Rolling bearing and methods for manufacture and assembly thereof

Abstract

Disclosed is a rolling bearing (100) having a rolling element (110) and a flat portion (125) which has, at an edge (130), two flanges (131, 132) which are integrally connected to the flat portion (125) and are designed to form a raceway (135) for the rolling element (110).

Description

[0001] 123-O188DE / 2024-24 09 / 23-2025

[0002] Rolling bearings and methods for their manufacture and assembly

[0003] The present invention relates to a rolling bearing, a method for manufacturing a rolling bearing, a method for assembling rolling bearings, and in particular to large rolling bearings and roller guides and their manufacturing methods.

[0004] BACKGROUND

[0005] Large machines and systems require large rolling bearings that should be simple in design and cost-effective to manufacture. The application range of large rolling bearings extends from space-saving industrial automation systems (e.g., for sorting, transport, or filling tasks) to interior building construction (e.g., turntables, flexible noise barriers), vehicle manufacturing (e.g., garbage trucks), furniture manufacturing (e.g., large rotary tables), and more recent applications such as easily maintained and harvestable green facades for urban gardening. In mechanical and plant engineering, therefore, in addition to increased size, greater flexibility and complexity are also desirable. Especially in novel applications, high demands are placed on lightweight construction and flexible connection points. However, the costs for manufacturing rolling bearings with their rotating or swiveling components increase significantly with size.

[0006] In the current state of the art, large slewing bearings are manufactured using very complex processes involving ring rolling, extensive machining, and heat and surface treatment. This is particularly costly for large diameters, as both machining tools and semi-finished products of this size are very expensive. Furthermore, these processes are very time-consuming and require extensive knowledge on the part of both manufacturers and users.

[0007] Therefore, there is a need for cost-effective, easy-to-manufacture and

[0008] Page 1 of 35 123-O188DE / 2024-24 23.09-2025 Large rolling bearings flexibly adaptable to a wide variety of applications.

[0009] BRIEF DESCRIPTION OF THE INVENTION

[0010] A contribution to fulfilling this need is achieved by a rolling bearing according to claim 1, a method for manufacturing a rolling bearing according to claim 9, and a method for assembling a rolling bearing according to one of claims 11 or 12. The dependent claims relate to advantageous embodiments of the subject matter of the independent claims.

[0011] The present invention relates to a rolling bearing with a rolling element and with a flat section having two flanges integrally connected to the flat section at one edge, which are designed to form a running surface for the rolling element.

[0012] In exemplary embodiments, the rolling bearing comprises several rolling elements. The rolling elements can be arranged in a holding device or in a cage. However, the rolling bearing can also be designed without such a holding device (full complement). The flat section can be part of a guide, e.g., a ring or a guide rail, of the rolling bearing. The flat section can be a sheet or have the shape of a sheet or plate. In exemplary embodiments, the flat section can thus, for example, be a rolled metal product whose width and length are greater than its thickness, where the thickness represents the diameter at the edge.

[0013] Optionally, the flat section is part of a guide rail of a roller guide. The flat section can also be part of a roller of a carriage of a roller guide.

[0014] Exemplary embodiments therefore include, in particular, a roller guide with a rolling bearing of the type described here. The roller guide can comprise a guide rail and at least one carriage with a roller. The rolling bearing can support the carriage on the guide rail.

[0015] Page 2 of 35 123-O188DE / 2024-24 23.09-2025

[0016] The guide rail can have flexible contours. The guide rail can be designed as a profile rail (for example, with a C-profile).

[0017] Alternatively or additionally, the flat section can be part of a ring of the rolling bearing, wherein the flat section is a ring disk section of the ring.

[0018] Exemplary embodiments therefore include in particular a rolling bearing with a rolling element and a ring comprising a ring disc section or web, wherein the ring disc section has two flanges integrally connected to the ring disc section at one edge, which are designed to form a running surface for the rolling element.

