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What Is Difference Between PCB Slip Ring and Split Ring?

Slip rings and split rings are two important devices used in electrical and

mechanical systems for transmitting power and signals across rotating

interfaces. Both allow transmission between stationary and rotating

components, but have some key differences in their design and

applications.

In this article, we will provide a detailed comparison between PCB slip

rings and split rings, including:

 Definitions and working principles

 Construction and design

 Materials and manufacturing

 Performance characteristics

 Advantages and disadvantages

 Typical applications

 Main differences summarized

Understanding the differences between slip rings and split rings enables

selecting the right device for different use cases requiring rotary

transmission.

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Table of Contents

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Defining Slip Rings and Split Rings

What is a Slip Ring?

A slip ring is an electromechanical device that allows transmission of

power and electrical signals from a stationary source to a rotating

structure. It consists of a stationary part called the stator, and a rotating

part called the rotor.

The stator contains conductive rings that are electrically insulated from

each other. The rotor contains metal brushes that make sliding contact

with the rings on the stator. As the rotor turns, the brushes maintain

continuous electrical connection by sliding over the rings, allowing

transmission of power/signals across the rotating interface.

Diagram showing construction of a slip ring.

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Common configurations of slip rings include:

 Pancake slip ring – Rings are arranged in a flat stack.

 Cylindrical slip ring – Rings are arranged concentrically on a

cylinder.

 PCB slip ring – Rings are etched on a printed circuit board.

Slip rings are bidirectional and can transmit power/signals in both

directions across the rotating interface. They allow transmission of low

to high power, as well as a wide range of analog and digital signals.

What is a Split Ring?

A split ring, also called a brush block commutator, is a modified slip ring

designed to transmit only low power signals or currents in one direction

across a rotating interface.

It consists of a rotor assembly containing conductive segments or poles

isolated from each other by small gaps. Stationary brushes contact these

rotating poles to transmit signals.

As the rotor turns, the brushes make sliding contact with each pole in

sequence, allowing transmission in only one direction – from the rotating

poles to the fixed brushes. The small gaps between the poles prevent

reverse transmission or short circuiting between segments.

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Diagram showing construction of a split ring.

Split rings are unidirectional and can only transmit signals in one direction

– from rotor to stator. They are suitable for low power signals, and not for

high power transfer.

Construction and Design

PCB Slip Ring Construction

PCB slip rings are constructed from rings etched on a printed circuit board,

which allows compact construction and precise control of ring placement.

Key components of a PCB slip ring include:

 Printed circuit board (FR4) that forms the stator, with conductive

copper rings etched on one side.

 Rotor containing metal brushes (copper, bronze, precious metals)

 Insulating cover/housing enclosing the PCB and rotor assembly

 Bearings allowing smooth rotation of rotor

The PCB is designed with the required number of concentric copper rings

etched at precise intervals needed for circuit contacts. The rotor fits over

the PCB and the brushes make sliding contact with the copper rings.

Cross section of a PCB slip ring showing copper rings and rotor brushes.

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Advantages of PCB slip rings include compact size, easy manufacturing,

precise control of tracks, and fast assembly.

Split Ring Construction

Split ring construction consists of a rotor containing segmented

conductive poles separated by small air gaps. Common materials used

include copper, brass or steel.

The rotor mounts on a bearing and is enclosed in a housing. Brushes are

fixed to the stator housing and make sliding contact with the rotor poles.

As the rotor turns, the brushes consecutively connect with each rotor pole,

allowing transmission from rotor to stator. The gaps between the poles

prevent reverse transmission through the brushes.

Diagram of a split ring showing segmented rotor poles and fixed brushes.

Split rings provide unidirectional transmission and are suitable for

intermittent signal contacts. Their simple construction allows low cost

manufacturing.

Materials and Manufacturing

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PCB Slip Ring Materials

PCB slip rings are manufactured from the following materials:

 Printed Circuit Board (FR4) – Forms the stator containing the copper

ring tracks. FR4 provides electrical insulation between rings.

 Copper – Used to etch the conductive rings on the PCB. Provides

excellent conductivity.

