Embedded self-powered intelligent bearing

Abstract

The invention belongs to the technical field of mechanical parts, and particularly relates to an embedded self-powered intelligent bearing which comprises a bearing outer ring, a bearing inner ring, a retainer and a plurality of rollers, the rollers are located in a raceway between the bearing inner ring and the bearing outer ring, the retainer is installed between the rollers, and the embedded self-powered intelligent bearing is characterized by further comprising a plurality of magnets, the magnet is fixed on the retainer between the rollers, a mounting cavity is formed in the roller, a plurality of turns of coils, a circuit board and a vibration sensor connected to the input end of the circuit board are arranged in the mounting cavity, the circuit board is in wireless communication connection with an external upper computer, and the coils are connected to the circuit board. Magnetic induction lines generated when the coil cuts the magnet supply power to the circuit board. The coil is arranged in the roller, the relative motion between the magnet and the coil can cut magnetic induction lines to the maximum extent, strong electromotive force is generated, and the energy conversion efficiency is improved; and meanwhile, the vibration sensor is arranged in the roller, so that the environmental interference is reduced, and the detection precision is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of mechanical components, and particularly relates to an embedded self-powered intelligent bearing. Background Art

[0002] In the modern industrial field, bearings, as key components in mechanical equipment, their performance and reliability directly affect the operation status of the entire equipment. However, traditional bearings face many challenges in design and manufacturing. On the one hand, to ensure their stable operation under complex working conditions such as high speed and heavy load, extremely strict requirements are imposed on accuracy and material properties. The high-precision processing technology and the selection of high-performance materials not only greatly extend the production cycle but also lead to high costs. On the other hand, due to the complex structure of the bearing and its core supporting role during equipment operation, once a failure occurs, it must be replaced. This process not only involves high maintenance costs but also brings huge economic losses to enterprises due to long-term equipment downtime, seriously affecting production efficiency and economic benefits.

[0003] In this severe situation, the concept of intelligent bearings emerged. Intelligent bearings, by integrating advanced technologies such as sensors and data communication, achieve real-time automatic perception of their own working status and can predict potential failures, providing a strong guarantee for the stable operation of equipment. For example, Patent CN118816984A proposes a multi-parameter thin-film sensor for intelligent bearings and its preparation method. This method effectively solves the problems that the external structure of high-end intelligent bearings cannot adapt to the internal structure of the original bearing housing, is inconvenient to install, and the monitoring object and range are limited by in-situ manufacturing of the sensor on the bearing end face. However, this solution still has obvious defects. The sensor is located outside the bearing and is extremely vulnerable to external environmental factors such as dust, moisture, and corrosive gases. This not only seriously affects the working state of the sensor but also greatly shortens its service life and reduces the reliability of the intelligent bearing.

[0004] In addition, it is publicly recorded in related technologies that electromagnetic induction is used for self-power supply between the bearing end face and the end cover, successfully solving the problems of limited working hours and high maintenance costs caused by wired power supply or battery power supply of intelligent bearings. However, this solution also has deficiencies. The contact area between the circuit board package and the inner ring end face of the bearing is small, and it is easy to loosen during long-term rotation of the bearing, affecting the power supply stability. In addition, due to structural limitations, the magnet and the coil can only be arranged on one side of the bearing, which makes the magnetic flux change small, the power generation efficiency limited, and the low-power consumption requirements for the sensor extremely demanding, restricting the wide application of intelligent bearings to a certain extent.

[0005] In summary, although the current intelligent bearing technology has made some progress, it still faces many problems that need to be solved. How to effectively protect the sensor from the external environment and innovate a self-powered solution with high energy conversion efficiency have become the key to promoting the further development of intelligent bearing technology, which has extremely important practical significance and broad application prospects. Summary of the invention

[0006] In view of the defects in the prior art that the sensor is arranged outside the bearing and is easily disturbed by the external environment, and due to structural limitations, the magnet and the coil can only be arranged on one side of the bearing, which makes the magnetic flux change small and the power generation efficiency limited, the present invention provides an embedded self-powered intelligent bearing to solve the above technical problems.

[0007] In the first aspect, the present invention provides an embedded self-powered intelligent bearing, including a bearing outer ring, a bearing inner ring, a retaining frame and a plurality of rollers, the rollers are located in the raceway between the bearing inner ring and the bearing outer ring, the retaining frame is installed between the rollers, and also includes a plurality of magnets, the magnets are fixed on the retaining frame between the rollers, an installation cavity is opened inside the roller, a plurality of turns of coils, a circuit board and a vibration sensor connected to the input end of the circuit board are arranged in the installation cavity, the circuit board is wirelessly connected to an external host computer, the coil is connected to the circuit board, and when in use, the coil cuts the magnetic induction lines generated by the magnet to power the circuit board.

