Sensorized Rolling Element With Microgenerator for Wireless Load Measurement
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Solution Overview
Problem
Existing load measurement technologies for slewing bearings, such as those in wind turbines, face challenges due to complex cabling requirements, wear issues with strain gauges, and limited capability for continuous operation, making reliable and permanent load measurement during operation difficult.
Innovation Solution
A rolling body with a bore and a microgenerator that provides autonomous energy for sensors and radio modules, enabling wireless data transmission and precise load measurement without cabling, using capacitive sensors and energy harvesting from the rolling movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are arranged in a bore of a rolling body to measure deformation, then load measurement capability is improved, but the strain gauges and their adhesive attachment are susceptible to wear from grease and lubricants contact, requiring regular replacement
Solution Approach 1:
The patent extracts the measurement function from the rolling element itself by placing sensors in a separate sensor unit within the bore, isolating the measurement system from the harsh lubricant environment that causes wear on traditional strain gauge attachments
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the sensor unit in the rolling element and the evaluation system outside. This allows measurement data to be transmitted without direct physical contact, eliminating wear from grease and lubricant exposure while maintaining measurement capability
2Use of energy by moving object
If cabling is used to supply energy to sensors and transmitters in the rolling bearing, then energy supply capability is improved, but complex cabling becomes disruptive during operation
Solution Approach 1:
The patent replaces the mechanical cabling system with an inductive energy transmission system using magnetic coupling. This allows energy to be transmitted wirelessly through the bearing structure, eliminating the need for physical cables that would be disruptive during operation
Solution Approach 2:
The patent uses magnetic field coupling as an intermediary to transfer energy and signals between the rolling element sensors and the external evaluation system, enabling power supply without direct mechanical connection
3Measurement precision
If sensors are arranged on a cage that fixes rolling bodies, then eddy current measurements can be taken, but energy must still be supplied inductively requiring complex arrangements
Solution Approach 1:
The patent combines the sensor unit, energy harvesting generator, and data transmission components into an integrated system within the rolling element itself. This consolidation simplifies the overall device complexity compared to separate sensor and energy transmission arrangements
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 and permanent load measurement during ongoing operation without cabling, providing precise data transmission and reducing maintenance needs, while maintaining structural stability and precision.
Implementation Method 1
the rolling element comprises a microgenerator, wherein the microgenerator is provided to provide the energy required to operate the sensor and/or the radio module
Implementation Method 2
to measure the deformation of the rolling body with the aid of strain gauges which are arranged in a bore of a rolling body, with the deformation of the rolling body being used to determine the forces acting on the rolling bearing
Implementation Method 3
a radio module for transmitting the sensor comprises data measured
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a rolling element (1) for use in a rolling-element bearing, comprising an outer shell (2) and a borehole (3), wherein the borehole is provided along a center axis of the rolling element, wherein the rolling element comprises at least one sensor (5) for load measurement, which is arranged in the borehole, and comprises a radio module for transferring the data measured by the sensor, wherein the rolling element comprises a microgenerator, wherein the microgenerator is provided for providing the energy required for the operation of the sensor and/or of the radio module.