Sensorized Roller With Integrated Energy Harvesting
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Solution Overview
Problem
Condition monitoring devices for roller bearings, especially in remote or inaccessible locations, face limitations due to the need for power sources like batteries, which restrict the number of measurements that can be taken, and existing energy harvesting solutions often require a bearing cage that not all bearings have.
Innovation Solution
A sensorized roller with an integrated energy harvesting device, comprising an electrical generator with an eccentric mass and stator coils, mounted within the roller bore, which generates power through rotation, allowing for energy harvesting without a cage, and includes a processor to transmit signals externally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a battery pack is used to power condition monitoring devices, then the device can operate in remote locations, but the number of measurements that can be performed is significantly limited
Solution Approach 1:
The patent combines the energy harvesting device directly with the sensorized roller by mounting both components within the same insert fitted in the roller bore. This integration allows the roller to simultaneously perform its mechanical function and generate electrical energy through its rotation, eliminating the need for separate battery packs and enabling continuous power supply for extended measurements.
Solution Approach 2:
The sensorized roller becomes self-powered through the integrated energy harvesting device that generates electricity from the roller's own rotation. The system harvests energy from its operational motion, allowing it to continuously power the measuring unit and processor without external power sources or limited battery capacity.
2Use of energy by moving object
If existing energy harvesting solutions are used, then power can be generated, but a bearing cage is required which not all bearings have
Solution Approach 1:
The patent segments the energy harvesting system into independent components (electrical generator, measuring unit, processor) that are all mounted within the roller bore insert. This modular arrangement within the roller eliminates the dependency on the bearing cage structure, allowing the system to be adapted to any bearing type regardless of cage presence.
Solution Approach 2:
The integrated insert design within the roller bore provides a universal mounting solution that works with all bearing types. The roller itself becomes the universal carrier for both the energy harvesting device and measurement sensors, making the system compatible with bearings that have cages, bearings without cages, and different cage designs.
3Use of energy by moving object
If an electrical generator with eccentric mass is integrated into the roller, then continuous power can be generated, but the device complexity increases
Solution Approach 1:
The patent merges the electrical generator, measuring unit, and processor into a single integrated assembly mounted within the roller bore insert. This consolidation reduces the overall number of separate components and simplifies the system architecture, making the increased complexity of the generator acceptable by combining it with other functional elements in a unified structure.
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
Enables continuous power for condition monitoring devices, allowing for extended measurement capabilities without the need for external power sources or bearing cages, enhancing monitoring efficiency in challenging environments.
Implementation Method 1
an electrical generator having an axis arranged along an axis of the bore of the sensorized roller and configured to produce energy from the rotation of said sensorized roller
Implementation Method 2
the eccentric mass or weight is driven by gravity and centrifugal force to maintain the main shaft of the generator during rotation of the sensorized roller
Implementation Method 3
the eccentric mass or weight is driven by gravity and centrifugal force to maintain the main shaft of the generator during rotation of the sensorized roller
Data Source
AI summary
A sensorized roller for a bearing includes a bore that extends through the roller, a sensor for measuring at least one physical state of the roller bore and producing a first signal indicative of the measured physical state, a wireless transmitter for receiving the first signal from the sensor and wirelessly transmitting a second signal based on the first signal, and a generator configured to be rotated by a movement of the roller, the generator being electrically connected to the sensor. The measuring unit, the wireless transmitter and the generator are located inside the bore.