Bearing assembly with sensors for monitoring loads

Abstract

A bearing assembly which couples a road wheel to a suspension system component on an automotive vehicle includes a hub to which the wheel is attached and a housing which is attached to the suspension system component. The housing has two tapered raceways which surround raceways on cones that are fitted on the hub. Organized in two rows between the raceways of the housing and cones are tapered rollers which roll along the raceways when the wheel rotates. The rollers as they pass over the outer raceway impart minute flexures to the housing and these flexures are monitored by multiple strain sensors on the housing. The strains—and the signals produced by the sensors—reflect conditions at the region of contact between a tire on the road wheel and the road surface over which the tire rolls. When the bearing assembly is used in industrial applications, such as rolling mills or machine tools, the electrical signals generated by the sensors provide indications usable by electronic processors and controllers which analyze these signals to determine the loads placed upon various components within a system which incorporates the bearing assembly.

1. In combination with an automotive road wheel and an automotive suspension system component, a bearing assembly for coupling the road wheel to the suspension system component so that the road wheel can rotate relative to the suspension system component about an axis of rotation while providing monitoring capabilities for bearing loading, said bearing assembly comprising:
 a hub including a flange and a spindle projecting from the flange, with its axis being the axis of rotation, the spindle having first and second inner raceways on it, with the raceways being presented outwardly away from the axis;    a housing surrounding the spindle of the inner race and having first and second outer raceways presented inwardly toward and surrounding the first and second raceways, respectively;    rolling elements arranged in first and second rows between the first and second raceways, respectively, and contacting the raceways to transfer both radial and axial loads between the housing and spindle; and    at least four first strain sensors located on the housing to measure circumferential strains and circumferential strains less axial strains, the at least four sensors being located on the housing such as to provide a series of signals, the signals being capable of providing information allowing the calculating of loads for at least four degrees of freedom.    
     
     
       2. The combination according to  claim 1  wherein one of the sensors being at the top of the housing, another at the bottom of the housing and others at the sides of the housing; the wheel being attached to the flange of the hub and the housing being attached to the suspension system component, whereby the bearing assembly couples the road wheel to the suspension system component and monitors forces transferred between the wheel and suspension system component. 
     
     
       3. The combination according to  claim 2  wherein the first sensors located at the top, bottom and sides of the housing are oriented to detect strains in the circumferential direction in the housing. 
     
     
       4. The combination according to  claim 3  wherein the first sensors are located on the housing around one of the outer raceways; and wherein the combination further comprises four second strain sensors located on the housing around the second outer raceway, with one of the second sensors being at the top of the housing, another at the bottom of the housing and the others at the sides of the housing. 
     
     
       5. The combination according to  claim 4  wherein the raceways are tapered and the rolling elements are tapered rollers. 
     
     
       6. The combination according to  claim 2  wherein the housing has a flange which projects outwardly, wherein the bearing assembly is attached to the suspension system component at the flange, and wherein the first sensors are located on the flange. 
     
     
       7. The combination according to  claim 6  wherein the first sensors are oriented to detect stain in the circumferential direction; and additional sensors attached to the flange and being offset circumferentially from the first sensors, the additional sensors being oriented to detect strains oblique to the circumferential direction. 
     
     
       8. The combination according to  claim 7  wherein the additional sensors are oriented at a 45 degree angle with respect to the circumferential direction of the housing. 
     
     
       9. The combination according to  claim 7  wherein one of the additional sensors is located between the top first sensor and one of the side first sensors, another of the additional sensors is located between the top first sensor and the other side first sensor; and still another of the additional sensors is located between one of the side sensors and the bottom sensor. 
     
     
       10. The combination according to  claim 9  where yet another additional sensor is located between the top first sensor and one of the side first sensors so that two additional sensors are located between the top sensor and said one side sensor. 
     
     
       11. The combination according to  claim 2  wherein the housing has an intervening surface located between the outer raceways, and the first sensors are located on the intervening surface. 
     
     
       12. The combination according to  claim 11  wherein the first sensors are oriented to detect strains in the circumferential direction; and wherein the combination further comprises additional sensors attached to the intervening surface and being offset circumstantially from the first sensors, the additional sensors being oriented to detect strains oblique to the circumferential direction. 
     
     
       13. The combination according to  claim 12  wherein the additional sensors are oriented at a 45 degree angle with respect to the circumferential direction of the housing. 
     
     
       14. The combination according to  claim 12  wherein one of the additional sensors is located between the top first sensor and one of the side first sensors, another of the additional sensors is located between the top first sensor and the other side first sensor; and still another of the additional sensors is located between one of the side sensors and the bottom sensor. 
     
     
       15. The combination according to  claim 14  wherein yet another additional sensor is located between the top first sensor and one of the side first sensors, so that two additional sensors are located between the top sensor and side one side sensor. 
     
