Sensorized Rolling Elements for Bearing Simulation Validation
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Solution Overview
Problem
Existing simulation models for machines with rolling-element bearings lack accuracy in representing the behavior of the bearing, making it difficult to validate the design and perform root cause analysis or optimization.
Innovation Solution
Incorporate sensorized rolling elements in the bearing to measure operating parameters, compare these measurements with simulation model outputs, and estimate the accuracy of the simulation model by determining and comparing bearing indicators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation models are used to design machines with bearings, then design validation can be performed, but the accuracy of the simulation model in representing actual bearing behavior is insufficient
Solution Approach 1:
The patent implements a feedback mechanism by comparing simulation model outputs with actual measurements from sensorized rolling elements. The measured bearing indicators (from sensors) are compared against simulated bearing indicators (from the model) to generate accuracy estimates, which then feed back into model validation and refinement processes.
Solution Approach 2:
The patent replaces complex physical measurement systems with a simulation model that can be validated through comparison. Instead of relying solely on complex physical testing, the model substitutes for physical experimentation while being grounded in actual measurements through the sensorized rolling elements.
2Measurement precision
If sensorized rolling elements are incorporated in the bearing, then actual bearing operating measurements can be obtained, but the complexity of the bearing structure increases
Solution Approach 1:
The patent segments the bearing structure by incorporating sensorized rolling elements as distinct, modular components within the bearing assembly. Each sensorized rolling element functions as an independent measurement unit, allowing the sensing capability to be added without redesigning the entire bearing structure.
Solution Approach 2:
The sensorized rolling elements serve multiple functions: they act as both load-bearing components and measurement sensors. This multi-functionality reduces the need for separate measurement systems, thereby limiting the increase in overall complexity.
3Reliability
If simulation model accuracy is improved through validation, then root cause analysis and optimization can be performed, but the time and resources required for validation increase
Solution Approach 1:
The patent performs preliminary validation by comparing simulation outputs with measurements from sensorized rolling elements during normal operation. This ongoing preliminary validation allows the model to be progressively refined without requiring extensive separate validation campaigns, reducing overall validation time.
Data Source
AI summary
A method for estimating an accuracy of a simulation model of a machine having a rolling-element bearing includes determining sets of machine operating measurements and sets of bearing operating measurements at certain reference moments, determining values of a bearing indicator from the sets of bearing operating measurements and determining values of the bearing indicator from the simulation model of the machine, comparing the values of the measured bearing indicator and the simulated bearing indicator for identical values of the operating parameter of the machine, and estimating an accuracy of the simulation model of the machine from the comparison. Also a device for performing the method.