Smart Bearing Sensor

Abstract

The recent increase in vessel shaftline bearing incidents indicates that a static shaft alignment design may not be suitable for all operational shaftline loading conditions. Hull deflections caused by vessel loading or propeller loads initiated by interaction with the wakefield have become important considerations in modern vessel design. Jack-up tests, typically used as a bearing load verification method, can only be accomplished under static shaft conditions and cannot verify the shaft dynamic behavior under running operational conditions. A newly developed sensor using strain gauge technology measures the bearing load and the shaft misalignment angle through the bearing housing's deformation-induced strain. It effectively converts the bearing housing into a weighing machine by mapping the bearing housing strain onto the bearing load. Unlike jack-up tests, this method allows for the continuous measurement of the bearing load and misalignment angle under all shaftline operational conditions. It is envisaged that this technologically simple system will allow for the earliest possible diagnosis of shaft alignment-related problems, such as bearing unloading, bearing overloading, or excessive shaft-bearing misalignment. This provides a much earlier warning indicator when compared with the bearing temperature alarm. The subject technology has been tested on intermediate bearings and is considered for future application into stern tube bearings. In post-IMO's (International Maritime Organization) Energy Efficiency Design Index vessel designs, the propulsion shafting arrangements become increasingly sensitive to shaft alignment with lower tolerances and margins, increasing the risk of stern tube bearing failures (Leontopoulos 2016a). This change is due to the wider use of more efficient, larger diameter propellers with increased cantilevered load on the shafting system and shorter shaftlines as a result of maximizing cargo space and minimizing engine room length. Widespread application of the single stern tube bearing design (an arrangement without a forward stern tube bearing) has also highlighted a decreased tolerance to eccentric propeller thrust and propeller forces in general. Reduced tolerance to shaft alignment sighting errors, bearing offset inaccuracies and other shaft installation errors, also affects the integrity of the shafting system and can result in complete bearing wiping with the consequence of vessel propulsion immobilization. This undesirable consequence has increased, particularly during the years 2013–2017.