2.

5D PCB Technology for

Slipring Assembly

Mélanie Henry
Final presentation days 2017 ESA Contract No. 4000110814/14/NL/US
Objectives
• The 2.5D technology for slipring Assembly project has
been performed to demonstrate that a slipring
assembly based on 2.5D printed circuit board (PCB)
technology can replace in future space mechanisms the
current concept.

• Several units with 2.5D technology have been

manufactured, assembled and tested in the frame of an
ARTES 5.2 project to validate this technology.

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Contents
• Sliprings presentation
• Slipring definition
• Slipring type
• 2.5D Slipring Design
• Description
• Optimisation (design, process)
• Qualification test results
• Conclusion

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Slipring definition
The slipring is a passive element that transmit power and signal
electrical transfer from a rotative part to a fixed part.

The electrical transfer is ensured by sliding contacts (wire brushes in

contact with the tracks)
Wire
brush

Track Contact

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Slipring type
Two different kinds of sliprings:
Cylindrical Planetary

Small diameter Short length

Standard solution for Processes
SADM

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2.5D Slipring design
2.5D Technology slipring description:
 Mechanical interface:

 Electrical interface per module

 20x power lines @ 5.4 A
 20x signal lines @ 1.1 A

 Modularity: possibility to stack 2 modules

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2.5D Slipring design
2.5D Technology slipring description:
Rotor sub-assembly 2x Stator sub-assembly

 Reduced number of parts

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2.5D Slipring design optimization
- Integrated PCB solution for the rotor
- Thermal dissipation
- Wire brushes circular distribution
- Thermal drain inside the PCBs

- Reduced number of parts

- Wire brushes adjusted by tooling
- Parts fixation done only with screws (no
bonding)

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2.5D Slipring MAI process optimisation
Standard planetary slipring process:

New 2.5D slipring process:

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2.5D Slipring MAI process optimisation
Standard planetary slipring process:

X X X XX X
X
New 2.5D slipring process:

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2.5D Assembly & Integration

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2.5D Qualification test sequence

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2.5D Typical results: Electrical resistance
Signal lines

Power lines

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2.5D High voltage Test results
Test performed according RETS project
(ref. ESA Contract 4 200 022 674)
Under vacuum environment

Ambient pressure

Minimum
voltage: 280V

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2.5D TVAC Test

GEO (SN001 & SN002): 30’000 revolutions

LEO (SN003 & SN004): 81’000 revolutions
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2.5D Stripdown Wire brush
GEO life test
wear

LEO life test

 Standard wear observed on wire brushes

 Wear particles as expected (small quantity)
 Gold plating visually not damaged

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Conclusion

Wayforward:
- Integrate the Slipring in a SADM design
- Increase the number of modules to be integrated
(three instead of two)
- Increase the transfered power
- Transfer the stator PCBs solution for cylindrical
slipring

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 Conclusion
The new rotor technology implemented in the 2.5D
Slipring has demonstrated its performance in term of:
• Electrical, mechanical and thermal properties
 The same level (even better) of performances is
achieved with this type of technology compared to the
standard one.

• Lead time reduction about 40%

• Time benefit of 50% in MAI process

• Final cost reduction about 30%

 This new Slipring is then available in RUAG product catalog

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 Thank you for your attention!

Questions?

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