Intelligent roller and state measuring method thereof

Abstract

The invention belongs to the field of bearing roller state measurement, and discloses an intelligent roller and a state measurement method thereof. The intelligent roller comprises a hollow roller and an embedded sensor, wherein the embedded sensor comprises an end cover, a shell, a temperature sensor, an attitude sensor, a strain sensor, a power supply and a flexible circuit board. The roller state measuring method comprises the following steps: placing the temperature sensor on the inner hole wall of the roller to measure the temperature of the roller, measuring the attitude angle and the rotating speed of the roller by the attitude sensor, measuring the radial deformation of the inner hole of the roller by the strain sensor, and calculating the contact load of the roller according to the attitude angle and the corresponding radial deformation of the roller.

Description

Technical Field

[0001] The invention belongs to the field of bearing roller state measurement and relates to an intelligent roller with an embedded sensor and a state measurement method thereof. Background Art

[0002] Roller bearings are critical components of major equipment. Equipment performance depends on the operating state of the bearings, especially under extreme operating conditions. Bearing design relies on bearing testing technology. By testing the operating state of the bearings within the equipment and evaluating their performance, targeted bearing optimization and manufacturing can be achieved. Furthermore, bearing testing technology provides data support for bearing life prediction and fault diagnosis. Advanced bearing testing technology can improve the reliability of bearing life prediction and fault diagnosis. Currently, traditional testing technologies primarily utilize external equipment, which makes it difficult to measure the internal operating state of the bearing.

[0003] Rollers are key components in bearings. The existing invention patent with authorization announcement number CN103867565B discloses a roller state detection device for measuring physical states such as roller strain, vibration, and temperature. The existing invention patent with authorization announcement number CN107542758B discloses a sensored roller that measures the amplitude of the deformation of the roller's center hole during roller rotation to obtain the roller load. However, since the angle between the sensor direction and the load direction is unknown, the above two methods can only determine the load by measuring the amplitude change of the strain after the roller has rotated for a certain period of time. The real-time load of the roller cannot be measured, and the load cannot be measured when the roller is stationary.

[0004] In order to overcome the above problems, the present invention proposes an intelligent roller and roller load measurement method with an embedded sensor, which can measure physical quantities such as roller load, temperature and posture in real time to determine the operating status of the roller in the bearing. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent roller with an embedded sensor and a roller state measurement method to solve the problem that the roller state inside the bearing is difficult to measure in real time.

[0006] The technical solution of the present invention:

[0007] An intelligent roller, comprising a hollow roller and an embedded sensor; wherein the embedded sensor comprises a strain sensor 3, a housing 5, a power supply 6, a temperature sensor 7, a posture sensor 8 and a flexible circuit board 9;

[0008] The housing 5 is used to fix the strain sensor 3, the power supply 6, the temperature sensor 7, the attitude sensor 8 and the flexible circuit board 9;

[0009] The attitude sensor 8 measures the angular velocity and acceleration of the roller, thereby calculating the rotation speed and revolution speed of the smart roller and the angle between the strain sensor direction and the contact load direction of the roller raceway.

[0010] The temperature sensor 7 measures the temperature in the roller stepped hole 15 .

[0011] The strain sensor 3 is affixed with four strain gauges 10. These are first connected by wires to form a full-bridge circuit, which is then connected to the flexible printed circuit board 9. The full-bridge circuit improves strain measurement sensitivity and provides temperature compensation, minimizing the effects of temperature changes on strain measurement. The contact load between the roller and raceway can be calculated based on the strain measured by the strain sensor 3 and the angle measured by the attitude sensor 8. Three strain sensors 3 are arranged along the roller's axial direction. The measurements from these three strain sensors 3 can be used to determine whether the bearing is experiencing bending moments and whether the roller is tilting or skewing.

[0012] The ESP32 control module 11 and the wireless communication module 12 are welded on the flexible circuit board 9. The flexible circuit board can be bent and folded, thereby improving space utilization and reducing the overall size of the embedded sensor.

