Sensorized Rolling Element With Inductive Load Measurement
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Solution Overview
Problem
Existing load measurement technologies for slewing bearings, such as those in wind turbines, face challenges with wear and aging issues in contact with lubricants, limited precision, and high manufacturing complexity, making them unsuitable for continuous and precise load monitoring.
Innovation Solution
A rolling element with an LC resonant circuit that induces high-frequency eddy currents for inductive load measurement, allowing for precise and durable load monitoring without the need for precise dimensional accuracy in manufacturing, and enabling wireless data transmission using a radio module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are used to measure deformation of the rolling body, then load measurement is possible, but the sensors are extremely susceptible to wear and aging due to contact with grease and lubricants
Solution Approach 1:
The patent replaces mechanical contact-based strain gauges with an inductive sensor system that uses electromagnetic fields to measure deformation. The inductive sensor detects changes in inductance caused by deformation of the rolling body without physical contact, eliminating wear and aging issues associated with traditional strain gauges exposed to grease and lubricants.
2Measurement precision
If capacitive sensors are used for load measurement, then distance measurement is possible, but manufacturing precision requirements are very high and the process is complex
Solution Approach 1:
The patent replaces capacitive sensors with an inductive sensor system that measures deformation through changes in inductance. This substitution eliminates the need for precise dimensional control and complex manual rework processes required by capacitive sensors, while maintaining high measurement precision through electromagnetic field-based detection.
3Manufacturing precision
If inductive sensors are used for load measurement, then manufacturing precision requirements are reduced, but the sensor must be integrated into the rolling body structure
Solution Approach 1:
The patent merges the inductive sensor directly into the rolling body structure by forming the sensor as an integral part of the rolling element. The sensor is embedded within the rolling body during manufacturing, eliminating separate assembly steps and reducing overall device complexity while maintaining ease of manufacture.
4Measurement precision
If high-frequency electrical oscillations are used to induce eddy currents, then measurement resolution is improved, but energy consumption increases
Solution Approach 1:
The patent uses periodic high-frequency electrical oscillations to induce eddy currents in the rolling body for measurement purposes. The oscillations are applied intermittently rather than continuously, allowing the sensor to achieve high measurement resolution while minimizing overall energy consumption through pulsed operation cycles.
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 reliable, precise, and permanent load measurement with higher resolution (up to 0.01 μm) and reduced maintenance, while being easier to manufacture and maintain, with autonomous energy supply from a microgenerator.
Implementation Method 1
The sensor (5) uses eddy currents that it induces in an object (11, 12) to which the distance is to be measured. For this purpose, the sensor contains an LC resonant circuit that is excited to produce high-frequency electrical oscillations.
Implementation Method 2
If an electrically conductive object approaches the LC resonant circuit, eddy currents are induced in the object, which dampen the oscillations. The damping of the vibrations is measured and evaluated.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention proposes a rolling element (1) for use in a rolling-element bearing (100), comprising an outer shell (2) and a bore (3), the bore (3) being preferably provided along a centre axis of the rolling element (1), the rolling element (1) comprising at least one sensor (5) for load measurement, which is arranged in the bore (3), and a transfer module for transferring the data measured by the sensor (5), the rolling element having an energy source, the energy source being provided for providing the energy required for the operation of the sensor (5) and/or of the transfer module, characterised in that the sensor (5) is a sensor that performs inductive measurement. The invention further proposes a rolling-element bearing and a method for load measurement.