Novel bearing roller running state monitoring device

Abstract

The invention provides a novel bearing roller running state monitoring device, which comprises a roller, a micro generator, a strain elastomer and a state monitoring circuit, and is used for acquiring internal information of the roller and wirelessly transmitting the internal information to an upper computer. The micro generator rotates along with the roller through the rotor winding, the design of the stator permanent magnet array and the gravity stabilizing block is matched, efficient self-power generation by cutting magnetic induction lines is achieved, and power supply is managed through the power management module. The strain elastomer remarkably improves the monitoring sensitivity by amplifying the strain borne by the roller, and accurately monitors the stress and motion states, including the stress size and the rolling and sliding states, of the roller. The device also adopts a low-power-consumption management mode, the main control chip starts a sleep mode to reduce energy consumption when the roller is not loaded, and the device is automatically awakened when the load is recovered to ensure efficient and stable operation. The overall design is compact and efficient, the reliability and long-term monitoring capacity of bearing roller state monitoring are greatly improved, and the requirement for monitoring the running state of a large bearing is met.

Description

Technical Field

[0001] The invention relates to the technical field of large bearing condition monitoring, in particular to a device integrating self-power supply capability and condition monitoring function. Background Art

[0002] With the development of industrial automation and intelligence, equipment condition monitoring and health management technologies have played an important role in ensuring the safety of mechanical equipment and extending its service life. Especially for large bearing systems, large bearings are prone to large recognition errors in fault detection under low speeds and weak vibration signals. Traditional external bearing monitoring devices cannot effectively adapt to the condition monitoring needs of low-speed and heavy-loaded bearings. A new type of bearing roller operation status monitoring device has been proposed in the prior art. The sensor is directly placed inside the bearing roller, which can avoid interference from the vibration characteristics of other components and reduce the loss of fault information during the transmission process, thereby more accurately capturing the roller's fault signal.

[0003] Most existing bearing monitoring power supply technologies use wired power supply or energy storage battery power supply, which not only increases the complexity of installation, but also makes maintenance difficult. At the same time, battery power supply is difficult to support long-term and continuous detection and cannot meet the needs of practical applications.

[0004] At present, some studies have proposed solutions to power sensors with different forms of micro-generators, but most of these generators are large in size and complex in structure, making them difficult to integrate into limited spaces such as bearing rollers. In addition, during roller status monitoring, long-term continuous operation will lead to increased energy consumption, and the traditional high-power consumption mode is difficult to meet the energy efficiency requirements of embedded devices.

[0005] In order to measure the strain generated when the hollow roller is subjected to force, the traditional practice is to fix the strain gauge on the inner wall of the roller hole to measure the circumferential strain. However, in order to meet the stiffness and deformation requirements of the roller in the bearing, the inner diameter of the roller hole is often very small, which makes it extremely difficult to manually fix the strain gauge accurately and safely in the inner wall of the roller hole. Summary of the invention

[0006] The purpose of the present invention is to solve at least one of the technical problems existing in the prior art, and to provide a new type of bearing roller operation status monitoring device, which can continuously generate electricity during the rolling process of the roller, thereby solving the problem of being unable to detect the roller's operation status in real time for a long time, including parameters such as vibration acceleration, temperature, rotation speed, and load. The present invention relies on the electric energy generated by the roller's rotational energy to achieve the self-powering function of the bearing roller operation status monitoring device, which will reduce dependence on traditional batteries, reduce maintenance costs, and improve the overall reliability and durability of the system. The device integrates a strain elastomer structure, based on a unique annular design and a cross-beam deformation amplification principle, to achieve high-sensitivity monitoring of the roller load and judgment of the roller's motion state, and also introduces a low-power management mode. Through real-time monitoring of the load size, the status monitoring circuit automatically enters sleep mode, thereby greatly reducing the system's energy consumption in the non-load area.

[0007] The present invention also provides a novel bearing roller operation status monitoring device, comprising: a roller, a micro-generator, a strain elastic body and a status monitoring circuit, and also comprising a connection cover, a rotor winding, a stator permanent magnet array, a gravity stabilization block, a strain elastic body, a lithium battery, a power management module and a wireless communication module, wherein a sealing cover is provided at the front end of the wireless communication module, and the outer surface of the sealing cover is in contact with the roller;

[0008] The micro-generator, strain elastic body and state monitoring circuit are installed inside the roller, and the internal shape of the strain elastic body is a cross beam structure for sensitive force measurement;

[0009] The stator permanent magnet array in the micro-generator is installed on the connecting shaft together with the gravity stabilizing block. The micro-generator is provided with a rotor winding that rotates synchronously with the roller and a relatively stationary stator permanent magnet array. The rotor winding has a rotor core and a coil winding.

