Bearing-Integrated Gear Failure Detection Device
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Solution Overview
Problem
Existing devices for detecting gear failure in gearboxes are unable to accurately detect failures in individual gears due to the influence of the vibration transfer path through the gearbox case, and they often require expensive and high-performance sensors.
Innovation Solution
A measuring device is attached to the bearing part of a gearbox, featuring a cover with an acceleration sensor and an angle sensor on the inner face, and a data collecting unit that obtains time-synchronous angle-acceleration pairs. This configuration allows for accurate detection of gear failure by minimizing the vibration transfer path and using a self-powered, sensor-equipped bearing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the acceleration sensor is fixed to the case of the gearbox, then the device structure is simple and easy to manufacture, but the vibration transfer path is long and causes measurement inaccuracy due to damping and stiffness properties of the case
Solution Approach 1:
The measuring device is nested within the bearing part, with the acceleration sensor housed inside the bearing assembly rather than being mounted on the external case. This nesting approach shortens the vibration transfer path from the gear mesh to the sensor while maintaining structural simplicity, as the sensor is integrated into the existing bearing structure that is already close to the gear.
Solution Approach 2:
The bearing part serves as an intermediary structure that directly connects the gear to the acceleration sensor. By using the bearing assembly as the mounting platform for the sensor, the invention creates a direct vibration transfer path through the bearing components rather than through the gearbox case, thereby improving measurement accuracy while keeping the device structure relatively simple.
2Measurement precision
If the acceleration sensor is attached to the bearing part, then the vibration transfer path is shortened and measurement accuracy is improved, but the device complexity increases due to additional components and assembly requirements
Solution Approach 1:
The bearing part serves multiple functions: it supports the rotating shaft, provides a mounting platform for the acceleration sensor, and acts as part of the vibration transfer path. By making the bearing assembly multi-functional, the invention avoids adding separate structural components for sensor mounting, thereby improving measurement accuracy without significantly increasing device complexity.
Solution Approach 2:
The measuring device is merged with the bearing part, combining the sensor housing, mounting structure, and bearing assembly into a single integrated unit. This merging eliminates the need for separate mounting brackets or additional structural elements, reducing overall device complexity while achieving the goal of shortening the vibration transfer path.
3Ease of manufacture
If conventional vibration detection methods are used with long transfer paths, then inexpensive sensors can be used, but the vibration characteristics are altered by the transfer path properties making failure detection inaccurate
Solution Approach 1:
The acceleration sensor is extracted from the external case environment and placed directly within the bearing part, removing it from the influence of the gearbox case's damping and stiffness properties. This extraction allows the use of inexpensive sensors while achieving accurate failure detection, as the sensor now measures vibrations before they are significantly altered by the case transfer path.
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 solution enables accurate detection of gear failure by minimizing the influence of the vibration transfer path and allowing for the use of inexpensive sensors, such as MEMS acceleration sensors, while also providing a self-powered and wireless communication capability for the measuring device.
Implementation Method 1
an acceleration sensor provided on an inner face of the cover to measure vibrations of the bearing part
Implementation Method 2
an angle sensor provided on the inner face of the cover to measure the angle between the outer ring and an inner ring of the bearing part
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A measuring unit (100) is attached to one side face of a bearing part, which supports a shaft (24a) having a gear (22) thereon such that the shaft can rotate. The measuring device ( 100) includes a cover (110) attached to an outer ring of the bearing part to cover the side face of the bearing part, an acceleration sensor (441) provided on an inner face of the cover to measure vibrations of the bearing part, an angle sensor (443) provided on the inner face of the cover to measure an angle between the outer ring and an inner ring of the bearing part, and a data collecting unit (456) provided on the inner face of the cover to obtain the acceleration measured by the acceleration sensor and the angle measured by the angle sensor in a linked manner, sharing one common time base.