or equal to 500A/cm 2 Can keep a stable electric contact state for a long time under the condition of large current carrying, the average static contact resistance is less than 10m omega, the average dynamic contact resistance is less than 20m omega, the average friction coefficient is stabilized between 0.5 and 0.8, and the average wear rate is less than 8 multiplied by 10 ‑11 m/m, average contact voltage drop < 80mV, average electrical noise < 1m Ω, cumulative service life or total mileage greater than 1 hundred million revolutions or 10000 km. The preparation method has the advantages of simple preparation process, low and controllable cost and convenience for large-scale industrial application.
Description
Technical Field
The invention relates to a 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush and a preparation method thereof, belonging to the technical field of space equipment development.
Background
The brush is a main contact part constituting the conductive slip ring, and the purpose of data signal or power transmission from a fixed position to a rotating position is realized through continuous friction contact between the brush and the rotor. The space precision conductive slip ring is needed to be adopted in various types of space aircrafts and extraterrestrial detectors to realize energy transmission and signal transmission, such as solar sailboards, radars, scanners and other various effective loads. Therefore, the electric brush is a key component of the space precision conductive slip ring and influences the performance of the conductive slip ring, and the length of the service life and the state stability of the electric brush directly determine the length of the in-orbit service life of the spacecraft and the success or failure of executing a specific task. With the deep exploration of outer space in China, the task of the spacecraft is more complex, the functions are diversified, the service life is prolonged, and the requirements of long service life, high rotating speed and large current carrying are provided for space precision conductive slip rings and electric brush materials thereof.
Long life electricity currently used in spaceThe brush material mainly has two forms of noble metal wire brush and rolling ring brush. The noble metal wire brush is composed of one or more than one
The noble metal alloy brush wire is formed by the brush wire side face and the ring body to keep tangential contact, so that the purpose of electricity transmission is achieved. The noble metal alloy wire brush has a relatively simple structure, but the abrasion life and the current-carrying capacity of the noble metal alloy wire brush are both limited by the wire diameter of the brush wire, and the service life of the noble metal alloy wire brush is generally below ten million turns. The space rolling ring is composed of a gold-plated flexible ring (electric brush) and an inner ring body and an outer ring body, and the purpose of electric power transmission is realized by the rolling of the flexible ring clamped between the inner ring body and the outer ring body. However, the stability and reliability of the rolling ring are desired to be low due to the complex structure and the risk of coating peeling. Therefore, the only application case of the rolling ring electric brush in the space field is the main solar panel of the international space station.
With the development of the space field in China, the construction of a space station, a deep space exploration project and an extraterrestrial planet exploration task are gradually developed, the service lives of a space vehicle and an extraterrestrial detector are gradually prolonged, and the borne scientific exploration task is more complicated. At present, the requirement of the service life of the brush material in the space precision conductive slip ring is raised to the tens of millions of revolutions. Although the requirement of hundred million revolutions of electric brushes is not clearly proposed in the domestic and aerospace field at present, the defense science and technology industry bureau develops the pre-research project of hundred million revolutions of long-life space precision conductive slip rings. With the continuous advance of aerospace industry, space electric brush materials have the development trends of long service life, high rotating speed and large current carrying, and the service life requirement of the space electric brush materials is bound to break through hundreds of millions of revolutions.
Aiming at the development needs of domestic aerospace industry at present, the invention designs the electric brush material prepared from the high-elastic gold alloy fiber, the load and current are dispersed through a large number of contact points, the contact stability is greatly improved, the abrasion is reduced, and the service life of the electric brush material can reach more than 1 hundred million turns.
The invention content is as follows:
the purpose of the invention is: through the optimized design of the structure and the material, the multi-point end face elastic contact electric brush material is prepared from high-elasticity gold alloy fibers, so that the problems of poor contact stability, serious abrasion, short service life and the like of the traditional block electric brush material are solved.
The invention relates to a 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush; the parts contain at least one highly elastic gold alloy fiber.
