Rolling Bearing Sensor Master Ring Potential Equalization
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Solution Overview
Problem
Rolling bearings in drive units experience premature failure due to undesired electrical voltage and high current density bearing currents, leading to damage and reduced service life.
Innovation Solution
A rolling bearing design with a master ring having an electrically conductive section and a contact element that establishes an electrical connection between the outer and inner rings, preventing voltage imbalances and reducing current density through potential equalization, while also serving as a mating piece for the sensor to monitor rotational position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is arranged on the outer ring to detect the master ring on the inner ring for monitoring rotational position, then measurement precision is improved, but undesired electrical voltage and bearing currents occur causing damage to the rolling bearing
Solution Approach 1:
The patent introduces a contact element as an intermediary component that establishes an electrical connection between the outer ring and the master ring. This mediator equalizes the electrical potential between the inner and outer rings, preventing the generation of harmful bearing currents while allowing the sensor to function properly for rotational position detection.
Solution Approach 2:
The contact element creates an equipotential connection between the outer ring and the master ring by conducting electricity between them. This eliminates the electrical potential difference that would otherwise cause harmful currents to flow through the bearing, while maintaining the sensor's ability to detect the master ring's position.
2Reliability
If a contact element is introduced to establish electrical connection between outer ring and inner ring to prevent bearing currents, then reliability is improved, but device complexity increases
Solution Approach 1:
The master ring serves multiple functions: it acts as the mating piece for the sensor to enable rotational position detection, and simultaneously provides the electrically conductive section that interfaces with the contact element to establish the electrical connection. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The patent combines the sensor mating function and the electrical conduction function into a single integrated master ring component. By merging these functions, the design avoids adding separate independent components, thereby limiting the increase in device complexity while still achieving the reliability improvement.
3Reliability
If the master ring has an electrically conductive section with direct contact to the substrate, then electrical conductivity is improved, but abrasion occurs on the substrate reducing service life
Solution Approach 1:
The patent introduces an electrically conductive coating as an intermediary layer between the contact element and the master ring substrate. This coating layer provides the necessary electrical conductivity for the connection while protecting the underlying substrate from direct contact and abrasion, thereby extending the substrate's service life.
Solution Approach 2:
The master ring's electrically conductive section utilizes a composite structure consisting of a substrate material combined with an electrically conductive coating layer. This composite approach allows the system to benefit from both the mechanical properties of the substrate and the electrical properties of the coating, while the coating protects the substrate from wear.
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 effectively prevents damage from bearing currents, extends the service life of the drive unit, and allows for a compact configuration by ensuring electrical conductivity without direct contact, using a flexible contact element and conductive coatings like silver for enhanced performance.
Implementation Method 1
The contact element and the electrically conductive section of the master ring establish an electrical connection between the outer ring and the inner ring of the rolling bearing
Implementation Method 2
The measuring scale can be a magnetic measuring scale that may comprise alternating north and south poles
Data Source
AI summary
A rolling bearing (1) has an outer ring (3) and an inner ring (2) that can rotate in relation to the outer ring (3). A sensor (8) is arranged on the outer ring (3) and a master ring (13) is arranged on the inner ring (2). The master ring (13) can be detected by the sensor (8). The master ring (13) has an electrically conductive section (15), and a contact element (10) fixed on the outer ring (3) bears against the electrically conductive section (15) of the master ring (13).