[0008] A further improvement of the technical solution is that the roller is made of silicon nitride material.

[0009] A further improvement of the technical solution is that the magnet is made of neodymium iron boron material.

[0010] A further improvement of the technical solution is that a heat sink is provided on the retaining frame.

[0011] A further improvement of the technical solution is that heat dissipation holes are provided on the retaining frame.

[0012] A further improvement of the technical solution is that the distance between the coil and the magnet is set to be one to five times the diameter of the coil.

[0013] A further improvement of the technical solution is that the vibration sensor adopts a thin film vibration sensor of model JYB-KB-CW2000, LD-3000 series or VT2000 series.

[0014] A further improvement of the technical solution is that a microcontroller of model MSP430 is arranged on the circuit board, the film vibration sensor is connected to the input end of the microcontroller, and the microcontroller is connected to an external host computer through wireless communication.

[0015] A further improvement of this technical solution is that a rectifying current, a filtering circuit, and a voltage stabilizing circuit are also provided on the circuit board. The input end of the rectifying circuit is connected to both ends of the coil, and the output end of the rectifying circuit is sequentially connected to the microcontroller and the thin-film vibration sensor through the filtering circuit.

[0016] A further improvement of this technical solution is that the rectifying circuit includes a rectifier U1, the filtering circuit includes a resistor R1 and a capacitor C1, and the voltage stabilizing circuit includes a voltage stabilizing chip U2 of model LM7805 and a capacitor C2; The first end of the rectifier U1 is connected to the first end of the coil, the second end of the rectifier U1 is connected to the second end of the coil, the third end of the rectifier U1 is connected to the first end of the capacitor C1 and the input end of the voltage stabilizing chip U2 through the resistor R1, the output end of the voltage stabilizing chip U2 is connected to the 5V power output end and the first end of the capacitor C2, and the fourth end of the rectifier U1, the second end of the capacitor C1, the grounding end of the voltage stabilizing chip U2, and the second end of the capacitor C2 are all grounded.

[0017] The beneficial effects of the present invention are as follows: High-efficiency self-power supply and reduced dependence: The present invention adopts a self-power supply method that combines a multi-turn copper wire coil with a neodymium iron boron magnet. During actual operation, when the roller rolls, the coil can fully cut the magnetic induction lines generated by the magnet. The neodymium iron boron magnet has a high magnetic energy product and can generate a strong magnetic field intensity, which perfectly matches the layout design of the coil. The coil is placed inside the roller, and the relative movement between the magnet and the coil can maximize the cutting of magnetic induction lines, thereby generating a strong electromotive force and significantly improving the energy conversion efficiency. Compared with traditional wired power supply or battery power supply, it greatly reduces the dependence on external power sources, not only reducing the maintenance cost, but also ensuring the continuous and stable operation of the intelligent bearing under various complex working conditions, effectively solving the problem of limited working hours of the intelligent bearing.

[0018] Optimizing the sensor environment and improving performance: Placing the vibration sensor inside the roller brings twofold advantages. On the one hand, the inside of the roller can provide a relatively stable and less interfering environment for the sensor, avoiding contact between the sensor and harsh environmental factors such as external dust, water vapor, and corrosive gases, effectively extending the service life of the sensor and ensuring the accuracy of measurement data. On the other hand, selecting silicon nitride material to make the roller, its excellent properties facilitate the efficient transmission of sensor data to the outside, enabling the sensor to more accurately obtain the vibration data inside the bearing, providing a reliable basis for the monitoring of the equipment operation status and the prediction of faults.

[0019] Good heat dissipation design to ensure operation: Heat sinks and heat dissipation holes are provided on the cage, forming an effective heat dissipation system. During the high-speed operation of the bearing, a large amount of heat is generated. The heat sinks increase the heat dissipation area and can quickly dissipate the heat to the surrounding environment; the heat dissipation holes promote air circulation and accelerate heat exchange. This design can timely reduce the temperature inside the bearing, avoid problems such as performance degradation and increased wear of components caused by excessive temperature, ensure the stable operation of the intelligent bearing under long-term and high-load working conditions, and extend the overall service life of the bearing.

[0020] In addition, the design principle of the present invention is reliable, the structure is simple, and it has a very broad application prospect. Brief Description of the Drawings

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, for those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0022] Figure 1 It is a schematic structural diagram of an embedded self-powered intelligent bearing.

[0023] Figure 2 It is a schematic internal structure diagram of a roller.

[0024] Figure 3 It is a schematic diagram of the rectifier circuit, filter circuit and voltage regulator circuit.

