Bearing Sensor Unit Embedded in Ring Recess
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Solution Overview
Problem
Existing sensor units for bearings are prone to damage from collisions and provide inaccurate measurements due to their surface-mounted configuration, which is remote from the rolling elements and lacks robustness.
Innovation Solution
Embedding the sensor unit within a recess of the bearing's inner or outer ring, closer to the rolling elements, and using a wireless transmitter, circlip for fixation, and adhesive sealing to enhance precision and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor unit is mounted on the surface of the bearing using adhesion or screws, then the assembly is simple and cost-effective, but the sensor housing is susceptible to damage from collisions and the measurement precision is reduced due to distance from rolling elements
Solution Approach 1:
The sensor unit is embedded within a recess in the bearing ring, nesting the sensor housing inside the bearing structure itself. This protects the sensor from external collisions while maintaining integration with the bearing, eliminating the need for separate surface-mounted housings.
Solution Approach 2:
The recess is created locally in the bearing ring at the specific position where sensor placement is required. This localized structural modification provides protection and precise positioning without requiring complex changes to the entire bearing assembly.
2Measurement precision
If the sensor is mounted on the surface of the bearing, then the installation is straightforward, but the measurement precision is compromised due to remote positioning from rolling elements
Solution Approach 1:
By nesting the sensor unit within the bearing ring's recess, the sensor achieves optimal proximity to the rolling elements for precise measurement, while the recess structure itself provides the mounting function, simplifying installation.
Solution Approach 2:
The recess is pre-formed in the bearing ring during manufacturing, so that when the sensor unit is installed, it automatically achieves the correct position and orientation for high-precision measurement without requiring additional alignment steps.
3Reliability
If screws or bolts are used to fix the sensor unit, then the fixation is secure, but the strain measurement is adversely affected by the fastening elements
Solution Approach 1:
The fastening elements (screws or bolts) that adversely affect strain measurement are completely removed from the design. Instead, the sensor unit is retained in the recess using alternative methods such as interference fits, adhesive bonding, or circumferential notches that do not interfere with strain measurement.
Solution Approach 2:
The recess structure itself serves as the retention mechanism, eliminating the need for separate fastening components. The bearing ring's own structure is used to hold the sensor unit securely without adding extraneous elements that would affect measurement.
Data Source
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AI summary
The invention relates to a sensor unit (14) for a bearing including at least one inner ring (10) and at least one outer ring (12), wherein the sensor unit (14) is configured to detect at least one state variable of the bearing. It is proposed that the sensor unit (14) is embedded in a recess (26) of the inner ring or the outer ring (10, 12).