[0013] The roller state measurement method according to the present invention is as follows:

[0014] When the roller is loaded, the radial dimension of the hole changes, causing the strain sensor to deform. The strain gauge then measures the strain of the cantilever beam on the strain sensor. Theoretical derivation reveals the relationship between the strain value ε measured by the strain sensor and the cross-sectional load P at the measuring point: ε = KP cos 2θ + C.

[0015] θ is measured by the attitude sensor, while K and C are related to the outer and inner diameters and material of the hollow roller. Calibration can be performed through simulation or experiment. During calibration, the load is continuously increased at different angles to obtain strain values ​​at different angles and loads. These values ​​are then fitted to obtain the parameters K and C. The measurements from the three strain sensors reveal the axial distribution of the roller load, allowing us to determine whether the roller is experiencing unbalanced loading and tilting.

[0016] Beneficial effects of the present invention: The device of the present invention can measure the temperature, posture, rotation speed and load data of the roller in real time, and realize the control of the intelligent roller and the transmission of data through wireless communication. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a cross-sectional view of the smart roller according to Embodiment 1 of the present invention.

[0018] Figure 2 It is a schematic diagram of a hollow roller according to Embodiment 1 of the present invention.

[0019] Figure 3 4 is a cross-sectional view of the smart roller embedded sensor according to the first embodiment of the present invention.

[0020] Figure 4 4 is an exploded view of the smart roller according to the first embodiment of the present invention.

[0021] Figure 5 Schematic diagram of the attachment position of the strain gauge on the strain sensor according to the first embodiment of the present invention.

[0022] Figure 6 Schematic diagram of a flexible circuit board according to Embodiment 1 of the present invention.

[0023] Figure 7 is a schematic diagram of the relative angle between the load direction and the strain sensor direction.

[0024] Figure 8 This is a graph of the strain change measured by the strain sensor when the roller is subjected to the same load at different angles.

[0025] In the figure: 1. End cap; 2. Threaded hole; 3. Strain sensor; 4. Hollow roller; 5. Housing; 6. Power supply; 7. Temperature sensor; 8. Attitude sensor; 9. Flexible circuit board; 10. Strain gauge; 11. ESP32 control module; 12. Wireless communication module; 13. Sealing ring; 14. Threaded hole; 15. Step hole. DETAILED DESCRIPTION

[0026] The specific implementation of the present invention is further described below in conjunction with the accompanying drawings and technical solutions.

[0027] Example 1

[0028] An intelligent roller comprises a hollow roller and an embedded sensor, such as Figure 1 and Figure 3 As shown, a stepped hole 15 is machined on the hollow roller 4, and a threaded hole 2 is machined on the end face of the first step of the stepped hole 15. The end cover 1 of the embedded sensor is fixed to the hollow roller 4 with screws through the threaded hole 2 to prevent the embedded sensor from moving or rotating in the axial or radial direction. The second step of the stepped hole 15 is used to accommodate a sealing ring 13, which can prevent contaminants such as lubricants and moisture from entering the embedded sensor.

[0029] The embedded sensor includes a strain sensor 3, a housing 5, a power supply 6, a temperature sensor 7, a posture sensor 8 and a flexible circuit board 9;

[0030] The end cap 1 comprises a circular plate and an integrally structured circular ring, the circular ring being provided with an internal thread; a sealing ring 13 is provided at the connection between the circular plate and the circular ring;

[0031] The housing 5 is used to mount the strain sensor 3, power supply 6, temperature sensor 7, attitude sensor 8, and flexible circuit board 9. The housing 5 is divided into three mounting spaces: a left end space, a middle space, and a right end space. The left end space is used to mount one strain sensor 3, the middle space is used to mount the power supply 6, and the right end space is used to mount two strain sensors 3 and the flexible circuit board 9. The left and right ends of the housing 5 are provided with external threads for mating with the internal threads of the circular ring of the end cap 1. The diameter of the housing 5 is smaller than the diameter of the stepped hole 15 to prevent the housing 5 from contacting the inner wall of the stepped hole 15. The housing 5 and the end cap 1 are made of nylon or non-metallic materials.

