Rolling Bearing Damage Localization Using Sensorized Element Phase Alignment
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Solution Overview
Problem
Existing sensorized rolling elements have a limited recording window, resulting in incomplete data collection around a bearing, and the non-unique path traced by the sensor as it spins makes aligning data from different sessions challenging, hindering effective damage detection and localization in rolling bearings.
Innovation Solution
The method involves sampling acceleration and load values, determining the rotation speed, calculating a phase function, processing load values to determine the frequency content, and using a continuous wavelet transform to detect and locate damage by aligning data from different recording sessions using a sensorized rolling element with an accelerometer, load sensor, and optionally a gyroscope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If multiple recordings are made to capture complete bearing data, then data completeness is improved, but data alignment difficulty increases due to non-unique sensor roller path
Solution Approach 1:
The system uses feedback from acceleration measurements to continuously update and refine the phase function, which models the sensor roller's position. This feedback mechanism enables accurate alignment of multiple recordings by comparing measured acceleration patterns with the modeled phase relationships, resolving the data alignment difficulty while maintaining data completeness.
Solution Approach 2:
The patent replaces direct mechanical position tracking with a mathematical phase function model that describes the sensor roller's position based on acceleration measurements. This substitution transforms the complex mechanical alignment problem into a signal processing problem that can be solved through phase comparison and synchronization algorithms.
2Device complexity
If a limited recording window is used in the sensorized roller, then device complexity is reduced, but data completeness deteriorates as full bearing pass may not be captured
Solution Approach 1:
The system employs periodic action by performing multiple recording sessions as the bearing rotates through different positions. Each recording captures a portion of the bearing pass, and the periodic nature of rotation allows the same features to be observed at different angular positions, enabling complete data collection through synthesis of multiple periodic measurements.
Solution Approach 2:
The patent applies preliminary action by first establishing a phase function model that predicts sensor roller position based on acceleration measurements. This preliminary modeling enables the system to plan and execute multiple recordings at optimal timing, ensuring that complete bearing data is captured across different rotational positions without requiring complex real-time decision-making.
3Measurement precision
If acceleration measurements are used to determine phase function, then measurement precision is improved, but calculation complexity increases
Solution Approach 1:
The patent introduces an intermediary phase function that acts as a bridge between raw acceleration measurements and final damage detection. This phase function serves as a mathematical mediator that transforms complex acceleration signal patterns into simplified position information, reducing the overall calculation complexity while maintaining high measurement precision for damage localization.
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
This approach allows for accurate alignment and analysis of data from multiple sessions, enabling effective detection and localization of damage in rolling bearings, improving the reliability of monitoring systems by ensuring comprehensive data capture and analysis.
Implementation Method 1
at least one accelerometer for measuring an acceleration of the sensorized rolling element
Implementation Method 2
at least one load sensor measuring a load applied on the sensorized rolling element
Implementation Method 3
the sensorized rolling element further comprises a gyroscope, the rotation speed of the rotatable ring being determined from measurement delivered by the gyroscope
Data Source
AI summary
A method for monitoring a rolling bearing that has a sensorized rolling element includes sampling acceleration signals and load signals from the sensorized rolling element to produce acceleration values and load values each associated with a time instant, determining a rotation speed of the rotatable ring, determining a phase function of the sensorized rolling element from the acceleration values and the rotation speed of the rotatable ring, processing the load values to determine a magnitude of a resulting signal representative of a frequency content of an envelope of the load values over time, and detecting a damage of the rolling bearing and a location of the damage on the rolling bearing from the magnitude of the resulting signal and the phase function.