The invention relates to a 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush; the electric brush consists of an outer coating layer, a fiber brush body, bottom brazing filler metal and a fixed end cap; the length of the fiber brush body is greater than that of the outer cladding layer; the fiber brush body, the outer coating layer and the fixed end cap are welded into a whole through bottom brazing filler metal; the outer coating layer is wrapped on the fiber brush body to form a fiber brush strip; the fiber brush strip is inserted into the fixed end cap to form a fiber brush; the fiber brush body contains gold alloy fibers. Preferably highly elastic gold alloy fibers; the material of the high-elasticity gold alloy fiber is selected from one of gold-nickel alloy, gold-copper-platinum-silver alloy, gold-copper-silver-zinc alloy or gold-silver-copper alloy.
The outer layer coating material is a silver alloy or gold alloy fiber woven net cover and is sealed and welded by solder A;
the fiber brush body, the outer cladding layer and the fixed end cap are welded into a whole through a bottom B brazing filler metal, and the melting point of B is lower than that of A.
The fiber brush body has an ultrafine crystal structure, and the ultrafine crystal structure means that the size of crystal grains is less than or equal to 120 nm.
Preferably, the invention relates to a 1 hundred million-turn long-life multipoint end-face contact gold alloy fiber electric brush; the fiber brush body material accounts for 50-55% of the mass of M; the low-temperature brazing filler metal accounts for more than 37% of the mass of M; the M consists of a coating material, a fiber brush body and low-temperature brazing filler metal. Preferably, the silver or gold containing low-temperature solder is a lead-free solder, and the soldering temperature of the lead-free solder is less than 300 ℃.
The outer coating layer is subjected to net sleeve sealing welding by using low-temperature brazing filler metal 1 as a preferred scheme; the low-temperature brazing filler metal 1 is Sn96.5/Ag 3/Cu0.5; the dosage of the compound is 10.5-14.5 wt% of M.
As a further preferred scheme, when the fiber brush body, the outer cladding and the fixed end cap are welded into a whole through bottom brazing filler metal, the low-temperature brazing filler metal used is Sn64/Bi35/Ag 1; the amount thereof is 24-31 wt% of M.
The invention relates to a 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush; the brush friction partner material is selected from at least one of silver alloy or gold alloy. Preferably 70Au20Ag10Cu alloy.
The invention relates to a 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush; the outer layer coating material of the material is a silver alloy or gold alloy fiber woven net cover, and the thickness of the material is 0.1-0.2 mm.
The inner layer fiber brush body of the electric brush is composed of one or more high-elasticity gold alloy fibers, the diameter range of the fibers is 20-50 mu m, the fiber filling rate is 10-20 vol.%, and the fiber shape is in a strip straight shape, a sawtooth shape or a wave bending shape. The highly elastic gold alloy fiber is preferably 91Au9Ni fiber.
The fiber brush body in the electric brush can be formed by three-dimensional weaving of gold alloy fibers.
The fixed end cap is a cap body prepared from copper alloy, silver alloy or gold alloy by adopting a machining, stamping or powder metallurgy process.
Preferably, the contact part of the electric brush and the friction counterpart is the end face of the gold alloy fiber, the number of contact points is not less than 100, and the abrasion direction of the material is the axial direction or the length direction of the fiber.
Preferably, the contact angle between the brush and the friction partner is 45 ° to 90 °, and more preferably 80 °. 90 degrees is the surface of the vertical ring body of the electric brush.
The invention relates to a preparation method of a 1 hundred million-turn long-life multipoint end-face contact gold alloy fiber electric brush; the method mainly comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (4) chopping the fibers obtained in the step one according to a designed length to form bundles, and bundling according to a designed filling rate to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net cover prefabricated part formed by three-dimensional weaving by using low-temperature brazing filler metal, wherein the sealing and welding temperature is not more than 300 ℃, and the sealing and welding time is not more than 30 s.
Step four preliminary assembly of fiber brush body and seal welding net cover
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
And (4) inserting the fiber brush strip obtained in the step four into the fixed end cap, and welding and solidifying the fiber brush strip by adopting low-temperature brazing filler metal, wherein the welding temperature is not more than 200 ℃, preferably not more than 180 ℃, and the welding time is not more than 20 s. (ii) a And the welding temperature is lower than the melting point of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 1-2 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time of each time is not less than 5 min.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
Preferably, the brazing filler metal Sn96.5/Ag3/Cu0.5 is used for brazing during the sealing welding of the net cover.
Preferably, in the step five, when welding and curing are carried out, the solder Sn64/Bi35/Ag1 is used for brazing.
