导电滑环刷丝的工作性能对卫星的整体能源安全与在轨寿命有着至关重要的影响。为了保证信号和电流的实时传递，需要对刷丝角度进行控制。本研究通过有限元法的理论分析，建立了电刷板和刷丝的三维模型；结合显式动力学和隐式静力学的有限元模拟方法，确定了刷丝最佳的角度成型方式，完成了刷丝角度成型与回弹的有限元模拟；提出了一种基于有限元针对刷丝角度回弹过程的测量方法，并对刷丝回弹角的仿真值与理论值进行了对比分析。结果表明：与单侧偏转板和双侧短夹持板相比，双侧长夹持板对刷丝角度成型的作用方式最佳；刷丝的回弹角度与成型角度呈正相关，刷丝的成型角度越大，刷丝成型后的回弹变形值越大；刷丝成型角度在120°以上时，由于残余应力过大，所以刷丝材料很可能发生破坏。为了防止刷丝在发生弹塑性变形时其材料左侧根部发生破坏，应将夹持板左侧夹紧面尽量贴近刷丝左侧根部位置，对刷丝根部增加约束，以保证刷丝角度成型的质量；刷丝回弹角度的最大相对误差约为2°，但平均误差值在1°左右，总体回弹趋势基本一致，可以很好地表示出刷丝回弹角度的变化规律。

The performance of the conductive slip ring brush wires has a vital impact on the lifespan of the satellite in orbit and the overall energy safety. In order to ensure the real-time transmission of signal and current, the brush wire angle needs to be controlled. This study established a three-dimensional model of the brush plate and the brush wire based on the theoretical analysis of the finite element method. The best way for producing the brush wire’s angles was identified by combining the explicit dynamics and implicit statics finite element simulation techniques. The brush wire angle forming and rebound were then fully simulated with these techniques. This paper presented a measurement method based on the rebound process of the brush wire angle, and compared the simulation value with the theoretical value of the brush wire rebound angle. The findings demonstrate that compared to the single-sided deflector plate and the double-sided short clamping plate, the double-sided long clamping plate performs at its finest when forming the brush wire’s angle; the brush wire’s rebound angle is positively correlated to the forming angle; the larger the forming angle of the brush wire, the larger the rebound deformation value of the brush wire after forming; when the brush wire is formed at an angle of 120° or more, the brush wire material is likely to be damaged due to excessive residual stresses. In order to prevent the destruction of the left root of the brush wire during elastic-plastic deformation, the left clamping surface of the clamping plate should be placed as close as possible to the left root of the brush wire to increase the constraints on the root of the brush wire, so as to ensure the quality of the angle forming of the brush wire; the maximum relative error in the angle of rebound of the brush wire is about 2°, but the average rebound inaccuracy is about 1°; the overall rebound trend is generally consistent, so the proposed method can well indicate the variation law of the rebound angle of the brush wire.