 Precious metal brushes (gold, silver, palladium) – Used for

contacting the copper rings due to high durability and low contact

resistance.

 Plastics like PTFE, PEEK – Used for casing and flange components.

Provide mechanical stability.

 Bearings – Allow smooth rotation and consist of steel balls/rollers

with a plastic retainer.

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The PCB fabrication process allows high precision patterning of ring tracks

in different configurations. The brushes are designed for stable

low-friction contact and minimal wear. High quality materials ensure

reliability with prolonged use.

Split Ring Materials

Split rings use the following common materials:

 Copper, brass or steel for the rotor segments. Copper provides the

best conductivity.

 Precious metal brushes (silver, gold) for low contact resistance and

reduced oxidation.

 Plastic housings like nylon, PTFE to enclose the rotor and provide

insulation.

 Bearings using steel balls/rollers to enable smooth rotor rotation.

Split rings use basic materials that provide stable performance at low cost.

The materials offer reasonable durability with low friction contacts

between the brushes and rotor segments.

Performance Characteristics

PCB Slip Ring Performance

PCB slip rings provide the following performance characteristics:

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 Number of circuits – Can support 10 to 100+ ring contacts for

multiple circuits.

 Current rating – Handle currents from a few mA to over 100 A. Gold

brushes allow up to 500 A on each ring.

 Voltage rating – Rated up to 1000V AC/DC for standard designs.

 Speed – Standard rings allow rotational speeds up to 1000

rpm. High speed rings support above 5000 rpm.

 Temperature range – Operate from -40°C to +80°C. Special designs

work upto 250°C.

 Noise – Low noise of 10-50 mΩ allows transmission of sensitive

signals.

 Contact resistance – Brush contact resistance of 1-10 mΩ allows

high power transfer.

 Lifetime – Brush lifetime over 100 million rotations with precious

metal contacts.

 Isolation – Up to 1000V isolation between adjacent rings.

PCB manufacturing provides precise ring dimensions and spacing for

reliable transmission of multiple power/data circuits.

Split Ring Performance

Split rings have the following typical performance ratings:

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 Current – Maximum current around 15-20A. Only suitable for low

power signal transmission.

 Voltage – Maximum voltage rating up to 60V DC.

 Speed – Standard split rings rated for speeds up to 3000 rpm.

 Poles – Typical number of poles is 6 to 20. More poles allow more

brush contacts.

 Temperature – Operating temperature range of -20°C to +80°C.

 Noise – Prone to electrical noise due to brush arcing.

 Contact resistance – Brush contact resistance around 50-100 mΩ.

Higher than slip rings.

 Wear – Brush wear out faster than slip rings due to arcing and

higher contact resistance.

 Lifetime – Brush lifetime around 25 million rotations. Less than slip

rings.

Split rings are designed for unidirectional transmission of intermittent, low

power signals. They offer lower performance than slip rings but at a lower

cost.

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Advantages and Disadvantages

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PCB Slip Ring Advantages

PCB slip rings provide the following benefits:

 Compact size due to PCB manufacturing

 Precise control and spacing of ring circuits

 Low and stable brush contact resistance

 Low electrical noise for reliable signal transmission

 High current and voltage capacity

 High rotational speeds capability

 Long service life with minimal wear

 Bi-directional transmission through rings

 Easy integration and installation

 Suitable for data and power transfer

PCB technology enables fabrication of small, high performance slip rings

with multiple circuit capacity.

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PCB Slip Ring Disadvantages

Some disadvantages of PCB slip rings include:

 More complex manufacturing process

 Higher cost than basic slip rings

 Larger minimum diameter required for ring spacing

 Not easy to repair or replace brushes

 Precious metal brushes can be expensive

 Requires smooth rotor shaft and precision assembly

While PCB slip rings provide superior performance, they also have higher

costs and complexity than basic slip ring types.

Split Ring Advantages

Split rings offer the following benefits:

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 Simple and low cost construction

 Compact, lightweight design

 High speed operation easily achievable

 Low friction provides smooth running

 Only basic tools needed for manufacturing

 Easy to repair and replace brushes

 No need for special materials or complex production

The simple design of split rings allows them to be manufactured cheaply

and used easily in applications requiring only low power transmission.

