| Summary: | With the continuous improvement of train speeds, it is necessary to find the possible problems of bearings in time, otherwise they will cause serious consequences. Aiming at the characteristics of rapid temperature change of bearings, a thin film thermocouple temperature sensor was developed to measure the real-time temperature of the bearing’s rolling elements during train operation. Using dc pulse magnetron sputtering technology, Al2 O3 film, NiCr film, NiSi film, and SiO2 film were successively deposited on an aluminum alloy substrate. We studied their microstruc-ture, static characteristics, dynamic characteristics, and repeatability. Finally, we installed an adaptive film temperature sensor on the bearing testing machine to measure the temperature of the rolling elements. The results show that the developed temperature sensor has good linearity in the range of 30~180 °C. The Seebeck coefficient is 40.69 µV/°C, the nonlinear fitting error is less than 0.29%, the maximum repeatability error is less than 4.55%, and the dynamic response time is 1.42 µs. The temperature of the measured rolling elements is 6~10 °C higher than that of the outer ring, which can reflect the actual temperature of the bearing operation. © 2022 by the authors. Licensee MDPI, Basel, Switzerland.
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