[0010] The rotor winding is interference fit with the roller and rotates along with the roller.

[0011] According to the novel bearing roller operation status monitoring device, the stator permanent magnet array has a permanent magnet, a stator core, a gravity stabilization block and a gravity stabilization block supporting bearing. Since the inertia moment of the gravity stabilization block on the stator permanent magnet array is greater than the friction force of the gravity stabilization block supporting bearing on the stator permanent magnet array, the stator permanent magnet array cannot rotate, so that the rotor winding and the stator permanent magnet array produce relative rotation, cutting the magnetic flux lines to generate electrical energy.

[0012] According to the novel bearing roller operation status monitoring device, the gravity stabilizing block is in the shape of a cam.

[0013] According to the novel bearing roller operation status monitoring device, the connecting cover is threadedly connected to a connecting shaft.

[0014] According to the novel bearing roller operation status monitoring device, the coil winding wound on the rotor core leads out a three-phase line connected to a power management module to charge a lithium battery, thereby realizing the self-power supply function of the status monitoring circuit.

[0015] According to the novel bearing roller operation status monitoring device, the permanent magnets of the stator permanent magnet array have opposite polarities.

[0016] According to the novel bearing roller running state monitoring device, the strain elastic body is annular, and has arc convex blocks on all four sides.

[0017] According to the novel bearing roller operation status monitoring device, the cross beam includes beam No. 1, beam No. 2, beam No. 3 and beam No. 4, the upper surface of beam No. 3 is provided with a resistance strain gauge R, the lower surface of beam No. 3 is provided with a resistance strain gauge R, the upper surface of beam No. 4 is provided with a resistance strain gauge R, and the lower surface of beam No. 4 is provided with a resistance strain gauge R.

[0018] According to the cross beam, the outer side of the No. 1 beam is connected to the arc protrusion, the outer side of the No. 2 beam is connected to the arc protrusion, the outer side of the No. 3 beam is connected to the arc protrusion, and the outer side of the No. 4 beam is connected to the arc protrusion.

[0019] According to the novel bearing roller operation status monitoring device, the status monitoring circuit includes a sensor module, a power management module and a wireless communication module, and the sensor module includes a load strain gauge, a temperature sensor, an acceleration sensor and an angular velocity sensor.

[0020] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present invention is further described below in conjunction with the accompanying drawings and embodiments;

[0022] Figure 1 It is a cross-sectional schematic diagram of a novel bearing roller running state monitoring device of the present invention;

[0023] Figure 2 A schematic diagram of an intelligent roller of a novel bearing roller operating status monitoring device of the present invention;

[0024] Figure 3 This is a structural schematic diagram of a novel micro-generator of a bearing roller operating status monitoring device of the present invention;

[0025] Figure 4This is a schematic diagram of the structure of a strain elastic body of a novel bearing roller running status monitoring device of the present invention;

[0026] Figure 5 It is a schematic diagram of the force on the strain elastic body of a novel bearing roller running state monitoring device of the present invention;

[0027] Figure 6 A schematic diagram of the structure of a state monitoring device of a novel bearing roller operation state monitoring device of the present invention;

[0028] Figure 7 The present invention is a schematic diagram of the internal structure of a new type of bearing roller operating status monitoring device of the present invention.

[0029] Legend:

[0030] 1. Roller; 2. Connecting cover; 3. Micro generator; 4. Stator permanent magnet array; 5. Rotor winding; 6. Gravity stabilization block; 7. Strain elastic body; 8. Lithium battery; 9. Power management module; 10. State monitoring circuit; 11. Wireless communication module; 12. Sealing cover; 13. Rotor core; 14. Coil winding; 15. Permanent magnet; 16. Stator core; 17. Gravity stabilization block support bearing; 18. Arc convex block; 19. Cross beam; 20. Resistance strain gauge R1; 21. Resistance strain gauge R2; 22. Resistance strain gauge R3; 23. Resistance strain gauge R4; 24. Beam No. 1; 25. Beam No. 2; 26. Beam No. 3; 27. Beam No. 4. DETAILED DESCRIPTION

[0031] This section will describe in detail the specific embodiments of the present invention. The preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the accompanying drawings is to supplement the description of the text part of the specification with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present invention, but it cannot be understood as a limitation on the scope of protection of the present invention.

