Sensor-Equipped Wheel Bearing Strain Detection
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Solution Overview
Problem
Existing wheel support bearing assemblies face challenges in detecting wheel loads with high sensitivity and accuracy due to difficulties in installing load sensors, which affects vehicle stability control and is prone to external damage and electromagnetic interference, leading to increased production costs and reduced bearing rigidity.
Innovation Solution
A sensor-equipped wheel support bearing assembly with a strain sensor unit comprising a strain generating member and a sensor element, where the strain sensor unit is fixed to the outer ring using a covering member made of resin or elastomer to protect the sensor element and reduce electromagnetic noise interference, allowing for precise load detection and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a strain gauge is affixed to the outer ring of the wheel support bearing assembly, then load detection capability is achieved, but manufacturing complexity and cost increase due to complicated process steps including plastic forming, turning process, heat treatment and grinding process
Solution Approach 1:
The invention separates the sensor mounting function from the bearing outer ring by introducing a dedicated sensor support member. This member is fixed to the outer ring and carries the load sensor, allowing the bearing to be manufactured using standard processes while the sensor assembly is added separately, thus reducing manufacturing complexity.
Solution Approach 2:
A sensor support member acts as an intermediary between the bearing outer ring and the load sensor. This intermediate structure provides a dedicated mounting platform for the sensor, eliminating the need to modify the bearing manufacturing process while enabling precise load detection.
2Measurement precision
If a strain gauge is attached directly to the outer ring, then load detection is enabled, but detection sensitivity is reduced making it difficult to detect strains occurring in the outer ring with high sensitivity
Solution Approach 1:
The sensor support member serves as an intermediary that enhances strain transfer to the sensor. By providing a dedicated mounting structure with appropriate mechanical properties, it amplifies the strain signal from the outer ring, improving detection sensitivity and accuracy.
Solution Approach 2:
The invention optimizes the mechanical parameters of the sensor support member (such as its geometry, material properties, and mounting configuration) to enhance strain transfer efficiency. This allows for high-sensitivity detection by adjusting structural parameters rather than directly modifying the bearing design.
3Measurement precision
If the sensor support member is fixed to the outer ring at two or more locations, then strain detection accuracy is improved, but the shape of the sensor support member becomes complicated making it difficult to fix in a stabilized posture
Solution Approach 1:
The sensor support member is designed with localized features at specific mounting positions rather than a uniformly complex shape. Each fixing location has optimized local geometry for stable attachment, while the overall structure remains simple and manufacturable.
4Ease of manufacture
If the sensor element is exposed to the outside environment, then installation is simplified, but the sensor element becomes prone to external damage and electromagnetic interference
Solution Approach 1:
The sensor element is nested within the sensor support member structure, which provides protective encapsulation. The support member acts as a housing that shields the sensitive sensor element from external damage and electromagnetic interference while maintaining a compact integrated assembly.
Solution Approach 2:
The sensor support member serves as an intermediary protective barrier between the sensor element and the external environment. It provides mechanical protection and electromagnetic shielding while allowing the sensor to function, thus improving reliability without significantly complicating installation.
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 enables compact, stable, and cost-effective installation of load sensors, allowing for precise and long-term strain detection while preventing external damage and electromagnetic interference, enhancing vehicle stability control and reducing production costs.
Implementation Method 1
a strain sensor unit, made up of a strain generating member and a sensor element fitted to the strain generating member for detecting strains induced in the strain generating member
Implementation Method 2
a covering member that covers at least the sensor element sealingly... preventing external damage and electromagnetic interference
Data Source
AI summary
A sensor equipped wheel support bearing assembly for supporting a vehicle wheel rotatably relative to a vehicle body, including an outer member; an inner member; a plurality of rows of rolling elements interposed between the outer and inner member; a strain sensor unit, made up of a strain generating member and a sensor element fitted to the strain generating member for detecting strains induced in the strain generating member, is fitted to one of the outer and inner members, that serves as a stationary member; and a covering member that covers at least the sensor element sealingly, provided on a mounting surface of the strain generating member of the strain sensor unit, on which the sensor element is mounted, the covering member being made of a resin which is over-molded or an elastomer bonded by vulcanization.