Sensorized Roller Bearing Housing for Deformation Monitoring
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Solution Overview
Problem
Existing load detection systems in roller bearings face issues with sensor detachment due to 'chewing motion' within the roller bore, leading to potential electrical connection strain or rupture, and inadequate protection against contaminants and friction.
Innovation Solution
A sensorized roller bearing with a rigid housing containing the measuring device and electronics, sealed by resilient elements to prevent contamination and friction, and designed for easy mounting and servicing, with a wireless transmission system to ensure accurate deformation measurement and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is attached directly to the inner surface of the roller bore using elastomeric material, then the sensor can detect deformation, but the elastomeric material becomes detached due to chewing motion causing strain on electrical connections
Solution Approach 1:
The sensor assembly is segmented into a separate housing unit that can be mounted independently within the roller bore, rather than attaching the sensor directly to the bore surface. This segmentation isolates the sensor from the chewing motion while maintaining measurement capability through the housing's interaction with the bore.
Solution Approach 2:
A rigid housing acts as an intermediary between the sensor and the roller bore, providing a stable mounting structure that prevents direct attachment issues. The housing translates the deformation measurements while protecting the sensor and its electrical connections from the harmful chewing motion.
2Device complexity
If the sensor and electronics are exposed within the roller bore, then the structure remains simple, but contaminants and moisture cause friction and damage to the components
Solution Approach 1:
The sensor and electronics are nested within a protective housing that fits inside the roller bore. This nested structure protects the sensitive components from contaminants and moisture while maintaining a compact configuration that does not significantly increase the overall device complexity.
Solution Approach 2:
The housing uses simple, easily replaceable sealing elements (such as O-rings or gaskets) that provide effective protection against contaminants. These sealing components are inexpensive and can be easily replaced if worn, maintaining protection without requiring complex maintenance procedures.
3Object-affected harmful factors
If the housing is made rigid to protect components, then protection against contaminants is improved, but friction with the bore surface increases
Solution Approach 1:
The housing exhibits local quality differentiation: the main body is rigid to protect components, while the sealing elements in contact with the roller bore are made of resilient, low-friction materials. This localized material selection reduces friction forces while maintaining overall structural protection.
Solution Approach 2:
The sealing elements use material parameter changes (resilience and friction characteristics) to adapt to the roller bore surface. These resilient materials can deform to accommodate surface irregularities and maintain sealing while minimizing friction during the roller's operation.
4Reliability
If the sealing elements are resilient to take up deformations, then protection from bore contact is improved, but the housing may rotate within the bore
Solution Approach 1:
The housing combines multiple functions: the resilient sealing elements provide both the seal against contaminants and the anti-rotation mechanism. By merging these functions into a single integrated component, the design achieves both sealing effectiveness and rotational stability without requiring separate mechanisms.
Solution Approach 2:
The sealing elements serve multiple functions simultaneously: they seal the housing against contaminants, accommodate bore deformations, and prevent housing rotation through their frictional engagement with the bore surface. This multi-functionality resolves the contradiction between sealing and stability.
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 effectively protects the sensor components from contaminants and friction, ensures accurate deformation measurement, and facilitates easy maintenance, enhancing the reliability and longevity of the load detection system in roller bearings.
Implementation Method 1
The resilient first and second sealing elements take up deformations of the roller bore, to prevent the housing from coming into contact with the bore
Implementation Method 2
Friction between the sealing elements and the bore surface also limits rotation of the housing within the bore
Data Source
AI summary
The present invention resides in a sensorized roller of a roller bearing. The sensorized roller includes a roller bore that accommodates a measuring device for measuring deformation of the roller bore and electronics for processing a deformation signal from the measuring device and wirelessly transmitting the processed deformation signal to an external receiver. According to the invention, the measuring device and electronics are mounted in a rigid housing that is shaped to fit within the roller bore. A radially outer surface of the housing includes at least one aperture associated with the measuring device. Furthermore, the rigid housing is resiliently mounted to the roller bore via first and second sealing elements that enclose a radial gap between a radially inner surface of the roller bore and a radially outer surface of the housing.