Modular Sensorized Roller Housing for Variable Bearing Lengths
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Solution Overview
Problem
The existing sensorized roller designs for rolling bearings require multiple variants of housings with different axial lengths, leading to increased manufacturing and storage costs due to the need for customized housing configurations.
Innovation Solution
A modular housing design for the sensorized roller, comprising a central sensing module, an antenna module, and a power module, which are segmented and manufactured separately, allowing for quick assembly and reducing the need for multiple housing variants by adjusting the axial lengths of the antenna and power modules to match the roller body length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece housing design is used for the sensorized roller, then the housing provides complete protection and alignment, but multiple housing variants with different axial lengths must be manufactured and stored to match different roller lengths
Solution Approach 1:
The housing is divided into three separate modular segments: a central sensing module housing, an antenna module housing, and a power module housing. Each segment can be manufactured independently and assembled together, eliminating the need to manufacture multiple complete housing variants for different roller lengths while maintaining full protective coverage.
2Manufacturing precision
If multiple housing variants are manufactured to match different roller lengths, then proper fit and protection are ensured, but manufacturing time and storage requirements increase
Solution Approach 1:
By segmenting the housing into standardized modules, each module can be manufactured using optimized processes independent of the final assembly size. The modules are then assembled through standardized interfaces, significantly reducing total manufacturing time compared to producing complete custom housings for each roller length.
Solution Approach 2:
The modular housing segments are designed with universal interfaces and standardized dimensions that can be used across multiple roller variants. A single set of housing modules can accommodate different roller lengths through reconfiguration, eliminating the need for roller-specific housing manufacturing.
3Manufacturing precision
If multiple housing variants are manufactured to match different roller lengths, then proper fit is ensured, but the number of stored housing variants increases
Solution Approach 1:
The housing is segmented into a limited set of standardized modules (central sensing module, antenna module, power module) that can be combined in different configurations. This reduces inventory requirements from storing multiple complete housing variants to storing a small library of interchangeable modular segments.
Solution Approach 2:
The modular housing segments are designed with universal interfaces that allow the same set of modules to serve multiple roller length requirements. A single standardized module inventory can be used across all roller variants, eliminating the need to maintain separate housing inventories for different roller sizes.
Data Source
AI summary
A sensorized roller for a rolling bearing includes a roller body having an axial length and a bore that extends axial through the roller body and a housing in the roller bore. The housing includes a central sensing module having an axial length and at least one sensor in the central sensing module configured to measure at least one parameter related to a condition of the sensorized roller, an antenna module having an axial length that is secured to a first axial end of the central sensing module and a power module having an axial length that is secured to a second axial end of the central sensing module.