Bearing Ring Groove for Embedded Glass Fiber Sensor
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Solution Overview
Problem
Existing methods for connecting glass fiber sensors to bearing rings, especially small or spherical ones, face challenges such as elasticity issues, reduced mechanical strength, and difficulties in high-temperature bonding, leading to inaccurate strain measurement and short service life.
Innovation Solution
A groove is machined in the bearing ring to house a glass fiber sensor encased in a metallic strip with a steel and nickel layered structure, using adhesive or brazing for fixation, allowing for minimal stiffness impact and robust high-temperature integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a groove is machined in the bearing ring to embed the glass fiber sensor, then the sensor can be mechanically connected to the bearing ring for strain measurement, but the mechanical strength and stiffness of the bearing ring are significantly reduced
Solution Approach 1:
The bearing ring is segmented by creating a groove that divides the structure into regions above and below the groove. The groove is designed to be shallow and narrow, segmenting only the minimal necessary material to accommodate the sensor while preserving the overall structural integrity of the bearing ring.
Solution Approach 2:
The groove is positioned locally at the outer circumference of the bearing ring, specifically designed to accommodate the sensor element without affecting the critical load-bearing regions. The local modification is minimized in depth and width to maintain overall bearing strength while enabling sensor integration for strain measurement.
2Ease of manufacture
If traditional polymer glue is used to bond the glass fiber to the bearing ring, then the connection is easy to establish, but the bonding fails at high temperatures required for fiber Bragg grating method
Solution Approach 1:
The bonding material is changed from polymer-based adhesive to inorganic adhesive or brazing material, fundamentally changing the chemical composition and thermal properties of the bonding agent. This parameter change enables the bonding to withstand high temperatures (typically above 200°C) required for fiber Bragg grating inscription while maintaining adequate bond strength.
3Reliability
If the glass fiber is equipped with multiple coaxial cover layers and strengthening fibers, then the fiber is protected and easier to handle, but elasticity is introduced between the glass core and the component, affecting strain measurement accuracy
Solution Approach 1:
The strengthening fibers and outer protective layers are removed or minimized in the region where the fiber contacts the bearing ring surface. Only the essential cladding layer is retained to protect the glass core, while the elastic-compliant strengthening fibers are excluded from the bonding interface to ensure direct strain transfer from the bearing ring to the glass core for accurate measurement.
4Volume of moving object
If small bearing rings are used, then the bearing size is reduced for compact applications, but machining grooves takes away much steel and significantly reduces bearing stiffness and strength
Solution Approach 1:
Instead of machining a deep groove that would remove significant material, only a shallow partial groove is machined into the outer circumference of the bearing ring. This partial action provides sufficient accommodation for the sensor element while removing minimal material, thereby preserving the stiffness and strength of the small bearing ring.
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 design enables precise strain measurement with enhanced mechanical strength and longevity of the bearing ring, suitable for small and high-temperature applications, including harsh environments like subsea and windmill use.
Implementation Method 1
For surveying temperatures it is essential that a thermal coupling between the glass fiber and the machine arrangement is established
Implementation Method 2
For monitoring strains it is necessary to mechanically connect firmly the glass fiber with the component to be monitored
Data Source
AI summary
A bearing ring having an elongated sensor element that runs along at least a part of a surface of the bearing ring. The connection between the sensor element and the bearing ring is established by a metallic metal material connected by material bonding with the bearing ring as well as with the sensor element. To improve the life of the bearing a sensor element is arranged in a groove that is machined in the bearing ring. The groove extends from the surface of the bearing ring. The metallic material includes or is connected with a flat metallic strip. The flat metallic strip is arranged at or in the surface of the bearing ring and covers the groove.