[0025] 110 is the bearing outer ring, 120 is the bearing inner ring, 130 is the roller, 140 is the magnet, 150 is the installation cavity, 160 is the coil, and 170 is the circuit board. Detailed Embodiments

[0026] To make the objectives, features, and advantages of the present invention more obvious and understandable, the following will clearly and completely describe the technical solutions in the present invention in conjunction with the drawings in the specific embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of this application.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs. The terms used in the description of the present invention in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0028] Such as Figure 1and Figure 2 As shown, the present invention provides an embedded self-powered intelligent bearing, which includes an outer bearing ring 110, an inner bearing ring 120, a cage, and a plurality of rollers 130. The rollers 130 are located in the raceway between the inner bearing ring 120 and the outer bearing ring 110, and the cage is installed between the rollers 130. It further includes a plurality of magnets 140, and the magnets 140 are fixed on the cage between the rollers 130. An installation cavity 150 is formed inside the roller 130, and a plurality of turns of coils 160, a circuit board 170, and a vibration sensor connected to the input end of the circuit board 170 are arranged in the installation cavity 150. The circuit board 170 is wirelessly communicatively connected to an external host computer, and the coil 160 is connected to the circuit board 170. During use, the coil 160 cuts the magnetic induction lines generated by the magnet 140 to supply power to the circuit board 170.

[0029] During the operation of the bearing, the rolling of the roller 130 causes relative movement between the magnet 140 and the coil 160, and the coil 160 fully cuts the magnetic induction lines generated by the magnet 140. The magnetic field intensity of the magnet 140 is high. In combination with the design of the multi-turn coil 160, according to Faraday's law of electromagnetic induction, the rate of change of magnetic flux is greatly increased, and then a stronger electromotive force is generated, significantly improving the energy conversion efficiency. Compared with traditional wired power supply, it gets rid of the trouble of complex wiring, reduces the installation complexity, and improves the flexibility of equipment layout; compared with battery power supply, it avoids the problems of limited battery life, frequent replacement, and high maintenance cost, providing sustainable and stable power support for the intelligent bearing, ensuring its continuous and stable operation under various working conditions.

[0030] Specifically, in order to improve the electric energy conversion efficiency, according to Faraday's law of electromagnetic induction, from the formula ( is the unit of induced electromotive force in V; N is the number of turns of the coil 160; is the magnetic flux per turn of the coil 160; is the time rate of change of magnetic flux), it can be seen that the induced electromotive force is proportional to the rate of change of magnetic flux and proportional to the number of turns of the coil 160. Therefore, the coil 160 adopts a multi-turn design, increasing the number of magnetic force lines cut, thereby increasing the amplitude of the induced current. In the application scenario of the intelligent bearing of the motor, according to the operating parameters of the motor and the spatial dimensions of the bearing, high-purity oxygen-free copper is selected as the material of the coil 160. Oxygen-free copper has excellent electrical conductivity, which can effectively reduce the resistance loss during current transmission, ensuring the efficient output of the induced current. According to the design requirements, the number of turns of the coil 160 is accurately calculated and determined.

[0031] In order to further improve the electric energy conversion efficiency, it is necessary to limit the distance between the coil 160 and the magnet 140. In the field of electromagnetic induction, the distance between the coil 160 and the magnet 140 has a significant impact on the magnetic flux. According to the magnetic flux Calculation formula (where is the magnetic flux, B is the magnetic induction intensity, S is the area of the coil 160, and θ is the angle between the magnetic induction intensity B and the normal direction of the plane of the coil 160). When the distance between the coil 160 and the magnet 140 changes, the magnetic flux will be changed by affecting the magnetic induction intensity. Generally speaking, the magnetic field generated by the magnet 140 is not evenly distributed. The closer to the magnet 140, the greater the magnetic induction intensity. As the distance between the coil 160 and the magnet 140 increases, the magnetic induction intensity will gradually decrease. If other conditions remain unchanged, when the magnetic induction intensity decreases, the magnetic flux will also decrease accordingly.

[0032] In the embedded self-powered intelligent bearing of the present invention, the distance between the coil 160 and the magnet 140 is set to be one to five times the diameter of the coil 160. When the distance is too close, although the magnetic flux is relatively large, the stability and continuity of the coil 160 cutting the magnetic induction line may be affected due to factors such as uneven magnetic field distribution; when the distance is too far, the magnetic flux drops significantly, and the induced electromotive force and induced current will also become weak, resulting in a decrease in the electric energy conversion efficiency. Therefore, reasonably controlling the distance between the coil 160 and the magnet 140 can ensure that the coil 160 stably cuts the magnetic induction line while keeping the magnetic flux within a suitable range, realizing efficient electric energy conversion.

