Spherical Roller Bearing Integrated Generator Design
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Solution Overview
Problem
Existing double-row rolling element bearings, such as spherical roller bearings, face challenges in integrating electrical energy generation due to the large radial space required by traditional electromechanical energy conversion systems, which are not suitable for all types of bearings.
Innovation Solution
A spherical roller bearing design incorporating an electromagnetic induction generator with a magnetic rotor between the roller sets and a stator coil on a flexible printed circuit board, allowing for efficient energy harvesting while maintaining standard ISO dimensions, using a magnet ring with alternating polarities and a stator coil configuration that maximizes energy generation within limited radial space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional electromechanical energy conversion systems are integrated into double-row rolling element bearings, then electrical energy can be generated, but the radial space required becomes too large for certain bearing types
Solution Approach 1:
The generator components are nested within the bearing assembly structure. The magnetic rotor is mounted on the guide element between the roller sets, while the stator is mounted to the inner surface of the outer ring, utilizing the existing bearing geometry to accommodate the energy conversion system without requiring additional radial space outside the bearing's normal dimensions.
Solution Approach 2:
The patent transitions from a traditional radial arrangement where the stator and rotor occupy significant radial space to a configuration where the generator components are distributed in the axial dimension between the roller sets. This allows the magnetic rotor to be positioned on the guide element and the stator to be mounted on the outer ring's inner surface, effectively utilizing the axial space between the two rows of rolling elements rather than requiring excessive radial clearance.
2Power
If a magnetic rotor with alternating polarities and stator coil configuration is used to maximize energy generation, then power output increases, but the assembly complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated components. The guide element serves both its mechanical function of guiding the rolling elements and acts as the mounting structure for the magnetic rotor. The outer ring's inner surface serves as both the bearing raceway and the mounting surface for the stator. This merging reduces the number of separate components and simplifies assembly while maintaining the multi-pole configuration for optimized power generation.
Solution Approach 2:
Existing bearing components are given multiple functions. The guide element not only guides the rollers but also supports the magnetic rotor. The outer ring provides both structural support and houses the stator coils. This multi-functionality approach allows the generator to be integrated into the bearing without requiring dedicated separate structures for each component, thereby reducing overall complexity.
3Reliability
If condition monitoring sensors are integrated with wireless transmission, then continuous monitoring capability is achieved, but power consumption increases
Solution Approach 1:
The generator is designed to continuously generate electrical energy during bearing operation by utilizing the rotational motion already present in the bearing. This continuous energy generation provides a constant power supply that can sustain the condition monitoring sensors and wireless transmission throughout the bearing's operational life, eliminating the need for batteries or periodic power interruptions.
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 continuous power supply for condition monitoring sensors without batteries, ensuring reliable operation and reduced assembly complexity, while maintaining the bearing's structural integrity and allowing for various power generation configurations.
Implementation Method 1
an electromagnetic induction generator for harvesting electrical energy from rotational kinetic energy
Data Source
AI summary
A spherical roller bearing having an inner ring, an outer ring, first and second roller sets disposed therebetween, and a guide element for guiding the rollers of at least one roller set. The guide element is rotational about a bearing axis of rotation during bearing operation. The bearing further includes a generator, arranged between the first and second roller sets, which includes a magnetic rotor with alternating polarities in circumferential direction and a stator having at least one stator coil. The magnetic rotor is mounted to the guide element, while the stator is mounted to a common outer raceway of the outer ring, radially opposite from the magnetic rotor. In accordance with the invention, the stator has the form of an annular band. The at least one stator coil is formed by a flat conductor provided on a flexible printed circuit board.