[0032] The power source 6 is a battery, which is connected to the flexible circuit board 9 via a wire;

[0033] The flexible circuit board 9 is bent into a concave shape and fixed in the housing 5. An ESP32 control module 11, a wireless communication module 12, and a posture sensor 8 are soldered to the flexible circuit board 9 and connected to the flexible circuit board 9 via copper wires. The ESP32 control module 11 controls the collection, processing, and transmission of sensor data and enables the smart roller to sleep and wake up.

[0034] The wireless communication module 12 is welded on the flexible circuit board 9 and is positioned as close to the end face of the smart roller as possible to prevent signal shielding caused by the smart roller. The wireless communication module 12 uses WIFI communication.

[0035] The temperature sensor 7 is connected to the flexible circuit board 9 with a wire. The probe of the temperature sensor 7 is attached to the side of the strain sensor 3 and contacts the inner wall of the roller stepped hole 15 together with the strain sensor 3 to measure the temperature inside the roller stepped hole 15.

[0036] The attitude sensor 8 is welded on the flexible circuit board 9. The attitude sensor 8 contains a three-axis accelerometer and a three-axis gyroscope, which measure the acceleration and angular velocity of the three axes. The attitude of the roller at each moment is obtained through a fusion algorithm. The revolution speed and rotation speed of the smart roller can be obtained through Fourier transform, and the relative angle between the direction of the strain sensor 3 and the contact load direction of the roller raceway can also be obtained.

[0037] The strain sensor 3 is π-shaped, with two legs formed into semicircular rings. This structure helps ensure that the contact position between the strain sensor 3 and the stepped hole 15 does not shift. The ends of the two legs of the strain sensor 3 are arc-shaped, with a diameter greater than that of the roller stepped hole 15, ensuring that both legs of the strain sensor 3 contact the inner wall of the roller stepped hole 15. The strain sensor 3 is fixed to the threaded hole 14 of the housing 5 by screws. Each strain sensor 3 is affixed with four strain gauges 10. These four strain gauges 10 are connected by wires to form a full-bridge circuit, which is then connected to the flexible printed circuit board 9. This allows for temperature compensation, preventing the effects of temperature changes on strain measurement.

[0038] In the figure: 1. End cap; 2. Threaded hole; 3. Strain sensor; 4. Hollow roller; 5. Housing; 6. Power supply; 7. Temperature sensor; 8. Attitude sensor; 9. Flexible circuit board; 10. Strain gauge; 11. ESP32 control module; 12. Wireless communication module; 13. Sealing ring; 14. Threaded hole; 15. Step hole.

[0039] A method for measuring the state of an intelligent roller is as follows:

[0040] When the hollow roller 4 is loaded, the radial dimension of the stepped hole 15 changes, causing the strain sensor 3 to deform. The strain gauge 10 measures the strain of the cantilever beam on the strain sensor 3. The relationship between the strain value ε measured by the strain sensor 3 and the cross-sectional load P at the measuring point is obtained through theoretical derivation: ε = KP cos 2θ + C

[0041] Among them, θ is measured by the posture sensor 8, K and C are related to the outer diameter, inner diameter and material of the hollow roller 4, and are calibrated through simulation or experiment; during calibration, the load is continuously increased at different angles to obtain the strain values ​​at different angles and loads, and fitting is performed to obtain the parameters K and C; the measurement values ​​of the three strain sensors 3 can be used to obtain the distribution of the roller load along the roller axis, and then determine whether the smart roller is subjected to unbalanced load and tilted.

Claims

1. A smart roller, characterized in that: The smart roller includes a hollow roller and an embedded sensor; A stepped hole (15) is machined on the hollow roller (4), and a threaded hole (2) is machined on the end face of the first step of the stepped hole (15). The end cover (1) of the embedded sensor is fixed to the hollow roller (4) through the threaded hole (2); the second step of the stepped hole (15) is used to place a sealing ring (13); The embedded sensor comprises a strain sensor (3), a housing (5), a power supply (6), a temperature sensor (7), a posture sensor (8) and a flexible circuit board (9); the housing (5) is used for installing the strain sensor (3), the power supply (6), the temperature sensor (7), the posture sensor (8) and the flexible circuit board (9).

