Bearing Seal Temperature Sensor for Early Fault Detection
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Solution Overview
Problem
Existing bearing apparatuses lack effective temperature monitoring, particularly in restricted spaces, making it difficult to predict and prevent temperature-related abnormalities, which can lead to inconvenient failures, especially in applications like automobile alternators and wind turbines, due to the limitations of traditional temperature sensors like stacked thermistors.
Innovation Solution
A downsized temperature sensor, such as a thermocouple formed on a high-molecular thin film, is integrated into the seal of the bearing apparatus, allowing direct measurement of the seal's temperature contact with the rotary wheel, facilitating early detection of potential issues without compromising fitting space or increasing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a stacked thermistor with fixed thickness is used for temperature measurement, then the manufacturing cost increases due to multiple processes, but the fitting space is restricted and it is difficult to measure the temperature of the desired bearing portion
Solution Approach 1:
The patent applies this principle by using a thin film substrate as the base for the temperature sensor. The sensor is formed on a flexible thin film that can conform to the curved surface of the bearing seal, enabling temperature measurement in restricted spaces while maintaining manufacturing feasibility through a simplified single-step formation process
Solution Approach 2:
The patent extracts only the essential temperature sensing function from the complex stacked thermistor structure. By forming the temperature sensor directly on a thin film substrate rather than using multiple stacked layers, the design eliminates unnecessary structural complexity while retaining the core temperature measurement capability
2Measurement precision
If a stacked thermistor with multiple manufacturing processes is used, then the measurement precision may be improved, but the manufacturing cost increases considerably
Solution Approach 1:
The patent changes the manufacturing approach from multiple sequential processes to a single-step formation process. The temperature sensor is formed directly on the thin film substrate in one operation, fundamentally altering the manufacturing parameters to reduce complexity and cost while achieving the required measurement precision
Solution Approach 2:
The patent adopts a simpler, more cost-effective sensor design that can be manufactured using economical processes. The thin film-based temperature sensor uses readily available materials and a single-step formation method, making it suitable for mass production in general-purpose bearings
3Measurement precision
If a temperature sensor is attached to the rubber lip of the seal, then the temperature of the contacting portion can be measured, but the installation becomes difficult due to the thin and flexible nature of the lip
Solution Approach 1:
The patent merges the temperature sensor with the seal structure itself. The sensor is integrated into the seal body or attached to its rigid support structure rather than being mounted on the flexible lip, combining the sealing function with temperature monitoring while avoiding the installation difficulties of flexible surfaces
Solution Approach 2:
The patent uses the seal structure as an intermediary between the bearing components and the temperature sensor. By attaching the sensor to the seal or its support rather than directly to the rotating components, the design facilitates easier installation and more reliable temperature measurement
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 early prediction and prevention of temperature-related inconveniences by allowing for immediate countermeasures, such as stopping the apparatus, by providing a quick-response, mass-producible temperature monitoring system that can be applied to various bearings without space or cost constraints.
Implementation Method 1
a temperature sensor is fitted to the seal... a temperature of the seal contacting with the rotary wheel can be directly measured
Data Source
AI summary
A bearing apparatus includes an outer ring (11), an inner ring (12), rolling elements (13) disposed between the two rings, and a seal (15) attached to one of the outer ring and the inner ring and extending toward the other ring. A temperature sensor is fitted to the seal, and hence a temperature of the seal contacting with a rotary wheel can be directly measured. Accordingly, if the temperature measured by the temperature sensor rapidly rises, this implies that some inconvenience might occur, and necessary countermeasures such as immediately stopping an apparatus using the bearing apparatus can be taken before the explicit inconvenience occurs.