The gold alloy fiber electric brush material designed and prepared by the invention has a three-dimensional network structure, the void ratio is more than or equal to 80 vol.%, the elastic constant is less than 50N/mm, the average static contact resistance is less than 10m omega, and the average dynamic contact resistance is less than 20m omega;
under the conditions of vacuum and high speed, when the coupling body is 78Ag20Cu2Ni, the average friction coefficient of the material is stabilized at 0.5-0.8, and the wear rate is stable<8×10 -11 m/m, average static contact resistance < 10m omega, average dynamic contact resistance < 20m omega, average contact voltage drop<60mV, average electrical noise<5m omega, the accumulated service life or the total mileage is more than 1 hundred million turns or 10000 km; the vacuum conditions were: air pressure less than 10 -5 Pa; the high speed conditions are: the rotation speed is not more than 300rpm or the linear speed is not more than 0.8 m/s.
The innovation point and the technical advantage of the invention are as follows:
1) the designed and prepared 1 hundred million-turn long-life multipoint end face contact gold alloy fiber electric brush material is characterized in that a multipoint end face electric contact material with low filling rate and high void ratio is prepared by adopting high-elastic gold alloy fibers, the number of contact points can reach thousands of points, and each fiber is equivalent to a small electric brush and can be adaptive to the change and fluctuation of a contact surface. Compared with the traditional block or contact brush, the contact stability of the brush is greatly improved.
2) The electric brush body is an elastomer structure of a three-dimensional network, has high adaptability to load, speed and current, and can still keep stable contact under small load, high speed and large current density. Compared with the traditional block or contact brush, the service load of the brush can be as low as about one tenth of that of the block brush under the same condition, the service rotating speed can reach 1500rpm, and the current density can reach 500A/cm 2 。
3) The brush according to the present invention has a brush body structure having a high filling factor and a high porosity, and the brush body is a noble metal material in an amount of more than 80 vol.% and less than 20 vol.%. Compared with the traditional block or contact electric brush, the electric brush reduces the usage amount of noble metal materials, and saves the manufacturing cost; meanwhile, under the same abrasion length, the abrasion dust amount of the electric brush is only less than 20 vol.% of that of the block electric brush; the gap of 80 vol.% can absorb and contain micro abrasive dust generated in the service process of the electric brush, and the problem of reliability reduction caused by excessive redundancy in the long-service process of the air-to-air electric brush is practically solved.
4) The gold alloy fiber brush material provided by the invention has the advantages that the service main body is a noble metal material, the chemical stability is good, and the environmental adaptability is high. Compared with the traditional carbon brush, silver-based block brush and contact brush, the brush has no greasy dirt, high and low temperature, strong oxidation, strong radiation and other severe environments, and can still keep stable performance.
5) According to the invention, through the optimization of the structure, a special preparation process is supplemented on the basis of the selection optimization of the raw materials, so that a product with the accumulated service life or the total mileage of more than 1 hundred million revolutions or 10000km is obtained, and the application range of the product is greatly widened.
Drawings
FIG. 1: the schematic structure (a) and the physical structure (b) of the silver-mesh-coated gold alloy fiber are shown.
FIG. 2 is a schematic diagram: is the EBSD topography map of the 30 μm 91Au9Ni fiber end face in example 1.
FIG. 3: the silver mesh-coated gold alloy fiber brush material prepared in example 1 was in a state before (a) and after (b) a 1.2 million rpm vacuum current-carrying friction test.
FIG. 4: is a graph of the overall friction coefficient and voltage drop of the silver mesh coated gold alloy fiber brush material prepared in example 1 in a 1.2 hundred million-rpm vacuum current-carrying friction test.
FIG. 5: the silver mesh-coated gold alloy fiber brush material prepared in example 2 was in a state before (a) and after (b) after completion of the 1.2 million rev vacuum current-carrying friction test.
FIG. 6: the silver mesh-coated gold alloy fiber brush material prepared in example 3 was in a state before (a) and after (b) a 1.2 million-rpm vacuum current-carrying friction test was completed.
FIG. 7: the silver mesh-coated gold alloy fiber brush material prepared in example 4 was in a state before (a) and after (b) after completion of the 1.2 million rev vacuum current-carrying friction test.
FIG. 8: is a diagram of a state to be measured after the silver mesh-coated gold alloy fiber brush material prepared in comparative example 1 is welded and cured.
