Wireless sensor device for bearing system and bearing system

Abstract

The invention relates to a wireless sensor device for a bearing system, comprising a first component, which is fastened to a stationary housing of the bearing system, and a second component, which is fastened to a bearing of the bearing system, the first assembly comprises a first antenna, a transceiver, a controller and a WPT module, the second assembly comprises a second antenna, a rectifier and a battery, the second antenna is provided with a first wave band and a second wave band, the first wave band is used for carrying out wireless energy transmission with the WPT module, and the second wave band is used for carrying out wireless energy transmission with the WPT module. And the second wave band is used for performing signal transmission with the first antenna.

Description

Technical Field

[0001] The present invention relates to the technical field of wireless power transmission, and in particular to a wireless sensor device for a bearing, which can monitor the bearing at any time. Background Art

[0002] Bearing condition monitoring requires real-time data acquisition (such as temperature, vibration, and load) to diagnose bearing faults. To address this issue, it is crucial to develop a condition monitoring system that can acquire useful data in real time. Several existing systems are currently available for bearing condition monitoring:

[0003] 1) Wired status monitoring system;

[0004] 2) Wireless condition monitoring system with active sensors;

[0005] 3) Wireless condition monitoring system with passive sensors (due to the low energy requirements of temperature measurement chips, temperature data can be obtained through RFID technology with passive sensors; however, vibration and load data may be difficult to obtain in this way).

[0006] Wired condition monitoring systems are complex to install and wire. Active sensors, due to the complex environment surrounding the bearing, are difficult to replace when the battery is depleted. Recharging is limited to self-charging (energy harvesting from the environment) or wireless charging (wireless power transmission). The need for a battery module makes the sensor bulky and unsuitable for small bearings. Passive sensors, however, lack a battery, which is both an advantage and a disadvantage. Advantages include small size, low price, and long service life. Disadvantages include limited received energy, limiting their use to temperature measurement. Furthermore, the received energy is easily affected by environmental factors (such as oil and water vapor), resulting in inconsistent data. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide an improved wireless sensor device for a bearing system, which can overcome the shortcomings of the above-mentioned prior art.

[0008] The technical problem is solved by a wireless sensor device for a bearing system. The bearing system has a fixed shell and a bearing surrounded by the fixed shell, and the invalid sensor device has a first component and a second component, the first component is fixed on the fixed shell, and the second component is fixed on the bearing, wherein the first component includes a first antenna, a transceiver, a controller and a WPT module (wireless charging module). The second component includes a second antenna, a rectifier and a battery, wherein the second antenna has a first band and a second band, wherein the first band is used for wireless energy transmission by the WPT module, and the second band is used for signal transmission with the first antenna. Wireless power supply for the sensor component fixed in the bearing by the WPT module can eliminate the need for battery replacement or wired power supply, significantly reducing maintenance costs and complexity. The dual-band design of the second antenna enables energy transmission and signal transmission to be performed simultaneously. This design increases the flexibility and efficiency of the system. The design of the entire system is compact and easy to integrate into the existing bearing system. This integrated design minimizes the impact of the system on mechanical operation and improves safety.

[0009] According to a preferred embodiment of the present invention, the gain of the first antenna is greater than 10 dBi. According to the Friis formula, the receiving power of the receiving antenna can be increased by increasing the gain of the transmitting antenna. To this end, the gain of the first antenna can be increased to greater than 10 dBi.

[0010] According to a preferred embodiment of the present invention, the rectifier circuit of the rectifier is a microwave rectifier circuit. A microwave rectifier circuit is a rectifier circuit specifically used to process microwave frequency signals. The main function of the microwave rectifier circuit is to convert the received microwave energy (usually a radio frequency (RF) signal) into direct current (DC) electrical energy, which can achieve efficient wireless energy transmission and high-frequency signal processing. It is also preferred that the microwave rectifier circuit includes an impedance matching part and a rectifier part, wherein the impedance matching part has a microstrip line and radio frequency electronic components. In order to maximize the energy conversion efficiency, the microwave rectifier circuit can include a carefully designed impedance matching network, which achieves impedance matching with the radio frequency input by adjusting the bandwidth of the radio frequency electronic components and the microstrip line to ensure optimal energy transmission between the antenna and the rectifier circuit.

[0011] According to a preferred embodiment of the present invention, the second antenna uses ceramic as a substrate. The second component is fixed on the bearing, so there is little space left for the second antenna. Therefore, using a high dielectric constant material such as ceramic as a substrate can reduce the occupied space.

[0012] According to a preferred embodiment of the present invention, the second component includes a power management module. This module is used to allocate energy so that the wireless sensor device spends part of its time charging the battery and part of its time communicating, thereby ensuring power balance and operating efficiency. Furthermore, the second component preferably includes a status monitoring module for collecting real-time data (such as temperature, vibration, load, etc.). Furthermore, the second component preferably includes a communication module for processing the collected real-time data and transmitting it to an antenna for communication with external devices.

[0013] In addition, the technical problem of the present invention can also be solved by a bearing system having the wireless sensor device as described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only one embodiment of the present invention. For ordinary technicians in this field, other similar embodiment drawings can be obtained based on the provided drawings without paying any creative work.

[0015] Figure 1 Shows a structural block diagram of a wireless sensor device designed according to the present invention;

[0016] Figure 2 Shows the layout of the microwave rectifier circuit.

