Design Analysis And Experimental Research Of Rolling Bearings Integrated With Micro Sensors

Using the traditional state of rolling bearings monitoring methods, it wasdifficult to effective monitoring bearing’s operation conditions; due to the faultpoints who could generate bearings fault information was far away from the sensorsinstalled positions. Developing a new type of bearing unit which was integrated withmicro sensors and met with the standard profile size of rolling bearings, not onlycould accurately monitor the early faults of bearings to take effective measures, butalso could according to the estimate of bearings operating conditions to have timelyrepair and reduce unnecessary repair. Which have very important theory andpractical meanings in the aspects of guarantying the machine operation’s reliabilityand reducing maintenance cost.To satisfy the rolling bearings operation performance, the article syntheticallythought about the bearing conditions and requirements of the parameters of themicro sensor. At last, we thought that the capacitive accelerometer was accorded therequirements of sensor’s integration on the bearing. In this paper, it designed onekind of micro capacitive accelerometer for integrated with rolling bearings, by usingthe theoretical calculation and simulation analysis methods.Combined with the rolling bearing’s analysis theory and the method of finiteelement simulation, it analyzed the slotted bearing structure, and confirmed thebearing force and deformation when the bearing was slotted. It established the finiteelement model for the bearings structure analysis and analyzed the bearing force anddeformation influenced with different slot depths and different working conditions,which was lay the foundation for the structure designing of rolling bearingsintegrated with sensors.It integrated an acceleration sensor module on the rolling bearings. Through theparameters calibration and performance testing with integrated bearing unit, itthought that could monitor the bearing’s early failure situations. In this paper wealso built the rolling bearing testing bench to explore the bearing’s early failuresituations. Accorded to bearing fault signals, it has had the rolling bearings skidexperiments and bearing outer ring fault experiments. By analyzed the fault signalswith the time domain method and frequency domain method, it confirmed thebearing integrated unit’s accuracy for the fault detection of early bearing failures.