MEMS Strain Rollers - Roller Bearings

The principal goal of this research is to leverage several aspects of MEMS technology to enhance roller-bearing elements. This will be accomplished through three research areas. First, we will design and develop a vacuum-sealed MEMS strain sensor module that can be bonded to steel components - where knowledge of local strain fields is important. The focus is on developing a strain gage capable of measuring mechanical strain with a 10 kHz bandwidth, resolving 0.1 micro-strain in a +-1000 micro-strain range, and operating over a temperature range of -40 _C to 150 _C. This includes sensor design and optimization, encapsulation design, and development of a rapid method to bond silicon to steel. Second, to enhance the applicability of the strain sensor, low power, low-noise wireless data telemetry and power coupling is being developed. CMOS circuitry will be developed that can interface with the MEMS strain sensor to provide remote communication as well as provide an inductive load in order to convert RF to DC power from a remote power source. Last, a MEMS fabrication technique is being developed to produce surface textures onto lubrication critical surfaces in radial lip seals of roller bearings to enhance lubrication. Bearings with lower friction seals to reduce fuel consumption and operating costs are in high demand. For example, railroad operations could save approximately 2-3% in fuel costs per year just by decreasing the seal friction in a Timken AP (Class F) bearing by 40%. A major railroad in the US can consume approximately 1,000,000,000 gallons of fuel per year. Therefore, the cost savings from reductions in seal friction will be significant.