[0019] The term "ring disk section" refers to a portion of the ring that has the shape of a ring disk. A ring disk can be considered a very shallow hollow cylinder; thus, it has a small thickness or height relative to the radius of the ring (the inner and / or outer radius) over the base of a circular ring. The ring disk section can, in particular, be conceived as or designed as a web for the two flanges.

[0020] A flange can be understood as a portion of the ring that projects beyond the annular disc section or protrudes from a plane defined by the annular base of the annular disc section. The flange can be perpendicular to the annular disc section, or more generally, the flat section, or it can form another angle with the annular disc section or the flat section. The running surface is at least partially determined by the shape of the flange. The flange is integrally connected to the annular disc section; that is, it is not glued, joined, bolted, or welded to the annular disc section. Rather, the annular disc section, and more generally the flat section, is monolithically connected to the two flanges.

[0021] Page 3 of 35 123-O188DE / 2024-24 23.09-2025

[0022] Optionally, the hardness of the running surface can be increased by plastic deformation. In particular, the flanges may have been formed by plastic deformation; to create them, the material of the flanges or the flat section may have been irreversibly deformed beyond its elastic limit.

[0023] Optionally, the plastic deformation was caused by slit profiling and slit bending.

[0024] In exemplary embodiments, the two flanges are produced by gap profiling at the edge of the ring or guide rail. This allows the use of harder materials for the guide than, for example, in extrusion; the guide can therefore be made of a material other than aluminum. The flanges can be thinner than the flat section. The combined thickness of the two flanges can correspond to the thickness of the flat section. Unlike, for example, I-beams produced by roll forming, the guide produced by gap profiling does not exhibit, or does not necessarily exhibit, a doubling of material in the area of ​​the flat section, i.e., the ring disc section or web.

[0025] Due to plastic deformation, and in particular split profiling and split bending, a region of the guide around a branch line (or a protrusion) of the flanges at the edge of the flat section or web exhibits a significantly higher hardness compared to the rest of the flat section. This can be demonstrated, for example, by a Vickers or Brinell hardness test. Specifically, the two flanges, and thus the running surface, can exhibit a hardness, for example, twice as high as a factor of 2 due to split profiling and split bending, compared to a region of the flat section or web away from (e.g., more than 2 cm away from) the branch line. The flat section or web can also exhibit higher hardness near the branch line; this can be attributed, in particular, to a change in microstructure (ultra-fine grain structure) that occurs in the flat section after split profiling and split bending.

[0026] Page 4 of 35 123-O188DE / 2024-24 23.09-2025

[0027] The section in this area remains. The flanges can also exhibit higher hardness. Overall, this allows for the production of particularly hard guides starting from relatively thin sheets.

[0028] In exemplary embodiments, the use of curved gap profiles as rolling bearings can therefore be an important aspect. The running surface for the rolling element(s) is designed as a gap-profiled surface in a geometric shape suitable for the rolling element(s). Here, rolling element shapes known in the prior art, such as balls or rollers, can be used, but especially also rolling elements optimized for the running surface. Conversely, the gap profiling allows the running surface to be designed for specific rolling element shapes. Different flange angles, geometric dimensions, or geometric shapes are possible.

[0029] Exemplary designs therefore particularly benefit from the combination of gap profile bending with gap profiling.

[0030] In exemplary embodiments, the guide, in particular the ring or guide rail, consists of a hard or high-strength material, for example, steel. In particular, the material can be harder than aluminum. Examples of embodiments include high-strength steels, micro-alloyed fine-grained steels, or ferritic stainless steels; in particular, the well-known material i00Cr6 can also be used. Advantageous materials exhibit good cold formability.

[0031] The rolling bearing can optionally be a ball bearing or a roller bearing. The rolling element can therefore be either a ball or a roller. In a ball bearing, it contacts the raceway essentially at one point; in a roller bearing, essentially along a line segment. The raceway can be adapted to the raceway profile of the rolling element. For example, the rolling element can be a cylindrical roller or a roller with a conical or truncated cone shape. Such adaptation of the raceway can be achieved particularly easily by gap profiling.

