Instrumented Bearing Sensor Fixation via Polymer Resin
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Solution Overview
Problem
Existing instrumented rolling bearings face challenges in achieving reliable and economical fixation, especially in environments with high pollution risks, and struggle with correct positioning and retention of sealing elements, particularly in small bearings.
Innovation Solution
The instrumented bearing employs a connecting element made of synthetic material that hardens in place, ensuring a secure attachment to the non-rotating part of the bearing by shape complementarity, and uses a groove system for both sealing and sensor fixation, allowing for a leak-tight seal and easy material introduction, utilizing thermosetting or thermoplastic polymer resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal cup crimped into the groove is used to secure the support block, then the attachment is suitable for many applications, but the sealing against external pollution becomes insufficient in high pollution risk environments
Solution Approach 1:
The patent employs a composite sealing structure combining a metal support block with a polymer resin seal. The metal cup provides mechanical attachment while the polymer resin material (epoxy or polyurethane) fills the annular groove to create a pollution-resistant seal, effectively combining the advantages of different materials to address both attachment and sealing requirements.
Solution Approach 2:
The patent uses a flexible polymer resin seal that can deform to conform to the groove geometry and provide effective sealing. The resin material acts as a flexible barrier that prevents pollution ingress while accommodating manufacturing tolerances and thermal expansion, resolving the contradiction between simple attachment and effective sealing.
2Object-affected harmful factors
If an annular sealing flange is mounted radially inside the crimped edge to provide sealing, then sealing is improved, but the correct positioning and retention of the shield becomes difficult in small bearings
Solution Approach 1:
The patent changes the physical state and geometry of the sealing element by using a fluid or semi-fluid polymer resin that is injected into the annular groove. This resin then cures to form a solid seal, eliminating the need for precise mechanical positioning of a rigid flange. The parameter change from rigid to fluid state during installation simplifies positioning and retention in small bearings.
Solution Approach 2:
The polymer resin seal is self-positioning and self-retaining. When injected into the annular groove, it automatically conforms to the groove geometry and cures in place, eliminating the need for external positioning mechanisms or complex retention features that would be required for a rigid flange in small bearings.
3Reliability
If a hardenable material is introduced into the sensor block to ensure shape concordance and sealing, then fixation reliability and sealing level are improved, but the complexity of the fixation process increases
Solution Approach 1:
The patent replaces complex mechanical fixation systems with a chemical bonding approach using hardenable polymer resin. Instead of multiple mechanical components and assembly steps, a single injection and curing process achieves both fixation and sealing, reducing overall system complexity despite the chemical process involved.
Solution Approach 2:
The patent merges multiple functions into a single material and process: the polymer resin simultaneously provides fixation (through adhesion to surfaces), sealing (through gap filling), and structural support. This consolidation of functions into one material system simplifies the overall fixation approach compared to using separate components for each function.
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 provides a reliable and economical fixation method that ensures a high level of sealing against external pollution, maintaining the integrity of the bearing's operation over its lifespan without additional machining costs.
Implementation Method 1
The connecting element is attached in the plastic state to the sensor block to ensure attachment to a side face of the non-rotating part. The connecting element ensures, in the hardened state, the fixing of the sensor block on the non-rotating part
Implementation Method 2
the insert material of the connecting element comprises a thermosetting or thermoplastic polymer resin
Implementation Method 3
the insert material of the connecting element comprises a thermosetting or thermoplastic polymer resin
Data Source
AI summary
The bearing has outer and inner rings (2, 4) with raceways (3, 5), and rolling elements, i.e. balls, between the raceways. A sensor (11) with a sensor block (12) is supported by the outer ring. The block is fixed on a lateral side of the outer ring by a connection element (14). The element (14) has a thermosetting/thermoplastic material connected at the plastic state on the block, for being fixed on the outer ring`s lateral face and ensures, at the hardened state, fixation of the block and outer ring by cooperation of block`s surfaces in shape complementarity with outer ring surfaces. An independent claim is also included for a method of fixation of a sensor block on a bearing.