Conductive carbon brushes are widely used in the industrial sector, including large-scale hydraulic generators and thermal power generators. They are highly effective in conducting low-frequency currents. However, as a single conductor, the effective conducting area of the carbon brush is limited, making it unable to address the skin effect of high-frequency currents. Additionally, carbon brushes, which are made by pressing carbon powder and metal powder, become loose and prone to wear in oil-immersed environments. Typically, they need to be replaced every 4-12 months in industrial motor applications. Moreover, carbon brushes are more susceptible to breakage under high vibration conditions. Carbon brushes also require the use of springs to apply pressure to the ends of the shaft. These springs are consumable items and undergo thermal treatment during operation, causing a gradual reduction in elasticity. When the carbon brush bounces, it generates discharge, which can accelerate bearing damage.

Conductive oil seals achieve conductivity by incorporating conductive powders or silver plating on their surfaces. However, this material has poor wear resistance and loses its conductivity after short-term friction, especially in oil-cooled environments. When oil permeates, the impedance increases, leading to a decrease in conductivity. This is why many customers have reported that the initial performance is good, but it deteriorates after a period of time.

Some customers or manufacturers use conductive bearings in two ways. One is to replace the bearings at the front or rear of the motor with conductive bearings, serving as working bearings. Conventional bearings only experience resistive discharge in the low-speed range, while intermittent capacitive breakdown discharge occurs in the high-speed range. However, conductive bearings discharge continuously throughout the entire operating period. After working for tens of thousands of kilometers, they are prone to electrocorrosion and develop abrasive surfaces. The other way is to use non-working sacrificial bearings, which do not bear torque and are installed in parallel with the working bearings to provide a conductive path. Sacrificial bearings also produce abnormal noise during sacrifice, and the timing of their failure is difficult to control. It cannot be guaranteed whether the failure will occur after the entire vehicle lifecycle or after the warranty period, making the after-sales cost uncontrollable.

Hangcheng's solution is the "Hu Cheng Core®" high-conductive fiber grounding ring/bar. The friction force between the fiber grounding and the shaft is very small, ensuring sufficient contact with the shaft surface. Additionally, the fiber is highly wear-resistant and has a long service life. Hangcheng conducted experiments where the fiber and shaft frictioned for 280,000 kilometers, and the fiber only wore down by 0.4mm, which can achieve effective use throughout the entire lifecycle of a vehicle. Furthermore, the "Hu Cheng Core®" can maintain normal conductivity even in oil-immersed environments.

Each bundle of fibers in the "Hu Cheng Core®" contains 12,000 strands, and the metal casing is assembled with conductive fibers, ensuring its high conductivity. Some manufacturers use conductive rings made of pure carbon fiber from abroad. However, carbon fiber has a higher impedance, resulting in higher resistance between the fiber and the shaft surface. Therefore, if pure carbon fiber is used as the conductive path, especially in the low-speed range, there is a possibility of contact between the ball and the raceway, which has low resistance. If the impedance of the parallel protective circuit is higher than the resistance, it cannot achieve the desired shunting effect. The "Hu Cheng Core®" is significantly different from pure carbon fiber. It is a carbon fiber modified with high-conductivity metal. The high-conductivity metal is distributed on the outer circumference to effectively ensure conductivity. Additionally, the "Hu Cheng Core®" does not contain any organic materials, making it highly resistant to various environmental conditions, such as high and low temperatures and chemical corrosion.

The "Hu Cheng Core®" has various structural forms, including press-fit, bolted, and rod-style (which extends into the bearing and discharges the electricity by contacting the inner wall of the bearing). The dimensions can also be customized. If the bearing is large, such as in wind power generation, it can be made into segmented sections. Currently, we have developed a series of product matrices, including air-cooled/water-cooled and oil-cooled series. The main difference lies in the length of the fiber and the clearance fit with the shaft surface. The fiber bundles used in oil-cooled applications are slightly shorter, while those used in air-cooled or water-cooled applications are longer. In water-cooled/air-cooled applications, the fiber and shaft have dry friction, resulting in a high coefficient of friction and increased fiber wear. Under oil-cooled conditions, the lubricating properties of oil slow down wear, but the insulating oil film, which becomes viscous and adhesive due to the high-speed rotation of the shaft, tends to carry the fiber. The shorter fiber design is harder and stiffer, effectively puncturing the oil film to achieve good contact with the shaft.

The effectiveness of shaft voltage reduction depends primarily on two types of discharge: resistive discharge in the low-speed range and capacitive breakdown discharge. In terms of resistive discharge, the parallel protective impedance should be lower than the bearing's impedance. Hangcheng conducted a comparison of the impedance between the bearing and the parallel protection under different speeds and frequencies. Without installing the conductive ring, the impedance of the bearing ranged from tens of ohms to over 30 ohms at 500 rpm or in static conditions, which increased to several tens of thousands of ohms at higher speeds. After installing the conductive ring, the impedance reduced to only a few ohms, with a maximum of four to five ohms. It is difficult to accurately measure the impedance of one's own car motor, as the testing power supply or tools can easily be influenced by shaft voltage, leading to distorted data. To avoid shaft voltage interference, Hangcheng used a very low-power industrial frequency motor for testing, which does not generate shaft voltage.

We will now present a practical application case to illustrate the effectiveness of our product in reducing shaft voltage. In 2020, the "Hu Cheng Core®" was mass-installed in new energy commercial vehicles. In a 400V/150kW drive motor, the bearing discharge voltage was 15.2V. After installing the "Hu Cheng Core®," the shaft voltage was reduced to only 2V, providing a significant safety margin and preventing discharge

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