[0032] Page 5 of 35 123-O188DE / 2024-24 23.09-2025

[0033] Alternatively, the rolling bearing can also be a needle roller bearing. In this case, the rolling element is essentially needle-shaped, and the two flanges are straight. They can be, for example, essentially or at least approximately perpendicular to the flat section or the ring section. The raceway formed by the flanges is then planar, possibly with the exception of circumferential grooves that may be formed on one or both outer edges of the flanges. The planar raceway can be perpendicular to the flat section or inclined at a fixed angle to it.

[0034] Optionally, the edge is a first edge of the flat section and the two flanges are first flanges, and the flat section has a second edge with two second flanges integrally connected to the flat section.

[0035] The first edge can be, for example, that of the inner circle, and the second edge that of the outer circle of the ring disc section or web. The second flanges can be designed to form the running surface, to create another running surface, or to form a surface through which the ring is connected to an surrounding structure.

[0036] Optionally, the rolling bearing includes a further guide with a further flat section (i.e., another ring with a wider ring disc section), wherein the further flat section has two further flanges integrally connected to the further flat section at a further edge, forming a further running surface for the rolling element.

[0037] The additional guide, regardless of its form, can be, for example, a ring, a roller, or a guide rail. The additional running surface is positioned opposite the primary running surface. During operation of the bearing, the rolling element rotates between the primary running surface and the additional running surface. A holding device, particularly a cage, can be used to fix the rolling element in place. Apart from the requirement that the rolling element rotates periodically during operation of the rolling bearing, the additional flanges do not necessarily have to be identical in design.

[0038] Page 6 of 35 123-O188DE / 2024-24 23.09-2025 The flanges may be designed symmetrically to the flanges. In exemplary embodiments, the shape of the additional flanges may differ from the shape of the flanges.

[0039] In exemplary embodiments, the rolling bearing is a radial rolling bearing. A radial rolling bearing generally comprises an inner ring and an outer ring, and rolling elements are arranged between the inner ring and the outer ring, between a running surface of the inner ring and a running surface of the outer ring.

[0040] The ring can then be either the inner ring or the outer ring of the radial rolling bearing. In particular, the ring can also be the inner ring of the radial rolling bearing and another ring the outer ring of the radial rolling bearing (or vice versa). Thus, both the inner and outer rings can correspond to the ring in their construction; for example, the inner ring can comprise a ring disk section, wherein the ring disk section has two flanges integrally connected to it at one edge, forming a raceway for the rolling element, and the outer ring can comprise the further ring disk section, wherein the further ring disk section has two further flanges integrally connected to it at one edge, forming a further raceway for the rolling element. The rolling element can then be arranged directly between the raceway and the further raceway.

[0041] In a radial rolling bearing, the two flanges at the edge of the ring section can together form the raceway for the rolling element. The two flanges are not necessarily symmetrical to each other. For example, one flange may be slightly larger than the other, or one flange may form a differently shaped part of the raceway than the other. The flanges of the inner and outer rings can therefore differ on their inner and outer surfaces, or top and bottom surfaces. The flange design can be optimized for the engagement of the rolling element or for protecting the contact point. Furthermore, the

[0042] Page 7 of 35 123-O188DE / 2024-24 23.09-2025

[0043] Flanges outside the rolling element engagement area may be modified or omitted for connection to an surrounding structure.

[0044] In further embodiments, the rolling bearing is an axial rolling bearing. The rolling bearing can then comprise the ring and the further ring, wherein the ring and the further ring are arranged along an axis. A bend about a transverse axis of a profile formed by the two flanges of the ring can be used. In particular, the ring can have two flanges each at the first and second edges of the ring disk section, as described above. The running surface of the rolling element can be formed by one of the two flanges at the first edge, one of the two flanges at the second edge, and the ring disk section. Thus, of the two flanges of the ring at the first edge of the ring disk section, only one flange bent in one direction onto the further ring can define a part of the running surface, while the other flange at the first edge does not directly contribute to the formation of this running surface.This other flange can be smaller and / or shaped differently than the flange that helps define the running surface.