     
       16. A bearing assembly for facilitating rotation about an axis and the monitoring of bearing loads, said bearing assembly comprising:
 an inner race having first and second inner raceways presented outwardly away from the axis;    a housing surrounding the inner race and having first and second raceways presented inwardly toward and surrounding the first and second inner raceways, respectively; first rolling elements arranged in a row between and contacting the first raceways and second rolling elements arranged in a row between and contacting the second raceways, whereby the inner race will rotate with minimal friction in the outer races and the rolling elements will roll along the raceways;    first sensors located around the housing radially outwardly from the first outer raceway to detect strains in the housing outwardly from the first outer raceway;    second sensors located around the housing radially outwardly from the second outer raceway to detect strains on the housing outwardly from the second outer raceway; and    the at least four sensors being located on the housing such as to provide a series of signals, the series of signals being capable of providing information allowing the calculating of loads for at least four degrees of freedom.    
     
     
       17. A bearing assembly according to  claim 16  wherein first and second sensors are attached to the housing at the top of the housing, more first and second sensors are attached to the housing at the bottom of the housing, and still more first and second sensors are attached to the housing at the sides of the housing. 
     
     
       18. A bearing assembly according to  claim 17  wherein the sensors are oriented to detect strains in the circumferential direction. 
     
     
       19. A bearing assembly according to  claim 17  wherein the sensors are oriented to detect oblique strains. 
     
     
       20. A bearing assembly according to  claim 17  wherein the sensors are oriented to detect circumferential strains less axial strains. 
     
     
       21. A bearing assembly for facilitating rotation about an axis and the monitoring of loads; said bearing assembly comprising:
 an inner race having first and second inner raceways presented outwardly away from the axis;    a housing surrounding the inner race and having first and second raceways presented inwardly toward the surrounding the first and second inner raceways, respectively;    first rolling elements arranged in a row between and contacting the first raceways and second rolling elements arranged in another row between and contacting the second raceways, whereby the inner race will rotate with minimal friction in the outer race and the rolling elements will roll along the raceways; and    sensors attached to the housing outwardly from the outer raceways to detect strains in the housing, each sensor having an axis along which it is sensitive to dimensional changes, some of the sensors being oriented with their axes extended in the circumferential direction to detect strains in that direction, and others of the sensors being oriented with their axis oblique to the circumferential direction to detect oblique strains, the sensors being located on the housing such as to provide a series of signals, the series of signals being capable of providing information allowing the calculating of loads for at least four degrees of freedom.    
     
     
       22. A bearing assembly according to  claim 21  wherein the sensors are arranged in a circumferentially extending row. 
     
     
       23. A bearing assembly according to  claim 22  wherein the housing has a flange which ends outwardly, and the sensors are on the flange. 
     
     
       24. A bearing assembly according to  claim 23  wherein the housing has an intervening surface between the outer raceways, and the sensors are on the intervening surface. 
     
     
       25. A method of evaluating the conditions that exist at a tire contact patch between a tire of a road wheel and a road surface, comprising the following steps:
 a. attaching a road wheel to a hub having a spindle that rotates about an axis and in a housing that is attached to a suspension system component of an automotive vehicle, the spindle having first and second inner raceways on it, with the raceways being presented outwardly away from the axis and inclined in opposite directions with respect to the axis, the housing having first and second outer raceways that surround the first and second inner raceways, respectively, there being first rolling elements located in a row between the second raceways, so that when rotation is imparted to the wheel, the first and second rolling elements will roll along the first and second raceways, respectively;    b. monitoring the stains in the housing at multiple locations;    c. measuring stains in the housing at multiple locations;    d. emitting signals related to the strains measured; and    e. calculating the loads for five degrees of freedom, said calculations being made based on the stains measured.    
     
     
       26. The method according to  claim 25  further comprising the step of monitoring the strains which are in the circumferential, axial, and oblique direction from the axis. 
     
     
       27. The method according to  claim 26  further comprising the step of monitoring the stains in the circumferential, axial, and oblique direction from the axis by detecting signals from at least four sensors located at a top of the housing, at a bottom of the housing, and at each side of the housing. 
     
     
       28. The method according to  claim 26  further comprising the step of monitoring the strains in the circumferential, axial, and oblique direction from the axis by detecting signals from at least four sensors located on a flange surface of the housing at a top of the flange surface, at a bottom of the flange surface, and at each side of the flange surface. 
     
     
       29. The method according to  claim 26  further comprising the step of monitoring the stains in the circumferential, axial, and oblique direction from the axis by detecting signals from at least four sensors located at a top edge of a flange of the housing, at a bottom edge of the flange of the housing, and at each side edge of the flange of the housing. 
     
