Adjustable Sensor Unit for Bearing Condition Monitoring

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Solution Overview

Problem

Existing sensor units for wind turbine main shaft bearings are not adaptable to various bearing types and arrangements, requiring machining of recesses that may not be feasible in all cases, limiting their applicability.

Innovation Solution

A sensor unit with adjustable mounting configurations, featuring a main body, sensor holder with extendable legs, and pivotable mounting brackets, allowing for secure attachment to different bearing types without drilling, using magnetic or bolted attachments and adjustable sensor positions for optimal measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a recess is machined into the bearing ring to accommodate the sensor unit, then the sensor unit can be securely mounted, but the bearing ring structure is damaged and applicability is limited

Engineering Contradiction:

Improvesensor mounting securityVSAvoidapplicability to different bearing types

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The sensor unit is divided into separate components: a sensor holder containing the sensors and a separate mounting bracket for attachment. This segmentation allows the sensor holder to contact the bearing ring surface without requiring deep recesses, while the mounting bracket provides secure attachment through surface-mounted fasteners, making the system applicable to various bearing types without structural modification.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A mounting bracket is introduced as an intermediary component between the sensor unit and the bearing ring. The bracket contacts the bearing ring surface through attachment surfaces rather than requiring recesses, and provides secure mounting through bolts or other fasteners. This intermediary enables secure mounting while preserving the bearing ring structure and maintaining applicability across different bearing types.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the sensor unit is designed for a specific bearing type with fixed mounting configuration, then the mounting is simplified, but the adaptability to different bearing arrangements is reduced

Engineering Contradiction:

Improvemounting simplicityVSAvoidcompatibility with various bearing arrangements

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The mounting bracket is designed with adjustable features including extendable legs with adjustable lengths and pivotable mounting surfaces. These dynamic adjustments allow the sensor holder to be positioned at optimal locations and orientations for different bearing types and arrangements, maintaining both mounting simplicity and broad adaptability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mounting bracket is designed as a universal component that can be adapted to multiple bearing types and arrangements. Through adjustable leg lengths, pivotable surfaces, and configurable attachment methods, a single bracket design serves multiple functions across different bearing configurations, eliminating the need for custom-designed sensor units for each bearing type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If extendable legs are provided to adjust the measurement surface position, then the adaptability to different bearing arrangements is improved, but the device complexity increases

Engineering Contradiction:

Improveadjustability to different bearing arrangementsVSAvoidsensor unit structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustment mechanism for the extendable legs utilizes simple mechanical principles such as threaded rods or slide threads rather than complex actuation systems. These basic mechanical elements provide adjustable leg lengths and pivotable mounting surfaces with minimal complexity, achieving adaptability through straightforward mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10190639B2Sensor unit for a bearing

Publication Date: 2019.01.29 AB SKF SKF PATENT DEPARTMENT

AI summary

A sensor unit for a bearing includes a main body, a sensor holder and a mounting bracket. The sensor holder has a measurement surface in a first plane on which at least one sensor is provided for measuring an operating parameter of the bearing. Each mounting bracket has an attachment portion having an attachment surface. The sensor unit is configured to contact the bearing ring that forms part of an assembly in which the bearing is mounted. The sensor holder has one or more extendable legs that are extendable in a longitudinal direction perpendicular to the first plane, such that the measurement surface is adjustable in longitudinal direction relative to the main body. The mounting brackets are linearly movable and pivotable relative to the main body. The sensor unit has a first attachment position and a second attachment position.