[0033] In addition, the roller 130 in the present invention is made of silicon nitride material. The silicon nitride roller 130 is installed in the raceway between the inner bearing ring 120 and the outer bearing ring 110 to ensure that the rollers 130 are evenly distributed and can roll freely. At the same time, the cage installed with the magnet 140 is installed between the rollers 130 to ensure the accurate relative positions of all components. During the entire installation process, collisions and damages to the silicon nitride roller 130 are avoided to ensure that its performance is not affected. Silicon nitride material has excellent dielectric properties and good wave transmission properties. In the intelligent bearing, a vibration sensor and related circuits are installed inside the roller 130. The wave transmission property of silicon nitride enables the sensor to communicate wirelessly with the outside more efficiently, reduces signal attenuation, and ensures that the vibration data collected by the sensor can be quickly and accurately transmitted to the circuit board 170 for processing. At the same time, the inside of the roller 130 provides a relatively stable working environment for the sensor, avoiding interference from external environmental factors such as lubricating oil and dust to the sensor, improving the accuracy and long-term stability of the measurement data of the sensor, and providing a reliable basis for accurately judging the working state of the bearing. As a high-performance ceramic material, silicon nitride has excellent wear resistance, high strength, and low thermal expansion coefficient. During the high-speed and high-load operation of precision machine tools, the roller 130 bears huge pressure and friction. The high wear resistance of silicon nitride makes the surface of the roller 130 not easily worn, enabling it to maintain a good working state for a long time, extending the replacement cycle of the roller 130, and reducing the maintenance cost of the equipment. Its high-strength characteristic ensures that the roller 130 will not deform or break under heavy loads, ensuring the structural stability and reliability of the bearing. The low thermal expansion coefficient enables the roller 130 to have extremely small dimensional changes under working conditions with large temperature variations, maintaining the high-precision operation of the bearing, and improving the machining accuracy and product quality of the machine tool.

[0034] Furthermore, the magnet 140 is made of neodymium iron boron material; during the intelligent bearing assembly stage, the qualified neodymium iron boron magnet is fixed on the cage using a high-strength and aging-resistant adhesive, ensuring that the magnet 140 is located at a predetermined position between the rollers 130 and will not displace or fall off during the high-speed operation of the bearing. The neodymium iron boron material has the characteristic of high magnetic energy product and can generate a strong magnetic field intensity. When the intelligent bearing of the wind turbine operates, the rolling of the rollers 130 drives the relative movement between the magnet 140 and the coil 160. Due to the strong magnetic field of the neodymium iron boron magnet, the coil 160 can cut more magnetic induction lines. According to Faraday's law of electromagnetic induction, the rate of change of magnetic flux is greatly increased, thereby generating a stronger electromotive force and significantly improving the power conversion efficiency. Compared with the magnet 140 made of other magnetic materials, the neodymium iron boron magnet can generate a higher induced current under the same relative movement conditions, providing more sufficient power for electronic components such as sensors and microcontrollers inside the intelligent bearing, ensuring the efficient operation of the self-powered system of the intelligent bearing. In addition, the neodymium iron boron magnet has good magnetic stability and can maintain the relative stability of its magnetic field performance under different environmental conditions such as temperature and humidity. In the complex outdoor environment where the wind turbine is located, the temperature change range is large and the humidity is also high. The neodymium iron boron magnet can adapt to these harsh conditions and ensure the continuous and stable operation of the self-powered system of the intelligent bearing. Even during long-term operation, the magnetic field intensity of the magnet 140 will not show obvious attenuation, ensuring the stability of the induced current and providing a reliable power guarantee for the intelligent bearing to monitor its own working state in real time.

[0035] In addition, in order to ensure that a large amount of heat generated during the high-speed operation of the bearing can be quickly dissipated to the surrounding environment, the present invention is provided with heat sinks on the cage. In the application of the intelligent bearing of a large industrial motor, the heat sinks are made of aluminum alloy. Aluminum alloy has excellent thermal conductivity, a relatively high thermal conductivity coefficient, can quickly conduct heat, and at the same time has the characteristics of light weight, high strength and corrosion resistance, and is suitable for long-term use in the environment where the bearing operates at high speed.

[0036] The heat sinks adopt a fin structure, and the thickness of each fin is designed to be 2 mm, which can not only ensure the sufficient strength of the heat sinks but also increase the heat dissipation area in a limited space. The height of the fins is 15 mm, the width is 10 mm, and the spacing between the fins is set to 5 mm. This spacing can not only ensure that air can flow smoothly between the fins to achieve efficient heat exchange but also prevent the accumulation of dust and other impurities due to too small a spacing from affecting the heat dissipation effect. In order to further enhance the structural stability of the heat sinks, reinforcing ribs are provided at the bottom and top of the heat sinks, and the thickness of the reinforcing ribs is 3 mm, which is integrally formed with the main body of the heat sinks.