FIG. 9: the silver mesh-coated gold alloy fiber brush material prepared in comparative example 2 is a state diagram of (a) and (b) before and after about 300 ten thousand revolutions of vacuum current carrying test.
FIG. 1 shows that the silver net coated gold alloy fiber has a complete structure, and the fiber brush body, the coated net sleeve and the fixed end cap are firmly welded.
FIG. 2 shows that the 30 μm 91Au9Ni fiber used in example 1 has an ultrafine crystal structure of about 100nm inside.
Fig. 3 shows that, in example 1, the silver mesh-coated gold alloy fiber brush material had good dispersibility of the fibers, and was uniformly filled in the brush body to form a three-dimensional network elastomer structure. After 1.2 hundred million turns of vacuum current-carrying friction test, the electric brush has a complete structure and less abrasion.
FIG. 4 shows that in example 1, the friction coefficient of the copper tube-clad gold alloy fiber brush material tends to be consistent and substantially stable at about 0.6; the voltage drop curve is slightly higher than 50 mV.
FIG. 5 shows that in example 2, the silver mesh-coated gold alloy fiber brush material has excellent dispersibility of the fibers, and is uniformly filled in the brush body to form a three-dimensional network elastomer structure. After 1.2 hundred million turns of vacuum current-carrying friction test, the electric brush has a complete structure and less abrasion.
Fig. 6 shows that, in example 3, the silver mesh-coated gold alloy fiber brush material had good dispersibility of the fibers, and was uniformly filled in the brush body to form a three-dimensional network elastomer structure. After 1.2 hundred million turns of vacuum current-carrying friction test, the electric brush has a complete structure and less abrasion.
Fig. 7 shows that, in example 4, the silver mesh-coated gold alloy fiber brush material had excellent fiber dispersibility, and was uniformly filled in the brush body to form a three-dimensional network elastomer structure. After 1.2 hundred million turns of vacuum current-carrying friction test, the electric brush has a complete structure and less abrasion.
Fig. 8 shows that, in comparative example 1, the silver mesh-coated gold alloy fiber brush material has a phenomenon of significant melting of the sealing mesh after welding and curing, and the structure is unstable.
FIG. 9: it is shown that in comparative example 2, after the silver mesh-coated gold alloy fiber brush material is subjected to vacuum current carrying test at about 300 ten thousand revolutions, the brush is seriously worn, and the sealing and welding mesh sleeve is melted.
Detailed Description
The invention will now be further illustrated by way of examples.
Example 1: silver mesh-coated gold alloy fiber brush
The electric brush material mainly comprises three parts of a coating material, a fiber brush body and low-temperature brazing filler metal, and the appearance size of the electric brush material is
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (7.2 wt%); the fiber brush body material was gold alloy fiber with a diameter of 30 μm and the material was 91Au9Ni (51.4 wt.%); the low temperature solders were SAC305(sn96.5/Ag3/cu0.5(10.9 wt.%)) and 6404(Sn64/Bi35/Ag1(30.5 wt.%)) lead-free solders. The friction matching pair is 78Ag20Cu2Ni alloy. The brush contact angle is 80 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (4) chopping the fibers obtained in the step one according to the designed length to form bundles, and weighing the fibers with the filling rate of 20 vol% for bundling to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Step four initial assembly
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing by adopting 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, the welding time is not more than 10s, and the welding temperature is lower than the melting point temperature of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 0.85 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time is not less than 5min each time.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa) and a high rotation speed (300rpm), the average static contact resistance is 5.3m omega, the average dynamic contact resistance is 8.6m omega, the average friction coefficient is 0.6, and the average wear rate is 6.2 multiplied by 10 -11 m/m, average contact voltage drop less than 52.2mV, average electrical noise less than 0.39 mOmega, and cumulative service life of 1.2 hundred million revolutions (9553 km). The preparation method has the advantages of simple preparation process, low and controllable cost and convenience for large-scale industrial application.
