Wheel Bearing Sensor Mounting for Load Detection Accuracy
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Solution Overview
Problem
Existing sensor-equipped wheel support bearing assemblies face issues with detection errors due to the complex shape of the outer ring flange, which leads to inaccurate load estimation and is prone to external environmental damage, such as corrosion and physical impairment.
Innovation Solution
A sensor-equipped wheel support bearing assembly with a simplified outer member flange shape, featuring sensor units strategically positioned to minimize the impact of temperature distribution and expansion/contraction variations, and protected by a tubular protective shroud with an elastic lip member to prevent external damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a strain gauge is pasted to the outer ring for load detection, then the sensor can detect strains, but the sensor is exposed to external environmental damage such as corrosion and physical impairment
Solution Approach 1:
The sensor unit is nested within the bearing assembly structure. Specifically, the strain generating member is integrated with the outer ring, and the strain sensor is positioned within the bearing assembly's protective housing, allowing the sensor to detect loads while being shielded from external environmental damage such as corrosion and physical impairment from gravel stones.
Solution Approach 2:
A protective housing or sealing structure acts as an intermediary between the sensor and the external environment. This intermediary element allows the sensor to function while preventing direct exposure to corrosive substances and physical damage, thus maintaining both measurement precision and reliability.
2Strength
If the outer ring flange has a complex shape for structural requirements, then the bearing assembly can meet design specifications, but detection accuracy deteriorates due to temperature distribution and expansion/contraction variations
Solution Approach 1:
The outer ring is divided into functionally distinct segments: a flange portion for structural connection and a cylindrical portion for sensor installation. This segmentation allows the flange to have the complex shape needed for structural integrity while the cylindrical portion provides a uniform geometry that minimizes temperature distribution variations and expansion/contraction effects on sensor measurements.
Solution Approach 2:
Different portions of the outer ring are given different geometric qualities suited to their functions. The flange portion has a complex shape optimized for structural strength and connection, while the cylindrical portion has a simplified, uniform shape that minimizes thermal and mechanical interference with sensor measurements, thus achieving both structural integrity and measurement precision.
3Measurement precision
If sensor units are exposed to the external environment for direct load detection, then the detection response is direct, but the assembly process becomes more difficult and costs increase due to required protective measures
Solution Approach 1:
The sensor unit is merged with the bearing assembly as an integrated component rather than a separate attached element. The strain generating member is formed as part of the outer ring structure, and the strain sensor is positioned within the bearing assembly housing, allowing load detection to be built-in during manufacturing. This integration simplifies the assembly process and reduces costs while maintaining direct load detection 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
The solution enables accurate load detection with reduced detection errors and prolonged operational reliability by shielding the sensors from environmental influences and simplifying the assembly process while reducing costs.
Implementation Method 1
the stationary ring is deformed through rolling elements, such deformation leads to a strain induced in the sensor unit. The strain sensor provided in the sensor unit detects the strain induced in the sensor unit.
Implementation Method 2
protected by a tubular protective shroud with an elastic lip member to prevent external damage
Data Source
AI summary
A sensor equipped wheel support bearing assembly, in which detection error is relieved to accurately estimate load is provided. A vehicle body fitting flange of an outer member of the bearing assembly has a front elevational shape of line symmetry or of point symmetry. A sensor unit including a strain generating member having two or more contact fixing segments to be fixed to the outer member and a strain sensor is provided at an arcuately sectioned portion lying from the flange to the outer member, or an outer peripheral surface portion of the outer member adjoining to the outboard side thereof, or a position crossing a line segment passing through a center of a rolling element or a position adjoining thereto. Alternatively, a plurality of sensor units are provided on the outer periphery of the outer member in a fashion spaced circumferentially equidistantly.