Wind Turbine Roller Bearing Load Sensing With Fiber Bragg Gratings
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Solution Overview
Problem
Large double-row tapered roller bearings in wind turbines face challenges in accurately determining preload during installation and measuring load deformations during operation, as conventional methods are ineffective for such large bearings and lead to inaccurate measurements.
Innovation Solution
Incorporating an optical fiber cable with Bragg grating into the roller bearing to measure preload/load conditions, allowing for real-time monitoring and adjustment, and providing a control and storage unit to compensate for temperature and vibration effects, along with multiple recesses for comprehensive strain measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional friction torque measurement method is used, then the measurement process is simple, but the measurement precision is poor for large bearings
Solution Approach 1:
The patent replaces the conventional mechanical friction torque measurement method with an optical measurement system using fiber Bragg grating (FBG) sensors. The FBG sensors embedded in the bearing components detect strain changes caused by preload, which are then converted to force measurements. This substitution of mechanical measurement with optical sensing significantly improves measurement precision for large bearings while the embedded nature of the sensors keeps the overall system complexity manageable.
Solution Approach 2:
The patent introduces fiber Bragg grating sensors as an intermediary element between the bearing structure and the measurement system. These sensors are embedded within the bearing components and detect internal strain states, serving as a mediator that translates mechanical deformation into measurable optical signals. This intermediary approach enables precise preload measurement without requiring external mechanical measurement devices.
2Loss of information
If multiple optical fiber cables are installed to measure circumferential load profile, then the measurement comprehensiveness is improved, but the device complexity increases
Solution Approach 1:
The patent divides the bearing structure into multiple measurement zones by installing optical fiber cables in different locations (inner ring, outer ring, and at various angular positions). Each fiber cable segment measures the load condition at its specific location, and the combined data from all segments provides a comprehensive circumferential load profile. This segmentation approach enables complete load distribution mapping while keeping each individual measurement point relatively simple.
Solution Approach 2:
The patent embeds the optical fiber cables within the bearing structure itself, nesting the measurement devices inside the bearing components. The fibers are integrated into the inner ring, outer ring, or roller structures, allowing multiple sensors to be housed within the bearing's existing geometry. This nesting approach reduces external complexity while enabling comprehensive internal monitoring.
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 precise measurement and monitoring of preload/load conditions, improving the design and operation of wind turbines by providing real-time data for adjusting installation and operation status, extending the service life of the bearing and enhancing bearing design.
Implementation Method 1
the optical fiber cable comprising at least one Bragg grating, and a signal in the optical fiber cable being used to determine a preload or load on the roller bearing
Data Source
AI summary
A roller bearing includes an outer ring, an inner ring, at least one row of rollers arranged between the outer ring and the inner ring, and at least one optical fiber cable mounted to the outer ring or the inner ring, the optical fiber cable including at least one Bragg grating. The optical fiber cable is configured such that a signal in the optical fiber cable is usable to determine a preload or load on the roller bearing.