Example 2
The electric brush material mainly comprises four parts, namely a coating material, a fiber brush body, low-temperature brazing filler metal and a fixed end cap, and has the overall dimension of
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (7.8 wt%); the fiber brush body material was gold alloy fiber with a diameter of 30 μm and the material was 91Au9Ni (51.8 wt.%); the low temperature solders were SAC305(sn96.5/Ag3/cu0.5(10.6 wt.%)) and 6404(Sn64/Bi35/Ag1(29.8 wt.%)) lead-free solders. The friction matching pair is 78Ag20Cu2Ni alloy. The brush contact angle is 80 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (4) chopping the fibers obtained in the step one according to the designed length to form bundles, and weighing the fibers with the filling rate of 20 vol% for bundling to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 low-temperature brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Step four initial assembly
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and curing in step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing by adopting 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, the welding time is not more than 10s, and the welding temperature is lower than the melting point temperature of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or arc polishing is carried out on the tail end of the electric brush material obtained in the fifth step by adopting a diamond grinding wheel not lower than 2000 meshes according to design requirements, the rotating speed does not exceed 300rpm, the time does not exceed 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 1.05 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time for each time is not less than 5 min.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa), high rotation speed (300rpm) and low load (0.31N), the average static contact resistance is 4.4m omega, the average dynamic contact resistance is 7.6m omega, the average friction coefficient is 0.56, and the average wear rate is 4.3 multiplied by 10 -11 m/m, average contact voltage drop of 45.6mV, average electrical noise less than 0.34m omega, and cumulative service life of 1.2 hundred million revolutions (9553 km). The preparation method has the advantages of simple preparation process, low and controllable cost and convenience for large-scale industrial application.
Example 3
The electric brush material mainly comprises four parts, namely a coating material, a fiber brush body, low-temperature brazing filler metal and a fixed end cap, and has the overall dimension of
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (8.5 wt%); the fiber brush body material was gold alloy fiber with a diameter of 30 μm and the material was 91Au9Ni (53.4 wt.%); the low temperature solders were SAC305(sn96.5/Ag3/cu0.5(13.7 wt.%)) and 6404(Sn64/Bi35/Ag1(24.4 wt.%)) lead-free solders. The friction matching pair is 70Au20Ag10Cu alloy. The brush contact angle is 90 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (3) chopping the fibers obtained in the step one according to the designed length to form bundles, weighing the fibers with the filling rate of 20 vol% and bundling the fibers to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 low-temperature brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Step four initial assembly
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing by adopting 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, the welding time is not more than 10s, and the welding temperature is lower than the melting point temperature of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 1.1 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time for each time is not less than 5 min.
Step nine electric brush drying
And (5) drying the electric brush obtained in the step eight in an oven at the temperature of not more than 60 ℃ for not less than 2 hours to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa), high rotation speed (300rpm) and low load (0.31N), the average static contact resistance is 6.4m omega, the average dynamic contact resistance is 12.3m omega, the average friction coefficient is 0.71, and the average wear rate is 7.5 multiplied by 10 -11 m/m, average contact voltage drop of 73.8mV, average electrical noise of 0.54m omega, cumulative service life of 1.2 hundred million revolutions (9553 km). The preparation method has the advantages of simple preparation process, low and controllable cost and convenience for large-scale industrial application.
Example 4
The electric brush material mainly comprises a cladding material, a fiber brush body, low-temperature brazing filler metal and a fixing materialThe end cap is composed of four parts with the external dimension of
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (8.8 wt%); the fiber brush body material is gold alloy fiber with the diameter of 30 μm and the material is 91Au9Ni (51.9 wt.%); the low temperature solders were SAC305(sn96.5/Ag3/cu0.5(14.1 wt.%)) and 6404(Sn64/Bi35/Ag1(25.2 wt.%)) lead-free solders. The friction matching pair is 70Au20Ag10Cu alloy. The brush contact angle is 80 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (3) chopping the fibers obtained in the step one according to the designed length to form bundles, weighing the fibers with the filling rate of 20 vol% and bundling the fibers to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 low-temperature brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Step four initial assembly
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing by adopting 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, the welding time is not more than 10s, and the welding temperature is lower than the melting point temperature of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 0.95 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time is not less than 5min each time.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa), high rotation speed (300rpm) and low load (0.31N), the average static contact resistance is 7.7m omega, the average dynamic contact resistance is 13.2m omega, the average friction coefficient is 0.68, and the average wear rate is 2.6 multiplied by 10 -11 m/m, average contact voltage drop of 79.2mV, average electrical noise of 0.57m omega, cumulative service life of 1.2 hundred million revolutions (9553 km). The preparation method has the advantages of simple preparation process, low and controllable cost and convenience for large-scale industrial application.
