Patent Application
20210328129
The invention concerns a sensor element for sensing load and vibration in a component such as a rolling element bearing and is more particularly directed to a sensor element which comprises a multilayer coating.
Bearings are used in many different types of machinery to retain and support rotating components such as, for example, a wheel on a vehicle, a vane on a windmill or a drum in a washing machine. During use, the bearing is subjected to different loads, both static and dynamic. The static load is due to the weight supported by the bearing, and may also be due to a preload with which the bearing is mounted. The dynamic loads are time dependent and are due to the operating conditions.
In many systems, it is desirable to be able to monitor the load acting on a bearing. In modern vehicles, for example, load data from the wheel bearings are used in the control of vehicle stability systems. Vibration is another physical parameter that is important with regard to bearings, as it provides an indication of the ‘health’ of a bearing. Excessive vibration may be a sign that a bearing is nearing the end of its life, and so bearings in vital machinery are often provided with sensors to monitor vibration.
Many examples of bearings provided with sensors are known in the art. Displacement sensors such as strain gauges are commonly applied to measure load and deformation, while thin film piezoelectric transducers may be used as vibration sensors. Preloaded piezoelectric sensors can also be used as displacement sensors.
A preloaded piezoelectric sensor needs to be clamped to a component surface. The clamping means takes up space and such a sensor is unsuitable for use on rotating parts. Strain gauges may be attached to a surface of a rotating part, such as a bearing inner or outer ring. The most widely applied method of attachment is adhesive bonding, which is both a delicate process as well as a time-consuming process, as the adhesive may need several hours to cure. Also, the surface cleanliness requirements for effective adhesion are incompatible with many production environments. Consequently there is a need for a sensor element that is easy to affix to a component surface.
Applications also exist, however, which are unsuited to the use of mounted sensor elements. For example, on component surfaces where it is important that the surface topography remains substantially unchanged, or where there is very little space, or where the sensor is subjected to high tribological stresses.
A sensor element that can be deposited on the surface of a component in the form of a coating overcomes these difficulties. Such a coating is known from DE10313060, which discloses a tribological layer comprising a piezoresistive element. The resistance of a piezoresistive element changes when the element is deformed, and load can thus be determined by measuring the resistance.
There is still room for improvement, however, in terms of accuracy, reliability and range of applications.
An object of the invention is therefore to define a sensor element which is capable of sensing load and/or vibration and which produces an accurate, strong and reliable signal.
A further object of the invention is to define a sensor element suitable for direct integration on a component of, for example, a rolling element bearing, which can be integrated on any surface without affecting the operation of the bearing.
A still further object of the invention is to define a sensor element that is also suitable for attachment on a component of, for example, a rolling element bearing by means of a straightforward procedure
The present invention also defines a method of producing such a sensor element.
The aforementioned objects are achieved according to the invention by a sensor element which comprises a multilayer coating deposited on a substrate, where the coating comprises a sensitive layer of a piezoelectric material and a first electrode layer of a metallic material, which electrode layer serves as a first electrode of the sensor element. The sensitive layer is located between the first electrode and a second electrode of the sensor element, where the second electrode is formed by the substrate or by a second electrode layer of the multilayer coating. In order to seal any pinholes in the sensitive layer and thereby prevent short-circuiting between the first and second electrodes, the multilayer coating further comprises a pinhole sealing layer deposited on top of the sensitive layer.
In a first embodiment of the invention, the substrate is formed by a surface of a metallic component, such as a raceway surface of a rolling element bearing. In this embodiment, the metallic substrate may serve as the second electrode. A preferred material for the sensitive layer is aluminium nitride, which is a hard and wear-resistant material and is therefore advantageous to use in a coating that could be subject to high tribological stresses. It also has excellent piezoelectric properties when deposited or “grown” with a crystallographic orientation that predominantly lies in the c-axis, <002> direction, i.e. perpendicular to the surface on which it is grown. A preferred method of depositing the aluminium nitride layer is by means of a physical vapour deposition process and, more preferably, by means of reactive sputtering. Reactive sputtering is advantageous, since the process parameters involved can be accurately controlled in order to obtain optimal c-axis orientation.
