Objective

• Measurement of kinematic data and vibrations of individual rolling elements in a wind turbine pitch bearing for the identification of slippage conditions

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Project period

2020/2021

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Challenges

• Small installation space and poor accessibility • Integration of measurement technology in a highly stressed component
• Optimal radio connection despite heavy covering by metal in the direct vicinity
• Contactless battery charging in grease via slim holes without disassembly
• Running time of at least 10 hours at 13600 measuring points per second per rolling element

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Realization

• Measuring system consisting of two interconnected boards per rolling element and a receiver module for data acquisition from several rolling elements
• In each rolling element: one sensor and data transmission board and one power management board for battery connection and charging
• Integrated measuring chain for recording rolling element rotation (acceleration, rotation rate and magnetic field sensors) and vibrations using high-performance MEMS sensor technology
• Wireless data transmission via integrated antenna using nemi Link 2400 radio link in the 2.4 GHz frequency band to a receiver module that is connected to a PC via USB
• Battery charging principle: Inductive via self-developed charging stick with integrated coil and USB connection for power supply

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Advantages

• Fully integrated, encapsulated measurement system with customized boards, wireless data transmission, MEMS sensors and rechargeable battery
• Reliable data transmission despite use in bearing component largely surrounded by metal and lubricant
• Long battery life due to highly efficient, robust i4M wireless technology
• Edge computing capability on the transmitter module
• Fast project implementation in only 4 months