Comparative example 1: silver mesh-coated gold alloy fiber brush
The electric brush material mainly comprises four parts, namely a coating material, a fiber brush body, low-temperature brazing filler metal and a fixed end cap, and has the overall dimension of
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (6.3 wt%); the fiber brush body material is gold alloy fiber with the diameter of 30 μm and the material is 91Au9Ni (53.4 wt.%); the low temperature solder was a SAC305(sn96.5/Ag3/cu0.5(40.3 wt.%)) lead free solder.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (4) chopping the fibers obtained in the step one according to the designed length to form bundles, and weighing the fibers with the filling rate of 25 vol% for bundling to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 low-temperature brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Step four initial assembly
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and solidifying the fiber brush strip by adopting SAC305 low-temperature brazing filler metal, wherein the welding temperature is 260 ℃, the welding time is not more than 30s, and the welding temperature is consistent with the welding temperature in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose about 1.5mm of the free end.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time of each time is not less than 5 min.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
in the fifth step, the same brazing filler metal is adopted as in the third step, so that the outer seal welding mesh sleeve is partially melted due to overhigh welding curing temperature and overlong time during welding, the structure is unstable, and the vacuum current-carrying friction test cannot be carried out.
Comparative example 2
The electric brush material mainly comprises four parts of a cladding material, a fiber brush body, low-temperature brazing filler metal and a fixed end cap, and has the overall dimension of
The coating material is a silver alloy fiber woven net cover, the thickness of the coating material is 0.15mm, and the material is 78Ag20Cu2Ni (8.9 wt%); the fiber brush body material is gold alloy fiber with the diameter of 30 mu m and the material is 75Au17Cu7Ag1Zn (51.6 wt.%); the low temperature solder was 6404(Sn64/Bi35/Ag1(39.5 wt.%)) lead free solder. The friction matching pair is a gold-plated ring body. The brush contact angle is 80 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (3) chopping the fibers obtained in the step one according to the designed length to form bundles, weighing the fibers with the filling rate of 25 vol% and bundling the fibers to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) sealing and maintaining the surface of the net cover prefabricated part formed by three-dimensional weaving by 6404 low-temperature brazing filler metal, wherein the sealing and maintaining temperature is 1800 ℃, and the sealing and maintaining time is not more than 30 s.
Welding and curing step four
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and curing in step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing the fiber brush strip by using 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, and the welding time is not more than 10 s;
six-step grinding flat polishing arc
Grinding or arc polishing is carried out on the tail end of the electric brush material obtained in the fifth step by adopting a diamond grinding wheel not lower than 2000 meshes according to design requirements, the rotating speed does not exceed 300rpm, the time does not exceed 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose about 1.5mm of the free end.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time of each time is not less than 5 min.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa), high rotation speed (300rpm) and low load (0.22N), after the test is carried out for about 300 thousands of turns, the gold plating layer of the ring body is broken and fails, the phenomenon of electric contact instability exists, the contact temperature of the friction interface is too high, the sealing and welding net sleeve is melted, and the hundred million turns test cannot be completed.
Comparative example 3: silver mesh-coated gold alloy fiber brush
The electric brush material mainly comprises four parts, namely a coating material, a fiber brush body, low-temperature brazing filler metal and a fixed end cap. The coating material is a silver alloy woven mesh sleeve, the fiber diameter is 50 mu m, and the material is 78Ag20Cu2Ni (9.6 wt%); the fiber brush body material was gold alloy fiber with a diameter of 70 μm and the material was 91Au9Ni (54.6 wt.%); the low temperature solders were SAC305(sn96.5/Ag3/cu0.5(11.2 wt.%)) and 6404(Sn64/Bi35/Ag1(24.6 wt.%)) lead-free solders. The friction matching pair is 70Au20Ag10Cu alloy. The brush contact angle is 80 °.
The preparation method of the electric brush comprises the following steps:
step one fiber forming
And bending and molding the gold alloy fiber by adopting a limiting mold according to the design requirement of the fiber shape.
Step two fiber bundling
And (3) chopping the fibers obtained in the step one according to the designed length to form bundles, weighing the fibers with the filling rate of 20 vol% and bundling the fibers to prepare the fiber brush body.
