Integrated Load-Sensing Bearing for Continuous In-Operation Measurement
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Solution Overview
Problem
Existing bearing assemblies require shutdown and partial disassembly for load measurement, causing stress and uneven material buildup, which affects long-term performance, especially in rotary structures like RBCs.
Innovation Solution
A load-sensing bearing assembly with an integrated sensor module, comprising a sensor pin and strain gauge within a sensor bore in the bearing housing, allowing continuous load measurement without disassembly, using a retention mechanism to maintain axial compressive load on the sensor pin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load measurement is performed using discrete load cells, then load measurement capability is improved, but device height increases and maintenance frequency increases
Solution Approach 1:
The patent combines the load measurement function directly into the bearing assembly by integrating a sensor module within the bearing housing. The sensor pin is positioned to receive compressive loads through the bearing element, eliminating the need for separate discrete load cells and reducing overall device height while maintaining measurement capability.
Solution Approach 2:
The sensor module is nested within the bearing housing structure. The sensor pin fits into a sensor bore formed in the bearing housing, and the strain gauge is mounted on the sensor pin. This nested arrangement allows the measurement function to be contained within the existing bearing footprint, avoiding height increase.
2Measurement precision
If load measurement requires bearing detachment, then measurement accuracy is improved, but productivity decreases and harmful factors increase
Solution Approach 1:
The load measurement function is merged with the bearing assembly itself, allowing simultaneous operation of the bearing and measurement system. The sensor module remains installed during bearing operation, enabling continuous load monitoring without requiring detachment or shutdown of the machinery.
Solution Approach 2:
The patent enables continuous load measurement during bearing operation. The sensor module is designed to function while the bearing is in use, with the sensor pin continuously receiving compressive loads from the bearing element. This eliminates interruptions and maintains continuous productive action while providing ongoing measurement data.
3Measurement precision
If bearing is shut down for measurement, then measurement capability is improved, but reliability worsens due to stress and material buildup
Solution Approach 1:
The bearing and measurement system operate continuously without shutdown. The sensor module is designed to function during normal bearing operation, eliminating the cyclic stress and material buildup issues that arise from repeated stopping and starting. This maintains reliability while providing continuous measurement capability.
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
Enables continuous load measurement during operation, reducing stress on machinery and extending the sensor's lifetime, while maintaining the bearing assembly's structural integrity and operational efficiency.
Implementation Method 1
a strain gauge supported by the sensor pin and oriented to provide an indication of a compressive load acting on the bearing assembly
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A bearing assembly may include an integral sensor module retained within a bore in the bearing housing. The sensor module includes at least one strain gauge oriented to sense a compressive load acting on the bearing housing. The sensor module may be retained within the bore under an axial compressive load. The sensor module may include a power source and a wired or wireless communications module for transmitting information indicative of the compressive load to an external instrument or other system.