For most of the conductive structures in aircraft &amp; spacecraft, the Micro-component brush wires are usually the key parts for electric signal transmission. The pressure of the brush wires has a crucial impact on product performance. Testing and adjusting the pressure of the brush wires on finished components is a key step in the production process of components. The difficulty of measuring the pressure of the brush wire lies in the semi-closed and small deformation. The squeezing depth between the brush wire and the contact plate is only 40 microns, which cannot be measured by inserting a sensor. The current situation of brush pressure adjustment is that there is no relevant theoretical support and it is heavily dependent on worker experience.In this paper, a brush pressure measurement and adjustment model is designed by the ABAQUS simulation software, which generates contact pressure by rotating the brush wire to squeeze with the contact plate, produces plastic deformation to change the contact pressure by loading rod to put the load on brush wire and realizes the measurement and adjustment of the brush pressure by the hook of the high-precision automatic dynamometer to lift the brush wire and use the dynamometer pull to characterize the contact pressure. A number of sets of the simulation models were tested by changing the position of the loading rod and the size of the load. By curve fitting the test data, the change trend of the brush pressure under the action of different parameters and the corresponding relationship between the value measured by the dynamometer and the actual contact pressure were analyzed. Then, according to the designed simulation model, a brush pressure tester and micro-component test pieces were made, and the validity of the simulation model and the rules obtained were verified by the pressure test of the micro-component brush wires.&nbsp;The results of this paper are to design a brush pressure measurement and adjustment program, and provide the concrete implementation scheme of simulation and testing instrument, which realizes the high-precision, automatic measurement and adjustment of the brush pressure, which can be used as a reference in similar fields. Through the finite element model test, it is concluded that the value measured by the dynamometer is linearly related to the actual contact pressure. The adjustment rule of the brush pressure is, when the direction of load applied by the loading rod to the brush is away from the contact plate, the closer to the root of the brush, the greater the load required for the same pressure change, When the direction of load applied by the loading rod to the brush is close to the contact plate, the contact pressure increases when the loading rod approaches the brush root, and the contact pressure decreases when it moves away from the brush root.

Development of an Automatic Detection and Regulation Model of Brush Wire Pressure for a Micro Aerospace Components

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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