Three-step net cover sealing welding
And (3) performing sealing and shape keeping on the surface of the net sleeve preform formed by three-dimensional weaving by using SAC305 low-temperature brazing filler metal, wherein the sealing and welding temperature is 260 ℃, and the sealing and welding time is not more than 30 s.
Welding and curing step four
And (4) inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting into required length to obtain the coated fiber brush strip.
Welding and solidifying step five
Inserting the fiber brush strip obtained in the fourth step into the fixed end cap, and welding and curing by adopting 6404 low-temperature brazing filler metal, wherein the welding temperature is 180 ℃, the welding time is not more than 10s, and the welding temperature is lower than the melting point temperature of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, the time is not more than 30min, and an electric brush semi-finished product is obtained
Step seven cutting net cover
And cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the step six by using a cutting tool to expose the free end by 0.5 mm.
Step eight ultrasonic cleaning
And (4) vertically placing the free end of the electric brush obtained in the step seven downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time is not less than 5min each time.
Step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
The properties of the finished product are as follows:
the material is under high vacuum (10) -5 Pa), ultrahigh rotating speed (1200rpm) and low load (0.31N),the average static contact resistance is 8.7m omega, the average dynamic contact resistance is 26.7m omega, the average friction coefficient is stabilized at 0.87, and the average wear rate is 5.1 multiplied by 10 -10 m/m, the average contact voltage drop is 160.2mV, the average electrical noise is 5.2m omega, the voltage drop is unstable, the abrasion is serious, and hundred million revolutions of test cannot be finished.
Claims (10)
1. A 1 hundred million-turn multi-point end-face contact gold alloy fiber brush; the method is characterized in that: the electric brush is composed of an outer coating layer, a fiber brush body, bottom brazing filler metal and a fixed end cap; the length of the fiber brush body is greater than that of the outer cladding layer; the fiber brush body, the outer coating layer and the fixed end cap are welded into a whole through bottom brazing filler metal; the outer coating layer is wrapped on the fiber brush body to form a fiber brush strip; the fiber brush strip is inserted into the fixed end cap to form a fiber brush; the fiber brush body contains gold alloy fibers;
the outer coating layer is a net cover woven by silver alloy or gold alloy fibers and is formed by sealing and welding A brazing filler metal;
the fiber brush body, the outer cladding layer and the fixed end cap are welded into a whole through bottom brazing filler metal B, and the melting point of B is lower than that of A.
2. A 1 hundred million turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that:
the fiber brush body is made of high-elastic gold alloy fibers; the material of the high-elasticity gold alloy fiber is selected from one of gold-nickel alloy, gold-copper-platinum-silver alloy, gold-copper-silver-zinc alloy or gold-silver-copper alloy.
3. A 1 billion turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that: the fiber brush body has an ultrafine crystal structure, and the ultrafine crystal structure means that the size of crystal grains is less than or equal to 120 nm.
4. A 1 billion turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that: the fiber brush body material accounts for 50-55% of the mass of M; the low-temperature brazing filler metal accounts for more than 37% of the mass of M; the M consists of an outer cladding layer, a fiber brush body and a bottom brazing filler metal, wherein the bottom brazing filler metal is a low-temperature brazing filler metal, the low-temperature brazing filler metal is a silver or gold-containing lead-free brazing filler metal, and the brazing temperature of the low-temperature brazing filler metal is lower than 300 ℃;
the outer coating layer is subjected to net sleeve sealing welding by using low-temperature brazing filler metal; the low-temperature brazing filler metal is Sn96.5/Ag 3/Cu0.5; the dosage of the compound is 10.5 to 14.5 weight percent of M;
when the fiber brush body, the outer cladding layer and the fixed end cap are welded into a whole through bottom brazing filler metal B, the used bottom brazing filler metal B is Sn64/Bi35/Ag 1; the amount thereof is 24-31 wt% of M.
5. A 1 hundred million turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that: the friction pairing material of the brush is selected from at least one of silver alloy or gold alloy.
6. A 1 billion turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that: the thickness of the silver alloy or gold alloy fiber woven net cover is 0.1-0.2 mm.
