ROTARY WING AIRCRAFT INSTRUMENTED MOTION CONTROL BEARINGS
[0001] This application claims the benefit of U.S. Provisional Application 61/472,923,
filed April 7, 201 1, entitled "ROTARY WING AIRCRAFT INSTRUMENTED MOTION
CONTROL DEVICE", which is herein incorporated by reference.
BACKGROUND
[0002] The invention relates generally to motion control bearings and methods of making
motion control bearings for monitoring of properties therein. The invention relates to rotary
wing aircraft and motion control bearings. The invention relates to motion control bearings
in helicopter rotary wing systems.
[0003] Motion control bearings are configured to be attached between two controlled
member structures in order to control relative motion between the two structures. The motion
control bearings preferably include at least one elastomer laminate bonded to two distal
surfaces subjected to relative motion. The motion control bearings control a motion.
SUMMARY
[0004] In one aspect the invention includes a bearing device for a rotary wing aircraft. The
bearing device provides a constrained relative motion between a first control member and a
second control member. The bearing device comprises an elastomeric laminate, a first end
bearing connector, a second end bearing connector and at least a first sensor member. The
elastomeric laminate including a plurality of mold bonded alternating layers of
nonelastomeric shims and elastomeric shims. The first end bearing connector bonded with a
first end of the elastomeric laminate. The first end bearing connector for grounding with the
first control member. The second end bearing connector bonded with a second distal end of
the elastomeric laminate. The second end bearing connector for grounding with the second
control member. The first sensor member coupled with the first end bearing connector, a
wireless transmitter, and a kinetic energy power harvester. The kinetic energy power
harvester is disposed proximate to the elastomeric laminate, wherein the kinetic energy power
harvester extracts an electrical energy from a energy source to provide electricity to the
bearing device, wherein the first sensor member senses a movement between the first end
bearing connector and the second end bearing connector, and the wireless transmitter
transmits sensor data of the sensed movement to a wireless receiver.
[0005] In one aspect, the invention includes a method of making a motion control bearing
device for a rotary wing aircraft. The method of making the bearing device includes
constraining a relative motion between a first control member and a second control member.
The method comprises providing an elastomeric laminate, at least a first sensor member, a
wireless transmitter, and a kinetic energy power harvester. The elastomeric laminate includes
a plurality of mold bonded alternating layers of nonelastomeric shims and elastomeric shims.
The elastomeric laminate includes a first end bearing connector bonded with a first end of the
elastomeric laminate. The elastomeric laminate includes a second end bearing connector
bonded with a second distal end of the elastomeric laminate. The kinetic energy power
harvester extracts an electrical energy from a energy source to provide electricity to the
bearing device, wherein the first sensor member senses a movement between the first end
bearing connector and the second end bearing connector, and the wireless transmitter
transmits sensor data of the sensed movement to a wireless receiver.
[0006] In another aspect, the invention includes a bearing device. The bearing device
provides a constrained relative motion between a first control member and a second control
member. The bearing device comprises an elastomeric laminate 16 and a sensing means.
The elastomeric laminate includes a plurality of mold bonded alternating layers of
nonelastomeric shims and elastomeric shims. The bearing device includes a first end bearing
connector bonded with a first end of the elastomeric laminate, the first end bearing connector
for grounding with the first control member. The bearing device including a second end
bearing connector bonded with a second distal end of elastomeric laminate, the second end
bearing connector for grounding with the second control member. The sensing means has a
means for powering the sensing means, wherein the sensing means senses a movement
between the first end bearing connector and the second end bearing connector, and transmits
sensor data of the sensed movement to a wireless receiver.
Brief Description of the Drawings
[0007] FIG. 1 illustrates a side view of a rotary wing aircraft.
[0008] FIG. 2 illustrates detailed cross-section of motion control bearing location on rotary
wing aircraft with wireless communications.
[0009] FIG. 3 illustrates a schematic of a motion control bearing positioned about the
center hub of a rotary wing aircraft.
[0010] FIG. 4 illustrates a schematic of a motion control bearing.
[0011] FIG. 5 illustrates a flow diagram of a wireless sensor for a motion control bearing.
[0012] FIGS. 6-9 illustrate placement of sensors in an elastomeric device.
[0013] FIG. 10 illustrates a schematic of the CF bearing and the placement thereof in the
hub configuration.
[0014] FIG. 1 1 illustrates wired communication through the fixed member of the CF
bearing.
[0015] FIG. 12 illustrates the attachment of the bonded spherical elastomeric bearing
package to major metal components.
[0016] FIG. 13 illustrates a section view of a bonded spherical elastomeric bearing with
major metal components.
[0017] FIG. 14 illustrates positioning bonded spherical elastomeric bearing package in a
mold.
[0018] FIG. 15 illustrates an exploded view of a rotary wing hub with the motion control
bearing instrumented for load sensing.
[0019] FIGS. 16 and 17 illustrate a sectional view of the motion control bearing in a
portion of a rotary wing hub.
[0020] FIG. 18 illustrates the kinetic energy power harvester.
[0021] FIGS. 19 and 20 illustrate an exploded view of the kinetic energy power harvester
without an elastomeric element.
[0022] FIG. 2 1 illustrates a bottom view of the kinetic energy power harvester without an
elastomeric element, including the winding and plurality of magnets.
[0023] FIG. 22 illustrates a sectional side view of the kinetic energy power harvester
without the elastomeric element, including the winding.
[0024] FIG. 23 illustrates a perspective sectional side view of the kinetic energy power
harvester without the elastomeric element, including the plurality of magnets.
[0025] FIG. 24 illustrates a perspective side view of the load sensing assembly.
[0026] FIG. 25 illustrates a control circuit for the load sensing assembly.
[0027] FIG. 26 illustrates a perspective exploded view of the load sensing assembly.
[0028] FIG. 27 illustrates the magnetic field associated with the motion control bearing.
[0029] FIG. 28 illustrates a longitudinally extending linear displacement sensor assembly.
[0030] FIG. 29 illustrates a schematic placement of multiple sensors.
[0031] FIG. 30 illustrates a schematic placement of multiple sensors.
Detailed Description
[0032] Additional features and advantages of the invention will be set forth in the detailed
description which follows, and in part will be readily apparent to those skilled in the art from
that description or recognized by practicing the invention as described herein, including the
detailed description which follows, the claims, as well as the appended drawings. Reference
will now be made in detail to the present preferred embodiments of the invention, examples
of which are illustrated in the accompanying drawings.
[0033] In an embodiment, the invention includes a rotary wing aircraft motion control
bearing device 10, hereinafter bearing device 10. The bearing device 10 provides a
constrained relative motion between a first rotary wing aircraft control member 12 and a
second rotary wing aircraft control member 14, hereinafter first control member 12 and
second control member 14. The bearing device 10 includes an elastomeric mold bonded
laminate 16. The elastomeric mold bonded laminate 16, is hereinafter referred to as
elastomeric laminate 16. Although illustrated in FIGS. 3 and 4 as a spherical elastomeric
laminate 16, elastomeric laminate 16 may be also be cylindrical.
[0034] The elastomeric laminate 16, including a plurality of mold bonded alternating
layers of interiorly positioned nonelastomeric shims 18 and elastomeric shims 20, preferably
vulcanized bonded inside an elastomeric curing mold 22 which contains and positions the
shims 18, 20 during an applied mold pressure and temperature to provide elastomeric
laminate 16 of cured elastomer shims 20 and nonelastomeric shims 18. The plurality of mold
bonded alternating layers make up the bonded spherical elastomeric bearing package of
elastomeric laminate 16.
