Slip ring with connector pins

A system for replacing worn brushes in a slip ring assembly, the system comprising:

• a slip ring comprising a first housing segment having a channel with a longitudinal axis;
• a second housing segment having a channel with a longitudinal axis;
• a brush holder removably held by a portion of the first housing segment;
• a plurality of brushes carried by a brush holder body and extending from a first side of the brush holder such that the brushes extend into a portion of the channel of the first housing segment;
• a plurality of connector pins carried by the brush holder body and extending from a second side of the brush holder, wherein the connector pins are more rigid than the brushes;
• a ring assembly removably received in the channels of the first and second housing portions, the ring assembly including a central body, a plurality of conductive rings, and a plurality of spacers;
• and
• at least one replacement brush holder, whereby the brush holder is configured to be removed from the first housing segment such that the replacement brush holder can be inserted therein.

A slip ring comprising:

• a housing comprising first and second halves, each half having a longitudinal channel, said first half being configured to receive an insert;
• a longitudinal, hollow tube with a longitudinal slot, the tube being insertable into the channels of the first and second housing halves;
• at least one roller bearing configured to be received on the tube;
• at least one electrically conductive ring configured to be disposed on the tube;
• a pair of electrically non-conductive spacers configured to be disposed on the tube on either side of the at least one electrically conductive ring, wherein the spacers have an outer diameter that is larger than an outer diameter of the at least one electrically conductive ring;
• and
• a brush holder having at least one brush extending into a portion of the channel of the first half, and having at least one connector pin extending from the brush holder and configured to be in electrical communication with the at least one brush;
• wherein the slip ring is configured such that the at least one brush is maintained in electrical contact with the at least one electrically conductive ring throughout rotation of the tube relative to the housing, and whereby the spacers maintain an axial position of the brush relative to the at least one electrically conductive ring;
• and
• wherein the at least one brush is integrally formed with the at least one connector pin, and wherein the at least one connector pin has a thickness dimension which is larger than a thickness of the brush.

A method of assembling a slip ring comprising:

• providing a longitudinal tube with a substantially hollow center, a first end, a second end, and a longitudinal slot;
• attaching lead wires to inner surfaces of a plurality of conductive rings;
• positioning at least one rotational bearing onto the first end of the tube;
• positioning a first ring on the tube between the bearing and the second end such that the lead wires extend through the slot, and out the second end of the tube;
• placing a non-conductive spacer adjacent to the first ring, the spacer having an outer diameter that is larger than an outer diameter of the conductive rings, and placing a second ring adjacent to the spacer, thereby sandwiching the spacer between the first and second rings;
• placing the tube in a slip ring assembly housing such that the at least one ring is in electrical communication with a brush, the housing comprising first and second halves, wherein one of the halves comprises a brush holder having a plurality of brushes and connector pins extending there from, the brush holder being removable from the housing;
• positioning the plurality of conductive rings on the tube, wherein a first ring has an axial length that is greater than an axial length of a second ring;
• and
• removing the brush holder, discarding the brush holder, and inserting a new brush holder;
• whereby the spacer prevents a brush which is in contact with the first ring from contacting the second ring.

A replacement brush holder for use in a slip ring having a housing configured to receive the brush holder, and a ring assembly comprising a plurality of conductive rings and a plurality of spacers supported in the housing, the brush holder comprising:

• a molded insert comprising a prismatic body having a first side and a second side, wherein the first side and the second side do not lie in the same plane;
• a plurality of brushes extending from the first side of the insert, each brush comprising a thin flexible finger extending from the insert in a cantilevered manner;
• a plurality of connector pins extending from the second side of the brush holder, wherein the connector pins are more rigid than the brushes;
• wherein the molded insert comprises features configured to correspond with features in the housing such that the brush holder can be frictionally retained in the housing such that the brushes extend into a portion of the housing and contact respective ones of the rings.