[0045] The rolling bearing can be connected to surrounding structures, thus forming a bearing assembly. In particular, the ring can be connected to a surrounding structure. Together with the surrounding structure, the ring can form a rotor or a stator of the bearing assembly. The bearing assembly can be, for example, a system in industrial automation (e.g., for sorting, transport, or filling tasks), in building interiors (e.g., a turntable or a flexible noise barrier), in vehicle manufacturing (e.g., a part of a garbage truck), in furniture manufacturing (e.g., a large rotary table), or even a device for urban gardening.

[0046] The rolling bearing can be designed as a driven slewing ring. The drive can be applied to a flange, the ring section or web, or the surrounding structure. Various options are possible.

[0047] Page 8 of 35 123-O188DE / 2024-24 23.09-2025

[0048] State-of-the-art drive systems, such as worm gears or directly applied rack and pinion drives, are used.

[0049] The rolling bearing can also be a rolling bearing of a roller guide. The flat section can be part of a guide rail. Optionally, the further flat section can be part of a roller of a carriage within the roller guide.

[0050] Optionally, at least one of the two flanges is formed on the guide or on the flat section in order to at least partially encompass at least one of the two further flanges on the further guide or on the further flat section.

[0051] In particular, at least one of the two flanges can have a bend that covers an opening between the running surface and the other running surface. The flange of the gap profile can therefore be bent to protect the rolling element engagement over a gap between the guides (e.g., between the rings). For this purpose, the flange can be reshaped after gap profile bending.

[0052] In embodiments where the rolling bearing is a radial bearing, both flanges can be formed on the edge of the ring, each completely or partially encompassing one of the two further flanges of the further ring.

[0053] Optionally, the rolling bearing includes a split swivel bearing. A split rolling bearing consists of an inner ring, a set of rolling elements (full complement or caged), and an outer ring. Either the inner ring, the outer ring, or both rings can be non-continuous. The corresponding ring is then split. The rolling bearing can include one or more clamping rings to secure the split rings.

[0054] Alternatively or additionally, the rolling bearing includes another segmented bearing. A segmented rolling bearing can be a bearing consisting of several separate segments or parts that work together to bear the loads and enable movement. This design allows for a

[0055] Page 9 of 35 123-O188DE / 2024-24 23.09-2025 Flexible adaptation to various applications and facilitates assembly and maintenance. The segmented bearing can be designed to provide even load distribution and minimize friction between the rolling element and the raceway.

[0056] Alternatively or additionally, the rolling bearing comprises a single-row radial rolling bearing, i.e., it only has the ring and the further ring or an inner and an outer ring in a concentric arrangement around an axis.

[0057] Alternatively or additionally, the rolling bearing comprises a multi-row radial rolling bearing. A multi-row radial rolling bearing comprises several single-row bearing arrangements. The rings of two rows of the bearing can be connected to each other. In particular, a connection can exist between ring disk sections or webs.

[0058] Alternatively or additionally, the rolling bearing or bearing assembly includes an angled bearing. The rolling bearing can then have two pairs of rings whose pressure or force flow lines are non-parallel. In this way, a preload and thus a special hold for an surrounding structure can be achieved. The ring pairs can be arranged in an X or O orientation; the geometric cones formed by the pressure lines can therefore lie with their apex on an axis between the two ring pairs or outside of the two ring pairs.

[0059] Alternatively or additionally, the rolling bearing includes a stationary bearing. In this case, an surrounding structure connected to the ring or to a further ring can be stationary. In particular, the stationary bearing can be an axial rolling bearing.

[0060] Exemplary embodiments also relate to a method for manufacturing a rolling bearing. The method comprises providing a flat sheet metal blank. The method further comprises gap profiling of the blank metal blank to create at least one flange on an edge of the blank metal blank. The method further comprises gap profiling of the blank metal blank to create a guide, in particular a ring, which has a flat section or ring-shaped disc section.

