Sensorized Rolling Element With Self-Powered Wireless Load Sensing
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Solution Overview
Problem
Existing load measurement technologies for large rolling-element bearings, such as those in wind turbines, face challenges including complex wiring for energy supply, susceptibility to wear from lubricants, and measurement inaccuracies due to external energy sources and shifting components.
Innovation Solution
Integration of a micro-generator within the rolling element for autonomous energy harvesting, combined with a capacitive sensor and radio module for wireless data transmission, allowing precise load measurements without the need for external wiring or energy supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gages are arranged in a bore hole in a rolling element to measure deformations, then load measurement capability is improved, but the strain gages become susceptible to wear from grease and lubricants requiring regular replacement
Solution Approach 1:
The patent replaces mechanical strain gages with capacitive sensors that measure distance changes between a circuit board and the bore wall. This substitution eliminates the need for physical contact with lubricants, as the capacitive measurement occurs through the insulation layer without mechanical wear, thereby maintaining measurement precision while improving reliability.
2Use of energy by moving object
If complex wiring is arranged to supply energy to strain gages and transmitters, then energy supply capability is improved, but device complexity and operational disruption increase
Solution Approach 1:
The patent implements self-service by generating electrical energy within the rolling element itself through a micro-generator. The micro-generator converts mechanical energy from the rolling element's rotation into electrical energy, which powers the capacitive sensors and radio module. This eliminates the need for external wiring and energy supply systems, reducing device complexity while maintaining continuous energy supply capability.
3Measurement precision
If boards are arranged parallel to measure distance changes through capacitance, then measurement capability is improved, but measurement accuracy decreases due to board shifting and bending
Solution Approach 1:
The patent uses a flexible insulation layer between the capacitive sensor and the bore wall instead of rigid parallel boards. This flexible film accommodates the deformation of the rolling element during operation, maintaining consistent capacitive coupling without shifting or bending issues. The flexible structure ensures accurate distance measurements while adapting to the dynamic mechanical conditions inside the rolling element.
4Use of energy by moving object
If external energy supply is arranged for sensors and radio module, then energy availability is improved, but wiring requirements and operational complexity increase
Solution Approach 1:
The patent implements self-service by generating electrical energy within the rolling element itself through a micro-generator. The micro-generator converts mechanical energy from the rolling element's rotation into electrical energy, which powers the capacitive sensors and radio module. This eliminates the need for external wiring and energy supply systems, reducing device complexity while maintaining continuous energy supply capability.
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, continuous, and long-term load measurement during operation, reducing maintenance needs and improving measurement accuracy by providing an integrated and autonomous energy source for sensors and data transmission.
Implementation Method 1
the rolling element has a micro-generator (4), provided to generate energy required for operation of the sensor (5) and/or of the radio module (6)
Implementation Method 2
the sensor (5) is a capacitive sensor, the sensor being provided to measure a distance between the sensor and the bore wall
Data Source
AI summary
A rolling element for use in a rolling-element bearing is proposed, including an outer casing and a bore hole. The bore hole is provided along a center line of the rolling element. The rolling element has at least one sensor arranged in the bore hole for load measurement and a radio module for transmitting the data measured by the sensor, wherein the rolling element has a micro-generator to provide the energy required for operation of the sensor and/or of the radio module.