Encoder System for Large Bearings

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Handling and integrating encoder systems into large diameter bearings is risky and costly due to potential damage and increased manufacturing time, especially when directly machining the bearing rings.

Innovation Solution

A tensioning assembly is mounted in a pre-machined portion of the inner ring, with a machined recess and grooves, and an encoder band is fixed within these grooves to prevent slippage, while an encoder assembly is mounted on the outer ring, using magnetic mounting and wireless sensors for secure and efficient installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If encoder systems are directly machined into the inner and outer bearing rings of large bearings, then the encoder system provides precise position sensing, but the handling and assembly become risky and difficult with potential damage occurring

Engineering Contradiction:

Improveencoder system integration reliabilityVSAvoidhandling and assembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The encoder system is divided into separate modular components: encoder discs mounted on the inner ring, encoder assemblies mounted on the outer ring, and an independent tensioning assembly. This segmentation allows each component to be manufactured, tested, and handled separately, reducing the risk of damage during assembly while maintaining precise position sensing functionality.

Inventive Principle:

Principle #1Segmentation

2Reliability

If encoder systems are directly machined into large diameter bearings, then the encoder provides integrated position sensing, but manufacturing time and costs increase due to damage and rework

Engineering Contradiction:

Improveencoder integration integrityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Encoder discs are pre-mounted onto the inner ring and tensioning assemblies are pre-assembled with encoder bands before final bearing assembly. This preliminary preparation allows quality control and fitting adjustments to be completed on smaller, more manageable components, reducing the need for costly rework and minimizing manufacturing delays.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A tensioning assembly with an adjustable tensioning mechanism serves as an intermediary component that connects and secures the encoder band between the encoder discs and encoder assemblies. This intermediary allows for precise tension adjustment and secure fixation without requiring direct machining of the bearing rings, streamlining the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If the encoder band is tensioned and fixed directly on the bearing rings, then the encoder system maintains precise alignment, but the risk of damage during handling increases

Engineering Contradiction:

Improveencoder band alignment precisionVSAvoiddamage risk during handling

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The encoder band system is segmented into discrete components (encoder discs, encoder assemblies, tensioning assembly) that can be handled and positioned separately. This reduces the risk of damage to the entire encoder system during handling, while the precise alignment is achieved through the modular interface design and adjustment mechanisms of each segment.

Inventive Principle:

Principle #1Segmentation

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 reduces the risk of damage and manufacturing costs by allowing for secure and efficient integration of the encoder system on large diameter bearings, facilitating handling and assembly operations.

Implementation Method 1

the second tensioning part provides at least one magnet that is configured to magnetically mount the second tensioning part to the first tensioning part on a rear inner portion of the first recess

Methodology Applied

Scientific EffectMagnetic mounting: Magnetism

Data Source

PatentUS10801550B1Encoder system and method of assembly for large bearings

Publication Date: 2020.10.13 AB SKF SKF PATENT DEPARTMENT

AI summary

An encoder system mounted on a large diameter bearing, the large diameter bearing having an inner ring and an outer ring, the encoder system providing a tensioning assembly mounted in a pre-machined portion of the inner ring, the tensioning assembly including a first tensioning part having a first machined recess and a first groove, and a second tensioning part having a second groove, the second tensioning part conforming in size and shape to the first recess and disposed within the first machined recess. The tensioning assembly is centered and fixed on to the inner ring. An encoder assembly mounted on the outer ring, the encoder assembly including a first encoder part fixed to the outer ring, and a second encoder part fixed to the first encoder part and aligned in front of the encoder band. A method of assembling an encoder system to a large diameter bearing is also provided.