Wireless Sensor for Rotating Elements Temperature Monitoring
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Solution Overview
Problem
Existing condition monitoring techniques for rotating bearing elements and mechanical face seals face challenges such as inaccurate temperature measurement due to heat dissipation in metal frames and difficulties in mounting wired sensors, which lead to increased maintenance costs and potential catastrophic failures.
Innovation Solution
A wireless sensor system utilizing a permanent magnet with a magnetic sensor that changes as a function of temperature, allowing for accurate temperature and vibration measurement by generating a voltage or current signal corresponding to the sensed magnetic field, even through metallic structures, and is affixed to rotating parts for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermocouple temperature sensors are coupled to the outer race for temperature monitoring, then the sensor can be easily installed, but the measured temperature is not reliable due to heat dissipation through the metal frame acting as a heat sink
Solution Approach 1:
The patent extracts the temperature sensing function from the outer race location and relocates it to the inner race, removing the sensor from the heat sink environment. The sensor is now positioned where it directly measures bearing temperature without the interfering heat dissipation effect of the metal frame.
Solution Approach 2:
The patent introduces a wireless sensor system as an intermediary between the bearing and the external monitoring system. This wireless sensor acts as a mediator that transmits temperature data without requiring physical connection to the rotating inner race, solving both the measurement accuracy and installation ease requirements.
2Reliability
If wired sensors are attached to rotating elements for condition monitoring, then temperature and vibration data can be collected, but circuit connection becomes difficult and maintenance costs increase
Solution Approach 1:
The patent replaces the mechanical wired connection system with a wireless sensing system. The wireless sensor on the inner race communicates with external receivers through electromagnetic fields, eliminating the need for physical circuit connections to rotating parts while maintaining reliable condition monitoring capability.
Solution Approach 2:
The patent changes the operational parameters of the sensor system by transitioning from wired to wireless communication. This parameter change allows the sensor to function on rotating elements without the complexity of maintaining electrical connections, reducing maintenance costs while preserving monitoring reliability.
3Ease of operation
If L-C oscillator wireless sensors are mounted on inner race or cage, then wire connection issues are avoided, but the sensor signal is disrupted by metal barriers and limited to short distances
Solution Approach 1:
The patent changes the electromagnetic parameters of the wireless sensor system to operate at frequencies and with characteristics that penetrate metal barriers effectively. This allows the wireless sensor to maintain reliable signal transmission through the metal components of the bearing assembly, overcoming the limitations of previous wireless designs.
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 system provides accurate temperature and vibration monitoring, reducing maintenance costs and preventing failures by directly sensing heat within the bearing and seal components, while being capable of operating through thick metal sheets and maintaining reliability over long durations.
Implementation Method 1
a permanent magnet and a magnet sensor. The permanent magnet is coupled to at least a portion of a bearing, and has a magnetic field that changes as a function of the physical characteristic
Implementation Method 2
The magnetic sensor is operably disposed in a magnetic field sensing relationship with the permanent magnet, and is configured to generate a voltage signal and/or current signal corresponding to a sensed magnetic field
Data Source
AI summary
A system for measuring a physical characteristic of mechanical face seal includes a permanent magnet and a magnetic sensor. The permanent magnet is affixed to a structure proximate to a bearing surface of the mechanical face seal. The permanent magnet has a magnetic field that decreases as a function of temperature. The magnetic sensor is mounted on the mechanical face seal in a magnetic field sensing relationship with the permanent magnet. The magnetic sensor is configured to generate a voltage signal corresponding to a sensed magnetic field.