[0035] The bearing device 10 includes a first end bearing connector 24 bonded with a first
end 26 of the elastomeric laminate 16, the first end bearing connector 24 for grounding with
the first controlled member 12, the bearing device 10 including a second end bearing
connector 28 nonelastomeric metal member bonded with a second distal end 32 of the
elastomeric laminate 16, the bearing device 10 second end bearing connector 28 for
grounding with the second control member 14.
[0036] The bearing device 10 includes at least a first sensor member 34, the first sensor
member 34 coupled with the first end bearing connector 24. The bearing device 10 includes
a sensor data wireless transceiver transmitter 36 and a kinetic energy ambient environmental
power harvester 38, hereinafter a kinetic energy power harvester 38. The sensor data wireless
transceiver transmitter 36 is hereinafter referred to as the wireless transmitter 36. Wireless
transmitter 36 is any type of wireless transmitter that is adaptable to bearing device 10 and
able to electronically communicate.
[0037] The kinetic energy power harvester 38 is disposed proximate the elastomeric
laminate 16 wherein the kinetic energy power harvester 38 extracts an electrical energy from
a energy source 40 associated with the rotary wing aircraft 42 to provide electrical energy in
the form of electricity to the bearing device 10. Preferably, the relative motion between the
first control member 12 and the second control member 14 drives the kinetic energy power
harvester 38. The kinetic energy power harvester 38 provides electricity wherein the first
sensor member 34 senses a movement between the first end bearing connector 24 and a
second end bearing connector 28, and the wireless transmitter 36 transmits sensor data of the
sensed movement to a data wireless transceiver receiver 44 and associated electronics 45.
The data wireless transceiver receiver 44 is hereinafter referred to as the wireless receiver 44.
Alternatively, first sensor member 34 is in electrical communication with the rotary wing
aircraft 42 power supply (not shown) receives supplemental power therefrom on an as
required basis.
[0038] Preferably, the elastomeric laminate 16 is comprised of a spherical shell segment 46
including a plurality of mold bonded alternating spherical segment shell layers of
increasing/decreasing radius of nonelastomeric spherical segment shell layer shims 48 and
elastomeric spherical segment shell layer shims 50, the first end bearing connector 24 having
a spherical shell segment 46 bonded with the first end 26 of the elastomeric laminate 16, the
bearing device 10 first end bearing connector 24 for grounding with the first control member
12, the bearing device 10 second distal end bearing connector 28 having a spherical shell
segment 46 bonded with the second distal end 32 of the elastomeric laminate 16. Preferably
the bearing device 10 is a replaceable limited use device in the rotary wing aircraft,
preferably with the aircraft bearing device exchanged out for a replacement part that replaces
the used bearing device.
[0039] Preferably, the bearing device 10 includes a second sensor member 52, the second
sensor member 52 coupled with the first end bearing connector 24. In a preferred
embodiment the first and second sensor members 34, 52 oriented and coupled on the bearing
device 10 are oriented accelerometers, with the accelerometers oriented relative to the rotary
wing hub axis of rotation 54. Preferably the accelerometers oriented relative to the rotary
wing hub axis of rotation 54 and opposite to each other with the longitudinally extending
blade axis 56 between and with the accelerometers oriented relative to the bearing center of
rotation 58, preferably with the opposing accelerometers providing rotational accelerometer
data from rotation about the rotary wing hub axis of rotation 54 to provide position
measurement data from the sensed rotational acceleration.
[0040] Preferably, the bearing device 10 first sensor member 34 is comprised of a
longitudinally extending sensor 60 extending along a longitudinal sensor axis 62 from a first
sensor end 64 to a distal second end 66. Preferably, the longitudinally extending sensor 60
distal second end 66 is coupled with the second end bearing connector 28. In a preferred
embodiment the longitudinally extending sensor 60 is a linear variable differential
transformer. In an embodiment, the longitudinally extending sensor 60 detects a targeted
detected section of the second end bearing connector 28, preferably with the longitudinally
extending sensor 60 comprised of a non-contact variable differential transformer 70. The
longitudinally extending sensor 60 distal second end 66 is coupled with the second end
bearing connector 28 and is preferably a complementing sensor member pair end 72 to the
first sensor member 34 first sensor end 64. The complementing sensor member pair ends 72
sensing a position characteristic between the first end bearing connector 24 and the second
end bearing connector 28 along a longitudinally extending axis 74. The longitudinal sensor
axis 62 is aligned with the longitudinally extending axis 74, a longitudinally extending linear
displacement sensor assembly 78, a longitudinally extending variable reluctance transducer
sensor assembly, and a longitudinally extending differential variable reluctance transducer
sensor assembly. Preferably, the longitudinally extending sensor 60 is comprised of a
longitudinally extending linear displacement sensor assembly 78. In embodiments the
longitudinally extending sensor 60 is a displacement transducer, preferably with axial
displacement between conductive surfaces changes the space between the conductive
surfaces with a sensed electrical change providing sensor data relative to the displacement
between the end bearing connector 24, 28.
[0041] In a preferred embodiment the longitudinally extending linear displacement sensor
assembly 78 includes an elongating electrical conductor, preferably a longitudinally
extending contained elongating electrical conductor fluid 88 with a change in electrical
characteristic relative to elongation. In a preferred embodiment, resistance of the electrical
conductor changes with the changing displacement. In a preferred embodiment, the electrical
conductor is a liquid metal mass, preferably a liquid metal mass comprised of Gallium and
Indium.
[0042] In preferred embodiments, the bearing device 10 includes a plurality of
complementing pair longitudinally extending sensor member assemblies 90 sensing position
characteristics between the first end bearing connector 24 and the second end bearing
connector 28, preferably with their longitudinally extending sensor 60 having nonparallel
axes. Preferably the longitudinally extending sensor member assemblies 90 extend through
the spherical shell segments 46, preferably with nonparallel axis 92 oriented nonparallel to
the bearing center z axis 94. Preferably four longitudinally extending sensor member
assemblies 90 extend through the spherical shell segments 46, preferably with their
longitudinally extending axis 74 nonparallel to each other and oriented relative to the rotary
wing hub axis of rotation 54.
[0043] The bearing device 10 includes a load sensing assembly 96, the load sensing
assembly 96 powered with the kinetic energy power harvester 38 with the load sensing
assembly 96 transmitting load sensor data through the wireless transmitter 36 to the wireless
receiver 44. Preferably the load sensing assembly 96 is comprised of a plurality of strain
gauge bridges coupled with the first end bearing connector 24.
[0044] Preferably, the kinetic energy power harvester 38 includes a winding 102 and a
plurality of magnets 104. Preferably, the kinetic energy power harvester 38 is an ambient
kinetic energy power harvester 38 including a winding 102 and a plurality of magnets 104.
[0045] Preferably, the bearing device 10 includes a second elastomeric mold bonded
laminate 106, hereinafter referred to as the second elastomeric laminate 106. The second
elastomeric laminate 106 including a plurality of second elastomeric laminate 106 mold
bonded alternating layers of interiorly positioned nonelastomeric shims 108 and elastomeric
shims 110, preferably vulcanized bonded inside an elastomeric curing mold 112 which
contains and positions the shims 108, 110 during an applied mold pressure and temperature to
provide second elastomeric laminate 106 of cured elastomer shims 110 and nonelastomeric
shims 108. Preferably the kinetic energy power harvester 38 is coupled with the second
elastomeric laminate 106. The second elastomeric laminate 106 is a cylindrical elastomeric
laminate with mold bonded alternating layers of flat planar nonelastomeric shims 108 and flat
planar elastomeric shims 110, circular flat planar shims providing the cylindrical mold
bonded laminate 114, and with the second elastomeric laminate 106 comprising a cylindrical
mold bonded laminate pitch bearing. Cylindrical mold bonded laminate 114 is second
elastomeric laminate 106 in cylindrical form.
