Roller Bearing Load Detection via Strain Gauge and Position Sensor
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Solution Overview
Problem
Existing load detection methods for roller bearings in wind power generators suffer from noise interference and lack accuracy in measuring the complex load distribution, especially due to the upsizing of generators and structural improvements, which complicates the analysis of durability and service life.
Innovation Solution
A load detecting device comprising a load detecting sensor, a position detecting sensor, and a recording device is integrated into a roller bearing, where strain gauges on the rollers detect load changes, and a data logger records and processes these signals to reduce noise interference and enhance accuracy, allowing for precise load analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a strain gauge is provided inside a rolling element to detect load, then load detection capability is achieved, but measurement precision deteriorates due to noise interference
Solution Approach 1:
The patent segments the detection system into three independent components: load detecting sensors mounted on the outer ring, position detecting sensors mounted on the inner ring, and a recording device. This segmentation allows each component to perform its specific function optimally without mutual interference, thereby improving measurement precision while isolating noise sources.
Solution Approach 2:
The patent introduces a recording device as an intermediary that receives signals from both load detecting sensors and position detecting sensors. This intermediary processes and correlates the data, enabling accurate load measurement by referencing position information, which helps filter out noise and improve overall measurement precision.
2Power
If the generator is upsized to obtain larger generated power, then power generation capacity is improved, but the load applied to the bearing increases and becomes more complex
Solution Approach 1:
The patent employs multiple load detecting sensors distributed around the outer ring and multiple position detecting sensors on the inner ring. This segmentation allows the system to capture the complex, multi-directional load distribution caused by upsized generator weights and structural improvements, providing detailed data for durability analysis.
Solution Approach 2:
The detection system is designed with multi-functionality to handle various complex load conditions. The combination of load detecting sensors, position detecting sensors, and recording device creates a universal measurement system that can accurately characterize different load patterns regardless of generator size or configuration, enabling comprehensive durability assessment.
3Measurement precision
If multiple sensors and recording devices are integrated into the roller bearing, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the load detection function and position detection function into a single integrated bearing assembly. By combining these functions within the same mechanical structure, the system achieves high measurement precision without proportionally increasing overall device complexity, as the sensors share common mounting structures and data processing pathways.
Solution Approach 2:
The recording device serves multiple functions: it records load detection signals, records position detection signals, correlates the two data streams, and enables comprehensive load analysis. This multi-functionality reduces the need for separate dedicated systems, thereby improving measurement capabilities while controlling device complexity.
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 highly accurate load detection signals with reduced noise influence, enabling reliable load analysis and improved understanding of load distribution across rolling elements, enhancing the durability assessment and service life prediction of roller bearings.
Implementation Method 1
a load detecting sensor which is provided in a roller arranged rollably between a first bearing ring and a second bearing ring, and detects a load applied to the roller
Implementation Method 2
a position detecting sensor which detects a rotation position of the roller in the revolution direction of the roller
Data Source
AI summary
A load detecting device for a roller bearing includes: a strain gauge that is provided in a roller arranged rollably between a first bearing ring and a second bearing ring and that detects a load applied to the roller; a position detecting sensor that detects a rotation position of the roller in a revolution direction of the roller; and a data logger that is provided for the roller and that records and stores a detection signal from the stain gauge.