The pancake slip ring is similar to through hole slip ring but is especially used for the rotating system with a height limit. Also called flat slip ring, flat disc electrical slip ring, or platter slip ring, since the shape is similar to a platter, rings, and brushes contact around the center of the circle. Pancake slip ring components include stator, rotor, and contacts, mainly used for transmitting precise signals and power or combined with pneumatic and hydraulic media. More electrical power, current, and signal circuits can extend broadwise limitless on flat diameter.
Pancake slip rings can be configured in two types, integrated and separated.
Integrated rings type can be designed for solid or through hole rotating systems.
The separated ring type is composed of a separated rotor and contact brush, which can be designed with PCB.
Available for Custom, Standard Min. Thickness 16mm, Can Be 6mm
GRAND technology can supply both of them. Please consider the installation space when choosing the model, miniature pancake slip ring is a good idea if space is limited very small. With years of R&D and manufacture assemblies experience, mass production capacity for 6mm thickness PCB slip ring, and sale well in the UK.
Designed with the best-advanced fiber brush technology and precious metal or gold contacts, they ensure low electrical noise, high data transmission, and low contact pressure. Fully custom speed, voltage, diameter, height & thickness, material, IP grade, PCB design, etc. are always requested, although GRAND offers modularized & standardized design for various application solutions as an original slip rings manufacturer. Please feel free to contact us to create your most suitable pancake slip ring connector.
Feature
High rotating speed
Min. 6mm thinckness
Can use superior fiber brushes, precious metal
Can combine power and signals
Fast delivery
Fully customized solution
Option
Operating speed customization
Housing material customization
Seal grade customization
Wire end plug-in customization
Lead exit way customization
Mixing power and signal
Through bore size
Model Breakdown
Model
ID(mm)
OD(mm)
No. of Rings
RPM
Thickness
IP
PDF
HP060-6
60
244
6
0~250
35 mm
IP51
HP085-10
85
180
10
0~300
16 mm
IP54
HP220-18-2RF
32
240
18
0~50
32.5 mm
IP51
Pancake slip rings, What Else Do You Want to Know?
Design and Structure: Pancake slip rings consist of two plates facing each other, with contact rings arranged in a circle on one plate. Each ring is soldered to a cable that leads out from one side of the pancake slip ring connector in a string, while spring contacts attached to the opposite plate ensure continuous signal transmission.The pancake slip ring developed ,also called Face Type Slip Ring.The face type slip rings provide reliable connectivity, allowing for seamless data transfer in applications where a slip-ring is essential for rotation, while the innovative design of the slippring enhances performance in tight spaces.
Functionality: The spring contacts are soldered to connecting cables, facilitating easy installation and minimizing confusion through color-coded connections. Pancake slip rings allow for 360° rotation and more, providing durability and reliability due to their design, which includes shielding against dust and moisture.
Application Areas: These pancake slipring are ideal for low rotational speeds and are widely used in actuation and control technology, slow-running servo motors, and modern multifunction steering wheels, where they reliably transmit signals to actuators.
Variety and Specifications: Available in configurations of 2 to 48 rings, pancake slip rings can be arranged in series, making them versatile for various setups. They are crafted with silver-silver or gold-gold contact materials, offering excellent corrosion resistance and operating efficiently within a temperature range of -30 °C to + 80 °C.
Repair and Maintenance: While repairing pancake slip rings is theoretically possible as they can be dismantled, it is advised against makeshift repairs due to their precision nature. Instead, routine maintenance includes occasional cleaning, while low-cost components can be easily replaced to ensure optimal performance.
Whether you need pancake slip ring assemblies for compact designs or flat slip rings for specific applications, our slip ring pancake solutions provide reliable power and signal transmission tailored to your operational requirements.
Structure and Unique Design of Pancake Slip Rings
Structure of Pancake Slip Rings
To appreciate the intricacies of pancake slip rings, it’s essential to delve into their construction and the components that constitute their structure. Pancake slip rings primarily consist of two parts: concentric rings and brushes, which work together to enable seamless transfer of electrical power and signals between stationary and rotating parts.
Concentric Rings: The core of the pancake slip ring’s structure lies in its concentric rings. These individually separated and electrically isolated conductive rings are mounted on a flat, circular insulation disc. They serve as pathways for the transfer of electrical signals or power. The rings must be precisely designed and arranged according to application requirements, as even minor irregularities can impact signal integrity and overall performance. The insulation disc ensures that the rings remain isolated from one another while supporting the slip ring’s size and weight restrictions.
Brushes: Brushes are a vital aspect of the pancake slip ring structure, organized radially around the insulation disc with consistent spacing to interface with the concentric rings. These contact elements effectively transmit electrical signals or power from the stationary section to the movable section of the device. Typically made of metal or metal alloys, their design varies based on application needs. Factors like the size of the disc, the number of circuits, and the required transmission capacity influence their construction. The precise arrangement of these brushes and their optimal contact with the concentric rings is crucial for efficient functioning. Wear and tear can lead to increased maintenance and eventual replacement needs.