[0046] Preferably, the bearing device 10 second elastomeric laminate 106 includes a
plurality of second elastomeric laminate 106 mold bonded alternating layers of interiorly
positioned nonelastomeric shims 108 and elastomeric shims 110, preferably vulcanized
bonded inside an elastomeric curing mold 112 which contains and positions the shims 108,
110 during an applied mold pressure and temperature to provide second elastomeric laminate
106 of cured elastomer shims 110 and nonelastomeric shims 108. The bearing device 10
second cylindrical second elastomeric laminate 106 is coupled with the kinetic energy power
harvester 38 which includes a winding 102 and a plurality of magnets 104. The bearing
device 10 second cylindrical second elastomeric laminate 106 coupled with the kinetic energy
power harvester 38 provides electrical power from the controlled cyclical pitching motion of
the rotor wing. Preferably, the second elastomeric laminate 106 includes mold bonded
alternating layers of flat planar nonelastomeric shims 108 and flat planar elastomeric shims
110, circular flat planar shims 108, 110 provide cylindrical mold bonded laminate pitch
bearing.
[0047] Preferably, the bearing device 10 includes a second sensor member 52, the second
sensor member 52 coupled with the second end bearing connector 28. In preferred
embodiments the bearing device 10 includes a first magnetic field sensing first sensor
member 118, preferably a magnetometer 118, and the second sensor member 52 is comprised
of a second magnetic sensor target 120 coupled with the second end bearing connector 28.
Preferably the magnetometer is a three axis magnetometer, oriented and centered on the first
end bearing connector 24 longitudinally extending axis 74. The three axis magnetometer is
comprised of three orthogonal vector magnetometers measuring magnetic field components
including magnetic field strength, inclination and declination.
[0048] The second oriented magnetic sensor target 120 is coupled with the second end
bearing connector 28. The permanent magnet target 122 is oriented and centered on the
second end bearing connector 28 longitudinally extending axis 74, with the permanent
magnet target 122 generating magnetic field lines 123. In an embodiment, the second end
bearing connector 28 is comprised of a nonmagnetic metal, the first end bearing connector 24
is comprised of a nonmagnetic metal, and the interior nonelastomeric shims 18 are comprised
of a nonmagnetic metal.
[0049] In an embodiment, the second end bearing connector 28 is comprised of a magnetic
metal. In an embodiment, the first end bearing connector 24 is comprised of a magnetic
metal. In an embodiment at least one of the nonelastomeric shims 18 are comprised of a
magnetic metal. Preferably with the oriented magnetometer and the distal permanent magnet
target 122, the relative location of the sensor within the magnet's magnetic field is measured.
The magnetometer readings from the three axes is filtered and processed to produce signals
which are proportional to the x, y, z axis displacement between the magnet and sensor.
Preferably the magnetometer is oriented and centered on the central axis 124 of the spherical
bearing 126, the magnetometer's three axes are oriented in relation to the magnetic field lines
123 of the permanent magnet target 122.
[0050] The bearing device 10 has an operational lifetime beginning spring rate SRB and an
operational lifetime end spring rate SRE with SRE < SRB. Preferably, the SRE is no greater
than .83SRB, preferably no greater than .81SRB, and preferably the operational lifetime end
spring rate is less than eighty percent of operational lifetime beginning spring rate. The
bearing device 10 has an operational lifetime OL measured by a plurality of operational
deflection cycles between the first end bearing connector 24 and the second end bearing
connector 28 until the operational lifetime end spring rate SRE is reached. Wherein, the
bearing device 10 has the operational lifetime OL with the at least first magnetic field sensing
first sensor member 118 monitoring an operational spring rate of the elastomeric laminate 16
between the first end bearing connector 24 and the second end bearing connector 28. The
device monitors the operational spring rate of the elastomeric laminate 16 relative to the SRB
and the SRE.
[0051] Preferably, the wireless transmitter 36 transmits sensor data to the wireless receiver
44 with the sensor data including operational spring rate data of the elastomeric laminate 16.
The sensor data is used to determine replacement of the bearing device 10. The sensor data is
used to monitor bearing device 10 usage, monitor and collect loading history statistics
experienced by the bearing, catalog usage exceedance events (bearing events that relate to
bearing stress and/or strain that exceeds predefined threshold indicating significant damage,
compromised bearing life, need for near-term inspection or removal/replacement, estimate
remaining bearing life, monitor loading history for tracking cumulative damage). Preferably,
the rotary wing aircraft constrained relative motion operational deflection cycles compress
the elastomers of the elastomeric laminate 16, compressing and/or shearing the intermediate
elastomer.
[0052] Preferably, the sensors monitor operational lifetime OL cycles of at least about
forty five million cycles to about eighty nine million cycles. Preferably, the sensors monitor
operational lifetime OL cycles for at least about 2,450 hours at about 5HZ to at least about
4,000 hours at about 6Hz. The operational lifetime OL cycles, hours and frequency ranges
are platform dependent and vary based upon the particular design requirements for the rotary
wing aircraft 42. Preferably the spring rate cycle sensor data is used to initiate a replacement
of the bearing device 10 in the aircraft, with the bearing device 10 comprised of a replaceable
limited use device, preferably with the device exchanged out for a replacement part.
[0053] FIG. 2 illustrates the placement of bearing device 10 on rotary wing aircraft 42 near
rotary wing hub 125 near blade root 127a and 127b.
[0054] In an embodiment, elastomeric laminate 16, spherical shell segment 46, and bonded
spherical elastomeric package each refer to elastomer layers and shims bonded together.
There are two approaches to make these parts. The first approach is by bonding
nonelastomeric shims 18, 48 and elastomeric shims 20, 50 in a mold 22. The bonded shim
package is then attached to first end bearing connector 24 and second end bearing connector
28. The second approach is by bonding nonelastomeric 18, 48 and elastomeric shims 20, 50
in a mold 22 together with first end bearing connector 24 and second end bearing connector
28.
[0055] In an embodiment, the invention includes a method of making a bearing device 10
for providing a constrained relative motion between a first control member 12 and a second
control member 14. The method includes providing an elastomeric laminate 16, the
elastomeric laminate 16 including a plurality of mold bonded alternating layers of
nonelastomeric shims 18 and elastomeric shims 20. Preferably, the elastomeric laminate 16
is provided by vulcanize bonding inside an elastomeric curing mold 22 which contains and
positions the shims 18, 20 during an applied mold pressure and temperature to provide the
elastomeric laminate 16 of cured elastomer shims 20 and nonelastomeric shims 18. The
plurality of mold bonded alternating layers make up the bonded spherical elastomeric bearing
package of elastomeric laminate 16. The elastomeric laminate 16 preferably includes a first
end bearing connector 24 bonded with a first end 26 of the elastomeric laminate 16. The
bearing device 10 first end bearing connector 24 is for grounding with the first control
member 12.
[0056] The elastomeric laminate 16 preferably includes a second end bearing connector 28
bonded with a second distal end 32 of the elastomeric laminate 16, the bearing device 10
second end bearing connector 28 for grounding with the second control member 14. The
method includes providing at least a first sensor member 34, the first sensor member 34
coupled with the first end bearing connector 24, a wireless transmitter 36, and a kinetic
energy power harvester 38. The kinetic energy power harvester 38 is disposed proximate the
elastomeric laminate 16, wherein the kinetic energy power harvester 38 extracts an electrical
energy flow from a energy source 40 to provide electricity. Preferably, energy source 40 is a
kinetic energy source. Wherein the first sensor member 34 senses a movement between the
first end bearing connector 24 and the second end bearing connector 28, and the wireless
transmitter 36 transmits sensor data of the sensed movement to a wireless receiver 44.