[0061] Page 10 of 35 123-O188DE / 2024-24 23.09-2025 includes, wherein the flat section has at least one flange integrally connected to the flat section at one of its edges, which is designed to form a running surface for a rolling element.

[0062] This method allows the production of a rolling bearing of the type described above. In particular, the guide can, as previously described, comprise a flat section, wherein the flat section has two flanges integrally connected to the flat section at one edge, which are designed to form a running surface for the rolling element.

[0063] The flat sheet metal can essentially have the shape of a long strip, i.e., a rectangular base with significantly different edge lengths and a thickness that is small compared to an edge length.

[0064] The term "slit profiling" refers to a bulk forming process in which a flat sheet metal is drawn through an obtuse-angled slitting roll and supporting auxiliary rolls. The slitting roll and auxiliary rolls are moved translationally relative to the flat sheet metal in a fixed arrangement. The slitting roll penetrates a strip edge of the sheet metal perpendicularly, forming a branch at that edge. This branching is created by an increase in the surface area of ​​the strip edge due to the material of the sheet metal spreading apart. The auxiliary rolls simultaneously define the beginning of the branching or the branching line of the sheet metal. In this way, a slit profile is formed, consisting of a straight web and two flanges. Slit profiling can be performed at room temperature.

[0065] Based on the splitting roller, one or more branching sections can be formed; the splitting roller can therefore perform one or more splitting profiling passes.

[0066] Split profile bending involves bending the sheet metal vertically, around a vertical axis. Split profile bending thus creates a bend in one direction perpendicular to the branching line in a plane of the sheet metal's base surface.

[0067] Page 11 of 35 123-O188DE / 2024-24 23.09-2025

[0068] The gap profile bending is advantageously carried out in direct temporal proximity to the gap profiling. An interaction then exists between the gap profiling and the edge bending, in that the gap profiling creates a hydrostatic compressive stress state in the sheet metal, which significantly influences the edge bending, as a branching zone and an edge bending zone overlap in the sheet metal. Due to the compressive stress state during gap profiling, the sheet metal becomes plastic, thus allowing edge bending to be carried out with exceptional precision and using very low forces compared to subsequent forming steps. Furthermore, the sheet metal exhibits very little springback in this state, so that the radius of the guide, especially of a ring, can be set very precisely, since hardly any restoring forces occur during or after the gap profile bending.In exemplary embodiments, the gap profile bending takes place together with or immediately after the gap profiling, or, in the case of several gap profiling operations at different locations on the sheet metal, with a final gap profiling operation.

[0069] In this way, the production of the running surface at an edge of the sheet metal and the bending of the sheet metal, particularly into a ring, can be advantageously combined in temporally separated process steps by means of gap profiling and gap profile bending. The at least one flange can be produced by this combination of gap profiling and gap profile bending in such a way that it forms a running surface for one or more rolling elements. The web or a section of the sheet metal away from the branching or the flanges forms the flat section or ring disc section described above.

[0070] Furthermore, gap profiling and gap bending can achieve a higher hardness in an area of ​​the guide around the branch line (or the point where the at least one flange meets the edge of the sheet metal). In particular, gap profiling and gap bending can increase the hardness of the at least one flange, and thus the running surface, by a factor of, for example, 2 compared to the hardness of the supplied sheet metal. Also, the

[0071] Page 12 of 35 123-O188DE / 2024-24 23.09-2025

[0072] The web may exhibit higher hardness near the branching line; this may be due in particular to a change in microstructure or an ultra-fine-grained microstructure that remains in this area of ​​the web after the slit profile bending.

[0073] In this process, it is particularly advantageous to initially produce a ring in an open state. The ends of the sheet or strip do not need to be joined immediately after the gap profile bending. This offers the advantage that, during assembly of the ring to an surrounding structure, the elasticity of the sheet can still be utilized, and the ring can be closed during assembly.

[0074] In contrast to conventional manufacturing processes, especially extrusion, the method presented here allows for the processing of significantly harder materials than extrusion, thus enabling the production of more durable rolling bearings.