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The distinct design of pancake slip rings differentiates them from traditional cylindrical slip rings, addressing specific challenges associated with space constraints while delivering seamless functionality. Their design exclusivity caters to various applications across multiple industries.
Flat and Compact: The most distinguishing factor of pancake slip rings is their flat, disc-like shape, which provides a significantly lower height compared to cylindrical counterparts. This compact design enables them to fit conveniently in applications with minimal vertical clearance, eliminating the need for design alterations or compromises in performance.
Larger Diameter: While the flat design reduces height requirements, it may necessitate an increase in diameter to accommodate the required number of circuits and their corresponding electrical pathways. By expanding their diameter, pancake slip rings can support additional concentric rings and brushes, meeting diverse power and signaling needs.
Brush Configuration: Unlike cylindrical slip ring with axial brushes, pancake slip rings utilize a radial brush arrangement around the insulation disc. This unique configuration enhances the contact area between brushes and concentric rings, optimizing electrical transmission capacity. However, it may result in increased wear and require more frequent maintenance.
Customization for Specific Applications: Pancake slip rings can be tailored to suit various electrical and mechanical requirements, accommodating specific current and voltage ratings, unique environmental conditions, and particular industrial challenges.
Use of the Pancake Slip Rings
Pancake slip rings have found extensive use across a variety of industries due to their unique design, structure, and ability to operate in a range of environments. They serve as an adaptable, flexible solution for providing uninterrupted power and signal transmission between stationary and rotating platforms, particularly when vertical space is at a premium.
Utilization Across Multiple Industries
Pancake slip rings are predominantly engaged across many sectors due to their ability to fulfill diverse power and signal transmission requirements. They can be found in automotive, aerospace, marine, healthcare, communication, manufacturing, and many more industries. Here are some key applications where pancake slip rings shine:
Cable reels, commonly used in the entertainment and broadcasting industry, require reliable rotational contact solutions to facilitate smooth transmission of signals. Pancake slip rings, with their compact dimensions and optimized electrical transmission capabilities, are ideal solutions for such devices.
Rotary tables
In manufacturing or imaging equipment, rotary tables need to rotate smoothly while consistently transmitting power and signals. The space-saving designs of pancake slip rings, coupled with their reliable performance, make them perfectly suitable in these situations.
In precise medical applications such as MRI and CT scanners, transferring high-quality data from the rotating parts to stationary systems with no interruption is critical. Given their compact structure and superior performance, pancake slip rings are often found in these imaging machines.
Radar systems necessitate continuous data and power transmission for accurate tracking and communication, additionally followed by space constraints. The flat design of the pancake slip rings coupled with the capability for high-frequency data transmission makes them an ideal choice.
Closed-circuit Cameras
Any disruption or lag in signal transmission in surveillance systems can have serious repercussions. Pancake slip rings installed in closed-circuit cameras ensure uninterrupted, smooth signal transmission even when the cameras are constantly rotating.
High Customizability: A Key to Versatile Use
The ability to adapt and change per the requirements of the application is a defining feature of pancake slip rings, leading to their vast utilization. They can be customized to handle different current and voltage ranges, change physical dimensions, and even withstand various environmental and temperature conditions.
In summary, pancake slip rings, with their unique structure and high degree of customizability, have become an invaluable component in many industrial applications. Their ability to provide reliable power and signal transmission, even in restrictive spatial circumstances, has ultimately earned them high regard in several industries.
Advantages of the Pancake Slip Rings
With their unique design and structure, pancake slip rings offer a plethora of advantages that not only make them superior to cylindrical slip rings in certain applications but also enable them to cater to a wide range of industries and sectors.
Minimized Vertical Space Requirement
The flat, compact design that is the hallmark of pancake slip rings significantly reduces vertical height, making them perfect for applications with restricted vertical space. This proves advantageous in numerous industries like automotive, medical, and aerospace, where space often comes at a premium.
High Capacity for Circuits
Despite their compact structure, pancake slip rings can house a large number of concentric circuits. The larger the diameter, the more circuits it can accommodate. Hence, the information and power transmission capabilities are not compromised, contrary to what one might expect given their small size.
Customizability
Pancake slip rings can be custom-engineered to suit various electrical and mechanical requirements. This edge in customizability includes modifications for current and voltage ratings, temperature ranges, and making the slip ring resistant to certain environmental conditions, making pancake slip rings versatile across applications.
Durability
Most pancake slip rings are produced using quality materials and possess a robust structure that makes them resilient to mechanical vibrations and shocks. This enhances their durability and reliability in arduous and challenging operating environments.