[0057] Preferably, the elastomeric laminate 16 is comprised of a spherical shell segment 46
including a plurality of mold bonded alternating spherical segment shell layers of
increasing/decreasing radius of nonelastomeric spherical segment shell layer shims 48 and
elastomeric spherical segment shell layer shims 50. The first end bearing connector 24 has a
spherical shell segment 46 bonded with the first end 26 of the elastomeric laminate 16. The
bearing device 10 first end bearing connector 24 for grounding with the first control member
12, the bearing device 10 second end bearing connector 28 having a spherical shell segment
46 bonded with the second distal end 32 of the elastomeric laminate 16.
[0058] Preferably, the method includes providing a second sensor member 52, the second
sensor member 52 coupled with the first end bearing connector 24. In preferred methods, the
first and second sensors 34, 52 are accelerometers oriented relative to the rotary wing hub
axis of rotation 54, with the coupled position of the accelerometer measured with rotational
acceleration.
[0059] Preferably, the method includes the first sensor member 34 comprised of a
longitudinally extending sensor 60 extending along a longitudinal sensor axis 62 from a first
sensor end 64 to a distal second end 66. The longitudinally extending sensor 60 distal second
end 66 is coupled with the second end bearing connector 28.
[0060] In an embodiment, the longitudinally extending sensor 60 distal second end 66
coupled with the second end bearing connector 28 is the second end bearing connector 28. In
an embodiment, the longitudinally extending sensor 60 is a linear variable differential
transformer. In an embodiment, the longitudinally extending sensor 60 is a non-contact
variable differential transformer sensing a targeted detected section of the second end bearing
connector 28.
[0061] Preferably, the longitudinally extending sensor 60 distal second end 66 coupled
with the second end bearing connector 28 is preferably a complementing sensor member pair
end 72 to the first sensor member 34 first sensor end 64, with the complementing sensor
member pair ends 72 sensing a position characteristic between the first end bearing connector
24 and the second end bearing connector 28 preferably along a longitudinally extending axis
74 with the longitudinal sensor axis 62 aligned with the longitudinally extending axis 74.
The sensor assembly comprises a longitudinally extending linear displacement sensor
assembly 78, a longitudinally extending variable reluctance transducer sensor assembly, and
a longitudinally extending differential variable reluctance transducer sensor assembly.
[0062] In embodiments, the sensor is a displacement transducer, preferably with axial
displacement between conductive surfaces changes the space between the conductive
surfaces with a sensed electrical change providing sensor data relative to the displacement
between the end bearing connector 24, 28.
[0063] In embodiments, the sensor is a longitudinally extending linear displacement sensor
assembly 78, preferably an elongating electrical conductor, preferably a longitudinally
extending contained elongating electrical conductor fluid 88 with a change in electrical
characteristic relative to elongation. Preferably, sensed change is resistance provides a
sensed change in displacement. In embodiments, the longitudinally extending contained
elongating electrical conductor fluid 88 is a liquid metal mass, and preferably a liquid metal
mass comprised of Gallium and Indium.
[0064] Preferably, the method includes disposing a plurality of the complementing pair
longitudinally extending sensor member assemblies 90 sensing position characteristics
between the first end bearing connector 24 and the second end bearing connector 28,
preferably with their longitudinally extending axis 74 nonparallel. The longitudinally
extending sensor member assemblies 90 extend through the spherical shell segments 46.
Preferably, four longitudinally extending sensor member assemblies 90 extend through the
spherical shell segments 46, preferably with their longitudinally extending axis 74 nonparallel
to each other and oriented relative to relative to the rotary wing hub axis of rotation 54.
[0065] Preferably, the method includes providing a load sensing assembly 96, the load
sensing assembly 96 powered with the kinetic energy power harvester 38 with the load
sensing assembly 96 transmitting load sensor data through the wireless transmitter 36 to the
wireless receiver 44. Preferably, the load sensing assembly 96 is comprised of a plurality of
strain gauge bridges coupled with the first end bearing connector 24.
[0066] Preferably, the method includes providing a kinetic energy power harvester 38 with
a winding 102 and a plurality of magnets 104. Preferably the kinetic energy power harvester
38 includes a winding 102 and a plurality of magnets 104 centered and coupled about a
second elastomeric laminate 106 with controlled rotary wing cyclical motions.
[0067] Preferably, the method includes providing a second elastomeric laminate 106, the
second elastomeric laminate 106 including a plurality of second elastomeric mold bonded
laminate mold bonded alternating layers of interiorly positioned nonelastomeric shims 108
and elastomeric shims 110. The method includes vulcanize bonding inside an elastomeric
curing mold 112 which contains and positions the shims during an applied mold pressure and
temperature to provide the second elastomeric laminate 106 of cured elastomer shims 110
and nonelastomeric shims 108. Preferably the kinetic energy power harvester 38 is coupled
with the second elastomeric laminate 106. The second elastomeric laminate 106 is mold
bonded alternating layers of flat planar nonelastomeric shims 108 and flat planar elastomeric
shims 110, preferably circular flat planar shims providing a cylindrical mold bonded
laminate, preferably cylindrical mold bonded laminate pitch bearing for controlling rotary
wing cyclical motions.
[0068] Preferably, the method includes providing a second elastomeric laminate 106, the
second elastomeric laminate 106 including a plurality of second elastomeric mold bonded
laminate mold bonded alternating layers of interiorly positioned nonelastomeric shims 108
and elastomeric shims 110, preferably vulcanize bonding inside an elastomeric curing mold
112 which contains and positions the shims during an applied mold pressure and temperature
to provide second elastomeric laminate 106 of cured elastomer shims 110 and nonelastomeric
shims 108. Preferably, the kinetic energy power harvester 38 includes a winding 102 and a
plurality of magnets 104, with the kinetic energy power harvester 38 coupled with the second
elastomeric laminate 106. Preferably, the second elastomeric laminate 106 is comprised of
mold bonded alternating layers of flat planar nonelastomeric shims 108 and flat planar
elastomeric shims 110, preferably circular flat planar shims to provide cylindrical mold
bonded laminate 114, preferably a cylindrical mold bonded laminate pitch bearing .
Cylindrical mold bonded laminate 114 is second elastomeric laminate 106 in cylindrical
form.
[0069] Preferably, the method includes providing a second sensor member 52, the second
sensor member 52 coupled with the second end bearing connector nonelastomeric 28.
Preferably, the second sensor member 52 coupled with the second end bearing connector 28
is a magnet. In preferred embodiments, the bearing device 10 is provided with a first
magnetic field sensing first sensor member 34, preferably a magnetometer, and the second
sensor member 52 is comprised of a second magnetic sensor target 120 coupled with the
second end bearing connector 28. Preferably, the provided magnetometer is a three axis
magnetometer, oriented and centered on the first end bearing connector 24 longitudinally
extending center axis 74. The three axis magnetometer is comprised of three orthogonal
vector magnetometers measuring magnetic field components including magnetic field
strength, inclination and declination. The second magnetic sensor target 120 is coupled with
the second end bearing connector 28, and the permanent magnet target 122 is oriented and
centered on the second end bearing connector 28 longitudinally extending axis 74, with the
permanent magnet target 122 generating magnetic field lines 123.
