Projects / Programmes
Nano-engineering-derived advanced sliding interfaces for a novel alternator slip-ring design with superior tribological and electrical performance
| Code |
Science |
Field |
Subfield |
| 2.11.03 |
Engineering sciences and technologies |
Mechanical design |
Special development know-how |
| Code |
Science |
Field |
| T210 |
Technological sciences |
Mechanical engineering, hydraulics, vacuum technology, vibration and acoustic engineering |
| Code |
Science |
Field |
| 2.03 |
Engineering and Technology |
Mechanical engineering |
Alternator, brush, slip ring, friction, wear, boundary films, graphite, copper, nano-engineering, electrical current
Researchers (17)
Organisations (2)
Abstract
In this project we will focus on developing tribological and electrically efficient and durable contact for the novel and PCT patent-pending design of sliding electric contacts used to conduct electric current from rotary to stationary mechanical components in electric devices. These systems has huge world economic value since they are used in almost every automotive and household electric appliance, such as alternators, motors, turbines, generators, etc. The research proposal will enable replacing current slip ring-brush systems by implementing this innovative and step-change disc-disc contact design, which, however, due to significant novelty, provoke remarkably modified sliding interface conditions. Accordingly, different boundary surface films need to be established in the contact interface - the key contact »component« through which all the current, heat and mechanical loads are actually transferred and carried by - for an efficient mechanical and tribological performance. Two world-renowned research groups will collaborate: an academic team with a world-leading position in boundary films and boundary lubrication of, primarily, carbon-based coating materials (Laboratory for Tribology and Interface NanoTechnology; L-TINT), and the R&D team of Kolektor group, a world-leading producer of the above-mentioned (conventional) system for car alternators with more than 20% of world-market and 75% of European-market share, which also owns the idea of this new product. A comprehensive and in-depth macro and nano scale tribological study of boundary films investigated in (i) short-term parametric and (ii) long-term durability experiments, with simultaneous current conduction will be performed, using real-scale experimental set-ups. Strong product-development skills from Kolektor and high scientific tribological-interface-based knowledge and capacity will join in this research to achieve the ambitious break-through of these systems and will design an effective, controllable and adaptable interface for the required performance.
The new system design also offers strong grounds for successful implementation of a completely new contact material combination for this application, i.e. graphite-graphite, with significant environmental, technological and economic advances compared to conventional copper-graphite pair. The newly developed electric sliding system rely on larger contact area, lower contact pressures, lower electric current densities, improved dynamic stability, lower temperatures and arcing and consequently better efficiency and durability. However, there exist no previous experience of graphite-graphite contacts under similar conditions and these require proper optimisation and tailoring, which can only be achieved through understanding of the mechanisms and key influencing factors, which will be addressed in this project through micro- and nano-engineering approaches. If project is successful, the result will be fully optimised sliding electric contact system (contact design and interface boundary film properties) with huge world market potential that will represent a step-change in the field. Apart from numerous novelties in science of boundary surface films due to completely new conditions and materials used in proposed research, the new disc-disc system will strengthen the global world-leading position of the company Kolektor, increase the number of its potential applications and develop new markets, increase their advantage toward tremendous Asian competition, give rise to new working-places and allow company economic growth and significantly advance the knowledge in the field of these tribo-elctrical systems and enhance cooperation between the academia and industry, which will have long-term benefits for future innovation.
Significance for science
The study investigates electrical sliding contacts. In addition to all classical tribological processes associated with sliding friction, the influence of electrical current, which is simultaneously flowing through the sliding contact, must be taken into account, as it significantly alters the contact conditions and increases the unpredictability of contact behaviour. Therefore the study deals with a very rarely investigated topic, compared to regular sliding contact studies. The increased complexity of the topic prevents the use of standard model test rigs, which demanded an innovative approach to the tribological test rig set-up and the experimental matrix determination. The combination of a new, innovative sliding contact configuration, where both materials are always in contact with each other, and the graphite-graphite material pairing ensures the study's uniqueness, as we could not find any comparable studies of such an electrical sliding contact. The extensive testing and surface analysis conducted had yielded new, important conclusions regarding electrical sliding contacts. The research papers, published based on these conclusions, present scientific evidence within a new research field. Due to rapid development of graphite materials and graphene availability, it could become a widely investigated field, and the results of this study could serve as an important reference.
Significance for the country
Results and findings of this research give conformation of feasibility of new product concept and ability of new product to functionally work in range of end application loads. This give the cooperating company encouragement and important information and knowledge for further development of new product. It also mean an important step towards end realisation and launch of product on demanding automotive market. Estimated launch of new product will represent an important achievement of Slovenian automotive industry and especially of company Kolektor as one of biggest Slovenian exporting company. New product will at least enable to maintain, but probably increase significant market share of company on alternator slip ring market and consequently increase of company income and preserving or even opening new workplaces. Internally developed such innovative product increase the company reputation and shows ability of Slovenian automotive industry for breakthrough innovations and its realisation. Such independent product indicate ability of the company to develop and produce more complex component and systems. What opens new opportunities for program expansions and for new more demanding projects and direct cooperation with automotive OEMs. This consequently leads to company expansion, new jobs, increase of business success and transformation from component to systems developer and producer. The development of new electrical sliding contact is even more important because it enables expansion of end application from automotive alternators to electrical vehicle drive motors, which have even higher market growth potential and higher added value!
Most important scientific results
Annual report
2014,
2015,
final report
Most important socioeconomically and culturally relevant results
Annual report
2014,
2015,
final report
