Structural design and analysis for a sensor-integrated ball bearing

The structural design issues associated with the development of a sensor-integrated ball bearing were investigated. A finite element model was established to analyze the structural integrity of a ball bearing whose outer ring was modified to accommodate a miniaturized load sensor module. The sensor module was designed to monitor dynamic load variations within the bearing, which is an important indicator of a bearings safe operation. This structural integration of “intelligence” is significant in that it bring's automated, on-line, self-diagnosis capability to a dynamic system for which reliable, safe operation is of critical importance. A design tool was developed to evaluate the effect of outer ring modification on the dynamic load-carrying capability of the bearing. The tool also provided quantitative guidelines for the design of load and other types of sensor modules that will be structurally embedded into the outer ring of a conventional bearing for industrial applications.