Methods and apparatus for assembling a bearing assembly

• US 20050286823A1
• Filed: 06/24/2004
• Published: 12/29/2005
• Est. Priority Date: 06/24/2004
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Singh, Anant Pal, Sexton, Larry Jay
• Granted Patent: US 7,182,519 B2
• Time in Patent Office: Days
• US Class Current: 384/448
• CPC Class Codes: F01D 17/02 Arrangement of sensing elements
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 21/14 responsive to other specific conditions
• CPC Class Codes: F05D 2270/09 to cope with emergencies
• CPC Class Codes: F05D 2270/305 Tolerances
• CPC Class Codes: F16C 19/52 with devices affected by abnormal or undesired conditions
• CPC Class Codes: F16C 2233/00 Monitoring condition, e.g. temperature, load, vibration
• CPC Class Codes: F16C 2360/23 Gas turbine engines in general F02C
• CPC Class Codes: F16C 33/586 outside the space between the races, e.g. end faces or bore of inner ring

Abstract

A method for predicting bearing failure, wherein the bearing includes an inner race, an outer race, and a plurality of rolling elements between the inner and outer race. The method includes coupling a sensor assembly to the outer race, the sensor assembly including at least one temperature sensor and at least one acoustic sensor, generating a bearing performance model based on an initial signal received from the sensor assembly, receiving a second signal from the sensor assembly, and comparing the second signal to the bearing performance model to predict a bearing failure.

Claims

1. A method for predicting bearing failure of a bearing including an inner race, an outer race, and a plurality of rolling elements positioned between the inner and outer race, said method comprising:

coupling a sensor assembly to the outer race, wherein the sensor assembly includes at least one temperature sensor and at least one acoustic sensor;

generating a bearing performance model based on an initial signal received from the sensor assembly;

receiving a second signal from the sensor assembly; and

comparing the second signal to the bearing performance model to predict a bearing failure.

2. A method in accordance with claim 1 wherein coupling a sensor assembly to the outer race further comprises:

removing a portion of the outer race which has a first cross-sectional profile; and

coupling the sensor assembly to the outer race, wherein the sensor assembly has a second cross-section profile that is similar to the portion of the outer race removed.

3. A method in accordance with claim 1 wherein coupling a sensor assembly to the outer race further comprises coupling a sensor assembly to a high DN ball bearing, wherein D is a bearing diameter, and N is a bearing operational speed in revolutions per minute.

4. A method in accordance with claim 1 further comprising coupling at least three sensor assemblies to a first side of the outer race, and coupling at least three sensor assemblies to an opposite second side of the outer race.

5. A method in accordance with claim 1 further comprising coupling a plurality of sensor assemblies to a first side of the outer race, and coupling a plurality of sensor assemblies to an opposite second side of the outer race such that the plurality of sensor assemblies are substantially equally spaced about an outer periphery of the outer race first and second sides.

6. A method in accordance with claim 1 further comprising determining at least one of a bearing load, a bearing speed, a bearing lubricant type, a bearing lubricant quantity, and a bearing temperature based on the second signal.

7. A method in accordance with claim 1 further comprising:

coupling a plurality of sensor assemblies to a first side of the outer race;

coupling a plurality of sensor assemblies to an opposite second side of the outer race;

receiving a temperature signal from at least one of the first side sensor assemblies and from at least one of the second side sensor assemblies; and

utilizing the received temperature signals to determine a thrust bearing load direction.

8. A method in accordance with claim 1 further comprising:

coupling a plurality of sensor assemblies to a first side of the outer race;

coupling a plurality of sensor assemblies to an opposite second side of the outer race;

receiving a signal received from at least one of the first side sensor assemblies and from at least one of the second side sensor assemblies; and

utilizing the received signals to determine at least one of a bearing misalignment and a non-uniform bearing load distribution.

9. A bearing assembly for a rotor, said bearing assembly comprising:

an inner race;

an outer race;

a plurality of rolling elements positioned between said inner and outer race; and

a sensor assembly coupled to said outer race, said sensor assembly comprising at least one temperature sensor and at least one acoustic sensor.

10. A bearing assembly in accordance with claim 9 wherein said bearing assembly comprises a high DN ball bearing, wherein D is a bearing diameter, and N is a bearing operational speed in revolutions per minute.

11. A bearing assembly in accordance with claim 9 wherein said bearing assembly comprises a thrust bearing.

12. A bearing assembly in accordance with claim 9 further comprising at least three sensor assemblies coupled to a first side of said outer race, and at least three sensor assemblies coupled to an opposite second side of said outer race such that said sensor assemblies are approximately-equally spaced about an outer periphery of said outer race first and second sides.

13. A bearing assembly in accordance with claim 12 wherein said temperature sensors are each configured to output a signal that is utilized to determine a thrust bearing load direction.

14. A bearing assembly in accordance with claim 9 wherein said sensor assembly is configured to output a signal that is utilized to determine at least one of a bearing load, a bearing speed, a bearing lubricant type, a bearing lubricant quantity, and a bearing temperature.

15. A bearing assembly in accordance with claim 9 wherein said sensor assembly is configured to output a signal that is utilized to determine at least one of a bearing misalignment and a non-uniform bearing load distribution.

16. A gas turbine engine comprising:

a rotor shaft; and

a bearing assembly configured to support said rotor shaft, said bearing assembly comprising;

an inner race;

an outer race;

a plurality of rolling elements positioned between said inner and outer race; and

a plurality of sensor assemblies coupled to said outer race, each said sensor assembly comprising at least one temperature sensor and at least one acoustic sensor.

17. A gas turbine engine in accordance with claim 16 wherein said bearing assembly comprises a high DN thrust bearing, wherein D is a bearing diameter, and N is a bearing operational speed in revolutions per minute.

18. A gas turbine engine in accordance with claim 16 wherein said bearing assembly further comprises at least sensor assemblies coupled to a outer race first side, and at least three sensor assemblies coupled to an opposite outer race second side such that said sensor assemblies are approximately equally spaced about an outer periphery of said outer race first and second sides.

19. A gas turbine engine in accordance with claim 16, wherein said bearing assembly comprises a thrust bearing, and said temperature sensors are each configured to output a signal that is utilized to determine a thrust bearing load direction.

20. A gas turbine engine in accordance with claim 16, wherein said bearing assembly comprises a thrust bearing, and said sensor assemblies are each configured to output a signal that is utilized to determine at least one of a bearing load, a bearing speed, a bearing lubricant type, a bearing lubricant quantity, and a bearing temperature.

21. A gas turbine engine in accordance with claim 16 wherein said sensor assemblies are each configured to output a signal that is utilized to determine at least one of a bearing misalignment and a non-uniform bearing load distribution.