Direct-Deposited Sensorized Components for Strain and Vibration Sensing

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Solution Overview

Problem

Existing methods for condition monitoring in mechanical components, such as rolling element bearings, face challenges in effectively integrating sensors to measure physical parameters like force and vibration, leading to suboptimal signal quality and sensitivity.

Innovation Solution

A sensorized assembly is created by directly depositing an electroactive composite with a conductive electrode onto a mechanically functional component, allowing for the integration of a transducer that converts physical magnitudes into electrical signals, enhancing sensitivity and signal quality by eliminating the need for gluing or welding sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors are attached to mechanical components using traditional methods (gluing or welding), then the sensor can be integrated to the component, but the signal-to-noise ratio and measurement sensitivity are suboptimal

Engineering Contradiction:

Improvesignal-to-noise ratioVSAvoidsensor integration process

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent merges the sensor transducer directly with the mechanically functional component by depositing electroactive composite material onto the component surface. This integration eliminates the need for separate attachment processes (gluing or welding) and creates a unified structure where the sensor becomes an intrinsic part of the component, thereby optimizing signal-to-noise ratio while maintaining manufacturing efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical attachment methods (gluing or welding) with a direct deposition process. Instead of mechanically attaching a separate sensor to the component, the electroactive composite is deposited directly onto the component surface, substituting the mechanical attachment system with a material deposition system that achieves better measurement precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If sensors are attached to mechanical components using traditional methods, then the integration is achieved, but the sensitivity of measurement is reduced

Engineering Contradiction:

Improvemeasurement sensitivityVSAvoidsensor integration structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor transducer and mechanically functional component are merged into a single integrated structure. The electroactive composite is deposited directly onto the component, eliminating the need for separate sensor units and their associated mounting hardware. This merging increases measurement sensitivity by improving coupling between the sensor and component while reducing the overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses electroactive composite materials that combine the functional properties of the mechanical component with the sensing capabilities of the transducer. This composite approach allows the sensor to be seamlessly integrated into the component structure, enhancing measurement sensitivity without adding complex integration structures

Inventive Principle:

Principle #40Composite materials

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 approach improves signal-to-noise ratio and sensitivity by integrating the transducer directly onto the component, enabling more efficient measurement of strain and vibration, and allows for the creation of specific sensor characteristics and patterns that optimize coupling with the component structure.

Implementation Method 1

A first layer with an electroactive composite deposited directly onto a whole of or a part of at least one of the one or more second surface areas

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

A second layer with at least one conductive electrode deposited directly on a part of the electroactive composite

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11131603B2Sensorized mechanical component

Publication Date: 2021.09.28 AB SKF SKF PATENT DEPARTMENT

AI summary

A mechanically functional component having at least one sensor arranged to convert one or more physical magnitudes to electrical sensor signals. The sensor includes an electroactive composite deposited directly onto the mechanically functional component and at least one conductive electrode deposited directly on a part of the electroactive composite.