An aluminium nitride piezoelectric layer has further advantages. It is self-polarizing and thus does not require polarization after deposition. Aluminium nitride also produces a strong signal with an excellent linear response when subjected to mechanical deformations. Moreover, the linear response is produced over a wide frequency range which extends from the sub-Hz range up to the Mega-Hz range. In the case of a rolling element bearing, the frequency of the time-varying loads on a bearing ring due to the passage of rolling elements is in the order of the rotational frequency of the bearing, e.g. 10-1000 Hz. If the bearing develops a surface defect such as a raceway crack or spall, the frequency of the vibrations generated is in the order of 10 to 100 times the rotational frequency of the bearing. A sensor element according to the invention is therefore cable of sensing dynamic loads and vibrations in a component. The invention is not restricted to the use of aluminium nitride, however; zinc oxide oriented in the <002> direction is another suitable piezoelectric material.
The piezoelectric layer is deposited in a thickness of less than 10 microns, with a preferred thickness of between 0.5 and 2 microns. Aluminium nitride and piezoelectric crystals in general are porous materials. At such small thicknesses, it becomes likely that the piezoelectric layer will contain pinholes, also in view of the fact that the layer thickness is in the same order of magnitude as the surface roughness of the surface on which the aluminium nitride is deposited. When the first electrode layer is deposited on the piezoelectric layer by means of a physical vapour deposition process, there is then a risk of metal atoms penetrating through the pinholes, which would lead to short-circuiting between the first and second electrodes and failure of signal generation.
Thus, according to the invention, a pinhole sealing layer is deposited on top of the piezoelectric layer, between the piezoelectric layer and the electrode layer. The pinhole sealing layer is an ultra-thin film of a dielectric material, which seals the pores in the piezoelectric layer without substantially adding to the thickness of the piezoelectric layer. The thickness of the pinhole sealing layer is less than 10% of the thickness of the piezoelectric layer, and is preferably less than 5% of the thickness of the piezoelectric layer. A material that may suitably be used for the pinhole sealing layer is aluminium oxide. The pinhole sealing layer is deposited with a preferred thickness of between 0.01 and 0.1 micron.
A pinhole sealing layer of aluminium oxide may also be deposited by means of a physical vapour deposition process. Reactive sputtering is a preferred method. This is advantageous as the pinhole sealing layer can be deposited in the same chamber of the equipment in which the piezoelectric layer is deposited, thereby contributing to time and cost savings. In an alternative method, the aluminium oxide layer may be provided by means of atomic layer deposition (ALD). In this process, alternate pulses of an aluminium precursor and an oxygen precursor are injected into the reaction chamber. In a first step of a cycle, aluminium precursor molecules are deposited on the exposed substrate surface. Typically, a purge gas is then injection into the chamber to remove excess precursor. In the next step, oxygen precursor molecules are deposited, which react with the aluminium molecules to form an atomic layer of aluminium oxide. The cycle is completed with a further injection of purge gas to remove unreacted precursor. Each cycle leads to the formation of a single atomic layer of aluminium oxide, and the thickness of a film can be controlled with extreme precision via the number of cycles. Using atomic layer deposition, the aluminium oxide pinhole sealing layer may be deposited in extremely small thicknesses from 0.001 micron up to e.g. 0.1 micron. A further advantage of atomic layer deposition is that the deposited film is highly conformal.
The pinhole sealing layer prevents short-circuiting between the electrodes of the sensor element. The first electrode consists of a metallic layer of e.g. nickel or copper, which is deposited on top of the pinhole sealing layer in a preferred thickness of between 0.1 and 2 microns. The electrode layer may be deposited by means of a physical vapour deposition process, and sputtering is again a preferred method.
In an advantageous development of the invention, the multilayer coating comprises a metallic bond layer that is deposited immediately prior to deposition of the piezoelectric layer. The bond layer improves the adhesion of the piezoelectric layer. Materials that may suitably be used for the bond layer are molybdenum and chromium. Again for reasons of cost and time savings, the bond layer is preferably deposited by means of sputtering. The bond layer may have a thickness of less than 1 micron, with a preferred thickness of between 0.05 and 0.5 micron.
The multilayer coating may further comprise an insulation layer that is deposited on top of the first electrode layer. This prevents the transfer of electrical charge to conductors that come in contact with the sensor element. The insulation layer may be an aluminium oxide layer or an amorphous (i.e. non-piezoelectric) aluminium nitride layer deposited in a thickness of between 0.05 and 10 microns by means of a physical vapour deposition process. Reactive sputtering is once again preferred, to enable production of the entire multi-layer coating in the same process chamber.
