A large bearing intelligent roller deformation measuring device based on a hollow shaft structure

Abstract

This invention discloses a large-scale intelligent roller deformation measurement device based on a hollow shaft structure, belonging to the field of intelligent bearing monitoring technology. The device includes a roller body with an axially extending central hole. A hollow shaft is interference-fitted into the central hole. The outer surface of the hollow shaft serves as the force-bearing surface, used to simultaneously sense the deformation of the roller body. The hollow shaft has at least one circumferential groove, within which strain gauges are attached, and wiring holes are provided for the strain gauge wires to pass through the hollow shaft. The strain gauges can be attached and wired outside the roller body before being installed as a whole, significantly reducing installation difficulty. By setting multiple circumferential grooves and multiple strain gauges, the deformation of different parts of the roller can be monitored separately, effectively identifying off-center loads. This application features a simple structure, high installation efficiency, and can achieve accurate measurement of contact loads on large bearing rollers.

Description

Technical Field

[0001] This application relates to the field of intelligent bearing monitoring technology, specifically to a large-scale intelligent roller deformation measuring device for bearings based on a hollow shaft structure. Background Technology

[0002] With the development of industrial intelligence, the bearing industry is gradually transforming from traditional passive maintenance to intelligent condition monitoring. As a new type of bearing core component embedded with micro-sensors and communication units, intelligent rollers can sense the force and deformation of the rollers in real time, providing key data support for bearing load monitoring, life prediction, and fault diagnosis, and are an ideal carrier for realizing bearing intelligence.

[0003] Currently, several intelligent roller structure designs have been proposed and preliminarily applied. For example, by setting an axially extending central hole or mounting cavity inside the roller body, resistance strain gauges are directly attached to the inner wall of the central hole. The strain gauges detect the deformation of the roller under pressure, and the contact load of the roller is then indirectly calculated. Some designs also integrate micro-signal processing circuits and wireless communication modules inside the roller, forming a complete embedded monitoring system. Compared with external sensors, this type of embedded structure has advantages such as high integration and good environmental adaptability, and has become the mainstream technology in the field of intelligent monitoring of large bearings.

[0004] However, existing intelligent roller structures still have significant shortcomings. First, strain gauges need to be adhered to the narrow inner wall of the central hole inside the roller body, resulting in extremely limited operating space, making it difficult to guarantee adhesion accuracy, and causing wiring difficulties and low installation efficiency. Second, the installation and fixation of internal power modules, signal processing units, and other devices are also limited by the confined space, which is not conducive to modular packaging and maintenance. In addition, since all operations of the strain gauges and wires must be completed inside the roller, if strain gauge adhesion failure or wire breakage occurs, rework and repair are difficult and maintenance costs are high. These problems restrict the mass production and engineering promotion of intelligent rollers. Summary of the Invention

[0005] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a large-scale intelligent roller deformation measuring device for bearings based on a hollow shaft structure. By pre-completing the bonding and wiring of strain gauges on the hollow shaft and then assembling it with the roller body via an interference fit, the internal packaging difficulty is greatly reduced, and the installation efficiency and assembly convenience are improved.

[0006] To achieve the above objectives, this application provides the following technical solution:

[0007] A large bearing intelligent roller deformation measuring device based on a hollow shaft structure includes a roller body with an axially extending central hole at the center of the roller body, and a hollow shaft installed in the central hole; at least one circumferential groove is provided on the hollow shaft, and a strain gauge is attached in the circumferential groove; a wiring hole is also provided in the circumferential groove for the wires of the strain gauge to pass through into the interior of the hollow shaft.

[0008] In some embodiments, the outer surface of the hollow shaft is the force-bearing surface, and it is interference-fitted with the central hole of the roller body to achieve synchronous sensing of the deformation of the roller body.

[0009] In some embodiments, at least one end of the hollow shaft is provided with a guide structure for guiding the hollow shaft to be smoothly installed into the roller body.