[0037] Install the designed heat sink on the outer circumferential surface of the cage. During specific installation, use a high-temperature resistant and high-strength adhesive to closely paste the heat sink on the cage to ensure good heat conduction between the heat sink and the cage. At the same time, the heat sinks are evenly distributed along the circumferential direction of the cage, with one heat sink installed every 10 mm, so as to ensure effective heat dissipation on the entire circumference of the cage. To avoid the heat sink affecting the normal operation of other components inside the bearing, a safety distance of 5 mm is maintained between the outer edge of the heat sink and the inner wall of the bearing outer ring 110 to ensure that the heat sink will not collide with other components during the high-speed rotation of the bearing.

[0038] The design of the finned heat sink greatly increases the heat dissipation area. During the high-speed operation of the bearing, heat is conducted from the cage to the heat sink. Due to the significant increase in the surface area of the heat sink, the heat can be quickly dissipated into the surrounding air. Excessive temperature will accelerate the wear and aging of each component inside the bearing and reduce the service life of the bearing. Through the efficient heat dissipation of the heat sink, the operating temperature of the bearing is reduced, and the wear rate of the components is slowed down. Additionally, in an intelligent bearing, excessive temperature may cause the magnet 140 to demagnetize, affecting the power generation efficiency of the self-powered system. The heat sink dissipates the heat generated by the bearing in a timely manner, maintaining the stability of the ambient temperature around the magnet 140, ensuring that the magnet 140 always maintains good magnetism, guaranteeing the stable operation of the self-powered system, and thus ensuring that the intelligent bearing can continuously and reliably monitor its own working state.

[0039] Furthermore, heat dissipation holes are provided on the cage; in the circumferential direction of the cage, a group of heat dissipation holes is evenly distributed every 30°. Each group contains 3 circular heat dissipation holes with a diameter of 5 mm, and these heat dissipation holes are arranged in a triangular pattern, with a center distance of 10 mm between the holes. Such a layout method can maximize the air circulation path while ensuring the structural strength of the cage. In the axial direction of the cage, 5 groups of the above-mentioned heat dissipation hole groups are evenly distributed along the length direction, and the distance between the groups is 15 mm. Through this combination of circumferential and axial layouts, the heat generated in all parts of the entire cage can be effectively dissipated.

[0040] The reasonable layout of the heat dissipation holes enables air to form an effective convection inside the cage. The hot air inside the bearing will rise through the heat dissipation holes, and the cold air outside will flow in from other heat dissipation holes, forming a continuous air circulation, effectively reducing the temperature of the bearing during operation. The lower temperature can reduce the oxidation and evaporation of the lubricating oil, maintain the good performance of the lubricating oil, thereby reducing the friction coefficient between the bearing components and reducing wear.

[0041] In particular, the present invention further includes that while installing heat sinks on the cage, heat dissipation holes are provided on the cage; the heat sinks are made of a copper alloy material with excellent thermal conductivity, and its thickness is 3 mm, which can not only ensure a certain structural strength but also have excellent thermal conductivity. The heat sinks are designed in a wavy shape to increase the heat dissipation area. The height of each wave unit is 10 mm, the width is 15 mm, and the distance between adjacent wave units is 5 mm. On the outer circumferential surface of the cage, a heat sink is installed every 15 mm along the circumferential direction. The heat sinks are firmly connected to the cage through a high-temperature and high-strength welding process to ensure that they will not fall off during the high-speed operation of the bearing. In order to prevent the heat sinks from affecting the normal operation of other components inside the bearing, a safety distance of 8 mm is maintained between the outer edge of the heat sink and the inner wall of the bearing outer ring 110. The magnet 140 is installed in the gap between the heat sink and the heat dissipation hole; the wavy design and dense arrangement of the heat sinks greatly increase the heat dissipation area, and the reasonable layout of the heat dissipation holes promotes the convection cycle of air. The combination of the two greatly improves the heat dissipation efficiency.

[0042] In order to improve the detection accuracy of the bearing itself, the vibration sensor in the present invention uses a thin-film vibration sensor of model JYB-KB-CW2000, LD-3000 series or VT2000 series.