When the substrate is a metallic surface of a component, the substrate may serve as the second electrode or, alternatively the multilayer coating may comprise a second electrode layer deposited prior to the piezoelectric layer. In this latter case, the multilayer coating suitably comprises an insulation layer between the metallic substrate and the second electrode layer. An insulation layer as described above may suitably be used. The multilayer coating of the inventive sensor element may comprise further layers of shielding, in order to comply with applicable electrical insulation requirements. Moreover, in applications where the coating is subject to high tribological stresses, an anti-wear coating such as a diamond-like carbon (DLC) coating may be provided on top of the insulation layer, to protect the insulation layer and improve the overall wear resistance of the inventive sensor element.
Thus, the multilayer coating of the inventive sensor element may have an overall thickness of less than 20 microns and is suitable for deposition on surfaces of mechanical components that are subject to dynamic loads and tribological stresses. One application of the sensor coating according to the invention is on component surfaces of a rolling element bearing. For the measurement of bearing load/deformation, the sensor coating could be deposited on the outer circumference of a bearing outer ring or the bore of a bearing inner ring. For the measurement of contact stress, the multilayer coating could be deposited on a bearing raceway or on a rolling element. The inventive sensor element can also be used to monitor vibrations in a bearing when the multilayer coating is applied on any of the aforementioned surfaces.
A sensor element according to the invention is not restricted to bearing applications, however. The substrate could be formed by a surface or surfaces of other metallic components that are subject to dynamic loads and tribological stresses, such as gear teeth and machine tools. Neither is the inventive sensor element restricted to direct integration (deposition) on a component surface.
In a second embodiment of the invention, the substrate may be formed by a surface of a carrier element, which carrier is attached to a surface of a component. If the surface of the carrier is a non-conductor, an electrode layer must be deposited to serve as the second electrode of the sensor element. If the surface of the carrier element is electrically conductive, this surface may serve as the second electrode. In this latter case, the carrier preferably consists of a sheet of metallic material, with a thickness of less than 0.5 mm. The metallic carrier is therefore flexible, which is advantageous as the inventive sensor element can be bent to follow the curvature of a curved component such as a bearing outer ring. Steel and stainless steel are suitable materials for the carrier element, as they possess the necessary strength and flexibility. A further important advantage is that a suitable steel or stainless steel carrier enables the sensor element to be welded to a steel component, such as bearing ring. A welding process is a faster and more economical means of attachment than e.g. adhesive bonding. A sensor element according to the second embodiment of the invention may be mounted on e.g. the outer circumference of a bearing outer ring or the bore of an inner ring, to measure loads and/or vibrations.
The present invention also defines a method of producing a sensor element, where the sensor element comprises a multilayer coating deposited on a substrate, the method comprising the steps of:
(i) depositing a sensitive layer of piezoelectric material;
(ii) depositing a pinhole sealing layer on top of the sensitive layer;
(ii) depositing an electrode layer on top of the pinhole sealing layer.
Examples of the inventive sensor element's uses and further advantages will become apparent from the detailed description and accompanying drawings.
The invention will now be described in more detail for explanatory and in no sense limiting purposes with reference to the following figures, in which
During operation of the bearing, the rolling elements overroll the coated raceway surface 200′ on the inner ring, causing mechanical deformation of the piezoelectric layer 204. This mechanical deformation produces a proportional change in the electric polarization of the piezoelectric layer. The sensor output is therefore an electric charge generated between the first and second electrodes, which charge is proportional to the mechanical deformation. One way of measuring the sensor output is by coupling the first and second electrodes to an appropriate charge amplifier by means of sensor connections 212. The charge amplifier suitably convents the electric charge output to a voltage output. Thus, a voltage signal may be produced during bearing operation which, with the aid of suitable processing means, can be used to determine the contact stresses.