[0070] In an embodiment the second end bearing connector 28 is comprised of a
nonmagnetic metal; the first end bearing connector 24 is comprised of a nonmagnetic metal;
and the nonelastomeric shims 18 are comprised of a nonmagnetic metal. In an embodiment,
the second end bearing connector 28 is comprised of a magnetic metal. In an embodiment,
the first end bearing connector 24 is comprised of a magnetic metal. In an embodiment, at
least one of the nonelastomeric shims 18 are comprised of a magnetic metal. Preferably, with
the magnetometer sensors and the distal permanent magnet targets, the relative location of the
sensor within the magnet's magnetic field is measured. Preferably the magnetometer
readings from the three axes is filtered and processed to produce signals which are
proportional to the x, y, z axis displacement between the magnet and sensor. Preferably the
magnetometer sensor is oriented and centered on the central axis of the spherical bearing, the
sensor's three axes are oriented in relation to the magnetic field lines 123 of the permanent
magnet target 122.
[0071] The bearing device 10 has an operational lifetime beginning spring rate SRB and an
operational lifetime end spring rate SRE with SRE < SRB. Preferably, the bearing device 10
has an operational lifetime beginning spring rate SRB and an operational lifetime end spring
rate SRE with SRE < SRB. Preferably, the SRE is no greater than .83SRB, preferably no
greater than .81SRB, and preferably the operational lifetime end spring rate is less than eighty
percent of operational lifetime beginning spring rate. Preferably, the bearing device 10 has
an operational lifetime OL measured by a plurality of operational deflection cycles between
the first end bearing connector nonelastomeric metal member 24 and the second end bearing
connector 28 until the operational lifetime end spring rate SRE is reached, wherein the
bearing device 10 has the operational lifetime OL with the at least first sensor member 34
monitoring an operational spring rate of the elastomeric laminate 16 between the first end
bearing connector nonelastomeric metal member 24 and the second end bearing connector
28.
[0072] Preferably, the bearing device 10 monitors the operational spring rate of the
elastomeric laminate 16 relative to the SRB and the SRE. Preferably, the wireless transmitter
36 transmits sensor data to the wireless receiver 44 with the sensor data including operational
spring rate data of the elastomeric laminate 16. Preferably, the sensor data is used to
determine replacement of the bearing device 10. Preferably the sensor data is used to monitor
bearing usage, preferably monitor and collect loading history statistics experienced by the
bearing, catalog usage exceedance events (bearing events that relate to bearing stress and/or
strain that exceeds predefined threshold indicating significant damage, compromised bearing
life, need for near-term inspection or removal/replacement, estimate remaining bearing life,
monitor loading history for tracking cumulative damage).
[0073] Preferably, the rotary wing aircraft constrained relative motion operational
deflection cycles compress the elastomers of the elastomeric laminate 16, preferably shearing
the intermediate elastomer, preferably compressing and shearing the intermediate elastomer.
Preferably, the sensors monitor operational lifetime OL cycles of at least about forty five
million cycles to about eighty nine million cycles. Preferably, the sensors monitor
operational lifetime OL cycles for at least about 2,450 hours at about 5HZ to at least about
4,000 hours at about 6Hz. The operational lifetime OL cycles, hours and frequency ranges
are platform dependent and vary based upon the particular design requirements for the rotary
wing aircraft 42. Preferably, the spring rate cycle sensor data is used to initiate a replacement
of the bearing device 10 in the aircraft, with the bearing device 10 comprised of a replaceable
limited use device, preferably with the device exchanged out for a replacement part.
[0074] The bearing device 10 preferably provides load sensing, and preferably provides
prognostics data for the bearing device 10 and preferably provides load information for
improved regime recognition and usage information of the aircraft. Preferably, the bearing
device 10 provides load and motion sensing. Preferably, the load sensing resolves moments
associated with blade flapping, lead-lag, and pitch or the rotary wing aircraft. Preferably, the
sensors provide for measuring in-plane and centrifugal forces with the bearing measuring
loads in six degrees-of-freedom. The bearing device 10 preferably provides comprehensive
loads and motions data on the rotor head, including six degrees-of-freedom blade/hub load
sensing related to helicopter usage, regime recognition and fatigue cycles. The bearing
device 10 preferably provides three axes of dynamic motion measurement (pitch, lead/lag,
and flap) with real-time stiffness monitoring of the bearing for assessing both bearing and
blade health. The bearing device 10 preferably provides static and dynamic blade orientation
for the aircraft including information on flight regime, thrust vectors, and gross vehicle
weight.
[0075] Preferably the bearing device's 10 power harvesting provides for powering wireless
communication of data to the fixed frame of the aircraft. The bearing device 10 preferably
includes Moment Sensors, preferably strain gauges coupled to the spherical bearing end
bearing connector member 128 to provide measurements of pitch, lead/lag and flap moments,
preferably with full bridge strain gauges. The bearing device 10 preferably includes Force
Sensors, preferably sensors providing measurements of in-plane, vertical and centrifugal
loads. The bearing device 10 preferably includes Inertial Sensors, preferably located
proximate the bearing device electronics module 130 to provide measurement of inertial
motion in the pitch, lead/lag and flap directions, preferably providing dynamic displacements
in these degrees-of-freedom. Preferably, the bearing device's 10 kinetic energy power
harvester 38 is coupled to the system within the hub arm and harvests kinetic energy
associated with the harmonic motion of the assembly. Preferably, the bearing device's
electronics module 130 includes six strain bridges and three inertial sensors feeding into a
sensor conditioning circuit. Preferably, the signal inputs are buffered and transmitted
wirelessly as data packets to a fixed system transceiver. Preferably the bearing device
electronics module 130 includes power management for optimal usage of harvested power.
[0076] The bearing device 10 provides sensing of health through in situ dynamic stiffness
measurements. The bearing device 10 provides load measurements to provide fatigue
loading cycle counts and regime recognition. The bearing device 10 provides blade static
position to provide regime recognition (e.g., pull-up, bank, etc) and aircraft gross weight (e.g,
blade coning angle). Preferably, blade static position is provided with the inertial sensors and
strain gauges to calculating bearing dynamic stiffness. Preferably, blade static position is
provided with an empirical model to inferring bearing static stiffness from dynamic stiffness.
Preferably, blade static position is provided with calculations from the strain gauges and
static stiffness. Preferably, the bearing device 10 with longitudinally extending sensors 60
measure bearing motion, and preferably the sensor data is used in combination with load
sensing data, preferably from the strain gages, to provide in situ stiffness measurements.
Preferably, the bearing device 10 with longitudinally extending sensors 60 in the spherical
elastomeric laminate measure bearing flap angle to provide data related to rotor coning angle
relating to aircraft gross weight. Preferably, the bearing device 10, with longitudinally
extending sensors 60 in the spherical elastomeric laminate, measures usage behavior and
operating regime recognition pertaining to the machinery, in which they reside. Preferably,
the bearing device 10 with longitudinally extending sensors 60 in the spherical elastomeric
laminate measure the bearing lead-lag angle to provide data on the operating state of the
helicopter. Preferably, the bearing device 10 with longitudinally extending sensors 60 in the
spherical elastomeric laminate measure motions of the bearing, preferably angular-x (leadlag),
angular-y (flap), angular-z (pitch) and z-displacement (CF).
[0077] In an embodiment, the invention includes a method of making a bearing device 10.
