IP-Rated / Environmentally Sealed Slip Rings for Harsh Environments: The Stone Aerospace BEAGLE Rover Case Study

Client: Stone Aerospace
Project: Buoyant Rover for Under-Ice Exploration (BEAGLE)
Application: Sonde Marine Slip Ring Winch Assembly
Product: Custom Sealed ROTOCON® Brushless Slip Ring

Stone Aerospace’s BEAGLE rover is a robot designed for a place few machines can go: the damp, highly unique, and incredibly remote underground lakes of Wind Cave National Park in South Dakota. This ambitious project, funded by NASA and led by researchers at the University of Alabama, required every component to be exceptionally robust. The goal is to chart, in 3D, the water chemistry in these unique underwater passages, which are believed to house microbial lifeforms that have evolved in isolation for millennia. The success of the mission hinged on long-term reliability in an environment where repairs are next to impossible.

The Engineering Challenge: A Zero-Failure, Zero-Maintenance Component

A critical system on the BEAGLE rover is the “Sonde Winch Assembly,” which deploys a scientific payload deep into the water. This application required a component with the reliability of a marine winch slip ring, but for a unique, subterranean environment. This system needed a rotary electrical union to pass power and data, but the operating conditions presented a major obstacle. The component would be constantly exposed to a wet, high-humidity cave environment.

The Stone Aerospace engineering team had three non-negotiable requirements:

• Absolute Ingress Protection: The unit had to be a completely environmentally sealed slip ring, effectively a waterproof slip ring solution. Any moisture intrusion would lead to premature failure.
• Long-Term, Maintenance-Free Operation: Because the rover operates in remote, difficult-to-access locations, the slip ring needed to function flawlessly for the life of the mission without any maintenance.
• Low Electrical Noise: The slip ring had to provide a clean, consistent electrical signal, free from noise, especially for the sensitive scientific instruments deployed into the water.

The project demanded a high-performance, IP-rated slip ring designed specifically for harsh environments.

A Collaborative Solution: The Right Referral to The Right Technology

In their search for a solution, Stone Aerospace was referred to Meridian Laboratory by another well-known slip ring manufacturer. Recognizing that the project’s need for a maintenance-free and IP-rated slip ring went beyond the capabilities of conventional brushed slip rings, they recommended Meridian Laboratory’s ROTOCON® brushless slip ring technology as the appropriate solution for the demanding application.

This kicked off a close, hands-on partnership between the two engineering teams. The ROTOCON® brushless slip ring was customized to meet the BEAGLE’s exact specifications, a process that included integrating specialized connectors to ensure a perfect fit within the winch assembly.

The Result: Confirmed Reliability Where It Matters Most

The custom ROTOCON® brushless slip ring performed flawlessly and reliably during BEAGLE’s recent field tests, providing a stable connection completely free of electrical noise for the winch assembly. The environmentally sealed slip ring successfully withstood the harsh cave environment, allowing the rover to carry out its mission objectives.

The successful partnership prompted Stone Aerospace’s COO, Vickie Siegel, to remark, “thanks for working (and) helping make this project succeed!”.

This project showcases ROTOCON® environmentally sealed slip ring technology as a proven solution for the most demanding applications, confirming its place as the premier choice for IP-rated slip rings where reliability and longevity are critical. See our MXO-Series of waterproof / dustproof slip rings for more information.

About Meridian Laboratory

Meridian Laboratory has been a leader in the design and manufacture of high-performance rotary electrical connectors and custom engineering solutions since 1963. Our unique and exclusive ROTOCON® brushless slip rings are renowned for their exceptional reliability, maintenance-free operation, and ability to perform in the most demanding environments, from deep-sea exploration to aerospace applications. We are committed to providing innovative solutions and unparalleled customer support to help our clients achieve their project goals.