Development of a Novel External Smart Bearing With Two Sensors and an Energy‐Harvesting Module: Structural Design and Performance Evaluation

Traditional fault diagnosis methods primarily rely on single‐parameter measurements, which often result in diagnostic inaccuracies. In addition, the power supply of the sensor in the smart bearing is usually a challenge. To address these two limitations, this study introduces an innovative smart bearing system that integrates two sensors with an energy‐harvesting module. First, bearing heat generation was theoretically calculated using the Palmgren friction torque model, and the bearing thermodynamics under 1000–3500 rpm are characterized by finite element thermal field simulations through Ansys. Then, a Hertz contact‐based dynamic model was developed, which is numerically solved by MATLAB, to capture the vibration characteristics for 1000–3000 rpm. The energy‐harvesting efficiency of the energy‐harvesting module in the smart bearing was systematically evaluated using Maxwell equation–driven electromagnetic analysis in Ansoft. Finally, the monitoring performance of the smart bearing was experimentally validated using a bearing life testing rig. The experimental results show that the temperature difference between the smart bearing and the simulation results is less than 3°C, and the vibration amplitude detected by the smart bearing is higher, which demonstrates the superior condition monitoring capabilities of the novel smart bearing. Furthermore, the experiment verified the energy‐harvesting effect of the energy‐harvesting module at 200–1000 rpm, and the output voltage could reach 2.151 V at 1000 rpm, verifying the rationality of the smart bearing’s energy‐harvesting module. This research presents a significant advancement in the integration of multiparameter sensors with self‐powered smart bearing technology, offering a new approach for condition monitoring in rotating machinery.