     
       30. The method according to  claim 25  further comprising the step of monitoring the strains in the circumferential, axial, and oblique direction from the axis by detecting signals a series of sensors located in a single row around the housing. 
     
     
       31. The method according to  claim 25  further comprising the step of monitoring the strains from a series of sensors located along an intervening surface that lies between the first and second outer raceways. 
     
     
       32. The method according to  claim 25  further comprising the step of monitoring the strains from a series of sensors located on the housing, said series of sensors being oriented at a 45 degree angle with respect to the circumferential direction of the housing. 
     
     
       33. In combination with a component for the suspension system of an automotive vehicle and a road wheel for the vehicle, with the road wheel being located adjacent to the suspension component, a bearing assembly for coupling the road wheel to the suspension component to enable the road wheel to rotate about an axis and to transfer loads between the road wheel and suspension component, all while detecting forces that reflect conditions where the wheel contacts a road, the bearing assembly comprising:
   a hub to which the road wheel is secured, the hub having a spindle located along the axis;        first and second inner raceways carried by the spindle of the hub, the inner raceways being presented outwardly away from the axis;        a housing located around the inner raceways and having circumferentially and generally axially directed exterior and interior surfaces that are presented outwardly away from and inwardly toward the axis and a flange which projects outwardly away from the circumferentially and axially directed exterior surface, the housing being secured to the suspension component at its flange, the circumferentially and axially directed exterior and interior surfaces and the flange together providing a sensing surface on the housing;        first and second outer raceways carried by the housing and presented inwardly toward the axis and the inner raceways, with the first outer raceway being presented toward as the first inner raceway and the second outer raceway being presented toward the same direction as the second inner raceway;        first rolling elements arranged in a row between and contacting the first raceways and second rolling elements arranged in a row between and contacting the second raceways, whereby the hub will rotate with minimal friction in the housing and the individual rolling elements will roll along the raceways to transfer between the housing and hub radial loads and thrust loads in both axial directions and impart to the housing strains that are reflected in flexures along the sensing surface; and        strain sensors located at multiple locations along the housing, the strain sensors being configured and oriented to detect strains along the housing in at least one axial, circumferential and oblique direction.     
     
     
       34. The combination according to  claim 33  further comprising modules located at multiple locations along the sensing surface of the housing, and wherein at least some of the strain sensors are located in the modules. 
     
     
       35. The combination according to  claim 34  wherein each module includes a temperature compensator. 
     
     
       36. The combination according to  claim 33  wherein the strain sensors are located in modules that are attached to the sensing surface and some of the modules have their strain sensors oriented obliquely to detect shear. 
     
     
       37. The combination according to  claim 33  wherein at least some of the strain sensors are located along a circumferentially and axially directed surface of the housing that is presented outwardly away from the axis. 
     
     
       38. The combination according to  claim 33  wherein at least some of the strain sensors are located along a circumferentially and axially directed surface of the housing that is presented inwardly toward the axis. 
     
     
       39. The combination according to  claim 33  wherein at least some of the strain sensors are located on the flange of the housing. 
     
     
       40. The combination according to  claim 33  wherein at least some of the strain sensors are located on the housing at  0 °,  90 °,  180 ° and  270 ° with respect to the vertical. 
     
     
       41. The combination according to  claim 40  wherein the strain sensors that are located at  0 °,  90 °,  180 ° and  270 ° are oriented to detect strains in both the circumferential and axial directions. 
     
     
       42. The combination according to  claim 41  wherein at least one more sensor is circumferentially offset with respect to the strain sensors located at  0 °,  90 °,  180 ° and  270 ° wherein the at least one more sensor senses shear. 
     
     
       43. The combination according to  claim 42  wherein the offset sensor senses strains oblique to the circumferential and axial directions. 
     
     
       44. In combination with a component for the suspension system of an automotive vehicle and a road wheel for the vehicle, with the road wheel being located adjacent to the suspension component, a bearing assembly for coupling the road wheel to the suspension component to enable the road wheel to rotate about an axis and to transfer loads between the road wheel and suspension component, all while detecting forces that reflect conditions where the wheel contacts a road, the bearing assembly comprising:
   a hub to which the road wheel is secured, the hub having a spindle located along the axis;        first and second inner raceways carried by the spindle of the hub, the inner raceways being presented outwardly away from the axis;        a housing located around the inner raceways and having circumferentially and generally axially directed exterior and interior surfaces that are presented outwardly away from and inwardly toward the axis and a flange which projects outwardly away from the circumferentially and axially directed exterior surface, the housing being secured to the suspension component at its flange, the circumferentially and axially directed exterior and interior surfaces and the flange together providing a sensing surface on the housing;        first and second outer raceways carried by the housing and presented inwardly toward the axis and the inner raceways, with the first outer raceway being presented toward the same direction as the first inner raceway and the second outer raceway being presented toward the same direction as the second inner raceway;        first rolling elements arranged in a row between and contacting the first raceways and second rolling elements arranged in a row between and contacting the second raceways, whereby the hub will rotate with minimal friction in the housing and the individual rolling elements will roll along the raceways to transfer between the housing and hub radial loads and thrust loads in both axial directions and impart to the housing strains that are reflected in flexures along the sensing surface; and        modules located at multiple locations along the sensing surface of the housing, the modules having strain sensors which are configured and oriented to detect strains along the sensing surface in circumferential and axial directions and to detect strains in directions oblique to the circumferential and axial directions.     
     