The method includes providing an elastomeric laminate 16, the elastomeric laminate 16
including a plurality of mold bonded alternating layers of nonelastomeric shims 18 and
elastomeric shims 20. Preferably the elastomeric laminate 16 is provided by vulcanize
bonding inside an elastomeric curing mold 22 which contains and positions the shims during
an applied mold pressure and temperature to provide the elastomeric laminate 16 of cured
elastomer shims 20 and bonded nonelastomeric shims 18. The plurality of mold bonded
alternating layers make up the bonded spherical elastomeric bearing package of elastomeric
laminate 16. The elastomeric laminate 16 includes a first end bearing connector 24 bonded
with a first end 26 of the elastomeric laminate 16. The first end bearing connector 24 is
preferably for grounding with a first control member 12. The elastomeric laminate 16
includes a second end bearing connector 28 bonded with a second distal end 32 of the
elastomeric laminate 16. The bearing device 10 second distal end 32 second end bearing
connector 28 preferably for grounding with the second control member 14. The method
includes providing at least a first sensor member 34, a wireless transmitter 36, and a kinetic
energy power harvester 38. The kinetic energy power harvester 38 is preferably disposed
proximate the elastomeric laminate 16 wherein the kinetic energy power harvester 38 extracts
an electrical energy flow to provide electricity wherein the first sensor member 34 senses a
movement between the first end bearing connector 24 and the second end bearing connector
28 and the wireless transmitter 36 transmits sensor data of the sensed movement to a wireless
receiver 44.
[0078] Preferably, the first sensor member 34 is coupled with the first end bearing
connector 24. Preferably, the kinetic energy power harvester 38 is a kinetic energy power
harvester 38. Preferably, the elastomeric laminate 16 is comprised a spherical shell segment
46 including a plurality of mold bonded alternating spherical segment shell layers of
increasing/decreasing radius of nonelastomeric spherical segment shell layer shims 48 and
elastomeric spherical segment shell layer shims 50, the first end bearing connector 24 having
a spherical shell segment 46 bonded with the first end 26 of the elastomeric laminate 16, the
bearing device 10 first end bearing connector 24 for grounding with the first control member
12, the bearing device 10 second distal end 32 second end bearing connector 28 having a
spherical shell segment 46 bonded with the second distal end 32 of the elastomeric laminate
16.
[0079] Preferably, the method including providing a second sensor member 52, the second
sensor member 52 coupled with the first end bearing connector 24, preferably with first and
second oriented accelerometers oriented relative to an axis of rotation, preferably with
positions measured with rotational acceleration.
[0080] Preferably, the first sensor member 34 is comprised of a longitudinally extending
sensor 60 extending along a longitudinal sensor axis 62 from a first sensor end 64 to a distal
second end 66. Preferably, the method includes the first sensor member 34 comprised of a
longitudinally extending sensor 60 extending along a longitudinal sensor axis 62 from a first
sensor end 64 to a distal second end 66. Preferably, the longitudinally extending sensor 60
distal second end 66 is coupled with the second end bearing connector 28. In an
embodiment, the longitudinally extending sensor 60 distal second end 66 coupled with the
second end bearing connector 28 is the second end bearing connector 28. In an embodiment,
the longitudinally extending sensor 60 is a linear variable differential transformer. In an
embodiment, the sensor is a non-contact variable differential transformer sensing a targeted
detected section of the second end bearing connector 28.
[0081] Preferably, the longitudinally extending sensor 60 distal second end 66 coupled
with the second end bearing connector 28 is a complementing sensor member pair end 72 to
the first sensor member 34 first sensor end 64. The complementing sensor member pair ends
72 sensing a position characteristic between the first end bearing connector 24 and the second
end bearing connector 28 preferably along a longitudinally extending axis 74 with the
longitudinal sensor axis 62 aligned with the longitudinally extending axis 74. Preferably, the
sensor assembly comprises a longitudinally extending linear displacement sensor assembly
78, preferably a longitudinally extending variable reluctance transducer sensor assembly, and
preferably a longitudinally extending differential variable reluctance transducer sensor
assembly. In embodiments, the longitudinally extending sensor 60 is a displacement
transducer, preferably with axial displacement between conductive surfaces changes the
space between the conductive surfaces with a sensed electrical change providing sensor data
relative to the displacement between the end bearing connector 24, 28. In embodiments, the
sensor is a longitudinally extending linear displacement sensor assembly 78, preferably an
elongating electrical conductor, preferably a longitudinally extending contained elongating
electrical conductor fluid 88 with a change in electrical characteristic relative to elongation.
Preferably, resistance provides a sensed change in displacement. Preferably, the
longitudinally extending contained elongating electrical conductor fluid 88 is a liquid metal
mass, more preferably a liquid metal mass comprised of Gallium and Indium.
[0082] Preferably, the method includes disposing a plurality of the complementing pair
longitudinally extending sensor member assemblies 90 sensing position characteristics
between the first end bearing connector 24 and the second end bearing connector 28, with
their longitudinally extending axis 74 nonparallel. Preferably, the longitudinally extending
sensor member assemblies 90 extend through the spherical shell segments 46. Preferably,
four longitudinally extending sensor member assemblies 90 extend through the spherical
shell segments 46, with their longitudinally extending axis 74 nonparallel to each other and
oriented relative to the rotary wing hub axis of rotation 54.
[0083] Preferably, the method includes providing a load sensing assembly 96, the load
sensing assembly 96 powered with the kinetic energy power harvester 38 with the load
sensing assembly 96 transmitting load sensor data through the wireless transmitter 36 to the
wireless receiver 44. Preferably, the load sensing assembly 96 is comprised of a plurality of
strain gauge bridges coupled with the first end bearing connector 24.
[0084] Preferably, providing the kinetic energy ambient harvester 38 includes providing a
kinetic energy power harvester 38 with a winding 102 and a plurality of magnets 104.
[0085] Preferably, the method includes providing a second elastomeric laminate 106, the
second elastomeric laminate 106 including a plurality of second elastomeric laminate 106
mold bonded alternating layers of interiorly positioned nonelastomeric shims 108 and
elastomeric shims 110. Preferably, the method includes vulcanize bonding inside an
elastomeric curing mold 112 which contains and positions the shims during an applied mold
pressure and temperature to provide the second elastomeric laminate 106 of cured elastomer
shims 110 and nonelastomeric shims 108. Preferably, the kinetic energy power harvester 38
is coupled with the second elastomeric laminate 106. Preferably, the second elastomeric
laminate 106 is mold bonded alternating layers of flat planar nonelastomeric shims 108 and
flat planar elastomeric shims 110, preferably circular flat planar shims providing a cylindrical
mold bonded laminate 114, preferably cylindrical mold bonded laminate pitch bearing for
controlling cyclical motions.
[0086] Preferably, the method includes providing a second elastomeric laminate 106, the
second elastomeric laminate 106 including a plurality of second elastomeric mold bonded
laminate mold 106 bonded alternating layers of interiorly positioned nonelastomeric shims
108 and elastomeric shims 110, preferably vulcanize bonding inside an elastomeric curing
mold 112 which contains and positions the shims during an applied mold pressure and
temperature to provide second elastomeric laminate 106 of cured elastomer shims 110 and
nonelastomeric shims 108. Preferably, the kinetic energy power harvester 38 includes a
winding 102 and a plurality of magnets 104, with the kinetic energy power harvester 38
coupled with the second elastomeric laminate 106. Preferably, the second elastomeric
laminate 106 is comprised of mold bonded alternating layers of flat planar nonelastomeric
shims 108 and flat planar elastomeric shims 110, preferably circular flat planar shims to
provide cylindrical mold bonded laminate 114, preferably a cylindrical mold bonded laminate
pitch bearing.
