Research on the method of contact load measurement of wind turbine conical roller bearings based on intelligent roller

ObjectiveIn response to the challenge of directly measuring the contact load of large wind turbine tapered roller bearings, the main shaft bearing of a specific model wind turbine as an example to implement intelligent modifications on the rollers of the bearing is took.MethodsFirstly, a load sensor and its associated circuitry were installed within a hollow roller to develop an intelligent roller designed for measuring contact load, along with corresponding load sensors. Secondly, finite element simulations were conducted to derive the radial strain distribution pattern of the metallic disc within the load sensor, followed by virtual bridge assembly simulations. Finally, experimental validation was performed to confirm the radial strain distribution pattern of the metallic disc and sensor calibration experiments were conducted.ResultsThe findings indicate that when subjected to fixed loads, the proposed bridge assembly method effectively mitigates the influence of roller rotation angle on load measurement, allowing for stable voltage output during roller rotation. The proposed measurement methodology provides a novel approach for obtaining contact loads in large tapered roller bearings.