Because the coating may be subject to high stresses, the piezoelectric layer 208 in this embodiment of the invention preferably consists of aluminium nitride that is deposited with a crystallographic orientation which predominantly lies in the c-axis, <002> direction, i.e. perpendicular to the surface on which it is deposited. This orientation ensures optimal piezoelectric properties, and aluminium nitride also possesses the necessary robustness. Another advantage of aluminium nitride is that it is self-polarizing and does not require subsequent polarization to enhance the piezoelectric effect. A drawback of aluminium nitride is that it is porous. To be suitable for integration on e.g. a bearing raceway, the piezoelectric layer 204 is preferably deposited in a thickness of less than 5 microns. At such small layer thicknesses, there is a risk that the piezoelectric layer 204 will contain pinholes. Such pinholes could allow short-circuiting between the first and second electrodes, leading to signal failure.
According to the invention, this difficulty is overcome by depositing a pinhole sealing layer 206 on top of the piezoelectric layer 204, prior to deposition of the electrode layer 208. The pinhole sealing layer 206 is an ultra-thin film of a dielectric material, which seals the pores in the piezoelectric layer without substantially adding to the thickness of the piezoelectric layer. Suitably, the thickness of the pinhole sealing layer 206 is less than 10% of the thickness of the piezoelectric layer 204 and is preferably less than 5% of the thickness of the piezoelectric layer. The pinhole sealing layer 206 preferably consists of aluminium oxide deposited in a thickness of between 0.01 and 0.1 micron. A sensor element according to the first embodiment of the invention therefore takes up very little space and produces a highly reliable signal.
As shown in
Thus, the multilayer coating 202 of a sensor element according to the invention may be deposited on surfaces of rotatable components. These surfaces include the inner and/or outer circumference of a bearing outer ring, the inner and/or outer circumferences of a bearing inner ring and even the surfaces of a rolling element. When deposited on a rolling element or on a bearing raceway, the piezoelectric layer 204 of the sensor element is subjected to compression and the piezoelectric effect is generated in d33 mode, meaning that the applied force is parallel to the direction of polarization. When deposited on an outer circumference of a bearing outer ring or the bore of a bearing inner ring, the piezoelectric layer bends as a result of deformation of the bearing ring due to the passage of rolling elements. Thus, the local bending component of the total movement of the piezoelectric layer will cause a difference in the strains induced on either side of the piezoelectric layer. The resulting forces act in a direction transverse to the direction of polarization, and piezoelectric effect is thus generated in d31 mode.
As well as being suitable for direct integration on a component, a sensor element according to the invention may also be integrated on a carrier element, which carrier element is then attached to the component on which measurements are to be performed.
The multilayer coating 302 may also be deposited on a non-metallic substrate, in which case a second electrode layer of e.g. copper or nickel would be deposited prior to deposition of the piezoelectric layer 304, to serve as the second electrode. The multilayer coating may also comprise a second electrode layer to serve as the second electrode when the coating is deposited on a metallic substrate (on a metallic carrier element or on a component surface). Suitably, a further insulation layer is then deposited between the substrate 300′ and the second electrode layer. Further layers of shielding may also be provided.
A carrier element 300 made of a sheet of e.g. stainless steel, with a thickness of less than 500 microns is flexible, strong and corrosion resistant. A sensor element that comprises such a thin metal sheet is therefore also flexible and resilient. This is particularly advantageous if the sensor element is to be mounted on a curved component, such as a bearing outer ring. The sensor element can then be made to follow the curvature of e.g. the bearing ring. A further advantage of a carrier element 300 made from stainless steel or other steel material is that the sensor element is then suitable for welding to a steel component. When the steel component is a bearing, suitable materials for the carrier element 300 include steels with no more than 0.2 wt. % carbon, nickel and nickel alloys, titanium and titanium alloys. For example, a sensor element according to the second embodiment of the invention could be mounted in a circumferential direction on a bearing outer ring and affixed by means of spot welding a first and second longitudinal end of the carrier to the surface of the bearing outer ring. Such a joining process is much faster and more economical than e.g. adhesive bonding.
Thus, a multilayer coating of a sensor element according to the invention may be deposited on one or more surfaces of a machine component or on a surface 300′ of e.g. a thin and flexible metallic carrier. The multilayer coating may have a thickness of less than 50 microns, with typical values of between 10 and 20 microns. The individual layers of the coating, of course, have even smaller thickness values. A suitable method of achieving such thin-film layers is by means of a physical vapour deposition process. A preferred method of producing one example of a multilayer coating of a sensor element according to the invention will now be described with reference to
In a first step 410, the metallic bond layer 301 is deposited on the metallic substrate 300 (which substrate can also be a surface of e.g. a bearing ring). A molybdenum target is sputtered in an inert gas environment, leading to the formation of a molybdenum film on the metallic substrate 300. The film preferably has a thickness of less than 1 micron, where 0.1 micron is a typical value.
