CN112780669B - 一种带监测装置的滚子轴承 - Google Patents
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Abstract
本发明涉及一种带监测装置的滚子轴承，属轴承监测与新能源技术领域。包括内外圈、滚子和支架，内外圈端部分别装有转板和壳体，壳体底板上装有电路板和传感器，壳体环板上设有内外接线柱组，转板上设有左右电极环，内接线柱组与左右电极环滑动接触；内外圈的里外层间均镶嵌由梳状的左右电极构成的电极组，左右电极均由梳背、梳齿和端子构成；左右电极的梳齿交叉安装且互相不接触，左右电极的端子分别与左右电极环的触头压接；滚子与内外圈滚动接触生成属性不同的感应电荷，内外圈各自电极间产生电势差，滚子转动时与内外圈上的左右电极交替地接触与分离并使电势差交替地增加和减小，所述两电极经负载连接后即有电流流过和功率输出，电能经处理后供给传感器。
Description
技术领域
本发明属于轴承监测与新能源技术领域，具体涉及一种带监测装置的滚子轴承。
背景技术
轴承是机床、载运工具、矿山机械及轻工机械等领域中不可或缺的标准件，也是相关传动***中最易损的零件之一，旋转机械故障的30%是因轴承失效所造成的。因此，轴承状态监测与早期故障诊断已引起人们的高度重视。轴承及其传动***的在线监测已经成为发电机、船舶、高铁以及航空器等领域相关设备可靠运行的前提保障，所需监测的性能指标包括温度、振动、转速及噪音等诸多方面。最初的轴承监测***主要为分体的外挂式结构，属于非接触的远距离间接测量，传感器与信号源间距离较远、误差较大。近年来，人们相继提出了不同形式的嵌入式轴承监测***以及基于轴承转动的微型发电装置，较好地解决了***集成化、测量精度及自主供电等问题。目前所提出的具有自供电监测功能的轴承大都是利用电磁原理和压电原理发电的，电磁发电的弊端是存在磁干扰、低速时发电能力弱，压电发电的弊端是所需附加空间相对较大、温度过高时会引起压电陶瓷退极化。显然，现有技术在实际应用中还存在较大的局限性，体积小、集成度高、尤其是适于高温环境的具有自供电监测功能的各类轴承依然是各行业所急需的。
发明内容
本发明提出一种带监测装置的滚子轴承，本发明采用的实施方案是：所提出一种带监测装置的滚子轴承主要包括内外圈、滚子、支架、壳体、转板、传感器及电路板，内外圈、壳体及转板的材料为非金属，滚子和支架的材料为与内外圈材料不同的金属或非金属。
外圈内缘上设有环形的滚道，外圈经支架和滚子安装在内圈上，滚子嵌入进外圈的滚道内；外圈的端部经螺钉安装有壳体，内圈的端部经螺钉安装有转板；壳体的壳壁一端设有底板、另一端设有环板，壳体的底板上安装有电路板和传感器，壳体的环板上设有内外接线柱组，内接线柱组包括内左接线柱和内右接线柱，外接线柱组包括外左接线柱和外右接线柱；转板上设有带左触头的左电极环和带右触头的右电极环，内接线柱组与左右电极环滑动接触，内左接线柱和内右接线柱分别顶靠在左电极环和右电极环上，传感器及内外接线柱组经不同的导线组与电路板相连。
滚子为圆柱滚子或圆锥滚子，滚子和支架的材料同为金属或非金属，内外圈材料为相同的非金属，所述非金属材料为尼龙、聚四氟乙烯、聚乙烯或聚酰亚胺等；外圈的里外层之间镶嵌有外电极组，内圈的里外层间镶嵌有内电极组，外电极组由梳状的外左电极和外右电极构成，内电极组由梳状的内左电极和内右电极构成，内外圈为分体结构或整体结构，所谓分体结构是指内外圈的里层和外层分别加工制作后组装在一起，所谓整体结构是指内外圈是通过注塑方法制作的含有内外电极组的整体结构。
本发明中，外左电极和内左电极结构形式完全相同，外右电极和内右电极的结构形式完全相同，下文将外左电极和内左电极统称为左电极、将外右电极和内右电极统称为右电极，左电极和右电极的材料为铜。
左电极由左梳背、左梳齿和左端子构成，左梳齿和左端子位于左梳背的两侧；右电极由右梳背、右梳齿和右端子构成，右梳齿和右端子位于右梳背的同一侧，右端子实为加长的右梳齿；左电极为非封闭的环形结构，右端子从左电极两端的间隙中穿过；左右梳齿交叉安装且互相不接触，安装后左右端子的自由端平齐且均处于内圈的同侧，左右端子分别与左右电极环的触头压接。
