A METHOD FOR MANUFACTURING A SENSORIZED BEARING RING

Abstract

A method for manufacturing a sensorized bearing ring includes the steps of: providing a metallic ring member, applying a sensor member on the metallic ring member, and applying a raceway layer onto the metallic ring member and the sensor member by use of a metallic wire Directed Energy Deposition (DED) operation and/or a metallic powder DED operation.

Claims

1. A method for manufacturing a sensorized bearing ring, the method comprising the steps of: providing a metallic ring member, applying a sensor member on the metallic ring member, and applying a raceway layer onto the metallic ring member and the sensor member by use of a metallic wire Directed Energy Deposition operation and/or a metallic powder DED operation.

2. The method according to claim 1, further comprising a step of applying a metallic or ceramic protecting member to cover the sensor member prior to applying the raceway layer.

3. The method according to claim 2, wherein the step of applying a metallic or ceramic protecting member is made by sintering.

4. The method according to claim 1, wherein the step of applying the raceway layer includes applying more than one layer by use of DED.

5. The method according to claim 1, wherein an application speed is varied during application of the metallic wire material and/or metallic powder on the metallic ring member.

6. The method according to claim 1, wherein the steps of applying the sensor member on the metallic ring member and applying a raceway layer on the metallic ring member and the sensor member are performed by the same apparatus.

7. A sensorized bearing ring, comprising: a metallic ring member, a raceway layer formed on the metallic ring member by use of a metallic wire Directed Energy Deposition operation and/or a metallic powder DED operation, and a sensor member positioned between the metallic ring member and the raceway layer.

8. The sensorized bearing ring according to claim 7, further comprising a metallic or ceramic protecting member between the sensor member and the raceway layer.

9. The sensorized bearing ring according to claim 7, wherein the raceway layer is formed of any of a Co-based alloy, a Ni-based alloy, or a Fe-based alloy.

10. A bearing comprising a sensorized bearing ring according to claim 7.

11. A bearing comprising a sensorized bearing ring manufactured by the method according to claim 1.

12. The method according to claim 4, wherein the step of applying the raceway layer includes applying 2-20 layers by use of DED.

13. The sensorized bearing ring according to claim 9, wherein the Fe-based alloy is a stainless steel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will hereinafter be further explained by means of non-limiting examples with reference to the appended schematic figures, where;

[0038] FIG. 1 is a view of a sensorized bearing ring according to an example embodiment of the present invention;

[0039] FIG. 2 is a cross sectional side view of the sensorized bearing ring in FIG. 1;

[0040] FIG. 3 is a cross-sectional view of the sensorized bearing ring in FIG. 1 along line A;

[0041] FIG. 4 is a cross-sectional view of the sensorized bearing ring in FIG. 1 along line B;

[0042] FIG. 5 is a flowchart of a method according to an example embodiment of the present invention;

[0043] FIG. 6 is a schematic view of a sensorized bearing ring before application of a raceway layer according to an example embodiment of the present invention;

[0044] FIG. 7 is a schematic view of a sensorized bearing ring before application of a raceway layer according to an example embodiment of the present invention; and

[0045] FIG. 8 is a schematic side view of a sensorized bearing according to the present invention.

[0046] It should be noted that the drawings have not necessarily been drawn to scale and that the dimensions of certain features may have been exaggerated for the sake of clarity. Like reference numerals in the drawings refer to similar parts unless expressed otherwise.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0047] FIG. 1 depicts a view of a sensorized bearing ring 1 according to an example embodiment of the present invention.