[0043] A microcontroller of model MSP430 is provided on the circuit board 170. The thin-film vibration sensor is connected to the input end of the microcontroller, and the microcontroller is wirelessly communicatively connected to an external host computer. The MSP430 microcontroller is a processor with ultra-low power consumption and stable performance, and is widely used in sensor networks and battery-powered devices. MSP430 has rich peripheral interfaces, such as ADC (Analog - to - Digital Converter), I2C (Inter - Integrated Circuit), SPI (Serial Peripheral Interface), UART (Universal Asynchronous Receiver / Transmitter), etc., and can perform efficient data exchange with sensors and communication modules. The low-power consumption characteristic of the microcontroller enables the system to have a long service life without an external battery. After receiving the sensor signal, the MSP430 microprocessor performs data sampling through the built-in analog-to-digital converter (ADC). After the data is processed by the algorithm, important parameters such as the state, vibration frequency, and operating conditions of the device can be calculated in real time, providing a basis for device maintenance and performance optimization.

[0044] To achieve wireless data transmission between the microcontroller and the external host computer, the present invention adopts low-frequency RF communication technology. Compared with high-frequency electromagnetic waves, low-frequency electromagnetic waves have stronger penetration ability, which is particularly suitable for data transmission in complex industrial environments. The low-frequency RF communication technology can ensure the stability and penetration ability of signals when passing through obstacles such as walls and metals under the condition of low power consumption, ensuring the reliable transmission of device status data to the remote monitoring system. To ensure the long-term stability of the system, the data transmission adopts an adaptive communication protocol, which automatically adjusts the data transmission rate and power consumption according to the actual transmission environment, enabling the system to maintain high-performance operation in different working states.

[0045] Finally, to ensure power supply stability, a rectifier circuit, a filter circuit, and a voltage regulator circuit are also provided on the circuit board 170. The input end of the rectifier circuit is connected to both ends of the coil 160, and the output end of the rectifier circuit is sequentially connected to the microcontroller and the thin-film vibration sensor through the filter circuit.

[0046] As Figure 3 shown, the rectifier circuit includes a rectifier U1, the filter circuit includes a resistor R1 and a capacitor C1, and the voltage regulator circuit includes a voltage regulator chip U2 of model LM7805 and a capacitor C2; the first end of the rectifier U1 is connected to the first end of the coil 160, the second end of the rectifier U1 is connected to the second end of the coil 160, the third end of the rectifier U1 is connected to the first end of the capacitor C1 and the input end of the voltage regulator chip U2 through the resistor R1, the output end of the voltage regulator chip U2 is connected to the 5V power output end and the first end of the capacitor C2, and the fourth end of the rectifier U1, the second end of the capacitor C1, the grounding end of the voltage regulator chip U2, and the second end of the capacitor C2 are all grounded.

[0047] The rectifier U1 in the rectifier circuit converts the alternating current generated by the coil 160 into direct current. During the operation of the intelligent bearing, the induced current generated by the coil 160 cutting the magnetic induction lines of the magnet 140 is alternating current, and its current direction changes periodically with time. However, electronic components such as the microcontroller and the thin-film vibration sensor require direct current to work stably. The access of the rectifier U1 makes the current direction fixed, providing a stable current input basis for the subsequent circuit, avoiding the situation that electronic components cannot work properly or even be damaged due to unstable current direction, and ensuring the power supply stability of the entire intelligent bearing system.

[0048] The filter circuit eliminates the interference of current fluctuations: The filter circuit is composed of resistor R1 and capacitor C1, which can effectively remove the fluctuation components in the rectified DC power. After the AC power generated by coil 160 is rectified, although the current direction has been unified, there are still certain ripples and noise in the voltage. These fluctuations will interfere with the normal operation of the microcontroller and the thin film vibration sensor, resulting in inaccurate data collection or unstable equipment operation. The filter circuit composed of resistor R1 and capacitor C1 smoothes the voltage through the charging and discharging characteristics of the capacitor and the current limiting effect of the resistor on the current, making the output DC power more stable, reducing the interference of current fluctuations on electronic components, improving the accuracy of sensor data collection and the reliability of microcontroller processing data, and thus improving the accuracy of the intelligent bearing's monitoring of its own working status. The voltage stabilization circuit uses the voltage stabilization chip U2 of model LM7805 and capacitor C2, which can stabilize the voltage at 5V output. When the intelligent bearing is working, the electromotive force generated by the coil 160 cutting the magnetic flux lines will be affected by many factors, such as changes in the magnetic field strength of the magnet 140 and fluctuations in the rotation speed of the roller 130, resulting in unstable output voltage. The LM7805 voltage regulator chip U2 can automatically adjust the output voltage, and can ensure a stable output voltage of 5V regardless of how the input voltage changes. Capacitor C2 further filters and stabilizes the output voltage to ensure that the voltage does not fluctuate. The stable 5V voltage provides a reliable power supply for the microcontroller and the thin film vibration sensor, ensuring that they can operate stably under various working conditions, avoiding equipment failures caused by excessively high or low voltage, extending the service life of electronic components, enhancing the stability and reliability of the intelligent bearing system, and providing a strong guarantee for the long-term stable operation of the equipment. The rectifier circuit, the filter circuit, and the voltage regulator circuit work together to form a complete and efficient power supply guarantee system. From the initial conversion of AC to DC, to the elimination of current fluctuations, and then to the stable voltage output, each link works closely together to provide a stable and reliable power supply for the microcontroller and the thin film vibration sensor in the intelligent bearing. This not only ensures that the sensor can accurately collect vibration data and the microcontroller can efficiently process and transmit data, but also enables the entire intelligent bearing system to continue to operate stably under complex and changeable working conditions, effectively reducing system failures caused by power supply problems, improving the operating efficiency and reliability of the equipment, and providing solid support for the continuity and stability of industrial production.