[0010] In some embodiments, the guide structure is a chamfer or fillet disposed at the end of the hollow shaft.

[0011] In some embodiments, multiple strain gauges are installed in the circumferential groove, and the multiple strain gauges are evenly distributed in a ring inside the circumferential groove.

[0012] In some embodiments, the hollow shaft has a through groove inside, and a metal plug is provided at the end of the through groove. A battery, a microcontroller unit, and an RF transmitter chip are installed inside the through groove. The battery, microcontroller unit, and RF transmitter chip are all fixed inside the through groove by a flexible buffer pad. The strain gauge is electrically connected to the microcontroller unit.

[0013] Compared with the prior art, this application has at least the following beneficial effects:

[0014] 1. The hollow shaft allows strain gauges to be attached, wires to be laid, and testing to be performed on the outside of the roller body before being inserted into the roller for assembly. This avoids the difficulties caused by direct operation inside the narrow central hole of the roller. The hollow shaft has chamfers at both ends, and with the interference fit, it ensures the synchronization of force transmission and makes the assembly process smoother, greatly improving the manufacturing and packaging efficiency of the smart roller.

[0015] 2. The hollow shaft has multiple circumferential grooves, each of which can be fitted with multiple strain gauges to monitor the deformation of different axial parts of the roller. By comparing the deformation at different locations, it is possible to effectively identify whether the roller is subjected to off-center load during use, providing richer diagnostic information for bearing operation status assessment.

[0016] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of the intelligent roller described in this invention;

[0019] Figure 2 This is a schematic diagram of the strain gauge installation according to the present invention;

[0020] Figure 3 This is a schematic diagram of the hollow shaft structure;

[0021] Figure 4 This is a sectional view of a hollow shaft.

[0022] In the figure: 1 Roller body, 2 Hollow shaft, 3 Circumferential groove, 4 Wiring hole, 5 Strain gauge, 6 Force surface, 7 Metal plug, 8 Battery, 9 Microcontroller unit, 10 RF transmitter chip.

[0023] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] It should be noted that in the description of this application, if directional descriptions are involved, such as "up," "down," "front," "back," "left," "right," etc., indicating directional or positional relationships, these are based on the appendix. Figure 1The orientations or positional relationships shown are merely for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. When a feature is referred to as "set," "fixed," or "connected" to another feature, it can be directly set, fixed, or connected to the other feature, or it can be indirectly set, fixed, or connected to the other feature. In addition, if the embodiments of this invention involve descriptions of "first," "second," etc., such descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Furthermore, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this application.

[0026] To address the difficulties and inefficiencies caused by the need to attach and wire strain gauges within the narrow space inside the roller body in existing technologies, this embodiment provides the following technical solution:

[0027] Reference Figures 1 to 4 As shown, this embodiment provides a large bearing intelligent roller deformation measuring device based on a hollow shaft structure, including a cylindrical roller body 1, with a through-hole machined at the center of the roller body 1 along its axial direction. This central hole is used to install a hollow shaft 2.

[0028] The hollow shaft 2 is a hollow tubular part whose outer diameter matches the inner diameter of the central hole of the roller body 1. The outer surface of the hollow shaft 2 forms the critical force-bearing surface 6. To form an effective force transmission path, the force-bearing surface 6 of the hollow shaft 2 is connected to the central hole of the roller body 1 by an interference fit. This fit ensures that when the roller body 1 is subjected to external loads and undergoes slight deformation, the deformation can be reliably and synchronously transmitted to the force-bearing surface 6 of the hollow shaft 2, thereby guaranteeing the accuracy and real-time performance of the measurement.

[0029] To facilitate the smooth insertion of the hollow shaft 2 into the central hole of the roller body 1, a guide structure is provided at at least one end of the hollow shaft 2. In this embodiment, the guide structure is a chamfer machined at the end of the hollow shaft 2. This chamfer can achieve centering and guidance during assembly, effectively avoiding scratches on parts and assembly jamming. Combined with the interference fit, it ensures both tightness of the connection and smoothness of assembly.

