Sensorized Rolling Elements for Early Bearing Damage Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing condition monitoring methods for rolling bearings rely on vibration analysis, which is ineffective at low speeds and high noise conditions, and fail to detect surface damage and contamination until after significant deterioration occurs.

Innovation Solution

Implementing sensorized rolling elements with sensors to measure parameters such as temperature, load, rotational speed, and acceleration, and using a processing device to analyze these measurements to detect damage and contamination through comparison with reference distributions or machine learning algorithms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If vibration analysis is used for bearing monitoring, then the method is simple to implement, but it cannot detect damage at early stages and fails at low speed or high noise conditions

Engineering Contradiction:

Improvedamage detection capabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces vibration-based mechanical monitoring with sensorized rolling elements that directly measure contact forces and deformation. Sensors embedded in the rolling elements substitute for external vibration sensors, enabling early damage detection through direct mechanical parameter measurement rather than indirect vibration analysis.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent embeds sensors, electronics, and power sources within the rolling elements themselves. The sensorized rolling element contains a nested structure with sensors measuring contact parameters, processing electronics, and power supply all integrated inside the rolling element, enabling monitoring without external complex equipment.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If sensorized rolling elements are implemented to improve detection accuracy, then early damage detection is enabled, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvebearing condition monitoring reliabilityVSAvoidsensorized rolling element manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sensorized rolling element serves multiple functions simultaneously: it acts as a load-bearing component, a sensor platform for measuring contact forces and deformation, a signal processing unit, and a wireless communication device. This multi-functionality reduces the need for separate monitoring components and simplifies the overall system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The rolling element monitors its own condition and the bearing's condition through embedded sensors. The sensorized rolling element autonomously measures contact parameters, processes signals, and transmits data without requiring external monitoring equipment, enabling self-diagnosis and reducing manufacturing complexity of the overall system.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12584820B2System for monitoring a rolling bearing, associated rolling bearing and method

Publication Date: 2026.03.24 AB SKF SKF PATENT DEPARTMENT

AI summary

A monitoring system is proposed.The monitoring system comprises a rolling bearing comprising a first ring and a second ring (7, 8) capable of rotating concentrically relative to one another, and at least one row of rolling elements (5) interposed between a first raceway and a second raceway respectively provided on the first and second rings, wherein:at least one of the rolling elements (5) of the rolling bearing is a sensorized rolling element comprises at least one sensor measuring at least one parameter of the sensorized rolling element and a wireless transmitter to transmit the measurements of the sensor, and wherein the system comprises:a receiving device (21) configured to receive the measurements of the sensor of the sensorized rolling element of the rolling bearing, anda processing device (23) configured to process the measurements received by the receiving device to detect damage and/or a contamination of the rolling bearing (2).