Simplified Integration
Their compact and simplistic design, combined with the capacity for customization, makes pancake slip rings easy to integrate within existing systems. This can prove advantageous in industries like manufacturing and automation, where any modification in machinery can disrupt operations.
Despite having several advantages, it’s important to note that pancake slip rings may not always be the optimal choice for all scenarios. They require regular maintenance due to the increased wear from their radial brush system, and in some applications, the increased diameter could also pose challenges. However, their unique design and structural advantages make them a valuable addition to many industries that deal with space constraints and complex power and signal transmission needs. In essence, the advantages of pancake slip rings significantly contribute to their popularity in multiple sectors.
Disadvantages of the Pancake Slip Rings
Pancake slip rings, despite their valuable advantages and versatile applications, come with certain drawbacks. Understanding these disadvantages is critical to making an informed decision about the utility of these components in specific applications.
Increased Maintenance
Due to the radial arrangement of brushes, the friction between the brushes and the concentric rings is typically higher in pancake slip rings, leading to increased wear and tear. As a result, they often require more frequent maintenance and replacement of brushes as compared to other types of slip rings. This can lead to higher operational costs in the long run.
Enlarged Diameter
While the flattened structure of pancake slip rings is advantageous in constrained vertical space, it generally leads to an increase in diameter. This enlarged diameter could pose a limitation in applications where there is not enough room horizontally, thereby restricting their use in such scenarios.
Limited High-Speed Applications
Pancake slip rings typically experience more considerable brush wear when turning at high speeds due to the larger contact surface area between the brushes and the rings. This limits their use in applications requiring high rotational speeds.
Issues in Data Transmission
The unique design of pancake slip rings may sometimes lead to a signal and data transfer that is less clean and has more interference compared to cylindrical slip rings. This might be a disadvantage in applications where precise and clear signal transmission is critical.
Complexity in Installation
Depending on the application, installing a pancake slip ring and maintaining the right amount of pressure on the brushes for effective contact can be more complex than implementing cylindrical slip rings. This could increase the overall setup time and efforts of the machinery or equipment.
In conclusion, while pancake slip rings offer numerous benefits due to their design and function, it’s vital to weigh these against potential disadvantages. Their suitability and efficiency will depend greatly on application-specific conditions and requirements. A comprehensive consideration of these factors will aid in choosing the most appropriate type of slip ring, ensuring optimal function and performance.
Enhance your project with our Pancake Slip Rings. Submit your inquiry, and let’s discuss how we can meet your specific needs.
Product Variety of the Pancake Slip Rings
Taking into account the diverse needs of various industries and applications, pancake slip rings are designed and produced in a wide range of variations, customizations, and specifications. This adaptability helps address specific challenges and fulfill unique requirements. Here is an overview of the product variety of pancake slip rings.
Current and Voltage Ratings
Pancake slip rings can be customized according to the required current and voltage ratings, ensuring compatibility with the application they are integrated with. These ratings can range from low-voltage and low-current scenarios to high-voltage and high-current settings, and may be further adjusted to cater to alternating current (AC), direct current (DC), or mixed types of electrical systems.
Material Selection
Choice of materials plays a significant role in the performance and longevity of pancake slip rings. Depending on the application, slip rings can be produced using various metals such as gold, silver, and copper, as well as specific composite materials tailored for unique operating conditions.
Different Configurations
Pancake slip ring configurations can be altered based on the design of the concentric rings, the number of brushes, and the mounting methods to adapt to application-specific requirements. This includes design modifications that improve the efficiency of signal transmission or enhanced convenience during installation and dismounting.
Environmental and Temperature Tolerance
With their product variety, pancake slip rings can be engineered to withstand exposure to various environmental or temperature conditions. From standard factory settings to extreme temperature variations or harsh marine environments, modifications to encapsulation and protective coatings can be introduced to make these slip rings more resilient and resistant.
Integrated Solutions
In some applications, integrating pancake slip rings with other contact solutions may be necessary. Many manufacturers offer hybrid slip rings that combine pancake slip rings with built-in fiber optic rotary joints, fluid rotary unions, or other contact technologies to suit the requirements of complex systems.
The broad product variety of pancake slip rings demonstrates the inherent flexibility and accommodation of the product to diverse application requirements. By offering customized current and voltage ratings, material selection, configuration options, and environmental resilience, manufacturers can tailor pancake slip rings to a wide range of needs, making them a go-to solution in various industries, from medical imaging to radar systems and more. This adaptability is an essential factor in the popularity and wide usage of pancake slip rings across numerous applications.