     
       45. The combination according to  claim 44  wherein at least some of the strain sensors are located on the housing at  0 °,  90 °,  180 ° and  270 ° with respect to the vertical. 
     
     
       46. The combination according to  claim 45  wherein the strain sensors that are located at  0 °,  90 °,  180 ° and  270 ° are oriented to detect strains in both the circumferential and axial directions. 
     
     
       47. The combination according to  claim 46  wherein at least one more sensor is circumferentially offset with respect to the strain sensors located at  0 °,  90 °,  180 ° and  270 ° wherein the at least one more sensor senses shear. 
     
     
       48. The combination according to  claim 47  wherein the offset sensor senses strains oblique to the circumferential and axial directions. 
     
     
       49. The combination according to  claim 44  wherein the strain sensors are located on the sensing surface adjacent to the suspension component, the suspension component influences strain distribution within the housing of the bearing such that the sensors measure the distributed strains. 
     
     
       50. The combination according to  claim 49  wherein the suspension component comprises a brake. 
     
     
       51. The combination according to  claim 44  wherein at least some of the sensors are located on a flange surface of the flange of the housing. 
     
     
       52. The combination according to  claim 44  wherein the housing has an intervening surface located between the outer raceways and the strain sensors are located on the intervening surface. 
     
     
       53. The combination according to  claim 52  wherein the strain sensors which are located on the intervening surface correspond to the positions of the strain sensors located along the flange surface. 
     
     
       54. The combination according to  claim 44  wherein the strain sensors are located along the sensing surface for measuring strains applied to the housing for each degree of freedom of the road wheel. 
     
     
       55. The combination according to  claim 44  wherein the strain sensors comprise strain gages. 
     
     
       56. A method of evaluating results from modules disposed on a housing of a bearing, the results relating to a suspension component of an automotive vehicle and a road wheel for the vehicle, with the road wheel being located adjacent to the suspension component, a bearing assembly for coupling the road wheel to the suspension component to enable the road wheel to rotate about an axis and to transfer loads between the road wheel and suspension component, all while detecting forces that reflect conditions where the wheel contacts a road, the method comprising:
   attaching the road wheel to a hub of the suspension component, the hub having a spindle located along an axis and in the housing that is attached to the suspension component, with      first and second inner raceways carried by the spindle of the hub, the inner raceways being presented outwardly away from the axis and, with respect to the axis;        the housing being located around the inner raceways and having circumferentially and generally axially directed exterior and interior surfaces that are presented outwardly away from and inwardly toward the axis and a flange which projects outwardly away from the circumferentially and axially directed exterior surface, the housing being secured to the suspension component at its flange, the circumferentially and axially directed exterior and interior surfaces and the flange together providing a sensing surface on the housing;        first and second outer raceways carried by the housing and presented inwardly toward the axis and the inner raceways, with the first outer raceway being presented toward and inclined in the same direction as the first inner raceway and the second outer raceway being presented toward and inclined in the same direction as the second inner raceway;        first rolling elements arranged in a row between and contacting the first raceways and second rolling elements arrange in a row between and contacting the second raceways, whereby the hub will rotate with minimal friction in the housing and the individual rolling elements will roll along the raceways to transfer between the housing and hub radial loads and thrust loads in both axial directions and impart to the housing strains along the sensing surface;          positioning modules at multiple locations along the housing, the modules having strain sensors which are configured and oriented for detecting strains along the housing in at least one axial, circumferential and oblique direction;        monitoring the strain sensors in the housing at the multiple locations; and        measuring the strains detected by the strain sensors wherein the modules calculate loads applied to the housing based on the detected strains.     
     
     
       57. The method according to  claim 56  wherein detecting the strains along the housing comprises detecting strains along the sensing surface in circumferential and axial directions and detecting strains in directions oblique to the circumferential and axial directions. 
     
     
       58. The method according to  claim 56  wherein positioning the modules comprises orientating the sensors obliquely on the housing to detect shear. 
     
     
       59. The method according to  claim 56  wherein positioning the modules comprises locating the strain sensors on the flange of the housing.