Split Ring Disadvantages

Some limitations of split rings include:

 Only allow unidirectional transmission

 Prone to electrical noise and interference

 Low power and voltage capacity

 Limited number of brush contacts

 Short service life due to brush wear

 Cannot transmit high speed data or multiple signals

 Contact resistance is higher than slip rings

 Not suitable for continuous power transfer

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Split rings are not capable of the bi-directional, high power and data

transmission possible with slip rings. Their design and materials impose

limits on performance.

Typical Applications

PCB Slip Ring Applications

Some common applications of PCB slip rings include:

 Industrial machinery – To transmit control and telemetry data

between stationary controls and rotating machinery.

 Medical equipment – MRI machines, CT scanners, etc. use slip rings

to transfer signals/power.

 Avionics – Used in radar systems, control surfaces, weapon turrets

that must rotate continuously.

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 Robots – For transferring signals between robot base and rotating

joints or platform.

 Amusement rides – Used on rotating food trays, lighting rings and

ride platforms.

 Wind turbines – Allow power transfer from rotating turbine hub to

stationary conductors.

 CCTV cameras – Enable continuous video feed transmission from

pan-tilt security cameras.

PCB slip rings are used anywhere continuous, bi-directional transmission

under rotation is needed. Their compact size and high performance allow

integration into complex systems.

Split Ring Applications

Typical applications of split rings include:

 Low voltage electric motors – For periodic power transmission to

rotor coils.

 Automotive systems – Used in sliding door connectors, seat and

mirror controls.

 Rotating displays – For transmitting display data from stationary

controllers to rotating signboards.

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 Assembly machinery – Allow power and control signals to rotating

tool heads and positioners.

 Material handling – Used on continuously rotating conveyors and

sorters for sensor signals.

Split rings are suitable for cost-sensitive, unidirectional transmission

applications that only require low power or occasional contacts.

Main Differences Between Slip Rings and Split Rings

Parameter PCB Slip Rings Split Rings

Construction Copper rings etched on PCB. Precious Segmented rotor poles separated by
metal brushes. gaps. Metal graphite brushes.
Transmission Bi-directional – Signals can pass in Unidirectional – Transmission only
either direction. from rotor to stator.

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Parameter PCB Slip Rings Split Rings

Power rating Up to 100s of Amps, 1000s of Volts. Less than 20A, under 60V.
Speed Up to 5000 rpm for standard rings. High Around 3000 rpm max speed.
speed rings even higher.
Noise Very low electrical noise. Suited for Prone to electrical noise due to arci
sensitive data.
Contacts 10 to 100+ separate isolated contacts. Typically 6 to 20 contacts.
Resistance 1-10 mΩ brush contact resistance. 50-100 mΩ typical contact resistan
Service life 100 million rotations or more. Around 25 million rotations max.
Cost Higher cost due to advanced materials Low cost because of simple
and production. construction.
Applications Industrial, Low power motors, basic machinery,
medical, military, robotics. For intermittent signals.
high speed data, video, power
transmission.

Conclusion

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PCB slip rings and split rings both allow transmission across rotating

interfaces, but have major differences in their design, capabilities and

applications.

Key Points:

 PCB slip rings use precise etched copper rings to enable

bi-directional, low noise transmission of multiple power and data

circuits simultaneously.

 Split rings consist of an insulated rotor with segmented contacts,

allowing only unidirectional, intermittent signal transmission.

 Slip rings handle high speeds, power, voltages and lifetimes. Split

rings are limited to low power signals and shorter lifetimes.

 PCB manufacturing provides slip rings with small sizes but higher

cost. Split rings have simple construction but lower performance.

 Slip rings are used where high speed rotation and reliable

transmission are needed. Split rings find use in cost-sensitive

applications requiring only simple unidirectional contacts.

In summary, PCB slip rings are the preferred choice wherever continuous,

reliable transmission of power and high-speed data in both directions is

required – such as in precision industrial machinery, robotics, medical

systems and military applications. Split rings are suitable for basic low cost

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systems involving only simple unidirectional signal contacts, like low

voltage motors, basic automated systems and rotating displays.

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