[0049] The working principle of this embedded self-powered intelligent bearing is: In terms of mechanical structure, the bearing outer ring 110 and the bearing inner ring 120 serve as support components. The rollers 130 are located in the raceways between the two. When the equipment is operating, the inner ring rotates with the shaft, driving the rollers 130 to roll. The rolling of the rollers 130 in turn pushes the outer ring to maintain relative stability. The cage is installed between the rollers 130, playing the role of isolating and guiding the rollers 130, ensuring that the rollers 130 are evenly distributed and roll stably in the raceways, and maintaining the smooth operation of the bearing.

[0050] The realization of the self-power supply function is based on the principle of electromagnetic induction. On the cage, a magnet 140 made of neodymium iron boron material is fixed. The neodymium iron boron material has a high magnetic energy product and can generate a strong magnetic field. At the same time, a number of turns of coils 160 are arranged in the installation cavity 150 inside the roller 130. When the bearing rotates, the rolling of the rollers 130 causes relative movement between the magnet 140 and the coils 160. According to Faraday's law of electromagnetic induction, the coils 160 cut the magnetic induction lines generated by the magnet 140, thereby changing the magnetic flux in the coils 160, and then generating an induced electromotive force and forming an induced current. Due to the design of using multiple turns of coils 160 and reasonably controlling the distance between the coils 160 and the magnet 140 (set at a distance of one to five times the diameter of the coils 160), the number of magnetic force lines cut is increased, greatly improving the change rate of the magnetic flux, significantly enhancing the amplitude of the induced electromotive force and the induced current, and realizing the efficient conversion of mechanical energy into electrical energy. In addition, the installation cavity 150 provides a relatively stable and safe environment for the coils 160. If the coils 160 are placed outside the rollers 130 and in contact with the external environment, in industrial production, they may be eroded by dust, water vapor, corrosive gases, etc. For example, in a chemical production environment, the corrosive gas will gradually corrode the coils 160, reducing their conductivity, affecting the power generation efficiency, and even causing damage to the coils 160. Inside the installation cavity 150, these external interference factors are effectively isolated, greatly extending the service life of the coils 160 and ensuring the long-term stable operation of the self-power supply system.

[0051] The generated alternating current first enters the rectifier circuit on the circuit board 170. The rectifier U1 in the rectifier circuit converts the alternating current into direct current, ensuring a stable current direction and providing a suitable current input for the subsequent circuit. Then, it passes through a filter circuit composed of a resistor R1 and a capacitor C1. This circuit uses the charging and discharging characteristics of the capacitor and the current limiting effect of the resistor to remove the fluctuating components and noise in the direct current, making the output direct current smoother and more stable. Finally, through a voltage stabilizing circuit, the LM7805 voltage stabilizing chip U2 in it can automatically adjust the output voltage. No matter how the input voltage changes, it can ensure a stable output voltage of 5V. The capacitor C2 further filters and stabilizes the output voltage, providing a stable and reliable power supply for the microcontroller and the thin film vibration sensor.

[0052] In terms of intelligent monitoring, a thin-film vibration sensor installed inside the roller 130, such as sensors of models JYB-KB-CW2000, LD-3000 series or VT2000 series, due to its high sensitivity and fast response characteristics, can accurately capture the minute vibrations generated by the roller 130 during rolling due to various conditions inside the bearing (such as the friction between the roller 130 and the raceway, the wear of the ball, etc.). After these vibration signals are converted into electrical signals by the sensor, they are transmitted to the MSP430 microcontroller on the circuit board 170. The MSP430 microcontroller has characteristics such as ultra-low power consumption, stable performance, and rich peripheral interfaces. The built-in analog-to-digital converter (ADC) in it converts the analog signals transmitted by the sensor into digital signals and analyzes and processes these data. Through the built-in algorithm, the microcontroller can calculate the working state parameters of the bearing in real time, such as vibration frequency, operating conditions, etc.