[0030] The hollow shaft 2 has three circumferential grooves 3, which are spaced apart along the axial direction of the hollow shaft 2. Each circumferential groove 3 is designed as a carrier for attaching strain gauges 5. This facilitates the accurate attachment, curing, and preliminary testing of strain gauges 5, greatly reduces the operational difficulty, and ensures the quality of attachment.

[0031] Furthermore, each circumferential groove 3 is provided with a wiring hole 4 penetrating the wall of the hollow shaft 2. The function of this wiring hole 4 is to provide a channel for the connecting wires of the bonded strain gauges 5 to pass through from the outside of the hollow shaft 2 into its internal cavity. In this way, all wires can be neatly stored inside the hollow shaft 2, avoiding interference or wear with the inner wall of the roller body 1, thus improving the reliability and safety of the system.

[0032] In some implementations, refer to Figure 2 As shown, in order to accurately measure the load borne by the roller and to identify off-center loading conditions, four strain gauges 5 are installed in each circumferential groove 3 in this embodiment. These four strain gauges 5 are attached to the bottom surface of the circumferential groove 3 in a ring-shaped evenly distributed manner.

[0033] Specifically, the four strain gauges 5 are arranged at 90° intervals, meaning one strain gauge is installed at every 90° central angle. This arrangement allows the group of strain gauges to comprehensively perceive the circumferential stress distribution of the roller on the axial cross-section. By comparing the deformation data measured by the strain gauges 5 at different circumferential grooves 3, it is possible to accurately calculate whether the roller is subjected to and to what extent it is subjected to eccentric load during operation, providing richer data support for the health status assessment of the bearing.

[0034] In some embodiments, each circumferential groove 3 is provided with four wiring holes 4, which are also evenly distributed circumferentially at 90°. Each strain gauge 5 and its nearest wiring hole 4 in the circumferential groove 3 are distributed at a 45° central angle along the circumference. This staggered layout allows the lead wire of each strain gauge 5 to smoothly reach an independent wiring hole 4, which facilitates the arrangement and fixation of the wires and effectively reduces the risk of wire breakage due to bending or stretching.

[0035] Furthermore, to achieve high-precision stress measurement and automatically compensate for the effects of temperature changes, the four strain gauges 5 are connected according to the principle of a Wheatstone bridge. Specifically, the four strain gauges 5, which are attached to the same circumferential groove 3, are connected to the four arms of the bridge, forming a full-bridge connection. This full-bridge connection not only converts minute deformation signals into amplified voltage signals, improving measurement sensitivity, but also automatically cancels out the thermal expansion and contraction effects caused by changes in ambient temperature, thereby obtaining stable and accurate deformation measurement results.

[0036] In some implementations, refer to Figure 4 As shown, the hollow shaft 2 has a through slot inside. This slot serves as a cavity for accommodating electronic components. During assembly, functional modules are installed into the internal through slot from the end opening of the hollow shaft 2.

[0037] Specifically, such as Figure 4 As shown, a battery 8, a microcontroller unit 9, and an RF transmitter chip 10 are sequentially installed inside the through-slot. The battery 8 provides power to the entire monitoring system. The microcontroller unit 9, as the core component, has its input terminal electrically connected to the strain gauge 5 wire introduced through the wiring hole 4. It is used to acquire the deformation signal output by the strain gauge 5 and perform analog-to-digital conversion, data processing, and packaging. The RF transmitter chip 10 is electrically connected to the output terminal of the microcontroller unit 9 and is used to wirelessly transmit the processed deformation data for external receiving equipment to monitor and analyze.