[0087] Preferably, the method includes providing a second sensor member 52, the second
sensor member 52 coupled with the second end bearing connector 28. Preferably, the second
sensor member 52 coupled with the second end bearing connector 28 is a magnet. In
preferred embodiments, the bearing device 10 is provided with a first magnetic field sensing
first sensor member 118, preferably a magnetometer, and the second sensor member 52 is
comprised of a second magnetic sensor target 120 coupled with the second end bearing
connector 28. Preferably, the provided magnetometer is a three axis magnetometer,
preferably oriented and centered on the first end bearing connector 24 longitudinally
extending axis 74. Preferably, the three axis magnetometer is comprised of three orthogonal
vector magnetometers measuring magnetic field components including magnetic field
strength, inclination and declination.
[0088] Preferably, the second magnetic sensor target 120 is coupled with the second end
bearing connector 28, preferably the permanent magnet target 122 is oriented and centered on
the second end bearing connector 28 longitudinally extending axis 74, with the permanent
magnet target 122 generating magnetic field lines 123. In an embodiment, the second end
bearing connector 28 is comprised of a nonmagnetic metal, the first end bearing connector 24
is comprised of a nonmagnetic metal, and the nonelastomeric shims 18 are comprised of a
nonmagnetic metal. In an embodiment, the second end bearing connector 28 is comprised of
a magnetic metal. In an embodiment, the first end bearing connector 24 is comprised of a
magnetic metal. In an embodiment, at least one of the nonelastomeric shims 18 are
comprised of a magnetic metal. Preferably, with the magnetometer sensor and the permanent
magnet target 122, the relative location of the second magnetic sensor target 120 within the
magnet's magnetic field is measured. Preferably, the magnetometer readings from the three
axes is filtered and processed to produce signals which are proportional to the x, y, z axis
displacement between the magnet and sensor. Preferably, the magnetometer sensor is
oriented and centered on the central axis of the spherical bearing. The sensor's three axes are
oriented in relation to the magnetic field lines 123 of the permanent magnet target 122.
[0089] The method includes providing a bearing device 10 with an operational lifetime
beginning spring rate SRB and an operational lifetime end spring rate SRE with SRE < SRB.
Preferably, the bearing device 10 has an operational lifetime beginning spring rate SRB and
an operational lifetime end spring rate SRE with SRE < SRB. Preferably, the SRE is no
greater than .83SRB, preferably no greater than .81SRB, and preferably the operational
lifetime end spring rate is less than eighty percent of operational lifetime beginning spring
rate. Preferably, the bearing device 10 has an operational lifetime OL measured by a
plurality of operational deflection cycles between the first end bearing connector 24 and the
second end bearing connector 28 until the operational lifetime end spring rate SRE is
reached. Wherein the bearing device 10 has the operational lifetime OL with the at least first
sensor member 34 monitoring an operational spring rate of the elastomeric laminate 16
between the first end bearing connector nonelastomeric metal member 24 and the second end
bearing member 28. Preferably, the bearing device 10 monitors the operational spring rate of
the elastomeric laminate 16 relative to the SRB and the SRE. Preferably, the wireless
transmitter 36 transmits sensor data to the wireless receiver 44 with the sensor data including
operational spring rate data of the elastomeric laminate 16. Preferably, the sensor data is
used to determine replacement of the bearing device 10. Preferably, the sensor data is used to
monitor bearing usage, preferably monitor and collect loading history statistics experienced
by the bearing, catalog usage exceedance events (bearing events that relate to bearing stress
and/or strain that exceeds predefined threshold indicating significant damage, compromised
bearing life, need for near-term inspection or removal/replacement, estimate remaining
bearing life, monitor loading history for tracking cumulative damage). Preferably, the
constrained relative motion operational deflection cycles compress the elastomers of the
elastomeric laminate 16, preferably shearing the intermediate elastomer, preferably
compressing and shearing the intermediate elastomer.
[0090] Preferably, the sensors monitor operational lifetime OL cycles of at least about
forty five million cycles to about eighty nine million cycles. Preferably, the sensors monitor
operational lifetime OL cycles for at least about 2,450 hours at about 5HZ to at least about
4,000 hours at about 6Hz. The operational lifetime OL cycles, hours and frequency ranges
are platform dependent and vary based upon the particular design requirements for the rotary
wing aircraft 42. Preferably the spring rate cycle sensor data is used to initiate a replacement
of the bearing device 10, with the bearing device 10 comprised of a replaceable limited use
device, preferably with the device exchanged out for a replacement part.
[0091] In an embodiment, the invention includes a bearing device 10, the bearing device
10 providing a constrained relative motion between a first control member 12 and a second
control member 14. The bearing device 10 includes an elastomeric laminate 16, the
elastomeric laminate 16 including a plurality of mold bonded alternating layers of
nonelastomeric shims 18 and elastomeric shims 20. The elastomeric laminate 16 is
preferably vulcanized bonded inside an elastomeric curing mold 22 which contains and
positions the shims during an applied mold pressure and temperature to provide an
elastomeric laminate 16 of cured elastomer shims 20 and nonelastomeric shims 18. The
bearing device 10 includes a first end bearing connector 24 bonded with a first end 26 of the
elastomeric laminate 16, the first end bearing connector 24 for grounding with the first
control member 12. The bearing device 10 including a second end bearing connector 28
bonded with a second distal end 32 of the elastomeric laminate 16, the second end bearing
connector 28 for grounding with the second control member 14. The elastomeric laminate 16
can be attached to the first end bearing connector 24 and the second end bearing connector 28
after the elastomeric laminate 16 is cured in the elastomeric curing mold 22. Sensor members
34, 52 may be attached after the elastomeric laminate 16 is cured in the elastomeric curing
mold 22.
[0092] The bearing device 10 includes a means for sensing and a means for powering the
sensing means, wherein the sensing means senses a movement between the first end bearing
connector 24 and the second end bearing connector 28, and transmits sensor data of the
sensed movement to a wireless receiver 44. Preferably, the elastomeric laminate 16 is
comprised of a spherical shell segment 46 including a plurality of mold bonded alternating
spherical segment shell layers of increasing/decreasing radius of interiorly positioned
nonelastomeric spherical segment shell layer shims 48 and elastomeric spherical segment
shell layer shims 50, the first end bearing connector 24 having a spherical shell segment 46
bonded with the first end 26 of the elastomeric laminate 16, the rotary wing aircraft bearing
first end bearing connector 24 for grounding with the first control member 12. The rotary
wing aircraft bearing second end bearing connector 28 having a spherical shell segment 46
bonded with the second distal end 32 of the elastomeric laminate 16.
[0093] It will be apparent to those skilled in the art that various modifications and
variations can be made to the invention without departing from the spirit and scope of the
invention. Thus, it is intended that the invention cover the modifications and variations of
this invention provided they come within the scope of the appended claims and their
equivalents. It is intended that the scope of differing terms or phrases in the claims may be
fulfilled by the same or different structure(s) or step(s).