7. A 1 billion turn multi-point end-contact gold alloy fiber brush according to claim 1; the method is characterized in that: the fiber diameter of the fiber brush body is 20-50 mu m, the fiber filling rate is 10-20 vol.%, and the fiber shape is in a strip straight shape, a sawtooth shape or a wave bending shape;
the fiber brush body in the electric brush is formed by three-dimensional weaving of gold alloy fibers;
the fixed end cap is a cap body prepared from copper alloy, silver alloy or gold alloy by adopting a machining, stamping or powder metallurgy process;
the part of the electric brush, which is in contact with the friction pairing body, is a gold alloy fiber end face, the number of contact points is not less than 100, and the material abrasion direction is the fiber axial direction or the length direction;
the contact angle between the electric brush and the friction pairing body is 45-90 degrees.
8. A preparation method of a 1 hundred million-turn multi-point end face contact gold alloy fiber electric brush; the method is characterized in that: the method comprises the following steps:
step one fiber forming
Bending and molding the gold alloy fiber by adopting a limiting die according to the design requirement of the fiber shape;
step two fiber bundling
Chopping the fibers obtained in the step one according to a designed length to form bundles, and bundling according to a designed filling rate to prepare a fiber brush body;
three-step net cover sealing welding
Performing sealing and shape keeping on the surface of the net cover prefabricated part formed by three-dimensional weaving by using low-temperature brazing filler metal, wherein the sealing and welding temperature is not more than 300 ℃, and the sealing and welding time is not more than 30 s;
step four preliminary assembly of fiber brush body and sealing welding net cover
Inserting the fiber brush body obtained in the step two into the sealing and welding net cover obtained in the step three, and cutting the fiber brush body into required length to obtain a coated fiber brush strip;
welding and solidifying step five
Inserting the fiber brush strip obtained in the step four into the fixed end cap, and welding and solidifying the fiber brush strip by adopting low-temperature brazing filler metal, wherein the welding temperature is not more than 200 ℃, and the welding time is not more than 20 s; and the welding temperature is lower than the melting point of the brazing filler metal in the third step;
six-step grinding flat polishing arc
Grinding or polishing the tail end of the electric brush material obtained in the step five by adopting a diamond grinding wheel not less than 2000 meshes according to design requirements, wherein the rotating speed is not more than 300rpm, and the time is not more than 30min, so as to obtain an electric brush semi-finished product;
step seven cutting net cover
Cutting the sealing and welding net sleeve of the non-welding end of the semi-finished product of the electric brush obtained in the sixth step by using a cutting tool to expose the free end by 1-2 mm;
step eight ultrasonic cleaning
Placing the free end of the electric brush obtained in the step seven vertically downwards into alcohol for ultrasonic cleaning for 3 times, wherein the time for each time is not less than 5 min;
step nine electric brush drying
And (5) placing the electric brush obtained in the step eight in an oven for drying at the temperature of not more than 60 ℃ for not less than 2h to obtain a finished product.
9. A method of making a 1 hundred million turn multi-point end-contact gold alloy fiber brush according to claim 8; the method is characterized in that:
thirdly, brazing by using brazing filler metal Sn96.5/Ag3/Cu0.5 during sealing welding of the net cover;
and step five, soldering by using a solder Sn64/Bi35/Ag1 when soldering is solidified.
10. A method of making a 1 hundred million turn multi-point end-contact gold alloy fiber brush according to any one of claims 8 to 9; the method is characterized in that: under the conditions of vacuum and high speed, when the coupling body is 78Ag20Cu2Ni, the average friction coefficient of the material is stabilized at 0.5-0.8, and the wear rate is stable< 8×10 -11 m/m, average static contact resistance < 10m omega, average dynamic contact resistance < 20m omega, average contact voltage drop<60mV, average electrical noise<5m omega, the accumulated service life or the total mileage is more than 1 hundred million turns or 10000 km; the vacuum conditions were: air pressure less than 10 -5 Pa; the high speed conditions are: the rotation speed is not more than 300rpm or the linear speed is not more than 0.8 m/s.
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| CN102060556B (en) * | 2010-11-30 | 2012-11-21 | 哈尔滨工业大学 | Method for soldering TiAlC ceramic and copper by using Ag-Cu eutectic solder |
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| DE102012204830A1 (en) * | 2012-03-26 | 2013-09-26 | Schleifring Und Apparatebau Gmbh | Brush block for a slip ring assembly |
| CN103122422A (en) * | 2013-03-03 | 2013-05-29 | 贵研铂业股份有限公司 | Au-based friction pair pairing material |
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