Bearing Wear Sensor with Fixed RF Communicator
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Solution Overview
Problem
Current methods for monitoring bearing wear in aerospace applications are unreliable and costly, particularly in helicopter rotor pitch control bearings, due to the difficulty in predicting wear based on flight hours and the lack of mechanical feedback, leading to increased maintenance costs and downtime.
Innovation Solution
A bearing wear sensor is integrated within the wear surface, using connecting wires to transmit data to a radio frequency communicator, which is fixed relative to the sensor to prevent wire flexure and ensure continuous communication, allowing for wireless monitoring of wear and other parameters like temperature and force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical gauging inspections are used to monitor bearing wear, then bearing condition can be assessed, but maintenance costs and downtime increase substantially
Solution Approach 1:
The patent replaces mechanical gauging inspection systems with an electronic sensor system that continuously monitors bearing wear. The wear sensor embedded in the bearing wear surface electrically signals when wear thresholds are reached, eliminating the need for manual mechanical inspections and reducing both maintenance costs and aircraft downtime.
Solution Approach 2:
The bearing becomes self-monitoring through the integrated wear sensor that automatically detects and signals its own wear condition. The sensor system enables the bearing to self-report its status without requiring external mechanical inspection, allowing for proactive maintenance scheduling.
2Ease of operation
If connecting wires are extended outside the bearing wear surface for data transmission, then wireless communication is enabled, but wire flexure and failure risk increase during bearing use
Solution Approach 1:
The patent introduces a radio frequency communicator as an intermediary device that receives data from the wear sensor through connecting wires and transmits it wirelessly to external systems. This mediator enables wireless communication functionality while isolating the fragile connecting wires from direct exposure to flexure and environmental damage.
Solution Approach 2:
The wear sensor with connecting wires is nested within or behind the bearing wear surface, while the radio frequency communicator is positioned externally. This nested configuration protects the vulnerable wire connections from mechanical stress while maintaining wireless communication capability.
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 provides reliable and accurate monitoring of bearing wear, reducing the need for expensive mechanical gauging and enabling Condition-Based Maintenance, thereby minimizing downtime and maintenance costs in aerospace applications.
Implementation Method 1
connected to a radio frequency communicator for transmitting a data signal from said sensor indicative of the state of wear of said bearing wear surface
Data Source
Figure 1
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Figure 2B
AI summary
A bearing with a wear surface sensor configured to wirelessly transmit information comprising a bearing wear surface containing a wear surface sensor wherein the wear surface sensor includes one or more connecting wires for transmitting a data signal from the wear surface sensor indicative of the state of wear of the bearing wear surface. The one or more connecting wires extend outside of the bearing wear surface and are connected to a radio frequency communicator for transmitting a data signal from the sensor indicative of the state of wear of the bearing wear surface. The radio frequency communicator and the sensor are fixed relative to one another such that the connecting wires are not flexed to failure during bearing use.