Rolling Bearing Sensor Layer Integration for Stable Force Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing force measurement technologies in roller bearings, such as strain gauges, face issues with long-term stability and require frequent recalibration, and the application process is complicated due to the need for placement in weak points like indentations or grooves, which can damage the bearing components.
Innovation Solution
A measuring bearing with integrated sensor layers protected within the bearing structure, utilizing force introduction rings to house the sensors and detect strains without the need for additional maintenance, allowing for radial and axial load measurement without compromising the bearing's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are applied to components for force measurement, then force measurement capability is achieved, but long-term stability deteriorates and recalibration is necessary
Solution Approach 1:
The sensor layer is extracted from the traditional strain gauge form and integrated directly into the bearing component structure. The sensor layer is applied to the inner ring or outer ring of the bearing, allowing force measurement while maintaining the structural integrity and long-term stability of the bearing components.
Solution Approach 2:
The measurement function is merged with the bearing structure itself. The sensor layer becomes an integral part of the bearing components (inner ring, outer ring, or cage), combining the load-bearing function with the measurement function in a single integrated system.
2Measurement precision
If layers are placed in weak points such as indentations, punctures or grooves for optimal force measurement, then measurement sensitivity is improved, but manufacturing complexity increases and component integrity deteriorates
Solution Approach 1:
The sensor layer is selectively applied to specific regions of the bearing components where stress concentrations naturally occur during operation. By placing the sensor layer on the inner ring, outer ring, or cage surfaces at strategic locations, the measurement sensitivity is maximized without requiring additional indentations, punctures, or grooves to be created in the components.
3Ease of operation
If strain gauges are left open and unprotected on components, then application simplicity is maintained, but reliability deteriorates due to damage risk
Solution Approach 1:
The protective function is merged with the structural components of the bearing. The sensor layer is applied directly to the inner ring, outer ring, or cage, which serve as both the structural support and the protective enclosure for the sensor layer, eliminating the need for separate protective housings.
4Reliability
If force introduction rings are used to house sensor layers, then sensor protection is improved and long-term stability is achieved, but device complexity increases
Solution Approach 1:
The force introduction rings serve multiple functions simultaneously: they act as structural components for load transmission, provide housing for the sensor layers, and create the necessary installation spaces for sensor integration. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The sensor layers are nested within the bearing structure, specifically within the installation spaces defined by the force introduction rings and bearing components. The sensor layers are positioned inside the bearing assembly, protected by the surrounding structural components while remaining functional for 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
The solution provides stable and long-term force measurement capabilities with reduced maintenance needs, enhancing the reliability and safety of roller bearings in various machinery applications.
Implementation Method 1
The sensor layer is set up to record strains occurring on a component as a measured variable
Implementation Method 2
The sensor layer preferably has at least one layer that can be produced using the thin-film method. In the thin-film process, preferably thin layers of different materials are produced and processed
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a measurement bearing (20), characterized in that the measurement bearing (20) has a rolling bearing (10), at least one force-introducing ring (7) and a space (6) for at least one sensor layer (6'), the space (6) being surrounded by the at least one force-introducing ring (7) and at least one other adjacent component (3, 5, 5', 7', 8, 9) of the measurement bearing (20).