Orthogonal simulation study on bending stress of flexible rings in power slip rings

The power slip ring is a core component for rotating electrical transmission in aerospace applications. Bending stress concentration in the flexible ring remains a critical bottleneck limiting service life, and quantitative characterization of stress sensitivity under multi-parameter coupling is lacking. Taking the maximum bending stress as the evaluation metric, an orthogonal numerical simulation was conducted. Three factors – the number of flexible rings/idler wheels, idler wheel radius, and rotational speed of the inner conductive ring – were selected, each with four levels. Range and variance analyses quantified the influence patterns. Results demonstrate that the idler wheel radius exerts a highly significant effect (P-value extremely small), while the number of flexible rings/idler wheels and rotational speed have relatively minor impacts. The idler wheel radius is identified as the primary control parameter for stress reduction, providing a quantitative basis for structural optimization and service life extension.