[0075] Optionally, the edge is a first edge of the sheet metal, the sheet metal has a second edge, and the process includes further gap profiling of the sheet metal to create at least a second flange on the second edge of the sheet metal. In this way, a running surface or a surface for connecting the sheet metal to an surrounding structure can again be created on the second edge.

[0076] In particular, at least one second flange can be formed to create the raceway together with the at least one flange at the first edge and the web or flat section formed between the first and second edges. Alternatively, two second flanges can be formed to create another raceway. The second flanges can also be designed to form a surface via which the guide, e.g., the ring, can be connected to an surrounding structure. This connection can be made during the assembly of the rolling bearing. The connection can be a material bond, such as by welding, or a force-fit connection, such as by bolting.

[0077] Page 13 of 35 123-O188DE / 2024-24 23.09-2025

[0078] As with the flanges on the first edge of the sheet, the combination of further gap profiling with gap profile bending allows for precise shaping of the second flanges while applying relatively low forces. The sequence of gap profiling and further gap profiling can be freely chosen or adapted to the production conditions. The further gap profiling can take place immediately before or after the first gap profiling. In advantageous embodiments, the gap profile bending then takes place together with the last gap profiling step, or, in the case of multiple gap profiling passes, during the last gap profiling pass on the sheet.

[0079] In embodiments where the rolling bearing is a radial bearing, the bending can take place on both flanges of the edge of the ring, so that the two flanges each partially encompass one of the two further flanges of the further ring.

[0080] The procedure may further include mounting the rolling bearing.

[0081] In exemplary embodiments, the steps of the method for manufacturing the rolling bearing can also be described as follows: providing a semi-finished product, in particular a flat sheet; gap profiling over all necessary passes; gap profile bending directly after the last gap profiling pass, and mounting the bearing.

[0082] Exemplary embodiments therefore also relate to a method for mounting the rolling bearing, in particular a radial rolling bearing with an inner and an outer ring. The method comprises providing an open ring and an open further ring, a preliminary closing of the ring and / or the further ring so that a gap remains, an arrangement of the ring and the further ring, and the insertion of at least one rolling element between the ring and the further ring based on a flexibility caused by the gap.

[0083] The ring and / or the further ring can have the features of the ring disc section and the flanges presented above, and as for the

[0084] Page 14 of 35 123-O188DE / 2024-24 23.09-2025 the previously presented method for manufacturing a rolling bearing by gap profiling and gap profile bending.

[0085] The ring can, for example, be the inner ring and the additional ring the outer ring of a radial rolling bearing (or vice versa). The ring and the additional ring can also be designed for an axial rolling bearing. In advantageous embodiments, the ring and / or the additional ring are produced by the previously described steps of the method for manufacturing a rolling bearing. Consequently, the ring and the additional ring can each have an annular disk section, on the first and / or second edge of which flanges are formed that are integrally connected to the annular disk section.

[0086] The temporary closure of the ring and / or the subsequent ring involves an incomplete connection between a first open end of the unclosed ring or subsequent ring and a second open end of the unclosed ring or subsequent ring. For example, the ring can be connected at only one point or along a section of the open ends. In this way, a gap remains between the first and second ends. Especially in large rolling bearings, this gap, combined with the elasticity of the ring or subsequent ring material, provides flexibility to the temporarily closed ring or subsequent ring. The incomplete connection can, for example, create a material-bonded connection, such as welding, or it can create a force-fit connection, such as bolting.

[0087] The arrangement of the ring and the additional ring can involve mounting or attaching the ring or the additional ring to corresponding surrounding structures. Furthermore, the ring and the additional ring are brought into a position that enables the intended operation of the rolling bearing. This arrangement can be carried out simultaneously with or sequentially with the preliminary closing.

[0088] The insertion of the rolling element (or elements) then utilizes the flexibility provided by the gap and the elasticity of the ring material or the subsequent ring. Through this insertion, the rolling element(s) are brought into contact with the surface.

