Sensorized Hub Bearing Structure for Protected Strain Sensing
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Solution Overview
Problem
Existing sensorized hub bearing units for vehicles are complex, expensive, and inefficient in detecting forces and moments in real-time, with sensors often exposed to contaminants and damage, making them unreliable for mass production and real-time use.
Innovation Solution
A sensorized hub bearing unit with integrated strain sensors housed within sealed chambers between the outer and inner rings of a rolling bearing, protected from external contaminants and damage, allowing for accurate and reliable detection of forces and moments applied to the hub bearing unit during vehicle operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are mounted on the outer ring of the hub bearing unit, then forces and moments can be detected, but the sensors are exposed to external contaminants and possible damage
Solution Approach 1:
The strain sensors are integrated into the outer ring structure itself, with sensors embedded within the ring wall or mounted on internal surfaces. This nesting approach protects sensors from external contaminants while maintaining their ability to detect forces and moments applied to the hub bearing unit.
Solution Approach 2:
A protective layer or coating is applied between the external environment and the strain sensors. This intermediary layer shields sensors from contaminants such as dust, moisture, and road salts while allowing strain measurements to be transmitted accurately from the outer ring to the sensors.
2Measurement precision
If multiple sensor modules are arranged circumferentially on the outer ring, then detection accuracy improves, but device complexity and cost increase
Solution Approach 1:
Multiple strain sensors are integrated into a single sensor module or array embedded within the outer ring structure. By combining multiple sensing elements into one unified component, the patent achieves accurate multi-axis force and moment detection while reducing overall device complexity and facilitating mass production.
Solution Approach 2:
The sensor module is designed to perform multiple detection functions simultaneously, measuring radial, axial, and tangential forces as well as moments. This multi-functional approach eliminates the need for separate sensor modules for each measurement type, thereby reducing complexity while maintaining high measurement precision.
3Ease of manufacture
If sensors are exposed on the outer ring surface, then installation and calibration are simpler, but sensors are vulnerable to damage and require repeated recalibration
Solution Approach 1:
The strain sensors are pre-integrated into the outer ring during the manufacturing process, such as during casting, machining, or assembly. This preliminary integration ensures sensors are properly positioned and protected before the hub bearing unit is put into service, eliminating the need for post-installation calibration and reducing vulnerability to damage.
Solution Approach 2:
Protective structures such as recesses, coatings, or encapsulation layers are incorporated into the outer ring design to cushion and protect the strain sensors from mechanical damage, contamination, and environmental factors before any damage can occur during operation.
4Productivity
If a complex sensorized system is implemented, then real-time force and moment detection is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The hub bearing unit and strain sensor system are integrated as a single unified component during manufacturing. By combining the bearing structure with embedded strain sensors, the patent achieves real-time force and moment detection capabilities while simplifying the overall system architecture and reducing manufacturing costs through consolidated production processes.
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 enables reliable, real-time detection of mechanical stresses with high repeatability, reducing recalibration needs and ensuring sensor protection from external factors, thus enhancing vehicle stability control and compatibility with mass production.
Implementation Method 1
at least one strain sensor (4) configured to detect mechanical stresses, such as loads, to which hub bearing unit (2) is subjected
Data Source
AI summary
A sensorized hub bearing unit having at least one strain sensor for detecting, in real time, forces and moments applied to an outer ring of the hub bearing unit, in which a radially outer ring of the hub bearing unit is formed by a coupling of a first annular element and a second annular element arranged coaxially, the second annular element radially fitted and integrally inside the first annular element and at least one strain sensor arranged in line with an interface between the first annular element and the second annular element.