Sensorized Bearing Roller With Proximity Gap Load Detection
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Solution Overview
Problem
Existing sensor configurations in roller bearings are prone to detachment and electrical connection strain due to the 'chewing effect' caused by radial load, leading to inaccurate load detection and potential rupture under dynamic conditions.
Innovation Solution
A sensor module with a rigid housing and proximity sensors arranged on the outer cylindrical surface, measuring the radial gap between the inner bore surface and the sensing element, which is insensitive to the chewing motion and protected from contamination by sealing elements, allowing for contact-free and accurate deformation measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is attached to the inner surface of the roller bore using elastomeric material, then the sensor can detect bore deformation, but the elastomer material becomes detached due to chewing motion causing strain or rupture of electrical connections
Solution Approach 1:
The patent replaces the mechanical attachment system (elastomeric material bonding sensor to bore surface) with a contact-free measurement system. The proximity sensor measures the radial gap between the housing and bore surface without physical contact, eliminating the chewing effect that causes detachment and electrical connection strain.
Solution Approach 2:
The patent introduces a rigid housing as an intermediary component that houses the proximity sensor and provides a stable reference frame. The housing with small radial clearance to the bore surface allows the sensor to measure bore deformation indirectly through gap changes, isolating the sensor from direct contact with the moving bore surface.
2Measurement precision
If a load cell spans the roller bore diameter and is in fixed contact with diametrically opposite portions of the bore surface, then the load cell can detect radial load, but the contact locations experience transverse displacement causing chewing effect that requires complex elastic deformation design
Solution Approach 1:
The patent replaces the complex mechanical load cell system with bending beams and hinges that must accommodate chewing motion with a simple proximity sensor measuring radial gap changes. The contact-free measurement eliminates the need for complex elastic deformation designs while maintaining accurate radial load detection capability.
3Reliability
If a sensor module with rigid housing and proximity sensors measuring radial gap is used, then contact-free and accurate deformation measurement is achieved, but the device complexity increases compared to simple attached sensors
Solution Approach 1:
The rigid housing serves multiple functions: it houses the proximity sensor, provides a stable reference frame for measurement, maintains small radial clearance to the bore surface for accurate gap measurement, and protects the sensor from contamination. This multi-functionality justifies the increased structural complexity by eliminating the need for attachment materials and complex deformation accommodation mechanisms.
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 precise and reliable detection of radial load and load distribution on roller bearings, reducing the risk of sensor detachment and maintaining accuracy under dynamic conditions, thus extending the service life and maintaining accurate load measurement.
Implementation Method 1
at least one proximity sensor is accommodated at the outer cylindrical surface of the housing such that a sensing element of the proximity sensor faces the inner cylindrical surface of the roller bore and measures a radial gap therebetween
Implementation Method 2
The resilient elements take up radial deformations of the bore and prevent contact between the bore surface and the housing outer surface
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a sensorized roller (10) of a bearing, the sensorized roller having a hollow cylindrical bore (15) extending in an axial direction of the roller in which a sensor module (20) is accommodated. The sensor module is equipped with one or more deformation sensors for detecting deformation of the roller bore due to a radial load acting on the roller. The sensor module (20) comprises a rigid housing (30) that is shaped to fit inside the roller bore (15) and is mounted to the roller bore with a small radial clearance between an outer cylindrical surface of the housing an inner cylindrical surface of the bore. Furthermore, each of the one or more deformation sensors is formed by a proximity sensor (25a, 26a, 27a) that is accommodated at the outer cylindrical surface of the housing (30) such that a sensing element of the proximity sensor faces the inner cylindrical surface of the roller bore (15) and measures a radial gap therebetween, which radial gap is indicative of bore deformation.