Bearing Diagnostic Device Using Frictional Torque and Rolling Speed
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Solution Overview
Problem
Existing bearing diagnostic methods for machine tools are either inaccurate, costly, or fail to detect failures early enough to prevent machine damage, due to indirect temperature measurement, high costs of vibration and sound analysis, and inaccuracies in frictional torque calculation.
Innovation Solution
A bearing diagnostic device that includes a rotation counting unit, temperature measuring unit, frictional torque calculating unit, rolling speed calculating unit, bearing characteristic calculating unit, storage unit, and determination unit, which measures and calculates key parameters to determine bearing failure by comparing calculated bearing characteristics with reference values, thereby accurately diagnosing failures at an early stage inexpensively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a temperature sensor is installed near the bearing to monitor temperature rise, then temperature measurement is possible, but the measurement is indirect and cannot observe rapid temperature changes accurately
Solution Approach 1:
The patent replaces the mechanical/thermal temperature sensing system with an optical measurement system. By measuring the rotation count during inertial rotation and calculating frictional torque, the system indirectly determines bearing temperature state without physical contact, achieving both accuracy and responsiveness.
Solution Approach 2:
The patent introduces frictional torque as an intermediary parameter to infer bearing temperature state. Instead of measuring temperature directly, the system measures rotation characteristics and calculates frictional torque, which serves as a mediator reflecting the bearing's thermal and lubrication state.
2Reliability
If vibration sensors and sound sensors are used to analyze sounds and vibrations for bearing failure detection, then bearing failure can be accurately sensed, but expensive measuring devices are required leading to cost increase
Solution Approach 1:
The patent makes the bearing diagnose itself by measuring its own rotation characteristics during inertial rotation. The system uses the bearing's inherent mechanical behavior (rotation deceleration due to friction) as the diagnostic signal, eliminating the need for external vibration or sound sensors.
Solution Approach 2:
The patent replaces complex vibration and sound analysis systems with a simple rotation counting system. By measuring only the rotation count during inertial rotation and calculating frictional torque, the system achieves reliable failure detection without expensive sensing equipment.
3Reliability
If frictional torque is calculated from the change in count of rotations during inertial rotation and compared with a reference value, then bearing failure determination is possible, but the frictional torque calculation is not accurate and determination accuracy is low
Solution Approach 1:
The patent changes the measurement parameter from simple rotation count to rotation count at specific rotation speeds. By measuring rotation count at multiple predetermined speeds and calculating the relationship, the system obtains more accurate frictional torque values that reflect the bearing's actual state.
Solution Approach 2:
The patent uses the calculated frictional torque as feedback to determine bearing state. The system continuously monitors frictional torque during operation and compares it with reference values, enabling accurate real-time determination of bearing health and early detection of failures.
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
The device accurately diagnoses bearing failures at an early phase, preventing machine damage while reducing costs by using a comprehensive calculation of frictional torque, rolling speed, and bearing characteristics, ensuring timely intervention and minimizing downtime.
Implementation Method 1
a frictional torque calculating unit configured to calculate a frictional torque of the rotation shaft device
Implementation Method 2
a temperature measuring unit configured to measure a temperature of the rotation shaft device
Data Source
AI summary
A bearing diagnostic device senses a failure in a bearing of a machine tool including a rotation shaft device. The bearing diagnostic device includes a rotation counting unit, a temperature measuring unit, a frictional torque calculating unit, a rolling speed calculating unit, a bearing characteristic calculating unit, a storage unit, and a determination unit. The frictional torque calculating unit is configured to calculate a frictional torque of the rotation shaft device. The rolling speed calculating unit is configured to calculate a rolling speed of the bearing from the count of rotations. The bearing characteristic calculating unit is configured to calculate a bearing characteristic from the frictional torque and the rolling speed. The determination unit is configured to compare the bearing characteristic calculated by the bearing characteristic calculating unit with a reference bearing characteristic stored in the storage unit to determine a presence of a failure.