ingiant technology | Industry new | March 4.2025
Ⅰ. Challenges of the vibration environment of mining equipment to the slip ring system
Mining vehicles are in harsh working conditions of multi-frequency vibration (20-2000Hz), instantaneous impact (peak acceleration ≥15g) and dust concentration >30mg/m³ for a long time 4. Traditional slip ring reels are prone to contact resistance fluctuations (±15%), increased signal error rate (>5‰) and other problems in this environment, which can lead to vehicle control system downtime accidents in severe cases. According to data from an open-pit copper mine in 2024, the unplanned downtime caused by slip ring failure accounts for 38% of the total failure time .
Ⅱ. Core technology solutions for vibration-resistant transformation
a. Impact-resistant slip ring structure upgrade
Adopt a three-level buffer architecture:
Contact layer: implanted beryllium bronze alloy contacts (hardness HV220), with hyperbolic raceway design, the contact pressure fluctuation is controlled within ±3N
Transmission layer: integrated disc spring damping module, can absorb instantaneous impact energy (＞8J), vibration transmission rate is reduced to 0.35
Installation layer: configured with polyurethane-steel composite base, laboratory verification can reduce 20Hz vibration amplitude by 62%
Shock and vibration test simulation diagram
b. Adaptation of mining equipment EMC certification system
The transformation plan strictly follows the GB/T 3836.4-202X explosion-proof electrical electromagnetic compatibility standard:
Install a multi-layer shielding cover (shielding effectiveness ≥70dB@1GHz)
Optimize the wiring topology and reduce the common mode interference voltage from 12V to 0.8V
Pass the 10V/m radiation immunity test, the bit error rate is <0.1‰ (1.2‰ before the transformation)
c.Waterproof and dustproof slip ring integrated solution
Adopts dynamic sealing combination technology:
Main seal: fluororubber rotary seal ring (temperature resistance -40℃~180℃)
Auxiliary seal: labyrinth air curtain barrier structure (air pressure difference 0.05MPa) Reaching IP68 protection level, continuous operation under the impact of dusty water flow (50L/min) for more than 2000 hours without leakage
Waterproof and dustproof slip ring picture
III. Project implementation and verification data
The transformation project implemented in an iron mine in October 2024 shows:
Vibration tolerance: In an 8-hour continuous vibration test (frequency 50Hz, amplitude 2mm), the signal transmission stability increased by 83%
Shock protection: Simulating the falling condition of the mine car (free fall from a height of 1.2m), the integrity rate of key components is 100%
Operation and maintenance cost: The maintenance cycle of the slip ring is extended from 500 hours to 2000 hours, and the annual spare parts consumption is reduced by 47%
main technical parameters
| Index | Before | After | Improvement | |
| Vibration transmissibility | 0.78 | 0.35 | 55%↓ | |
| Signal error rate (‰) | 5.2 | 0.09 | 98%↓ | |
| Protection level | IP54 | IP68 | Dustproof/waterproof | |
| Impact resistance (g) | 8 | 15 | 87%↑ | |
Ⅳ. Extension of intelligent maintenance system
Implant vibration sensor (sampling rate 10kHz) to monitor the status of slip ring in real time
Establish health assessment model to accurately predict remaining service life (error <8%)
Analysis of electromagnetic interference spectrum of 20 equipment clusters through EMC cloud platform
Conclusion
This solution builds a complete vibration protection system through the innovation of impact-resistant slip ring structure, adaptation of mining equipment EMC certification system and integration of waterproof and dustproof slip ring technology. Actual test data shows that the mean time between failures (MTBF) of the equipment after the transformation has increased from 1800 hours to 5200 hours, providing a good foundation for the intelligent transformation of mines.
Post time: Mar-04-2025