Welded Bearing Sensor Support for Load Monitoring

Solution Overview

Problem

Existing methods for attaching sensors to bearings, such as adhesive bonding, are cumbersome and inefficient, requiring extensive surface preparation and long curing times, which hinder effective load and vibration monitoring in machinery.

Innovation Solution

A combination of a bearing component made from bearing steel and a sensor support formed from low carbon steel or nickel alloys, welded together using nickel or nickel-containing compositions, with dielectric interlayers for improved bonding and measurement accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive bonding is used to attach sensor to bearing component, then the sensor can be attached to the bearing, but the process requires extensive surface preparation and long curing time

Engineering Contradiction:

Improvesensor attachment reliabilityVSAvoidattachment process time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the chemical adhesive bonding system with a mechanical welding system. The sensor support is welded directly to the bearing component using arc welding or resistance welding, eliminating the need for adhesive curing time while providing a strong, immediate mechanical bond that ensures reliable sensor attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a sensor support as an intermediary component between the sensor and the bearing component. This sensor support, made from conductive material, provides a dedicated welding interface that facilitates reliable electrical and mechanical connection while protecting the sensor element itself from direct exposure to welding heat and stress.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive bonding is used to attach sensor to bearing component, then the sensor can be attached to the bearing, but extensive surface preparation is required

Engineering Contradiction:

Improvesensor attachment reliabilityVSAvoidsurface preparation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the chemical adhesive bonding system with a mechanical welding system. The sensor support is welded directly to the bearing component using arc welding or resistance welding, eliminating the need for adhesive curing time while providing a strong, immediate mechanical bond that ensures reliable sensor attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies local quality by creating a specific weldable surface on the sensor support that is localized to the attachment area. This localized treatment ensures that only the necessary surface area requires preparation, and the preparation is tailored specifically for welding rather than adhesive bonding, reducing overall complexity.

Inventive Principle:

Principle #3Local quality

3Strength

If welding is used to attach bearing component and sensor support, then strong bonding is achieved, but material compatibility challenges arise between bearing steel and sensor support materials

Engineering Contradiction:

Improvebond strengthVSAvoidwelding process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent introduces a sensor support as an intermediary component between the sensor and the bearing component. This sensor support, made from conductive material, provides a dedicated welding interface that facilitates reliable electrical and mechanical connection while protecting the sensor element itself from direct exposure to welding heat and stress.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs composite material strategy by selecting sensor support materials (stainless steel, nickel, or copper alloys) that are compatible with both the bearing steel and the sensor requirements. This intermediate material layer creates a metallurgically compatible transition zone that enables successful welding while maintaining the mechanical and electrical properties needed for sensor function.

Inventive Principle:

Principle #40Composite materials

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

This approach provides a strong, reliable, and accurate signal for measuring loads, vibrations, and deformations, enhancing the predictive maintenance of bearings by simplifying the attachment process and improving measurement reliability.

Implementation Method 1

the bearing component and the support are welded to one another via said respective portions

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP2210077B1Combination of bearing component and sensor

Publication Date: 2016.08.10 AB SKF SKF PATENT DEPARTMENT

AI summary

A combination of a bearing component and a sensor, wherein: (a) at least a portion of the bearing component is formed from a bearing steel; (b) the sensor comprises a sensor element and a support therefor; (c) at least a portion of the support is formed from a low carbon steel comprising no more than 0.2 wt. % carbon or from nickel or an alloy thereof or from titanium or an alloy thereof; and (d) the bearing component and the support are welded or brazed to one another via said respective portions.