Sensorized Roller Bearing Reliability From Real-Time Load and Speed
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Solution Overview
Problem
Existing methods for monitoring the reliability of roller bearings in wind turbines are not real-time and require frequent and costly maintenance, leading to potential under or overestimation of bearing life and operational margins.
Innovation Solution
A process using sensorized roller bearings to determine bearing reliability in real-time by measuring load, speed, and temperature, and calculating the L10 life and reliability using the Palmgren-Miner rule and Weibull curve, allowing for adjustments to wind turbine operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If real-time monitoring of bearing reliability is implemented using sensorized rollers, then operational efficiency and maintenance cost optimization improve, but device complexity and initial cost increase
Solution Approach 1:
The sensor is integrated inside the roller itself, nesting the sensing function within the existing bearing component. This eliminates the need for separate external sensors and reduces overall system complexity despite adding monitoring capabilities.
Solution Approach 2:
The sensorized roller serves multiple functions: it acts as both a load-bearing component and a sensing element that measures acceleration, temperature, and operational parameters. This multi-functionality reduces the need for additional separate components.
2Measurement precision
If traditional bearing life estimation methods are used, then device complexity remains low, but measurement precision and reliability determination are inaccurate
Solution Approach 1:
The patent replaces mechanical inspection methods (lubricant sampling, clearance measurement) with electronic sensing using accelerometers and temperature sensors integrated into the roller, enabling precise real-time monitoring without mechanical intervention.
Solution Approach 2:
The bearing monitors its own operational parameters and reliability status through integrated sensors, eliminating the need for external inspection systems and providing self-diagnostic capabilities.
3Reliability
If frequent manual inspections are performed to monitor bearing condition, then reliability determination improves, but loss of time and operational disruption increase
Solution Approach 1:
The integrated sensors enable continuous monitoring of bearing parameters without interruption to the wind turbine operation, eliminating the need for periodic shutdowns and manual inspections while providing uninterrupted reliability data.
Solution Approach 2:
The system provides real-time feedback on bearing condition through continuous sensor data acquisition and processing, enabling immediate detection of degradation trends without waiting for periodic manual inspections.
Data Source
AI summary
A process for determining the reliability of a sensorized bearing configured to measure load and speed is provided. The process includes the following steps. Bearing load and rotational speed are determined from data acquired from the sensorized bearing. Next, an array linking the determined load to the determined n·dm value is filled until that all available loads are parsed. Then a L10 life is determined for each load within a distribution based on the array. Finally, an overall L10 life is determined based on the Palmgren-Miner rule. The load distribution and the L10 lives a bearing reliability R for a given date is determined based on a Weibull curve and the overall L10 life. The process may be carried out by a computer having a processor and a memory.