Additively Manufactured Sensor Rolling Body for Bearing Signal Transmission
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Solution Overview
Problem
Existing sensor rolling bodies are costly to produce due to separate manufacturing of rollers and sensor inserts, and wireless sensors face interference from metal shielding in bearings, making data transmission difficult.
Innovation Solution
A sensor rolling body with a raceway layer and embedded electronic devices produced via additive manufacturing, allowing integrated production of the sensor layer and devices in a single step, enabling flexible adaptation to shape and size, and using electromagnetically permeable materials for signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor rolling bodies are produced by separate manufacturing of roller and sensor insert followed by assembly, then functional requirements are met, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent combines the roller and sensor insert into a single integrated component produced by additive manufacturing. The sensor layer is built directly within the roller structure in one manufacturing process, eliminating the need for separate production and assembly operations. This merging of components resolves the contradiction by maintaining functional requirements while significantly reducing production cost and manufacturing complexity.
2Strength
If metal-based materials are used in bearing, then mechanical strength is sufficient, but signal transmission is blocked by electromagnetic shielding
Solution Approach 1:
The patent applies local quality by using electromagnetically permeable materials specifically in the sensor layer and antenna regions, while other parts of the bearing can use traditional metal-based materials for mechanical strength. This localized material selection allows signal transmission through the bearing structure without compromising overall mechanical performance, resolving the contradiction between strength and signal transmission.
3Device complexity
If wireless sensors are used in bearing, then cabling complexity is reduced, but signal reception is hampered by metal shielding
Solution Approach 1:
The patent introduces electromagnetically permeable materials as intermediaries between the wireless sensors and the external environment. These materials act as mediators that allow electromagnetic signals to pass through the bearing structure without being blocked by metal shielding, thereby maintaining wireless operation while ensuring reliable signal reception and transmission.
4Ease of manufacture
If additive manufacturing is used for sensor rolling body, then production cost decreases and manufacturing simplicity increases, but manufacturing precision must be maintained
Solution Approach 1:
The patent leverages parameter changes in additive manufacturing technology to achieve the required manufacturing precision. By optimizing printing parameters, material properties, and post-processing conditions, the additive manufacturing process can produce sensor rolling bodies with sufficient dimensional accuracy while maintaining cost-effectiveness and manufacturing simplicity.
Data Source
AI summary
A sensor rolling body has a raceway layer and a sensor layer arranged radially on the inside of the raceway layer. At least one electronic device embedded in the sensor layer. The sensor layer and the at least one electronic device are each produced by an additive manufacturing process.