Bearing Housing Wireless Power Layout for Steel Mill Monitoring
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Solution Overview
Problem
Existing solutions for capturing and transmitting data from bearings in steel mills or rolling mills face challenges due to the limitations of cabling, battery damage from overheating, and the impracticality of energy sources within the bearing housing, especially under high thermal loading conditions.
Innovation Solution
A device comprising a bearing housing with a sensor and data processing unit, a wireless data transmission unit, an energy receiving unit within the housing, and an external energy source and transmitting unit, where the energy source is positioned outside the housing and remains on the supporting structure during maintenance, ensuring continuous energy supply and reduced thermal exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries or generators are installed in the bearing housing to supply energy to the sensor and data transmission unit, then the sensor system can operate wirelessly, but the energy source is damaged by overheating from process heat in steel mills or rolling mills
Solution Approach 1:
The energy source (battery or generator) is extracted from the bearing housing and relocated to a position outside the hot zone, specifically on the supporting structure. This separates the heat-sensitive energy source from the thermal environment while maintaining wireless energy transmission to the sensor system in the bearing housing through an energy transmitting unit
Solution Approach 2:
An energy transmitting unit is introduced as an intermediary component that receives energy from the external energy source and wirelessly transmits it to the energy receiving unit in the bearing housing. This mediator enables energy transfer without direct physical connection, allowing the energy source to remain outside the thermal zone while still powering the internal components
2Use of energy by moving object
If cabling arrangements with slip rings are used to supply energy to sensors in the bearing, then energy can be transmitted to rotating components, but the cables may get in the way or be damaged during operation and maintenance
Solution Approach 1:
The mechanical cabling system with slip rings is replaced by a wireless energy transmission system. The energy transmitting unit and energy receiving unit communicate through electromagnetic fields, eliminating physical cables and slip rings that obstruct maintenance operations and rotating components
3Strength
If the bearing housing is designed for high loading of rotatable components, then it can withstand industrial conditions, but only very limited space is available for batteries or generators
Solution Approach 1:
The energy source is extracted from the bearing housing, eliminating the need to compromise the structural integrity or load-bearing capacity of the housing. The external placement on the supporting structure provides ample space for the energy source without interfering with the bearing housing's mechanical strength
4Productivity
If sensors and data transmission units are installed in the bearing housing for continuous monitoring, then real-time data can be captured, but the system requires continuous energy supply in a harsh thermal environment
Solution Approach 1:
The energy transmitting unit acts as an intermediary that bridges the external energy source and the internal energy receiving unit. This allows continuous energy supply to the monitoring system while the actual energy source remains protected from thermal damage, ensuring both continuous operation and system reliability
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
Enables continuous data transmission from bearings, allowing for real-time monitoring and predictive maintenance, while maintaining the energy source at a safer distance from thermal loads, thus ensuring reliable and long-term operation.
Implementation Method 1
The sensor-signal receiving unit, which is arranged at a distance from the wheel bearing, has a feed-current transmitting part and a sensor-signal receiving part. The sensor-signal receiving part receives the sensor signals from the wireless sensor units, the feed-current transmitting part transmits the electrical operating power by means of electromagnetic waves to the wireless sensor units.
Data Source
AI summary
A device for capturing and transmitting data of a bearing of a steel mill or rolling mill includes a sensor with a data processing unit arranged in a bearing housing capturing and storing data of a bearing. A data transmission unit in the bearing housing wirelessly transmits data of the sensor to a remote receiver. An energy receiving unit in the bearing housing receives energy wirelessly and transmits it to the data transmission unit and the data processing unit. An energy source with an energy transmitting unit arranged outside the bearing housing supply the energy unit wirelessly. The energy transmitting unit is covered by the bearing housing and is arranged on or in a structural part which adjoins the bearing housing and is part of the supporting structure of mill and remains on the supporting structure of the mill when the bearing housing is removed for maintenance purposes.