Instrumented Rolling Element Assembly for PCB Stress Isolation
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Solution Overview
Problem
In large diameter bearings, such as those used in wind turbines, the integration of electronics for load measurements is hindered by the mechanical stress on circuit boards due to deformation, leading to reduced service life.
Innovation Solution
A rolling element design with a bore closed at one end face, allowing the circuit board to be fixed without direct mechanical contact with the bore wall, using epoxy resin plugs and protective layers to stabilize and protect the board, and a measuring contact fixed magnetically to the bore wall for data recording.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit board is fixed directly on the bore walls, then the assembly is simple, but the deformations of the rolling element are transferred to the circuit board, significantly reducing service life
Solution Approach 1:
The patent introduces an intermediary substance (epoxy resin or rubber-elastic mass) between the circuit board and the bore wall. This mediator absorbs mechanical deformations and prevents direct stress transfer to the electronics, thereby extending service life while maintaining assembly simplicity through a straightforward embedding process.
2Ease of manufacture
If a through hole is used for mounting the circuit board, then assembly is simplified, but lubricants can penetrate into the bore, contaminating the electronics
Solution Approach 1:
The epoxy resin or rubber-elastic mass acts as a barrier that fills the bore and seals around the circuit board. This intermediary material prevents lubricants from penetrating into the bore while still allowing the circuit board to be mounted through the through hole, thus eliminating contamination risk without complicating assembly.
3Stability of the object's composition
If the circuit board is compressed to fit in the bore, then secure fixation is achieved, but mechanical stress on the board increases, reducing service life
Solution Approach 1:
The compliant intermediary material (epoxy resin or rubber-elastic mass) provides secure fixation by filling gaps and anchoring the circuit board, while its elastic properties allow it to deform under compression without transmitting damaging stresses to the board. This maintains fixation security while protecting the electronics.
Solution Approach 2:
The patent changes the mechanical parameters of the mounting medium by using materials with different compliance levels (epoxy resin vs. rubber-elastic mass). These materials can accommodate compression through deformation rather than rigid resistance, reducing peak stresses on the circuit board while maintaining secure fixation.
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 design enhances the service life of electronics within the rolling element by reducing mechanical stress and preventing lubricant ingress, while allowing for accurate load measurements without altering the bearing's spatial shape or requiring changes to the bore wall.
Implementation Method 1
the plate is fixed by the closure. It is thus advantageously possible for the plate not to be compressed by deformation of the rolling body when the rolling body is subjected to loads
Implementation Method 2
a measuring contact fixed magnetically to the bore wall for data recording
Implementation Method 3
using epoxy resin plugs and protective layers to stabilize and protect the board, and a measuring contact fixed magnetically to the bore wall for data recording
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a rolling element (1), for use in a rolling bearing (100), having an outer casing (2), a first end face (4), a second end face (5) and a bore (3), wherein the bore (3) is provided along a centre axis of the rolling element (1), the rolling element (1) having a PCB (8) arranged substantially parallel to the centre axis of the rolling element (1) in the bore (3), the bore (3) being sealed on the first end face (4) by a closure (10), characterized in that the PCB (8) is fixed in place by the closure (10). The invention furthermore relates to a rolling bearing (100) and a method for producing a rolling element (1).