[0017] It should be noted that the numerals ("first," "second," ...) used herein are primarily (only) used to distinguish between multiple similar objects, quantities, or processes. In other words, they do not necessarily specify any relationship, quantity, and / or order between these objects, quantities, or processes. If any relationship, quantity, and / or order is required, this is explicitly stated herein or will be apparent to a person skilled in the art upon studying the specifically described design. DETAILED DESCRIPTION

[0018] like Figure 1 As shown, the wireless sensor device comprises a first component 1 and a second component 2. In a bearing system, the first component 1 is fixed to a stationary housing of the bearing system, and the second component 2 is fixed to a bearing of the bearing system, wherein the stationary housing surrounds the bearing. If the bearing system is used in a gearbox, the stationary housing can be, for example, the gearbox housing. The first component 1 can then be mounted on the gearbox housing to communicate with the second component 2 attached to the bearing.

[0019] The first component 1 comprises a first antenna 11, a transceiver 12, and a controller 13. The first antenna 11 can be mounted on the inner wall of the gearbox. To ensure compatibility with metallic environments, the first antenna 11 uses a patch antenna or PIFA antenna with a certain degree of metal interference immunity. The transceiver 12 is located outside the gearbox and connected to the first antenna 11 via a coaxial cable. It processes the signals received by the first antenna 11. The controller 13 displays status monitoring data and controls the entire system.

[0020] The first component 11 also includes a WPT module 14, which includes a transmission antenna and a signal generator. The transmission antenna is also mounted on the inner wall of the gearbox and is used to charge the battery 25. According to the Friis equation, the received power of the receiving antenna can be increased by increasing the gain of the transmission antenna (e.g., a patch array antenna) and reducing polarization loss (e.g., using a linearly polarized antenna aligned with the second antenna 21). To achieve this, the antenna gain of the WPT module 14 can be increased to 10 dBi.

[0021] The second component 2 includes a second antenna 21, a rectifier 22, a power management module 23, a communication module 24, a battery 25, and a status monitoring module 26. The second antenna 21 is designed as a dual-band antenna, for example, with one frequency band used for communication with the first antenna 11 and the other frequency band for energy transmission with the WPT module 14. This reduces the number of components and, in turn, the overall structural volume.

[0022] The rectifier circuit of rectifier 22 is used to convert radio frequency (RF) to direct current (DC). The efficiency of this conversion significantly affects charging efficiency. Generally speaking, the maximum power a signal generator provides to the transmitting antenna is 30 dBm (1 W). Due to the attenuation of electromagnetic waves in free space, the power reaching the RF input of the rectifier circuit is significantly reduced. Therefore, a rectifier circuit with high conversion efficiency at low input is required. Figure 2 The structure shown is a microwave rectifier circuit, comprising an impedance matching section 221 and a rectifier section 222. Impedance matching section 221 consists of transmission lines TL1, TL2, and TL3, and an inductor Ld1. Impedance matching with the RF input is achieved through the bandwidth of the RF electronic components and the microstrip line. The circled portion 222 in the figure represents the rectifier section, which converts RF to DC. Increasing the number of rectifier components improves rectification efficiency.

[0023] In addition, if Figure 1As shown, the second component also includes a power management module 23, a communication module 24, and a status monitoring module 26. The power management module 23 is used to distribute energy so that the wireless sensor device spends part of its time charging the battery 25 and part of its time communicating, ensuring power balance and operating efficiency. The status monitoring module 26 is fixed to the bearing and collects real-time data, such as temperature, vibration, and load, to obtain more accurate data. The communication module 24 processes the collected real-time data and transmits it to an antenna for communication with external devices. The communication module 24 can use all common wireless communication protocols, such as RFID and Bluetooth, thereby reducing component costs.

[0024] Reference Signs List

[0025]

[0026] 11 First Antenna

[0027] 12 transceivers

[0028] 13 Controller

[0029] 2 Second component

[0030] 21 Second Antenna

[0031] 22 Rectifier

[0032] 23 Power Management Module

[0033] 24 Communication Module

[0034] 25 batteries

[0035] 26 Condition Monitoring Module

Claims

1. A wireless sensor device for a bearing system, the wireless sensor device comprising a first component (1) and a second component (2), wherein the first component (1) is fixed to a fixed housing of the bearing system, and the second component is fixed to a bearing of the bearing system, wherein: The first component (1) includes a first antenna (11), a transceiver (12), a controller (13) and a WPT module (14), The second component (2) comprises a second antenna (21), a rectifier (22) and a battery (25), wherein the second antenna (21) has a first band and a second band, wherein the first band is used for wireless energy transmission with the WPT module (14), and the second band is used for signal transmission with the first antenna (11).

2. The wireless sensor device according to claim 1, wherein The gain of the first antenna (11) is greater than 10dBi.

3. The wireless sensor device according to claim 1, wherein The rectification circuit of the rectifier (22) is a microwave rectification circuit.

4. The wireless sensor device according to claim 3, wherein The microwave rectification circuit comprises an impedance matching section (221) and a rectification section (222), wherein the impedance matching section (221) has microstrip lines (TL1, TL2, TL3) and an inductor (Ld1).

5. The wireless sensor device according to any one of claims 1 to 4, characterized in that The second antenna (21) uses ceramic as a substrate.

6. The wireless sensor device according to any one of claims 1 to 4, characterized in that The second component (2) has a power management module (23).

7. The wireless sensor device according to any one of claims 1 to 4, characterized in that The second component (2) has a condition monitoring module (26).

8. The wireless sensor device according to any one of claims 1 to 4, characterized in that The second component (2) has a communication module (24).

9. Bearing system, characterized in that, The bearing system comprises a wireless sensor device according to any one of claims 1 to 8.

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