Rolling Bearing with Integrated Cage Pulse Ring Sensor
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Solution Overview
Problem
Conventional rolling bearings, particularly tapered roller bearings, lack an integral rotation sensor to accurately detect the number of rotations of the cage, leading to structural complexity, size issues, and high costs, as well as the inability to measure cage rotation due to space constraints in lubricated environments.
Innovation Solution
A rolling bearing design featuring a magnetic rotation sensor integrated with a pulse ring on the cage or inner ring, and a seal member with recesses and protrusions, allowing for accurate detection of cage and inner ring rotations, while maintaining a simple structure and reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotation sensor is mounted to the inner ring using conventional methods, then the sensor can detect inner ring rotation, but it cannot accurately measure cage rotation and increases structural complexity
Solution Approach 1:
The pulse ring is integrally formed with the cage as a single unit, eliminating the need for separate mounting components. This merging of the pulse ring and cage reduces structural complexity while enabling accurate cage rotation measurement through the magnetic rotation sensor
Solution Approach 2:
The cage serves multiple functions: it retains the rolling elements and simultaneously acts as the mounting structure for the pulse ring. The seal member also provides both sealing and sensor mounting functions, reducing the need for additional components and simplifying the overall structure
2Measurement precision
If an encoder with alternating north and south poles is mounted to the inner ring, then rotation detection is enabled, but the bearing unit becomes complicated, large, and expensive
Solution Approach 1:
The complex encoder structure with alternating north and south poles is replaced by extracting only the essential function: a simple pulse ring with recesses and protrusions that generates magnetic field variations when rotated, achieving rotation detection without the complexity of a full encoder
Solution Approach 2:
The pulse ring is made from the same material as the cage (resin or metal) using integral formation, making it a simple, inexpensive component compared to expensive encoders. The simple magnetic field detection system replaces complex encoder mechanisms
3Measurement precision
If a tone ring is separately mounted to the inner ring for rotation measurement, then inner ring rotation can be detected, but the bearing becomes complicated, large, and expensive, and cage rotation cannot be measured
Solution Approach 1:
The pulse ring is integrally formed with the cage, creating a unified structure that eliminates separate mounting requirements. This merging reduces complexity and enables simultaneous measurement of both cage rotation (via the pulse ring) and inner ring rotation (via the magnetic interaction with rolling elements)
Solution Approach 2:
The integrated pulse ring-cage structure serves multiple measurement functions: it detects cage rotation directly and enables indirect measurement of inner ring rotation through magnetic field interactions, replacing the need for separate tone ring and sensor assemblies
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise monitoring of bearing behavior and rotation measurements, reducing complexity and cost by integrating sensors within the bearing, and allowing simultaneous measurement of cage and inner ring rotations, with optional temperature detection.
Implementation Method 1
a magnetic rotation sensor which rotates together with the cage or the inner ring; and a pulse ring integrally formed at an end of the cage or the inner ring opposed to the seal member, the pulse ring having recesses and protrusions
Data Source
AI summary
A rolling bearing is provided which includes an inner ring; an outer ring; rolling elements disposed in the bearing space; a cage rollably retaining the rolling elements; and a seal member made of a resin. The seal member includes a support frame, a plurality of window holes, and a filter closing the window holes. Lubricating oil flows through the bearing space to lubricate the interior of the rolling bearing. The cage is made of a magnetic material, and has a pulse ring integrally formed at an end of the cage. The rolling bearing further includes a magnetic rotation sensor mounted to the seal member so as to be capable of being opposed to any of recesses and protrusions of the pulse ring.