Thin-film sensor strain and temperature measurement in cylindrical roller thrust bBearings

M.Sc. Marie Kleinhans

Summary

The implementation of sensor-integrated machine elements into existing systems enables continuous acquisition of process and condition data. This data forms the basis for advanced condition monitoring strategies capable of detecting incipient damage at an early stage, thereby allowing for predictive maintenance and optimized service intervals.

This study focuses on the application of component-integrated thin-film sensor technology to monitor and predict load conditions in tribologically highly stressed zones, particularly the raceways of rolling bearings. Thin-film strain gauges and temperature sensors are directly deposited onto the housing washers of GS89312 cylindrical roller thrust bearings using photolithography and magnetron sputtering techniques. To enhance durability under severe contact conditions, a protective Al₂O₃ layer is applied, providing both electrical insulation and wear resistance.

The performance of the sensor-integrated components is evaluated on an FE8 test rig equipped with 81212 cylindrical roller thrust bearings, operated under varying load and rotational speed conditions with oil lubrication. Sensor placement is strategically chosen so that some sensors are located within the rolling contact path while others are positioned outside it. This configuration enables indirect inference of contact zone conditions from sensors placed outside the tribological interface, substantially extending sensor service life by reducing direct mechanical stress exposure.

The approach not only improves sensor longevity but also advances the feasibility of long-term, in-situ monitoring of highly loaded rolling bearing components. By correlating sensor signals with operating conditions and fatigue progression, the methodology supports the development of more robust predictive maintenance algorithms for critical mechanical systems.