2. The smart roller according to claim 1, characterized in that: The end cover (1) comprises a circular plate and an integral circular ring, wherein the circular ring is provided with an internal thread; and a sealing ring (13) is provided at the connection between the circular plate and the circular ring.

3. The smart roller according to claim 1, characterized in that: The housing (5) is used to install a strain sensor (3), a power supply (6), a temperature sensor (7), a posture sensor (8) and a flexible circuit board (9), and is divided into three installation spaces, a left end space, a middle space and a right end space; the left end space is used to install one strain sensor (3), the middle space is used to install the power supply (6), and the right end space is used to install two strain sensors (3) and the flexible circuit board (9); the left and right ends of the housing (5) are provided with external threads for matching and connecting with the internal threads of the circular ring of the end cover (1).

4. The smart roller according to claim 1, characterized in that: The power source (6) is a battery, which is connected to the flexible circuit board (9) via a wire.

5. The smart roller according to claim 1, characterized in that: The flexible circuit board (9) is bent into a concave shape and fixed in the housing (5). An ESP32 control module (11), a wireless communication module (12) and a posture sensor (8) are welded on the flexible circuit board (9), and the three are connected to the flexible circuit board (9) through copper wires.

6. The smart roller according to claim 5, characterized in that: The ESP32 control module (11) is used to control the collection, processing, and transmission of data from various sensors and to realize the sleep and wake-up of the smart roller; The wireless communication module (12) adopts WIFI communication and is positioned as close as possible to the end face of the intelligent roller; The attitude sensor (8) contains a three-axis accelerometer and a three-axis gyroscope, which are used to measure the acceleration and angular velocity of the three axes, obtain the attitude of the smart roller at each moment through a fusion algorithm, and obtain the revolution speed and rotation speed of the smart roller through Fourier transform, and also obtain the relative angle between the direction of the strain sensor (3) and the contact load direction of the smart roller raceway.

7. The smart roller according to claim 1, characterized in that: The temperature sensor (7) is connected to the flexible circuit board (9) via a wire, a probe of the temperature sensor (7) is attached to the side of the strain sensor (3), and both the temperature sensor (7) and the strain sensor (3) are in contact with the inner wall of the roller stepped hole (15) to measure the temperature inside the roller stepped hole (15).

8. The smart roller according to claim 1, characterized in that: The strain sensor (3) is π-shaped, and a semicircular ring structure is provided on its two legs. The semicircular ring structure ensures that the contact position between the strain sensor (3) and the stepped hole (15) does not move; the ends of the two legs of the strain sensor (3) are arc structures, and the diameter of the arc structure is larger than the diameter of the roller stepped hole (15) to ensure that the two legs of the strain sensor (3) are in contact with the inner wall of the roller stepped hole (15); the strain sensor (3) is fixed on the housing (5); four strain gauges (10) are attached to each strain sensor (3), and the four strain gauges (10) on each strain sensor are connected to form a full-bridge bridge by wires and then connected to the flexible circuit board (9).

9. The smart roller according to claim 1, characterized in that: The diameter of the shell (5) is smaller than that of the stepped hole (15) to prevent the shell (5) from contacting the inner wall of the stepped hole (15); the shell (5) and the end cover (1) are made of nylon or non-metallic materials.

10. A method for measuring the state of a smart roller according to any one of claims 1 to 9, characterized in that: Here are the steps: When the hollow roller (4) is loaded, the radial dimension of the stepped hole (15) changes, causing the strain sensor (3) to deform. The strain gauge (10) measures the strain of the cantilever beam on the strain sensor (3). The relationship between the strain value ε measured by the strain sensor (3) and the cross-sectional load P at the measuring point is obtained through theoretical deduction as follows: ε = KP cos 2θ + C; Among them, θ is measured by the attitude sensor (8), K and C are related to the outer diameter, inner diameter and material of the hollow roller (4), and are calibrated through simulation or experiment; during calibration, the load is continuously increased at different angles to obtain strain values ​​at different angles and loads, and fitting is performed to obtain parameters K and C; through the measurement values ​​of the three strain sensors (3), the distribution of the roller load along the roller axis can be obtained, and then it can be judged whether the smart roller is subjected to an unbalanced load and tilted.

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