Rolling Bearing Load Sensing With In-Operation Sensor Calibration

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Solution Overview

Problem

Calibration of load sensors for rolling bearings, particularly in large applications like wind turbines, is challenging due to their mounted condition and the need for precise calibration in situ.

Innovation Solution

A sensor arrangement comprising a first sensor device on the inner or outer ring to measure load over the entire circumference and a pre-calibrated second sensor device within a rolling element to calibrate the first sensor device during operation, using a processing unit for calibration and load computation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a first sensor device is arranged on the inner ring or outer ring to measure load over the entire circumference, then the measurement coverage is improved, but the calibration complexity increases due to mounted conditions

Engineering Contradiction:

Improvemeasurement coverage areaVSAvoidcalibration complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

A second sensor device is introduced as an intermediary calibration tool. This second sensor device is pre-calibrated and arranged within a rolling element to measure a reference load value, which is then used to calibrate the first sensor device that measures the overall load. The second sensor device acts as a mediator that transfers the calibration information from a controllable environment to the mounted first sensor device.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The second sensor device is pre-calibrated before being installed in the bearing assembly. This preliminary calibration action is performed in a controlled environment where calibration is easier, and the calibration data is then used during operation to calibrate the first sensor device that is difficult to calibrate once mounted.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If sensors are arranged on the inner ring and/or outer ring to measure load over the complete circumference, then the monitoring capability is improved, but the calibration difficulty increases in large sized bearing applications

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidcalibration difficulty

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The second sensor device serves as an intermediary that provides a reference measurement for calibrating the first sensor device. By placing the second sensor within a rolling element, it can measure local load conditions that serve as a reference for the overall load measurement by the first sensor, thereby enabling calibration in the mounted state without requiring complex external calibration equipment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses feedback from the second sensor device's pre-calibrated measurements to adjust and calibrate the first sensor device. The second sensor provides reference load values that feed back into the calibration process of the first sensor, ensuring accurate overall load measurement while avoiding complex external calibration procedures.

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If a pre-calibrated second sensor device is arranged within a rolling element to calibrate the first sensor device, then the calibration process is simplified, but the device structure becomes more complex

Engineering Contradiction:

Improvecalibration process simplicityVSAvoidsensor arrangement structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The first and second sensor devices are merged into a single sensor arrangement system that works together to achieve load measurement and calibration. The second sensor device is integrated within the rolling element structure, and both sensors are coordinated through a processing unit, merging their functions into a unified system that simplifies the overall calibration process despite the additional component.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12523557B2Sensor arrangement for measuring the load of a rolling bearing and method for calibrating the sensor arrangement

Publication Date: 2026.01.13 AB SKF SKF PATENT DEPARTMENT

AI summary

A sensor arrangement is provided for measuring the load of a rolling bearing with an inner ring, an outer ring and rolling elements arranged between the inner ring and the outer ring. The sensor arrangement includes a first sensor device arranged on the inner ring and/or the outer ring and measuring a load over the entire circumference of the rolling bearing. The sensor arrangement further includes a second sensor device arranged within a rolling element and measuring a locally restricted load of the rolling bearing, the second sensor device being pre-calibrated and calibrates the first sensor device.