Application Case of Slip Rings in Aerospace Test Turntables

The turntable’s azimuth axis operates at a maximum rotation speed of 100 rpm, with a positioning accuracy of ±0.001°. Traditional cable-driven transmission faced three critical issues:

1. Mechanical Fatigue: Repeated bending of cables during rotation led to frequent wire breakage, requiring monthly maintenance and increasing downtime.
2. Signal Interference & Loss: Twisted cables generated electromagnetic interference (EMI) that disrupted weak analog signals from inertial sensors, resulting in test data errors of up to 5%.
3. Limited Rotation Range: Cables restricted continuous 360° rotation, forcing the turntable to pause and reverse direction periodically—compromising the realism of dynamic simulation tests.

To address these challenges, the company integrated a customized capsule-type slip ring (model: SR-CT-12-ETH) developed by a professional slip ring manufacturer. This slip ring was engineered to meet the turntable’s unique requirements, with the following key features:

The SPR-ing‘s slip ring integrates 12 electrical channels (for 24V DC power and RS485 signals) and 1 optical fiber channel (for 10Gbps Ethernet), enabling simultaneous transmission of power, control signals, and high-bandwidth data—all in a single compact unit (diameter: 45mm, length: 80mm) that fits seamlessly into the turntable’s axis.

• Gold-Gold Contact Technology: The SPR-ing's slip ring uses gold-plated brass rings and gold-clad brushes, minimizing contact resistance (≤0.01Ω) and signal attenuation. This reduced noise in analog sensor signals to less than 1mV, cutting test data errors to below 0.5%.
• Shielded Design: A nickel-plated aluminum housing and internal EMI shielding layers prevented cross-talk between channels, ensuring stable transmission of high-frequency Ethernet signals even at maximum rotation speed.

• Maintenance-Free Operation: The SPR-ing's slip ring is filled with high-temperature grease for self-lubrication, eliminating the need for regular oiling. Its service life exceeds 10 million rotations (equivalent to 5+ years of continuous operation in the test turntable).
• Wide Environmental Adaptability: It operates reliably in temperatures ranging from -40°C to 85°C and vibration levels up to 10G—meeting the harsh conditions of aerospace test environments.

Since integrating the slip ring, the test turntable has achieved remarkable improvements:

1. Uninterrupted Continuous Rotation: The slip ring enables 24/7 360° rotation without cable tangling, allowing dynamic simulation tests that mimic real-world flight conditions (e.g., satellite antenna tracking during orbital maneuvering).
2. 10x Reduction in Downtime: Mechanical failures from cable fatigue have been eliminated, reducing maintenance costs by 60% annually.
3. Test Accuracy Elevation: High signal integrity ensures that inertial navigation system tests meet military-grade precision standards, supporting the company’s development of next-generation aerospace equipment.

In high-precision rotary systems like aerospace test turntables, slip rings act as the critical "neural hub" that connects stationary and rotating components. By solving the inherent limitations of cable-driven transmission—such as mechanical wear, signal degradation, and limited rotation—slip rings not only enhance operational reliability and lifespan but also unlock the full performance potential of rotary equipment. For applications requiring high accuracy, high bandwidth, and continuous rotation, customized slip rings are an indispensable core component.