ROTARY POWER TRANSFER APPARATUS

Abstract: An apparatus for reducing terminal-to-terminal circuit resistance and enhancing heat transfer in a rotary power transfer apparatus of the roll ring type comprising a connecting thimble (11) for attaching an external power cable (23) to a cone shaped terminal (14) which is attached to a tab (18) integral with outer ring (19). An inner ring (25) having a spherical recess mates with the spherical end (30) of a tie connector (26). A cone shaped terminal (14) is fitted to a second connecting thimble (11) for attaching a second external power cable (23).

Description: This invention relates to rotary power transfer devices and has for its main object the provision of such a device which has increased transfer efficiency with reduced operating temperature and greater utilisation of external interface connections. One means of transferring electrical power across a rotating interface, even in a vacuum, is provided by the roll ring, a concept described in Applicants' US-A-4,098,546, and US-A-4,372,633. US-A-4,098,546 describes the basic roll ring concept of conducting electrical signals and power across the rotating interface by means of a flexible hoop (flexure) captured in shallow grooves in two circular rings. US-A-4,372,633 describes a roll ring configuration which utilises a set of multiple flexures between the two rings, a set of idlers to separate the flexures and a set of guides to pilot the idlers, thereby providing multiple paths through the assembly and an increase in current carrying capacity. There is no known alternative means of transferring large currents at high voltage levels across a rotary interface with the transfer efficiency provided by the roll ring configuration of US-A-4,372,633. The roll ring configuration, however, presents design and application problems relating to heat transfer, terminal-to-terminal electrical resistance and connection to external power cables. The present invention addresses the problem of reducing terminal-to-terminal resistance and improving heat transfer from the interior to the exterior of the roll ring module. Materials of high dielectric strength needed electrically to insulate high current and voltage carrying components are also generally poor heat conductors. If the terminal-to-terminal resistance can be reduced, the transfer efficiency is increased resulting in less power being converted into heat. Every interconnection represents a resistance in the series chain between the external terminations in a given circuit. Part-to-part manufacturing tolerances also contribute to this variation of resistance. The external terminations themselves add to the total resistance and also introduce a variability to the total resistance which may vary each time a connection is made. Additionally, the power cables used to make connections to the various terminals for various applications are stiff and not only introduce variations in connection resistance, but require adequate working space for the connections. Terminals which face in a given axial direction for one application are not necessarily optimum for other applications. The present invention is defined in the appended claims and provides apparatus for reducing terminal-to-terminal transfer resistance and improved heat transfer in a high power rotary roll ring module. A connecting thimble accepts a stiff power cable at one end. The opposite end of the connecting thimble contains a recess in the shape of a tapered cone for accepting a tapered cone terminal connected to an outer ring tab of the roll ring module. The tapered cone terminal is reinforced with a stiffening bolt and secured to the connecting thimble by a threaded thimble lock nut. Heat transfer is enhanced by positioning a wavy spring between the outer circumference of the outer ring and the inner circumference of an electrical insulator in contact with the outer housing of the roll ring module. A shim whose thickness is chosen to optimise heat transfer between the outer ring and the housing is positioned between the wavy spring and the electrical insulator. An inner ring, having a spherical recessed cup accepts power transferred from the outer ring through a flexure. The recessed spherical cup accepts the spherical end portion of a tie connector. The opposite end of the tie connector is configured as a tapered cone for insertion into the tapered cone recess of the connecting thimble to which is attached a connecting cable. Rotary power transfer apparatus in accordance with the present invention will now be described in greater detail, by way of example, with reference to the accompanying drawings, in which:- Figure 1 is a partial sectional view of an eight-circuit roll ring power transfer apparatus, Figure 2 illustrates the terminal-to-terminal circuit path of the present invention, Figure 