Bearing Load Estimation via Adaptive Carrier Waveform Extraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for sensing bearing loads are limited in bandwidth, unable to effectively measure high-frequency oscillations and broadband load frequencies, which are common in applications like pumps and gear drive trains.
Innovation Solution
A device comprising a receiving unit for sensor signals and an electronic control unit that processes these signals to determine the rolling element frequency, carrier waveform, and load waveform, allowing for the estimation of bearing loads with frequencies up to the rolling element frequency or higher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If known methods and algorithms are used for load sensing on bearings, then the measurement is limited to low-frequency loads (upper limit less than a quarter of the rolling element frequency), but high-frequency oscillations cannot be measured
Solution Approach 1:
The patent applies dynamics by making the carrier frequency adaptive rather than fixed. The carrier frequency is dynamically adjusted based on the rolling element frequency, allowing the system to track and measure loads across a broad frequency spectrum. This dynamic adjustment enables the measurement system to adapt to varying operating conditions and measure both low-frequency and high-frequency oscillations effectively.
Solution Approach 2:
The patent changes the parameter of carrier frequency from a fixed value to a variable that can be adjusted according to the rolling element frequency. By modifying this parameter, the system overcomes the bandwidth limitation and extends the measurable frequency range beyond the traditional quarter of the rolling element frequency, enabling accurate measurement of high-frequency oscillations in applications like pumps and compressors.
2Measurement precision
If the frequency of the load acting on the bearing becomes too high, then the frequency bands overlap with the carrier signal bands, but extracting the loads acting on the bearing directly from the raw frequency data becomes complicated
Solution Approach 1:
The patent extracts the carrier waveform as a separate component from the measured sensor signal. By identifying and separating the carrier frequency component, the system can then extract the load waveform independently. This extraction approach simplifies the processing of high-frequency data by eliminating the overlap problem between load frequency bands and carrier signal bands, making load extraction straightforward even at high frequencies.
Solution Approach 2:
The patent segments the measured sensor signal into two distinct components: the carrier waveform and the load waveform. This segmentation is achieved by determining the carrier frequency from the rolling element frequency and separating the corresponding frequency bands. By dividing the complex frequency data into manageable segments, the system simplifies the extraction process and avoids the complications of overlapping frequency bands.
3Adaptability or versatility
If broadband load frequencies are present in applications like pumps and gear drive trains, then accurate load estimation is needed, but existing methods cannot effectively measure high-frequency oscillations
Solution Approach 1:
The patent creates a universal measurement approach that can handle both low-frequency and high-frequency loads within a single system. By making the carrier frequency adaptive and extending the measurable frequency range up to the rolling element frequency, the system achieves multi-functionality. This allows accurate load estimation across the entire broadband frequency spectrum present in applications like pumps and gear drive trains, eliminating the need for different measurement methods for different frequency ranges.
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 solution enables the accurate estimation and evaluation of bearing loads with a broad range of frequencies, overcoming the limitations of previous methods by shifting the frequency estimation beyond the rolling element frequency.
Implementation Method 1
the at least one sensor probe is configured to measure a displacement and/or strain of the bearing
Data Source
AI summary
Disclosed is a device for estimating a load in a bearing, including a receiving unit for receiving a sensor signal waveform. The sensor signal waveform is provided by at least one sensor probe arranged at the bearing. The at least one sensor probe is configured to measure a displacement and/or strain of the bearing. The sensor signal waveform is a product of a carrier waveform and a load waveform, and an electronic control unit configured for processing the received measured sensor signal waveform, by determining a rolling element frequency from the measured sensor signal waveform, determining the carrier waveform based on the determined rolling element frequency and the measured sensor signal waveform, determining the load waveform based on determined carrier waveform and the measured sensor signal waveform, and estimating the load in the bearing from the determined load waveform.