We Claim:
1. A bearing device 10 for a rotary wing aircraft, said bearing device 10 providing a
constrained relative motion between a first control member 12 and a second control member
12, said bearing device 10 comprising:
an elastomeric laminate 16, said elastomeric laminate 16 including a plurality of mold
bonded alternating layers of nonelastomeric shims 18 and elastomeric shims 20;
a first end bearing connector 24 bonded with a first end 26 of said elastomeric
laminate 16, said first end bearing connector 24 for grounding with said first control member
12;
a second end bearing connector 28 bonded with a second distal end 32 of said
elastomeric laminate 16, said second end bearing connector 28 for grounding with said
second control member 14; and
at least a first sensor member 34, said first sensor member 34 coupled with said first
end bearing connector 24, a wireless transmitter 36, and a kinetic energy power harvester 38,
said kinetic energy power harvester 38 disposed proximate said elastomeric laminate 16,
wherein said kinetic energy power harvester 38 extracts an electrical energy from an energy
source 40 to provide electricity to said bearing device 10, wherein said first sensor member
34 senses a movement between said first end bearing connector 24 and said second end
bearing connector 28, and said wireless transmitter 36 transmits sensor data of said sensed
movement to a wireless receiver 44.
2. The bearing device 10 as claimed in claim 1, including a second sensor member 52,
said second sensor member 52 coupled with said first end bearing connector 24.
3. The bearing device 10 as claimed in claim 1, said first sensor member 34 comprised
of a longitudinally extending sensor 60 extending along a longitudinal sensor axis 62 from a
first sensor end 64 to a distal second end 66.
4. The bearing device 10 as claimed in claim 1, including a load sensing assembly 96,
said load sensing assembly 96 powered with said kinetic energy power harvester 38 with said
load sensing assembly 96 transmitting load sensor data through said wireless transmitter 36 to
said wireless receiver 44.
5. The bearing device 10 as claimed in claim 1, wherein said kinetic energy power
harvester 38 includes a winding 102 and a plurality of magnets 104.
6. The bearing device 10 as claimed in claim 1, including a second elastomeric laminate
106, said second elastomeric laminate 106 including a plurality of second elastomeric mold
bonded laminate mold bonded alternating layers of nonelastomeric shims 108 and
elastomeric shims 110, with said kinetic energy power harvester 38 coupled with said second
elastomeric laminate 106.
7. The bearing device 10 as claimed in claim 1, including a second elastomeric laminate
106, said second elastomeric laminate 106 including a plurality of second elastomeric
laminate 106 mold bonded alternating layers of nonelastomeric shims 108 and elastomeric
shims 110, with said kinetic energy power harvester 38 including a winding 102 and a
plurality of magnets 104, said kinetic energy power harvester 38 coupled with said second
elastomeric laminate 106.
8. The bearing device 10 as claimed in claim 1, including a second sensor member 52,
said second sensor member 52 coupled with said second end bearing connector 28.
9. The bearing device 10 as claimed in claim 1, said bearing device 10 having an
operational lifetime beginning spring rate SRB and an operational lifetime end spring rate
SRE with SRE < SRB, with an operational lifetime OL measured by a plurality of operational
deflection cycles between the first end bearing connector 24 and the second end bearing
connector 28 until the operational lifetime end spring rate SRE is reached, wherein said
bearing device 10 has an operational lifetime OL with said at least first sensor member 34
monitoring an operational spring rate of the elastomeric laminate 16 between the first end
bearing connector 24 and the second end bearing connector 28.
10. A method of making a bearing device 10 for a rotary wing aircraft, said method
comprising:
providing an elastomeric laminate 16, said elastomeric laminate 16 including a
plurality of mold bonded alternating layers of nonelastomeric shims 18 and elastomeric shims
20, said elastomeric laminate 16 including a first end bearing connector 24 bonded with a
first end 26 of said elastomeric laminate 16, said elastomeric laminate 16 including a second
end bearing connector 28 bonded with a second distal end 32 of said elastomeric laminate 16;
and
providing at least a first sensor member 34;
providing a wireless transmitter 36; and
providing a kinetic energy power harvester 38, said kinetic energy power harvester 38
disposed proximate said elastomeric laminate 16, wherein said kinetic energy power
harvester 38 extracts an electrical energy from a energy source 40 to provide electricity to the
bearing device 10, wherein said first sensor member 34 senses a movement between said first
end bearing connector 24 and said second end bearing connector 28, and said wireless
transmitter 36 transmits sensor data of said sensed movement to a wireless receiver 44.
11. The method as claimed in claim 10, the method further comprising providing a first
control member 12 and a second control member 14 and constraining a relative motion
therebetween.
12. The method as claimed in claim 10, said method including providing a second sensor
member 52, said second sensor member 52 coupled with said first end bearing connector 24.
13. The method as claimed in claim 10, said first sensor member 34 is comprised of a
longitudinally extending sensor 60 extending along a longitudinal sensor axis 62 from a first
sensor end 64 to a distal second end 66.
14. The method as claimed in claim 10, said method including providing a load sensing
assembly 96, said load sensing assembly 96 powered with said kinetic energy power
harvester 38 with said load sensing assembly 96 transmitting load sensor data through said
wireless transmitter 36 to said wireless receiver 44.
15. The method as claimed in claim 10, wherein said kinetic energy power harvester 38
includes a winding 102 and a plurality of magnets 104.
16. The method as claimed in claim 10, including providing a second elastomeric
laminate 106, said second elastomeric laminate 106 including a plurality of second
elastomeric laminate 106 mold bonded alternating layers of nonelastomeric shims 108 and
elastomeric shims 110, with said kinetic energy power harvester 38 coupled with said second
elastomeric laminate 106.
17. The method as claimed in claim 10, including providing a second elastomeric
laminate 106, said second elastomeric laminate 106 including a plurality of second
elastomeric laminate 106 mold bonded alternating layers of nonelastomeric shims 108 and
elastomeric shims 110, with said kinetic energy power harvester 38 including a winding 102
and a plurality of magnets 104, said kinetic energy power harvester 38 coupled with said
second elastomeric laminate 106.
18. The method as claimed in claim 10, including providing a second sensor member 52,
said second sensor member 52 coupled with said second end bearing connector 28.
19. The method as claimed in claim 10, wherein said bearing device 10 has an operational
lifetime beginning spring rate SRB and an operational lifetime end spring rate SRE with SRE
< SRB, with an operational lifetime OL measured by a plurality of operational deflection
cycles between the first end bearing connector 24 and the second end bearing connector 28
until the operational lifetime end spring rate SRE is reached, wherein said bearing device 10
has an operational lifetime OL with said first sensor member 34 monitoring an operational
spring rate of the elastomeric laminate 16 between the first end bearing connector 24 and the
second end bearing connector 28.
20. A bearing device 10, said bearing device 10 providing a constrained relative motion
between a first control member 12 and a second control member 14, said bearing device 10
comprising:
an elastomeric laminate 16, said elastomeric laminate 16 including a plurality of mold
bonded alternating layers of nonelastomeric shims 18 and elastomeric shims 20, said bearing
device 10 including a first end bearing connector 24 bonded with a first end 26 of said
elastomeric laminate 16, said first end bearing connector 24 for grounding with said first
control member 12, said bearing device 10 including a second end bearing connector 28
bonded with a second distal end 32 of said elastomeric laminate 16, said second end bearing
connector 28 for grounding with said second control member 14; and
a sensing means having a means for powering said sensing means, wherein said
sensing means senses a movement between said first end bearing connector 24 and said
second end bearing connector 28 and transmits sensor data of said sensed movement to a
wireless receiver 44.
21. The bearing device 10 of claim 20, wherein the elastomeric laminate 16 is attached to
the first end bearing connector 24 and the second end bearing connector 28 after the
elastomeric laminate 16 is cured in the elastomeric curing mold 22.
22. The bearing device 10 of claim 22, wherein the sensing means is attached after the
elastomeric laminate 16 is cured in the elastomeric curing mold 22.
23. The bearing device 10 of claim 22, wherein the sensing means is sensor member 34.
24. The bearing device 10 of claim 22, wherein the sensing means is sensor member 52.