[0053] The processed data is transmitted through a wireless communication module. The present invention adopts low-frequency RF communication technology. The electromagnetic waves in the low-frequency band have stronger penetration ability and can overcome the obstacles such as walls and metals in a complex industrial environment to stably transmit the data to the external host computer. After receiving the data, the host computer monitors and analyzes the working state of the bearing in real time. Once an abnormality is found, measures can be taken in a timely manner, such as adjusting the operating parameters of the equipment, arranging equipment maintenance, etc., to avoid the huge economic losses caused by the sudden failure of the bearing leading to equipment shutdown, and realizing the intelligent operation and maintenance of the equipment.

[0054] To sum up, this embedded self-powered intelligent bearing realizes the functions of self-power supply and intelligent monitoring through the coordinated operation of the mechanical structure, electromagnetic induction for self-power supply, and the signal acquisition, processing and transmission of electronic components, providing a strong guarantee for the stable operation of industrial equipment.

[0055] Although the present invention has been described in detail by referring to the accompanying drawings and in combination with the preferred embodiments, the present invention is not limited thereto. Without departing from the spirit and essence of the present invention, those of ordinary skill in the art can make various equivalent modifications or substitutions to the embodiments of the present invention, and all such modifications or substitutions should be within the scope of the present invention. / Any person familiar with the technical field of the present invention can easily think of changes or substitutions within the technical scope disclosed by the present invention, and all should be covered within the protection scope of the present invention.

Claims

1. An embedded self-powered intelligent bearing, comprising an outer bearing ring, an inner bearing ring, a cage and a plurality of rollers. The rollers are located in a raceway between the inner bearing ring and the outer bearing ring, and the cage is installed between the rollers. It is characterized in that, It also includes a number of magnets which are fixed on the cage between the rollers. An installation cavity is provided inside the roller, and a number of turns of coils, a circuit board and a vibration sensor connected to the input end of the circuit board are arranged in the installation cavity. The circuit board is wirelessly communicatively connected to an external host computer. The coils are connected to the circuit board. During use, the coils cut the magnetic induction lines generated by the magnets to supply power to the circuit board.

2. The embedded self-powered intelligent bearing according to claim 1, wherein, The roller is made of silicon nitride material.

3. The embedded self-powered intelligent bearing according to claim 1, characterized in that, The magnet is made of neodymium iron boron material.

4. The embedded self-powered intelligent bearing according to claim 1, wherein A heat sink is provided on the cage.

5. The embedded self-powered intelligent bearing according to claim 1, wherein Heat dissipation holes are provided on the cage.

6. The embedded self-powered intelligent bearing according to claim 1, characterized in that The distance range between the coils and the magnets is set to be one to five times the diameter of the coils.

7. The embedded self-powered intelligent bearing according to claim 1, wherein The vibration sensor uses a thin-film vibration sensor of model JYB-KB-CW2000, LD-3000 series or VT2000 series.

8. The embedded self-powered intelligent bearing according to claim 7, characterized in that, A microcontroller of model MSP430 is provided on the circuit board. The thin-film vibration sensor is connected to the input end of the microcontroller, and the microcontroller is wirelessly communicatively connected to an external host computer.

9. The embedded self-powered intelligent bearing according to claim 7, wherein, A rectifier circuit, a filter circuit and a voltage stabilizing circuit are also provided on the circuit board. The input end of the rectifier circuit is connected to both ends of the coils, and the output end of the rectifier circuit is sequentially connected to the microcontroller and the thin-film vibration sensor through the filter circuit.

10. The embedded self-powered intelligent bearing according to claim 9, characterized in that, The rectifier circuit includes a rectifier U1, the filter circuit includes a resistor R1 and a capacitor C1, and the voltage stabilizing circuit includes a voltage stabilizing chip U2 of model LM7805 and a capacitor C2; The first end of the rectifier U1 is connected to the first end of the coils, the second end of the rectifier U1 is connected to the second end of the coils, the third end of the rectifier U1 is connected to the first end of the capacitor C1 and the input end of the voltage stabilizing chip U2 through the resistor R1, the output end of the voltage stabilizing chip U2 is connected to the 5V power output end and the first end of the capacitor C2, and the fourth end of the rectifier U1, the second end of the capacitor C1, the grounding end of the voltage stabilizing chip U2 and the second end of the capacitor C2 are all grounded.

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