为确保所有的滚子同时与内圈上的左梳齿或右梳齿接触，或同时与外圈上的左梳齿或右梳齿接触，左右梳齿数量相等且为滚子数量的整数倍，左右梳齿的长度相等且均大于滚子的长度，滚子两端不与左右梳背交叉，即滚子和左右梳背在内圈或外圈的同一轴截面上的投影不交叉。
工作中，滚子在内外圈中间滚动，滚子与内外圈相互接触并滚动的过程中会产生电荷，左右电极产生感应电荷，由于不同材料吸引电子的能力不同，滚子与内外圈滚动接触所生成的感应电荷属性不同；在滚子和内外圈的表面存在异种静电荷的情况下，外圈的左右电极间产生电势差、内圈的左右电极间产生电势差；滚子转动时与内外圈上的左右电极交替地接触与分离，从而使内外圈各自的两个电极间的电势差交替地增加和减小，所述两个电极经负载连接后即有电流流过和功率输出；所生成的电能经电路板上的转换电路处理后供给传感器，传感器实时地获得轴承温度、转速或振动参数，所获得的性能参数信息再经电路板上的发射单元发射出去，进而完成轴承的自供电监测过程。
上述工作中，滚子与某个电极接触是指所述滚子的圆心角与左梳齿或右梳齿的圆心角有重叠，滚子与某个电极分离是指所述滚子的圆心角与左梳齿或右梳齿的圆心角无重叠。
本发明中，各部件间相对运动生成的电荷特性与零部件材料有关，内外圈材料为相同的非金属，滚子材料为金属或非金属；滚子与内外圈滚动接触时产生异种电荷，如：滚子材料为金属或尼龙、内外圈材料为聚四氟乙烯时，滚子带正电荷、内外圈带负电荷；滚子与内外圈的非金属材料互换时，它们所带的电荷属性相反。
优势与特色：总体结构简单、体积小、集成度及可靠性高，无电磁干扰、耐高温，发电单元输出电压受转速影响小或无影响、发电与供电能力强，可作为独立部件用于轴系的状态监测。
附图说明
图1是本发明一个较佳实施例中轴承的结构剖面图；
图2是图1的A-A剖视图；
图3 是本发明一个较佳实施例中外圈结构剖视图；
图4 是本发明一个较佳实施例中内圈结构剖视图；
图5是本发明一个较佳实施例中左电极和右电极组合后的展开示意图；
图6是本发明一个较佳实施例中壳体的结构示意图；
图7是图6的右视图；
图8是本发明一个较佳实施例中转板的结构示意图；
图9是图8的右视图。
具体实施方式
本发明提出一种带监测装置的滚子轴承，主要包括内圈b、外圈a、滚子c、支架d、壳体f、转板g、传感器s及电路板p，内圈b、外圈a、壳体f及转板g的材料为非金属，滚子c和支架d的材料为与内圈b和外圈a材料不同的金属或非金属。
外圈a的内缘上设有环形的滚道，外圈a经支架d和滚子c安装在内圈b上，滚子c嵌入进外圈a的滚道内；外圈a的端部经螺钉安装有壳体f，内圈b的端部经螺钉安装有转板g；壳体f的壳壁f2一端设有底板f1、另一端设有环板f3，壳体f的底板f1上安装有电路板p和传感器s，壳体f的环板f3上设有内接线柱组和外接线柱组，内接线柱组包括内左接线柱j1和内右接线柱j2，外接线柱组包括外左接线柱j3和外右接线柱j4；转板g上设有带左触头k1的左电极环k和带右触头m1的右电极环m，内接线柱组与左电极环k和右电极环m滑动接触，即内左接线柱j1和内右接线柱j2分别顶靠在左电极环k和右电极环m上，传感器s及内外接线柱组经不同的导线组与电路板p相连。
滚子c为圆柱滚子或圆锥滚子，滚子c和支架d的材料同为金属或非金属，外圈a和内圈b材料为相同的非金属，所述非金属材料为尼龙、聚四氟乙烯、聚乙烯或聚酰亚胺等；外圈a的里层a1和外层a2之间镶嵌有外电极组，内圈b的里层b1和外层b2之间镶嵌有内电极组，外电极组由梳状的外左电极h和外右电极i构成，内电极组由梳状的内左电极h’和内右电极i’构成，外圈a和内圈b为分体结构或整体结构，所谓分体结构是指外圈a的里层a1和外层a2分别加工制作后组装在一起、内圈b的里层b1和外层b2分别加工制作后组装在一起，所谓整体结构是指外圈a和内圈b都是通过注塑方法制作的含有内电极组或外电极组的整体结构。
本发明中，外左电极h和内左电极h’结构形式完全相同，外右电极i和内右电极i’的结构形式完全相同，下文将外左电极h和内左电极h’统称为左电极h、将外右电极i和内右电极i’统称为右电极，左电极h和右电极i的材料为铜。
左电极h由左梳背h1、左梳齿h2和左端子h3构成，左梳齿h2和左端子h3位于左梳背h1的两侧；右电极i由右梳背i1、右梳齿i2和右端子i3构成，右梳齿i2和右端子i3位于右梳背i1的同一侧，右端子i3实为加长的右梳齿i2；左电极h为非封闭的环形结构，右端子i3从左电极h两端的间隙中穿过；左梳齿h2和右梳齿i2交叉安装且互相不接触，安装后左端子h3和右端子i3的自由端平齐且均处于内圈b的同一侧，左端子h3和右端子i3分别与转板g上的左触头k1和右触头m1压接在一起。