[0032] like Figure 1-6As shown, a novel bearing roller operation status monitoring device according to an embodiment of the present invention includes a roller 1, a micro generator 3, a strain elastic body 7 structure, a status monitoring circuit 10 and a lithium battery 8. The micro generator 3 is connected to the strain elastic body 7 through the threads on both sides of the connection cover 2. The micro generator 3 outputs electric energy to the power management module 9 in the status monitoring circuit 10 to continuously charge the lithium battery 8. The status monitoring circuit 10 is bolted to the lead-out board on the strain elastic body 7. The strain gauges on the strain elastic body 7 form a full-bridge circuit output connected to the status monitoring circuit 10 for amplification and A / D conversion processing. The status monitoring circuit 10 also includes a microprocessor, a temperature measurement module, a vibration acceleration module, an angular velocity gyroscope module, a data storage module and a wireless communication module 11. The collected sensor data is transmitted to the host computer in real time through the wireless communication module 11.

[0033] like Figure 1 and Figure 2 The roller 1 shown in the figure, in order to realize the real-time monitoring of the internal parameters of the roller 1, a through hole is processed on the central axis of the roller 1 without affecting the working strength of the roller 1. After multiple simulations and mechanical analysis, the diameter of the through hole should be less than 30% of the roller diameter. For example, the maximum diameter of the roller 1 in this example is 96mm, and the diameter of the through hole processed along the central axial direction is 30mm. The elastic deformation and equivalent force changes of this hollow roller 1 bearing under radial load are relatively small, and the load-bearing capacity does not change much, which does not affect the normal use of the roller 1.

[0034] The state monitoring circuit 10 is provided with a microprocessor for controlling the operation and sleep of each sensor and completing the processing and transmission of sensor data. An STM32 single-chip microcomputer is used as the control and data processing center of the system.

[0035] The wireless communication module 11 is arranged near the edge of the inner hole of the smart roller 1 to maximize the efficiency of wireless data transmission. The wireless transmission module needs to meet the requirements of strong signal penetration, low power consumption and strong anti-interference. For this reason, the present invention selects a wireless transmission module of LoRa communication technology.

[0036] The LoRa module has strong signal penetration capability and is particularly suitable for data transmission needs in complex environments. The frequency spectrum range of the LoRa module is 410MHz to 525MHz. When working in the low frequency band, its signal penetration is strong, and it is particularly suitable for environments with more metal obstructions. The maximum transmission distance of the LoRa module can reach two kilometers, which can meet the data transmission needs in industrial application scenarios. In addition, the module works in low-power mode, which effectively reduces the energy consumption of the system and extends the operating time of the equipment. At the same time, the anti-interference ability is improved through spread spectrum modulation technology.

[0037] like Figure 3 and Figure 4 As shown, the micro generator 3 is composed of a rotor core 13, a coil winding 14, a permanent magnet 15, a stator core 16, a gravity stabilizing block 6 and a gravity stabilizing block support bearing 17. The rotor core 13 is connected to the roller 1 by an interference fit and rotates and rolls with the roller 1. The rotor core 13 is provided with 12 slots, and the coil winding 14 is wound in the slots. Twelve permanent magnets 15 are pasted on the stator core 16, and the magnets are arranged adjacent to each other with NS polarity. The gravity stabilization block 6 is welded to the stator core 16. The friction force of the supporting bearing 17 of the gravity stabilization block is offset by the inertia moment of the gravity stabilization block 6, so that the stator core 16 remains stable, thereby realizing the rotation of the rotor core 13 relative to the stator core 16. According to the principle of electromagnetic induction, the coil winding 14 generates electrical energy when cutting the magnetic flux lines, realizing electromagnetic induction power generation. The three-phase electricity output by the coil is connected to the power management module 9 through the three-phase rectifier circuit to charge the lithium battery 8. The lithium battery 8 supplies power to the status monitoring circuit 10 through the power management module 9BQ25570, thereby realizing the self-power supply function.

