Sensorized Rolling Elements for Large Bearing Online Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing large rolling bearings face challenges in accommodating sensors, energy harvesting systems, and data transmission interfaces within the rolling elements without compromising strength or stability, particularly due to sensitivity to vibrations, heat, and magnetic fields, and the need for precise positioning.
Innovation Solution
Distribute the sensor system, power-generating means, and data transmission components across opposite axial ends of the rolling element, utilizing the available space efficiently while maintaining balance and avoiding interference, with the generator and electronic components arranged on the end-faces and circuit boards configured annularly to avoid protrusion and interference with the rolling element's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sensors, generators, and electronic components are integrated into the rolling element, then monitoring capability and energy supply are improved, but the rolling element strength and stability deteriorate due to additional holes and mounted parts
Solution Approach 1:
The patent integrates the sensor, generator, and electronic components into the rolling element by creating cavities within the rolling element structure. The sensor is mounted in a first cavity, the generator in a second cavity, and electronic components in a third cavity, all nested within the rolling element volume. This nesting approach allows integration of multiple functional components while maintaining the overall structural integrity of the rolling element.
Solution Approach 2:
The patent utilizes the axial dimension of the rolling element by providing cavities at different axial positions. The generator cavity extends in the axial direction, and components are arranged along the axial axis, effectively using the third dimension (axial direction) to accommodate multiple components without compromising the radial and circumferential strength of the rolling element.
2Adaptability or versatility
If multiple components are integrated into the rolling element, then functionality is improved, but device complexity increases due to precise positioning requirements
Solution Approach 1:
The patent divides the rolling element into distinct functional zones by creating separate cavities for different components. The sensor, generator, and electronic components are segregated into different cavities located at specific axial positions, allowing each component to be independently positioned and installed without interfering with the others, thereby simplifying the overall integration process.
Solution Approach 2:
The patent applies different structural characteristics to different regions of the rolling element. Specific cavities are created at defined axial positions with specific geometries suitable for mounting particular components. The generator cavity extends axially, while sensor and electronic component cavities are positioned at different axial locations, allowing each region to be optimized for its specific function.
3Reliability
If generator and electronic components are arranged at opposite axial ends, then interference between components is reduced, but space utilization becomes more challenging
Solution Approach 1:
The patent exploits the axial dimension of the rolling element to arrange the generator and electronic components at opposite axial ends. The generator cavity extends in the axial direction, with the generator positioned at one axial end and electronic components at the opposite axial end. This axial arrangement effectively uses the available volume while minimizing electromagnetic interference between components.
Solution Approach 2:
The patent nests multiple cavities within the rolling element volume, with the generator cavity extending axially and other cavities positioned at different axial locations. This nested cavity structure allows maximum space utilization by efficiently packing multiple functional components into the available rolling element volume without excessive spacing.
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
Ensures balanced arrangement, prevents interference, maintains strength and smooth operation, and facilitates stable data transmission to external units, enabling online monitoring without charging pauses.
Implementation Method 1
it has already been proposed to use miniaturized generators or, in the case of large rolling bearings, generators adapted to other dimensions, which are attached partly to the rolling elements and partly to the rolling element cages or spacers in order to exploit the rotary movement of the rolling elements relative to the cage to generate electricity
Data Source
AI summary
A rolling bearing, in particular an open-center large rolling bearing, comprising two concentric bearing rings which are rotatable relative to one another and between which there is provided at least one bearing row comprising rolling elements, wherein at least one of the rolling elements is provided with at least one sensor for detecting at least one operating parameter, a power-generating means, in particular a generator, for supplying electrical power to the sensor, and an electronic component for transmitting the sensor data to an external evaluation and/or storage unit, for supplying the sensor with electrical power, and an electronic component for transmitting the sensor data to an external evaluation and/or memory unit, wherein the power-generating means and the electronic component for transmitting sensor data are provided at opposite axial ends of the rolling element.