为确保所有的滚子c同时与内圈b上的左梳齿h3或右梳齿i3接触，或同时与外圈a上的左梳齿h3或右梳齿i3接触，左梳齿h2和右梳齿i2的数量相等且为滚子c数量的整数倍，左梳齿h2和右梳齿i2的长度相等且均大于滚子c的长度，滚子c的两端不与左梳背h1和右梳背i1交叉，即滚子c和左梳背h1及右梳背i1在内圈b或外圈a的同一轴截面上的投影不交叉。
工作中，滚子c在内圈b和外圈a中间滚动，滚子c与内圈b及外圈a相互接触并滚动的过程中会产生摩擦电荷，左电极h和右电极i产生感应电荷，由于不同材料吸引电子的能力不同，滚子c与内圈b和外圈a滚动接触所生成的感应电荷属性不同；在滚子c和内圈b及外圈a的表面存在异种静电荷的情况下，外圈a上的左电极h和右电极i之间产生电势差，内圈b上的左电极h和右电极i之间产生电势差；滚子c转动时与内圈b和外圈a上的左电极h和右电极i交替地接触与分离，从而使内圈b和外圈a各自的两个电极间的电势差交替地增加和减小，所述两个电极经负载连接后即有电流流过和功率输出；所生成的电能经电路板p上的转换电路处理后供给传感器s，传感器s实时地获得轴承温度、转速或振动参数，所获得的性能参数信息再经电路板p上的发射单元发射出去，进而完成轴承的自供电监测过程。
上述工作中，滚子c与某个电极接触是指所述滚子c的圆心角Q与左梳齿h2或右梳齿i2的圆心角q有重叠，滚子c与某个电极分离是指所述滚子c的圆心角Q与左梳齿h2或右梳齿i2的圆心角q无重叠；图2所示为滚子c与左电极h接触、与右电极i分离的情况。
本发明中，各个部件间相对运动生成的电荷特性与零部件材料有关，内圈b和外圈a的材料为相同的非金属，滚子c的材料为金属或非金属，滚子c与内圈b和外圈a滚动接触时产生异种电荷，如：滚子c材料为金属或尼龙、内圈b和外圈a的材料为聚四氟乙烯时，滚子c带正电荷、内圈b和外圈a带负电荷；滚子c与内圈b和外圈a的非金属材料互换时，它们所带的电荷属性相反。
与现有的自发电监测轴承相比，本发明轴承的总体结构简单、体积小、集成度及可靠性高，无电磁干扰、耐高温，发电单元输出电压受转速影响小或无影响、发电与供电能力强。
Claims (2)
1.一种带监测装置的滚子轴承，包括内外圈、滚子和支架，内外圈端部分别装有转板和壳体，壳体的底板上装有电路板和传感器，其特征在于：壳体的环板上设有内外接线柱组，转板上设有带左触头的左电极环和带右触头的右电极环，内接线柱组与左右电极环滑动接触，传感器及内外接线柱组经不同导线组与电路板相连；内圈的里外层间镶嵌内电极组、外圈的里外层间镶嵌外电极组，内外电极组均由梳状的左右电极构成，左电极由左梳背、左梳齿和左端子构成，右电极由右梳背、右梳齿和右端子构成；左右梳齿交叉安装且互相不接触，左右端子分别与左右电极环的触头压接；左右梳齿数量相等且为滚子数量的整数倍，左右梳齿的长度相等且均大于滚子的长度，滚子两端不与左右梳背交叉；滚子与内外圈滚动接触生成属性不同的感应电荷，内外圈各自的左右电极间产生电势差，滚子转动时与内外圈上的左右电极交替地接触与分离并使内外圈各自电极间的电势差交替地增加和减小，所述两电极经负载连接后即有电流流过和功率输出，所生成的电能经电路板上的转换电路处理后供给传感器。
2.根据权利要求1所述的滚子轴承，其特征在于：滚子为圆柱滚子或圆锥滚子，内外圈材料为相同的非金属，所述非金属材料为尼龙、聚四氟乙烯、聚乙烯或聚酰亚胺；滚子和支架的材料同为金属或非金属，滚子与内外圈滚动接触时产生异种电荷。
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| JP2016084843A (ja) * | 2014-10-24 | 2016-05-19 | 日本精工株式会社 | 転がり軸受装置 |
| WO2019134065A1 (zh) * | 2018-01-02 | 2019-07-11 | 舍弗勒技术股份两合公司 | 能够发电的轴承配件和能够发电的轴承 |
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