[0038] like Figure 5 and Figure 6 As shown, the strain elastic body 7 includes a plurality of resistance strain gauges 20-23, four arc convex blocks 18 and a cross beam 19. The strain elastic body 7 is composed of four beams, which are marked as beam No. 1 24, beam No. 2 25, beam No. 3 26 and beam No. 4 27. The beams are connected by a central disk and are evenly distributed in the circumferential direction. The strain gauges are respectively attached to the middle areas of the four beams according to the mechanical simulation results, and form a detection circuit with the bridge.

[0039] The design purpose of the strain elastic body 7 is to improve the sensitivity of signal detection under the condition of accurate affixing of the strain gauge, thereby achieving high-precision measurement of the radial force in the rotating system.

[0040] like Figure 6 The working principle of the strain elastic body 7 shown is that during the operation of the device, when the radial force F acts on the beam No. 1 24, the beam No. 1 24 and the beam No. 2 25 are directly loaded beams, and their deformation strain is small, while the beam No. 3 26 and the beam No. 4 27 are indirectly loaded beams, and significant bending deformation occurs due to the structural coupling.

[0041] Four strain gauges are respectively attached to the middle area with larger strain of the thin wide surface of the third beam 26 and the fourth beam 27 to detect the tensile and compressive strain signals on the upper and lower surfaces. Since the strain signals of the third beam 26 and the fourth beam 27 are significant and linearly related to the radial force F, their signal output is used as the main detection signal. Since the strain elastic body 7 rotates, the strain of each beam will show periodicity with the change of position. In a complete rotation cycle, the strain signal will have two major fluctuations. The frequency of the signal has the following relationship with the rotation frequency.

[0042] fs=2f

[0043] The wide thin surface of the third beam 26 and the fourth beam 27 of the strain elastic body 7 is respectively attached with resistance strain gauges R120, resistance strain gauges R221, resistance strain gauges R322, and resistance strain gauges R423, which are connected to form a Wheatstone bridge for accurately measuring the strain state of the beam. The bridge output signal Vout is linearly related to the strain and resistance change of the beam. When the radial force F acts on the first beam 24, the force is transmitted to the third beam 26 and the fourth beam 27 through the first beam 24, resulting in compression and tensile strains on the wide thin surfaces of the two beams. The resistance strain gauge R120 and the resistance strain gauge R322 are respectively attached to the lower surface of the No. 3 beam 26 and the No. 4 beam 27, mainly detecting the compressive strain of the No. 3 beam 26 and the No. 4 beam 27, thereby causing the resistance of the strain gauge to decrease. The resistance strain gauge R221 and the resistance strain gauge R423 are respectively attached to the upper surface of the No. 3 beam 26 and the No. 4 beam 27, mainly detecting the tensile strain of the No. 3 beam 26 and the No. 4 beam 27, thereby causing the resistance of the strain gauge to increase. The resistance strain gauge R120 and the resistance strain gauge R221 form a differential signal pair for detecting the bending strain of the No. 3 beam 26. The resistance strain gauge R322 and the resistance strain gauge R423 form another differential signal pair for detecting the bending strain of the No. 4 beam 27. The differential signal design of the Wheatstone bridge can effectively eliminate the influence of temperature changes and other common-mode interference, and can more accurately measure the strain caused by bending.

[0044] The bridge output is then connected to the state monitoring circuit 10 for processing, and the load on the roller 1 can be obtained through the HX711 analog-to-digital conversion module. The structure of the strain elastic body 7 improves the sensitivity of the detection signal, especially in the case of low speed and high noise loading, and can capture clearer signal fluctuations.

[0045] The state monitoring circuit 10 monitors the load data of the roller 1 in real time and intelligently determines whether the roller 1 is in the non-load area based on the change characteristics of the load signal. When the load signal is continuously lower than the preset load area average threshold, the system performs logic analysis through the microprocessor, confirms that the roller 1 enters the non-load area, and automatically switches to the sleep mode.