3 illustrates, in cross section, the assembly for improving heat transfer, and Figure 4 is a plot for optimising heat transfer. The present invention is generally useful in applications requiring transfer of large amounts of power across a rotary junction and in particular is useful in satellite and spacecraft applications utilising the roll ring configuration disclosed in US-A-4,372,633 which is incorporated herein by reference. Referring to Figures 1 and 2, the structure of the invention will now be described. Increased transfer efficiency is provided by reducing terminal-to-terminal circuit resistance. Figure 2 illustrates a terminal-to-terminal circuit 10. A connecting thimble 11 is attached to a cable 23 by means of the conventional solder pot 12 in one end of the thimble 11. The thimble 11 also contains a tapered cone 13 which engages a terminal cone 14 at an interface 15 and is held securely in place with a thimble lock nut or ring 16 by means of a threaded interface 17. The terminal cone 14 is firmly engaged with an integral ring tab 18 which is an integral part of an outer ring 19. A stiffening bolt 20 assures a positive contact between the terminal cone 14 and a ring tab interface 21 by means of a backing ring 22. The stiffening bolt 20 and backing ring 22 assure full contact even when the external cable 23 induces mechanical load strains on the external connection tending to bend and twist the integral ring tab 18. The foregoing type of loading is a common source of resistance change on more conventional existing connecting means such as spring-loaded pins and plugs and bolted connections used on spade lugs commonly employed on power cables. The outer ring 19 transfers current through flexures 24 (as shown in Figure 1 and described in US-A-4,372,633, the typical roll ring configuration having multiple flexure circuits to increase current carrying capacity). Connection at an inner ring 25 to the terminal cone 14 is made by a tie connection 26 which has a spherical interface 30 which engages with a like interface in the inner ring 25. The centre of radious of the spherical interface 30 is located at a connection pilot 27 which is at the outer extremity of the tie connection 26. A lock nut 28 engages the tie connection 26 radius centre at the pilot 27, thereby avoiding any movement within the spherical interface 30 when the locknut 28 clamps the connection 26. The lock nut 28 is not secured until the terminal cone 14 on the inner ring 25 is secured into position in the rest of the assembly. This assures that no mechanical strain is developed in any of the current transfer components which could change after the unit is in service resulting in a changed interface resistance. In addition, the self-aligning feature of the spherical interface 30 eliminates the possible effects of manufacturing and assembly variations. A terminal lockscrew 29 is used to secure the terminal cone 14 to the connection 26 in a manner similar to the locknut 28 engagement in the ring 25 against the connection 26. This preloading arrangement ensures that temperature excursions and mechanical loading of circuit components after the module is placed in service do not result in resistance changes at any of these interfaces since the preload loops are short. Preload loops 21a are illustrated as dashed lines in Figure 2. Enhanced heat transfer away from the circuit conducting components is provided as follows. All of the power loss from the input to the output of the module 40 in Figure 1 is transformed to heat. This heat is predominantly transferred into the inner ring 25 and the outer ring 19. The inner housing 31 and the outer housing 32, respectively, are the heat sinks to which it is desired to transfer the heat for eventual transfer to the spacecraft or other collecting point. Figure 3 shows the preferred embodiment for transferring heat by conduction from the outer ring 18 to the outer housing 32. A similar arrangement conducts heat from the inner ring 25 to the inner housing 31. A wavy (sinusoidal) spring 50 is inserted in a circumferential slot between the outer ring 19 and an insulator 51, the latter being provided with a gap 52 which allows the walls of the insulator 51 to be forced into intimate contact with the wall of the housing 32 by the action of the wavy spring 50. Various thickness optimising shims 53 may be inserted between the spring 50 and the housing 32 until maximum heat conduction through contact points 54 is achieved. A shim 53 thickness which results in minimum temperature differential between the ring 19 and the housing 32 for a given heat source at the ring 19 is that thickness which provides optimum heat transfer efficiency. Obtaining optimum heat transfer efficiency is illustrated in Figure 4. The thermal transfer between two clamped members is related to the effective thermal