Gear Unit Housing Cover with Integrated Sensor Unit

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Solution Overview

Problem

Gear units in installations lack reliability due to limited monitoring capabilities and functionality, relying on simple housing covers for closure without additional features.

Innovation Solution

Integration of a sensor unit on the housing cover connected to an evaluation unit, enabling monitoring of physical quantities and providing additional functions such as vibration, inductive proximity, oil condition, torque, and displacement sensing, while offering electromagnetic shielding and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a simple housing cover is used for closure only, then manufacturing costs are low and assembly is simple, but functionality and monitoring capabilities are limited

Engineering Contradiction:

ImprovefunctionalityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The sensor unit is merged with the housing cover, allowing the cover to serve both as a closure element and as a mounting platform for sensors. This integration enables the housing cover to provide both mechanical protection and sensing capabilities, resolving the contradiction between simplicity and functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing cover is designed to perform multiple functions: it serves as a closure element, a mounting base for the sensor unit, and potentially provides electromagnetic shielding. This multi-functionality approach allows a single component to address multiple requirements without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple sensors are integrated into the housing cover, then monitoring capabilities and reliability are improved, but manufacturing complexity and cost increase

Engineering Contradiction:

ImprovereliabilityVSAvoidmanufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sensing functionality is segmented into a separate sensor unit that can be independently manufactured and then integrated with the housing cover. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process compared to integrating all sensors directly into the cover.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor unit is prepared as a pre-assembled module with all necessary sensors and connections before being mounted on the housing cover. This preliminary preparation of the sensor unit simplifies the final assembly process and reduces manufacturing complexity at the integration stage.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the sensor unit is made in one piece with the housing cover, then fewer interfaces and sealing problems occur, but accessibility and flexibility are reduced

Engineering Contradiction:

ImprovesealingVSAvoidaccessibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The sensor unit is kept as a separate, removable module rather than being permanently integrated into the housing cover. This segmentation maintains a clear interface that can be properly sealed while allowing the sensor unit to be easily accessed, removed, or replaced for maintenance or calibration purposes.

Inventive Principle:

Principle #1Segmentation

4Object-affected harmful factors

If a metallic housing cover is used, then electromagnetic shielding and mechanical stability are improved, but production complexity and cost increase

Engineering Contradiction:

Improveelectromagnetic shieldingVSAvoidproduction

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The housing cover may use composite construction, combining metallic elements for shielding-critical areas with non-metallic materials for other portions. This composite approach provides the necessary electromagnetic shielding and mechanical stability only where required, reducing overall production complexity and cost compared to a fully metallic construction.

Inventive Principle:

Principle #40Composite materials

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

Enhances reliability by allowing for real-time monitoring and variance in gear unit configurations with reduced parts, lower manufacturing costs, and improved assembly efficiency.

Implementation Method 1

a first sensor is a vibration sensor, particularly for detecting structure-borne noise generated by bearings and/or toothing parts

Methodology Applied

Scientific EffectVibration detection: Vibration

Implementation Method 2

a further sensor is an inductive proximity sensor, particularly for determining the rotation of a toothing part

Methodology Applied

Scientific EffectInductive proximity sensing: Electromagnetic Induction

Implementation Method 3

a further sensor is an oil-condition sensor, implemented particularly as an infrared sensor, especially for determining the condition, particularly the age, of the lubricating oil

Methodology Applied

Scientific EffectInfrared sensing: Infrared Radiation

Data Source

PatentUS9958052B2System having a gear unit

Publication Date: 2018.05.01 SEW EURODRIVE GMBH & CO KG

AI summary

A system includes a gear unit, the gear unit including at least one housing cover, a sensor unit, on which sensors are provided, being provided on the housing cover, the sensors being connected at least electrically to an evaluation unit.