[0046] In sleep mode, the microprocessor in the status monitoring circuit 10 will control non-essential modules to shut down, such as vibration sensors, temperature sensors, angular velocity sensors and wireless communication modules 11, etc., and only retain the basic load monitoring and low-power operation of the main control chip, and only wake up periodically to detect the change signal of the load signal. Once the load signal is detected to be restored to a value higher than the set threshold, the roller 1 re-enters the load area, and the system will quickly wake up and restore all functional modules. Through the above-mentioned low-power management mode, the monitoring system of the present invention can significantly reduce the power consumption in the non-load area, which not only prolongs the battery life of the equipment, but also improves the energy efficiency and reliability of the overall system, and is suitable for long-term monitoring needs under low-speed and heavy-load conditions.

[0047] In summary, the present invention provides a bearing roller operation status monitoring device, which can integrate self-power supply capability and multi-parameter status monitoring functions in the roller 1. Through ingenious structural design and functional integration, the device can work stably for a long time under low-speed and heavy-load conditions, and effectively improves the accuracy and real-time performance of fault detection.

[0048] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the knowledge scope of ordinary technicians in the technical field without departing from the purpose of the present invention.

Claims

1. A new type of bearing roller running status monitoring device, characterized in that: include: The invention relates to a roller (1), a micro generator (3), a strain elastic body (7) and a state monitoring circuit (10), and further comprises a connection cover (2), a rotor winding (5), a stator permanent magnet array (4), a gravity stabilizing block (6), a strain elastic body (7), a lithium battery (8), a power management module (9) and a wireless communication module (11), wherein a sealing cover (12) is provided at the front end of the wireless communication module (11), and an outer surface of the sealing cover (12) is in contact with the roller (1); The micro-generator (3), the strain elastic body (7) and the state monitoring circuit (10) are installed inside the roller (1), and the internal shape of the strain elastic body (7) is a cross beam (19) structure for sensitive force measurement; The stator permanent magnet array (4) and the gravity stabilizing block (6) in the micro-generator (3) are mounted on a connecting shaft together. The micro-generator (3) is provided with a rotor winding (5) that rotates synchronously with the roller (1) and a relatively stationary stator permanent magnet array (4). The rotor winding (5) has a rotor core (13) and a coil winding (14); The rotor winding (5) is interference fit with the roller (1) and rotates along with the roller (1).

2. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The stator permanent magnet array (4) comprises a permanent magnet (15), a stator iron core (16), a gravity stabilizing block (6) and a gravity stabilizing block supporting bearing (17). Since the moment of inertia of the gravity stabilizing block (6) on the stator permanent magnet array (4) is greater than the friction force of the gravity stabilizing block supporting bearing (17) on the stator permanent magnet array (4), the stator permanent magnet array (4) cannot rotate, so that the rotor winding (5) and the stator permanent magnet array (4) generate relative rotation, cutting the magnetic flux lines to generate electric energy.

3. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The gravity stabilizing block (6) is in the shape of a cam.

4. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The connection cover (2) is threadedly connected with a connection shaft.

5. A novel bearing roller running status monitoring device according to claim 1, characterized in that: A three-phase line derived from a coil winding (14) wound around a rotor core (13) is connected to a power management module (9) to charge a lithium battery (8), thereby realizing a self-power supply function of a state monitoring circuit (10).

6. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The permanent magnets (15) of the stator permanent magnet array (4) have opposite polarities.

7. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The strain elastic body (7) is annular, with arc convex blocks (18) on all four sides.

8. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The cross beam (19) comprises a first beam (24), a second beam (25), a third beam (26) and a fourth beam (27); the upper surface of the third beam (26) is provided with a resistance strain gauge R2 (21); the lower surface of the third beam (26) is provided with a resistance strain gauge R1 (20); the upper surface of the fourth beam (27) is provided with a resistance strain gauge R4 (23); and the lower surface of the fourth beam (27) is provided with a resistance strain gauge R3 (22).

9. The cross beam (19) according to claim 8, characterized in that The outer side of the No. 1 beam (24) is connected to the circular arc convex block (18), the outer side of the No. 2 beam (25) is connected to the circular arc convex block (18), the outer side of the No. 3 beam (26) is connected to the circular arc convex block (18), and the outer side of the No. 4 beam (27) is connected to the circular arc convex block (18).

10. A novel bearing roller running status monitoring device according to claim 1, characterized in that: The state monitoring circuit (10) comprises a sensor module, a power management module (9) and a wireless communication module (11), wherein the sensor module comprises a load strain gauge, a temperature sensor, an acceleration sensor and an angular velocity sensor.

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