Bearings with built-in smart wireless technology `could revolutionise monitoring`

SKF has succeeded in integrating “intelligent” wireless technology into its bearings, allowing them to communicate their operating conditions continuously so that users can take action before damage occurs. The Insight technology, unveiled at the Hannover Fair this week, includes internally-powered sensors and data acquisition electronics.

“These innovations are set to revolutionise condition monitoring for bearings, especially in critical machinery and technically challenging applications,” says Tom Johnstone, SKF`s president and CEO. “SKF Insight technology will make condition monitoring more widely available, especially in applications where it was previously impossible or impractical.

“With our integrated diagnostic technology,” he adds, “our customers can get even better control over the lifecycle of their machinery, leading to lower total costs with higher reliability and machinery uptime.”

Previously, condition monitoring techniques could monitor damage only after it had occurred. Now, by sensing variables directly inside a bearing, the new technology can monitor damage as it happens, from the first microscopic effect, allowing users to tackle the causes of the damage – by, for example, adding lubricant or mitigating transient overloads.

It is also possible to measure the load a bearing is actually experiencing, rather than what is was designed for. This information can be fed back into the design phase to improve both the system and bearing design.

“Three years ago we had a vision to create an integrated, self-powered sensor package that could wirelessly communicate the condition of a bearing at any time – making a smart bearing capable of sending a message when something happens to it," says Alan Begg, SKF`s senior vice-president for group technology development. "Following extensive r&d work, including miniaturisation, solving power generation challenges, and developing unique packaging of sensors and electronics, the introduction of SKF Insight technology makes this a reality.

“Making the bearing the brain, as well as the heart, of rotating machinery has long been a dream of the engineering community,” he continues, “and I am proud that SKF, with our long tradition of innovation leadership, is the first to make this happen.”

SKF says that with the new technology integrated into bearings, it will be easier to perform condition monitoring. It argues that better operational knowledge, better maintenance planning, optimised manpower and spare parts management, will combine to reduce operating costs.

Key elements of the Insight technology include:
•  Miniaturised sensing technologies This allows critical parameters such as rpm, temperature, velocity, vibration and loads to be measured in the bearing.
•  Self-powering The smart bearings generate their own operating power.
•  Intelligent wireless technology This allows the bearings to communicate in environments where conventional WiFi could not operate.
•  Smart networks The bearings can communicate with each other via wireless gateways, forming “mesh networks”, and can transmit information on their condition for analysis.

The new technology is already on trial with bearings users in industries including wind energy, railways and metals. SKF is planning further application trials in other industries.