[0048] The sensorized bearing ring 1 has a metallic ring member 2, a raceway layer 3, and a sensor member 4 positioned between the metallic ring member 2 and the raceway layer 3. The raceway layer 3 is formed by use of a metallic wire Directed Energy Deposition (DED) operation and/or a metallic powder DED operation. The raceway layer 3 is shown here as a see-through layer. This to increase clarity of the parts inside the sensorized bearing 10 for to better see where the cross-sectional views have been made from in the FIG. 3-4. The sensor member 4 further comprises a sensing layer 4.1, such as a conductive layer, for sensing and generating signals. The sensing layer 4.1 may be a conductive layer that has been printed to the metallic ring member 2. The sensing member is further equipped with an insulation layer 4.4 for insulating the sensing layer 4.1 from the surrounding materials to achieve an accurate reading from the sensing layer 4.1. FIG. 1 further shows wiring contacts 4.3 for connecting wires from equipment to finally collect the collected data generated from the sensing layer 4.1.

[0049] FIG. 2 depicts a cross sectional side view of the sensorized bearing ring 1 in FIG. 1 according to an example embodiment of the present invention. Here, the metallic ring member 2 and the raceway layer 3 applied by a DED-operation can be seen in greater detail. Here a thrust rolling bearing ring 2 is shown, i.e. a rolling bearing which loads are taken up substantially along an axial direction of a shaft (not shown). The rolling bearing may as well be a radial roller bearing 10 (see FIG. 8), i.e. a rolling bearing 10 where the loads are taken up substantially perpendicular to the axial extension of a supported shaft (not shown).

[0050] FIG. 3 depicts a cross-sectional view of the sensorized bearing ring 1 in FIG. 1 along line A, according to an example embodiment of the present invention. Here, the sensorized bearing ring 1 further comprises an optional metallic or ceramic protecting member 5 covering the sensor member 4. The protecting member 5 may be made by sintering. Sintering forms a less solid material, thereby further isolating and reliably protecting the sensor members 4 from load and temperature emanating from the rolling elements 11 during operation of the sensorized bearing 10 comprising the sensorized bearing ring 1.

[0051] FIG. 4 depicts a cross-sectional view of sensorized bearing ring 1 in FIG. 1 along line B, according to an example embodiment of the present invention. Here, the wiring contacts 4.3 of the sensing member is shown in greater detail, covered in the insulation layer 4.4 except at a point intended to connecting wire. This point is separated by the other metallic surfaces by the insulation layer 4.4, so that the sensing layer 4.1, such as a conductive sensing layer 4.1, is not interfered, by other metallic surfaces.

[0052] FIG. 5 depicts a flowchart of a method according to an example embodiment of the present invention. Here, a method for manufacturing a sensorized bearing ring 1 is provided. The method comprises the steps of: [0053] providing a metallic ring member 2, [0054] applying a sensor member 4 on the metallic ring member 2, [0055] applying a raceway layer 3 onto the metallic ring member 2 and the sensor member 4 by use of a metallic wire Directed Energy Deposition (DED) operation and/or a metallic powder DED operation.

[0056] In an optional embodiment, the method comprising applying an optional metallic or ceramic protecting member 5. In a further optional embodiment, the metallic or ceramic protecting member 5 is applied by using sintering. By sintering is meant the process of compacting and forming a solid mass of material by heat or pressure without melting it to the point of liquefaction. As such, sintering forms a less solid material, thereby further isolating and reliably protecting the sensor members 4 from load and temperature emanating from the rolling elements 11 during operation of the sensorized bearing 10 comprising the sensorized bearing ring 1.

[0057] In an optional embodiment, the sintering layer is formed by the same tool that applies the sensor layer.

[0058] FIG. 6 depicts a schematic view of a sensorized bearing ring 1 before application of a raceway layer 3 according to an example embodiment of the present invention.

[0059] FIG. 7 depicts a schematic view of a sensorized bearing ring 1 before application of a raceway layer 3 according to an example embodiment of the present invention.

[0060] FIG. 8 depicts a schematic side view of a sensorized bearing according to the present invention. Here, the rolling bearing is shown as a radial rolling bearing 10 comprising rolling elements 11 in between two bearing rings, of which at least one is a sensorized bearing ring 1. Here, the outer bearing ring is a sensorized bearing ring 1, but it may be so that the inner ring or even both rings are sensorized.

[0061] It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.