[0038] Specifically, to prevent electronic components from loosening or being damaged under high-speed rotation and vibration conditions of the rollers, the battery 8, microcontroller unit 9, and RF transmitter chip 10 are all fixed inside the through-slot using flexible buffer pads. These flexible buffer pads are made of silicone, which fills the gap between the components and the inner wall of the through-slot, absorbing vibration and impact energy and ensuring the long-term reliable operation of the electronic components. Finally, a metal plug 7 is provided at the end of the through-slot. This metal plug 7 is fixed to the end of the hollow shaft 2 by interference fit or other means, completely encapsulating the internal components inside the through-slot, providing dustproof, oil-proof, and physical protection.

[0039] In use, this device is installed as a roller in a large bearing, with multiple devices installed in each bearing. When the bearing is under load, the surface of the roller body 1 experiences pressure and undergoes slight compressive deformation. Due to the interference fit between the roller body 1 and the hollow shaft 2, this deformation is synchronously and accurately transmitted to the force-bearing surface 6 of the hollow shaft 2. The strain gauges 5, which are attached to the circumferential grooves 3 of the hollow shaft 2, deform accordingly, causing a change in their resistance value. The full-bridge circuit composed of four strain gauges 5 converts this resistance change into a voltage signal proportional to the deformation. This signal is transmitted to the microcontroller unit 9 inside the hollow shaft 2 via wires and wiring holes 4. The microcontroller unit 9 amplifies, filters, and performs analog-to-digital conversion on the signal, calculates the current deformation, and then uses a preset algorithm model to deduce the contact load borne by the roller. Finally, the processed data is wirelessly transmitted to an external monitoring system via an RF transmitter chip 10, enabling real-time, online monitoring of the large bearing's operating status.

[0040] It is worth noting that the control methods of the microcontroller unit 9 for the strain gauge 5 and the radio frequency transmitter chip 10 both adopt conventional technical solutions in this field. The algorithm model adopts the conventional calibration-fitting-inversion scheme in this field, that is, the mapping relationship between deformation and contact load is pre-calibrated through experiments, and the load value is directly calculated by substituting the current deformation into the model during real-time measurement.

[0041] Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A large bearing intelligent roller deformation measuring device based on a hollow shaft structure, comprising a roller body (1), characterized in that, The roller body (1) has an axially extending central hole at its center, and a hollow shaft (2) is installed in the central hole; at least one circumferential groove (3) is provided on the hollow shaft (2), and a strain gauge (5) is attached in the circumferential groove (3); a wiring hole (4) is also provided in the circumferential groove (3) for the wire of the strain gauge (5) to pass through into the interior of the hollow shaft (2).

2. The intelligent roller deformation measuring device for large bearings based on a hollow shaft structure according to claim 1, characterized in that, The outer surface of the hollow shaft (2) is the force-bearing surface (6), and it is in an interference fit with the center hole of the roller body (1) to achieve synchronous sensing of the deformation of the roller body (1).

3. The intelligent roller deformation measuring device for large bearings based on a hollow shaft structure according to claim 1 or 2, characterized in that, At least one end of the hollow shaft (2) is provided with a guide structure to guide it to be smoothly installed into the roller body (1).

4. The intelligent roller deformation measuring device for large bearings based on a hollow shaft structure according to claim 3, characterized in that, The guide structure is a chamfer or fillet provided at the end of the hollow shaft (2).

5. The intelligent roller deformation measuring device for large bearings based on a hollow shaft structure according to claim 1, characterized in that, Each of the circumferential grooves (3) is provided with multiple strain gauges (5), which are evenly distributed in a ring along the circumferential grooves (3).

6. The intelligent roller deformation measuring device for large bearings based on a hollow shaft structure according to claim 1, characterized in that, The hollow shaft (2) has a through groove inside, and a metal plug (7) is provided at the end of the through groove. A battery (8), a microcontroller unit (9) and a radio frequency transmitter chip (10) are installed inside the through groove. The battery (8), the microcontroller unit (9) and the radio frequency transmitter chip (10) are all fixed inside the through groove by a flexible buffer pad. The strain gauge (5) is electrically connected to the microcontroller unit (9).

Images