In a second step 420, the piezoelectric layer 304 is deposited on the bond layer 301 by means of reactive sputtering. A pure aluminium target is sputtered in a nitrogen-containing environment, leading to the formation of an aluminium nitride film on the bond layer 301. The aluminium nitride film 304 has a thickness of less than 10 microns, with a preferred value of between 0.5 and 2 microns. During this step of the process, the process parameters are controlled to ensure that the aluminium nitride is formed with a crystallographic orientation which predominantly lies in the c-axis.
In a third step 430, the pinhole sealing layer 306 is deposited on the piezoelectric layer 304 by means of reactive sputtering. A pure aluminium target is sputtered in an oxygen-containing environment, leading to the formation of an aluminium oxide film on the piezoelectric layer 304. The aluminium oxide film may have a thickness of less than 0.5 micron, with a preferred value of between 0.01 and 0.1 micron.
In a fourth step 440, the electrode layer 408 is deposited on the pinhole sealing layer 306. A nickel target is sputtered in an inert gas environment, leading to the formation of a nickel film on the pinhole sealing layer 308. The nickel film may have a thickness of less than 5 microns, with a preferred value of between 0.1 and 2 microns. During the deposition, suitable masks are used to enable an electrical connection from the electrode layer 408 to be made.
In a fifth step 450, the insulation layer 410 is deposited on the electrode layer 308 by means of reactive sputtering. A pure aluminium target is sputtered in an oxygen-containing environment as described above for the third step. The resulting aluminium oxide insulation layer has a thickness of less than 10 microns, with a preferred value of between 0.1 and 1 micron.
The above process may be carried out in commercially available sputter deposition equipment. Magnetron sputtering or RF sputtering, for example, may be applied. An advantage of the sputtering technique is that the entire multilayer coating of the sensor element may be deposited in the same chamber of the process equipment, thereby saving time and costs. According to an alternative method and embodiment of the sensor element, the aluminium oxide sealing layer may be provided by means of atomic layer deposition.
A sensor element according to the invention can be used to determine loads in a component such as a rolling element bearing. The sensor element produces a strong signal with an excellent linear response over a wide frequency range. Loads/deformations of a bearing ring—due to the passage of the rolling elements—may be measured by applying the sensor element on e.g. an inner circumference of the inner ring and suitably filtering the signal produced. The cut-off frequency is selected depending on the application conditions, e.g. speed of rotation. The inventive sensor element could also be used on a hub bearing unit. For example, an inboard side of the hub mounting flange could be provided with a multilayer coating according to the invention, to detect loads between the flange and the part to which it is affixed (e.g. a steering knuckle). In a further example, the coating could be provided on the flange radius at the outboard side of the hub mounting flange. This radius refers to an arcuate portion between the hub outer ring and the hub mounting flange, and a sensor element located here could be used to determine bending moment due to cornering forces.
A sensor element according to the invention may also be used for condition monitoring purposes, e.g. to monitor high-frequency vibrations in a rolling element bearing. For the sensing of vibrations, a higher cut-off frequency is suitably selected. As will be clear to persons skilled in the art, suitable pass-band filters and processing circuitry may be employed to process the sensor signal in the desired frequency range or ranges. Depending on the stiffness, damping and mass characteristics of the system in which the e.g. bearing is mounted, it may also be advantageous to filter out certain resonances from the system
Thus, a sensor element according to the invention may be used to sense dynamic loads and/or vibrations in a component. A sensor element according to the first embodiment of the invention is suitable for direct integration on one or more surfaces of the component. A sensor element according to the second embodiment of the invention may be quickly and easily affixed to the surface of a component.
A number of aspects/embodiments of the invention have been described. It is to be understood that each aspect/embodiment may be combined with any other aspect/embodiment. Moreover the invention is not restricted to the described embodiments, but may be varied within the scope of the accompanying patent claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP08/00863 | 2/4/2008 | WO | 00 | 6/3/2011 |