resistivity at the interface therebetween. Figure 4 shows the qualitative relationship between thermal resistivity R T and the clamping pressure P. Unfortunately, the quantitative relationship even for common materials is rarely available. For a given design, therefore, using specific materials, the heat transfer characteristics must be determined empirically. Data is collected relative to the steady state temperature differential between the outer ring 19 and the housing 32 for various shim 53 thicknesses T. Referring again to Figure 4, as shim 53 thickness is varied, the deflection of the wavy spring 50 is changed and the normal contact force F at the insulator 51 and the housing 32 inner wall is also changed as shown in the plot. In addition, contact area A of the wavy spring 50 at the outer ring 32 and at the insulator 51 is also affected by the various shim 53 thicknesses. Since both the normal force F and the area A are being influenced but not equally, the ratio of the two, normal pressure P, is also changing with shim 53 thickness. The heat transfer is effected by the thermal resistivity R T and the area of contact A. Starting at the optimum point shown in Figure 4, as shim 53 thickness T increases, contact force F and contact area A increase, contact pressure P decreases and resistivity R T increases. Since the resistivity R T is increasing faster than is the area A, the heat transfer Q decreases. Conversely, as shim 53 thickness T decreases, contact force F and contact Area A decreases, contact pressure P increases and resistivity R T decreases. Since area A is decreasing faster than is the resistivity R T , the heat transfer Q decreases. Thus, it can be seen that an optimum heat transfer can be effected by selecting a particular shim 53 thickness. In the preferred embodiment of the invention, optimum shim 53 thickness was found to be 0.040 inches (1.016mm). Universal utilisation of the external terminal interfaces is also provided. Figure 1 shows the spiral configuration of the terminals on the outer housing 32 to which the cables 23 are attached. Figure 1 also shows the advantage provided by the axial reversibility of the terminals. These terminals may be reversed, even in the field, by removing and reassembling the stiffening bolt 20, backing ring 22 and terminal cone 14 on any selected circuit connection. The thimble lock 16 provides a positive cone interface 15 clamping action of the thimbles 11. The short preload loops 21a assure a positive and low interface resistivity even under the bending moment influence from external cable deflections and movements.

Claims: 1. A rotary powered transfer apparatus of the type having a plurality of roll ring flextures (24) for transferring power between an inner (25) and an outer (19) circular ring characterised in that it further comprises a first connecting thimble (11) coupled to a first external power cable (23) at a first end, a second end of the first connecting thimble having a recessed seat (13), a tab (18) integral with the outer ring (19) at one end and surrounding a first terminal (14) at an opposite end, the first terminal being shaped to fit within the connecting thimble recessed seat (13), first clamping means (16) for holding the first connecting thimble (11) and the first terminal (14) in intimate contact, stiffening bolt and backing ring (20,22) for holding the first terminal (14) in intimate contact with the tab (18), a tie connection (26) having a spherical end (30) for fitting within a spherical recess in the inner ring (25), the opposite end of the tie connection being coupled to a second shaped terminal, locking means (27,28) for keeping the tie connection spherical end (30) positioned at the centre of radius of the inner ring spherical recess, a second connecting thimble (11) having a recessed seat (13) at one end for accepting the second terminal and coupled at a second end to a second external power cable (23), and second clamping means (16) for holding the second connecting thimble and second terminal in intimate contact. 2. A rotary power transfer apparatus according to claim 1, characterised in that it further comprises a wavy spring (50), a split electrical insulator ring (51), and a shim (53), the wavy spring being positioned between and in contact with, the outer circumference of the outer ring (19) and the inner circumference of the shim, the split electrical insulator (51) being positioned between the outer circumference of the shim (53) and the outer housing (32) of the rotary power transfer apparatus, the shim thickness being selected to provide a wavy spring pressure for optimum heat transfer from the outer ring (19) to the outer housing (32).

Inventors: JACOBSON, PETER EARL, PORTER, RYAN STUART
Applicants: HONEYWELL INC.
Application year: 1986
Main classification: H01R39
IPC codes: H01R39, B64G1