Retrofit Bearing Sensor Mounting for Limited Installation Space
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Solution Overview
Problem
Existing bearing monitoring systems are complex and costly to install, often requiring significant modifications to the bearing, making it difficult to retrofit or monitor various types of bearings, especially those with limited installation space, such as needle roller bearings.
Innovation Solution
A bearing monitoring system with a sensor element, transmitter, and power supply unit connected via an adapter that can be easily attached to the bearing without major modifications, using a carrier element and adapter that can accommodate different bearing sizes and designs, allowing for contactless detection of conditions like temperature, speed, and load, and enabling energy harvesting or battery power, with options for wireless communication and signal amplification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor is integrated inside the bearing or on the bearing seal, then bearing monitoring is enabled, but installation space is consumed and bearing structure is weakened
Solution Approach 1:
The patent introduces an adapter as an intermediary component that couples the bearing to the bearing housing. The adapter is fastened to the bearing via fastening elements that engage with bearing components (such as clamping onto the outer ring or engaging with grooves), while the sensor system is mounted on the adapter rather than directly on the bearing. This intermediary structure enables monitoring functionality without consuming valuable installation space within the bearing itself or weakening the bearing structure.
2Reliability
If bearing monitoring system is integrated into the bearing, then monitoring function is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the bearing monitoring system into separate functional modules: the bearing itself, the adapter (which can be a separate component), and the sensor system. The adapter serves as a coupling element that connects the bearing to the housing and provides mounting for the sensor. This segmentation allows each component to be manufactured independently using standard processes, avoiding the need for complex integrated manufacturing while still achieving the monitoring function.
Solution Approach 2:
The adapter serves multiple functions: it couples the bearing to the housing, provides structural support for the sensor system, and enables retrofitting of existing bearings. This multi-functionality reduces the need for specialized components and simplifies manufacturing across different bearing types and sizes.
3Reliability
If bearing monitoring system is modified into existing bearing, then monitoring is enabled, but intervention in bearing structure is required
Solution Approach 1:
The adapter acts as an intermediary that attaches to the bearing through relatively simple fastening elements (such as clamping mechanisms or engagement with existing grooves) rather than requiring complex structural modifications. The sensor system then mounts to the adapter, completely avoiding the need to intervene in the bearing's internal structure or rolling element arrangement.
4Ease of manufacture
If standardized sensor system is used, then cost-effectiveness improves, but adaptability to different bearing sizes is reduced
Solution Approach 1:
The adapter is designed with adjustable or variable parameters such as outer diameter, width, and fastening element configuration that can be adapted to different bearing sizes and types. This allows a standardized sensor system to be mounted on adapters that are customized to fit specific bearing dimensions, maintaining cost-effectiveness through standardization while achieving adaptability through parameter variation in the adapter design.
Data Source
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AI summary
The invention relates to a bearing monitoring system (6), preferably for a roller bearing (1) having a first bearing ring (2) and a second bearing ring (3), which are rotatably arranged relative to each other, with at least one sensor element having one or more sensors (28) for contactless detection of a bearing condition, at least one transmitter for transmitting a signal and a power supply unit for supplying electrical energy to the sensor element and the transmitter, the at least one sensor element being connected to the transmitter and being arranged on a carrier element (9) which is fastened to the bearing via an adapter (8). This provides a bearing monitoring system that enables simple and cost-effective installation, which can also be retrofitted to almost any type of bearing.