Hinged Stator Antenna Assembly for Gearbox Telemetry Integration
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Solution Overview
Problem
Existing sensor components for monitoring load conditions in gearboxes face challenges in arrangement and interaction, particularly due to mechanical stress and exposure to environmental conditions, leading to potential damage and communication errors.
Innovation Solution
A stator antenna unit with a pivotable, multi-part annular antenna holder and signal receiver, integrated with a signal evaluation unit, which is securely attached and grounded to the gearbox housing, ensuring reliable data transmission and protection against mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the antenna holder is designed as a single circumferentially closed piece, then the structure is rigid and stable, but it cannot be easily installed around rotating components and is difficult to adapt to different gearbox sizes
Solution Approach 1:
The antenna holder is divided into two separate half-shells that can be opened and closed around the rotating component. This segmentation allows the holder to be easily installed by opening the half-shells, placing them around the component, and closing them, while still providing structural stability when closed and locked together.
Solution Approach 2:
The antenna holder transitions from a static closed structure to a dynamic assembly process. The hinge connection allows the half-shells to pivot between open and closed positions, enabling flexible installation and removal while maintaining structural integrity during operation.
2Reliability
If the signal receiver is exposed to mechanical forces inside the gearbox, then it can detect real operational conditions, but it becomes vulnerable to damage from vibrations and mechanical stress
Solution Approach 1:
The signal receiver is nested within the protective enclosure formed by the antenna holder's half-shells. This nested structure allows the receiver to be positioned close to the rotating component for accurate measurement while being shielded from direct mechanical stress and vibrations by the holder structure.
Solution Approach 2:
The antenna holder acts as an intermediary structure between the signal receiver and the harsh gearbox environment. It transmits necessary mechanical movements for measurement while filtering out harmful vibrations and stresses from reaching the sensitive receiver components.
3Reliability
If the evaluation unit is placed outside the gearbox housing, then it is protected from environmental conditions, but it increases the complexity of signal transmission and system integration
Solution Approach 1:
The evaluation unit is combined with the antenna holder structure, forming an integrated assembly. This merging allows the evaluation unit to be positioned optimally for signal processing while sharing the mechanical support structure, thereby reducing overall system complexity and improving integration efficiency.
4Reliability
If a circumferentially closed antenna holder is used, then the signal receiver is fully enclosed and protected, but the device cannot be easily disassembled for maintenance or replacement
Solution Approach 1:
The antenna holder is segmented into two separable half-shells connected by a hinge. This segmentation provides full enclosure and protection when closed, while allowing easy separation by opening the hinge for maintenance, replacement, or inspection of the signal receiver and other components.
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
The solution provides a robust and reliable telemetry system that is easily integrated into gearboxes, enhancing measurement reliability and applicability to various gearbox series, while minimizing design and assembly efforts.
Implementation Method 1
The rotor element, in particular in the form of a coil with a ferrite core, surrounded by a stator antenna unit, interacts with the stator antenna unit
Data Source
Figure 1~2
Figure 3a~3b
Figure 4a~4b
AI summary
Stator antenna unit (10) for mounting in a transmission housing structure (4) and for interaction with a rotor element (8) arranged in the transmission housing structure (4) on a transmission component (6) and describing an axial direction, having an annular antenna holder (12), a signal receiver (14) extending circumferentially on the antenna holder (12), a signal evaluation unit (16) connected electrically and according to signal technology to the signal receiver (14) and fastened to the antenna holder (12). The antenna holder (12) is of multi-part design and can be pivoted between a circumferentially closed position and a circumferentially open position via a hinge (18). The stator antenna unit (10) can be completely integrated with its components in a transmission and can be used universally, since it can be used as a series solution for different transmission series purely by scaling.