Grand: Excellence in slip ring manufacturer
At Grand, we are committed to delivering custom slip ring solutions with industry-leading quality systems that ensure excellence from start to finish. Our comprehensive quality management extends throughout the entire supply chain, from the careful selection of raw materials to the final delivery of products.The growing demand for innovative solutions has led to a competitive landscape among slip ring manufacturers in India, highlighting the importance of quality and customization in meeting diverse industry needs.As a leading slip ring supplier, we pride ourselves on our extensive range of products, including those from notable through hole slip ring manufacturers that ensure seamless performance in various applications. Our commitment to quality and innovation sets Grand slip apart in the industry, and our expertise as slip ring assemblies manufacturers enables us to deliver customized solutions that meet the specific needs of our clients.
Our operations are backed by full ISO-9001 compliance, providing complete traceability and assurance of product integrity. We utilize the S.Q.D.I.P. system to drive excellence in every aspect of our production: Safety, Quality, Delivery, Inventory, and Performance. Our customers benefit from our innovative labs for testing and verification solutions, which include:
Incoming Quality Control (IQC): All incoming raw materials are thoroughly checked upon receipt. Various measurements are taken against the agreed parameter sheet. Should any materials be rejected, suppliers are required to conduct a failure mode analysis report for our review.
In Process Quality Control (IPQC): We perform online inspections throughout the manufacturing process. The frequency of inspections is determined by quality standards or specific project requirements, with all process data recorded for thorough checks.
Final Quality Control (FQC): Each slip ring undergoes individual testing according to stringent quality standards before being sent to the warehouse, ensuring every product meets our high expectations.
Outgoing Quality Control (OQC): Prior to shipment, our quality control team conducts random checks on slip rings to ensure that the right products are delivered in excellent condition.
Our factory workshop boasts hundreds of skilled workers who perform a wide variety of tasks with flexibility and precision. With significant investments in automation, we enhance our productivity, repeatability, and overall quality, leading to shorter lead times for our customers.
As leading slip ring suppliers, we specialize in providing bespoke slip ring solutions tailored to meet specific customer needs. Our range of products includes custom sliprings and slip ring assemblies designed for various applications, ensuring that we can cater to a diverse clientele.
When you choose Grand as your slip ring manufacturer, you are partnering with a company dedicated to quality and innovation. Experience the Grand difference, where excellence in slip ring manufacturing is not just a goal but a standard. Let us be your trusted slid ring supplier and provide you with the reliable solutions you need for your projects.
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Slip rings can be relatively expensive due to several factors that influence their design and manufacturing process. Firstly, the quality of materials used, such as precious metals like gold and silver for the contacts, significantly impacts the overall cost. These materials are essential for ensuring good conductivity and durability, which are critical for reliable operation over time. Additionally, the complexity of the design, including the number of circuits, size, and required customization, can drive up manufacturing costs. The precision engineering required to create slip rings that operate smoothly and effectively in high-speed environments also adds to the expense. Furthermore, the demand for high-quality slip rings in specialized applications, such as aerospace, medical devices, and industrial automation, often necessitates stringent quality control and testing procedures, which can contribute to higher prices. Overall, while the initial investment may be significant, the reliability and performance of slip rings often justify their cost in critical applications.
What is the purpose of the slip ring on a generator?
The primary purpose of a slip ring in a generator is to facilitate the transfer of electrical power from the rotating rotor to the stationary components of the generator. In a typical generator setup, the rotor spins within a magnetic field, generating alternating current (AC) electricity. Slip rings serve as electrical connectors that allow this generated current to be transmitted continuously without interruption, regardless of the rotor’s rotation. By providing a seamless connection between the moving parts and the external circuit, slip rings enable the efficient operation of generators. They are critical in ensuring that power can be delivered to the load without the limitations that would come with a stationary connection. Additionally, slip rings can also help maintain the stability of the electrical output by reducing electrical noise and interference, ensuring that the generator operates effectively and safely. In essence, slip rings are vital for the reliable performance of generators in various applications, from small-scale power generation to large industrial systems.
What is the difference between a rotary union and a slip ring?
Rotary unions and slip rings serve distinct functions in rotating systems, and understanding their differences is crucial for selecting the right component for a specific application. A slip ring is primarily designed for the transfer of electrical signals and power between stationary and rotating parts, facilitating continuous electrical connectivity. This allows for seamless operation in applications like robotics, wind turbines, and medical devices where rotation is necessary. On the other hand, a rotary union, also known as a rotary joint, is used to transfer fluids or gases (such as water, air, or oil) from a stationary source to a rotating element. While both components enable movement, their primary purposes are different: slip rings focus on electrical connectivity, while rotary unions concentrate on fluid transfer. Additionally, slip rings typically involve complex electrical connections and often incorporate multiple circuits, whereas rotary unions may have simpler designs focused on ensuring fluid flow without leaks. Choosing between a rotary union and a slip ring depends on the specific requirements of the application, including whether electrical or fluid transfer is needed.