[0089] Page 15 of 35 123-O188DE / 2024-24 23.09-2025

[0090] Rolling elements on the running surfaces of the ring and the subsequent ring. A holding device or cage can also be incorporated to fix the rolling element(s) by utilizing the flexibility of the incompletely closed ring or subsequent ring.

[0091] After insertion, the procedure can include complete closure of the ring or the subsequent ring.

[0092] In exemplary embodiments, the steps of this method for assembling the rolling bearing can also be described as follows: The ring and the subsequent ring are each joined by a material bond, leaving a gap, and rolling elements are mounted through the gap based on the elasticity of the material; advantageously, a cage is only inserted afterwards.

[0093] Exemplary embodiments also relate to a further method for mounting the rolling bearing, in particular a rolling bearing with an inner ring and an outer ring. This further method comprises providing an open ring and an open second ring. The further method further comprises closing the ring, inserting at least one rolling element onto a running surface of the ring, arranging the open second ring, and preloading the second ring.

[0094] The ring can, for example, be the inner ring and the additional ring the outer ring of a radial rolling bearing (or vice versa). The ring and the additional ring can also be designed for an axial rolling bearing. In advantageous embodiments, the ring and / or the additional ring are produced by the previously described steps of the method for manufacturing a rolling bearing. Consequently, the ring and the additional ring can each have an annular disk section, on the first and / or second edge of which flanges are formed that are integrally connected to the annular disk section.

[0095] Closing the inner ring can involve joining a first open end and a second open end of the unclosed inner ring, and it can connect the inner ring to an surrounding structure. Joining the two open ends can create a metallurgical bond and

[0096] Page 16 of 35 123-O188DE / 2024-24 23.09-2025, for example, includes welding, or it can create a friction-fit connection and, for example, include screwing. The inner ring is completely closed; no gap remains between the first and second ends.

[0097] The rolling element is advantageously inserted before the open outer ring is positioned. A holding device or cage can be mounted for the rolling element(s), designed to fix the rolling element(s) to the running surface of the inner ring.

[0098] Arranging the open outer ring brings the inner and outer rings into a position that allows the rolling bearing to operate as intended.

[0099] In exemplary embodiments, the steps of this further method for assembling the rolling bearing can also be described as follows: the inner ring is joined by material bonding, the rolling elements are mounted, the outer ring is attached and preloaded.

[0100] Optionally, pre-tensioning the additional ring involves encircling the entire additional ring, for example with a tensioning strap or a metal band, and tightening the additional ring. This tightening closes a separation point in the additional ring, which in a radial rolling bearing can be, in particular, an outer ring.

[0101] Optionally, the method or further method for mounting the rolling bearing also includes preloading the ring based on spreading the ring apart. This involves applying a radial force to the ring. The ring in question can be, in particular, the inner ring of a radial rolling bearing.

[0102] Optionally, the method for manufacturing a rolling bearing, the method for assembling a rolling bearing, or the further method for assembling a rolling bearing may also include bending over an outer surface of at least one flange to form a circumferential grip. The circumferential grip may be designed, in particular, to provide protection for the rolling element engagement.

[0103] Page 17 of 35 123-O188DE / 2024-24 23.09-2025

[0104] In particular, at least one of the flanges of the ring or the subsequent ring can be bent in such a way that, in the assembled or finished rolling bearing, an opening between the raceway and the subsequent raceway is completely or partially covered by the flange. The flange, which is created in particular by gap profiling, can therefore be bent so that it engages another flange. For example, the flange can be formed on the ring and the other flange on the subsequent ring.

[0105] The bending can take place after the gap profiling, further gap profiling, or gap profile bending. However, the bending can also be carried out during or after a step in the process for mounting a rolling bearing or in the further process for mounting a rolling bearing.

[0106] Important aspects of the presented rolling bearing and the presented methods for its manufacture and assembly can also be presented as follows.

[0107] The rolling bearing offers a design specifically for large-diameter bearings. The manufacturing process includes, in particular, gap profiling and gap profile bending. The rolling bearing can also be used in roller guides; specifically, a guide rail of the roller guide and / or a roller of a carriage of the roller guide can have a guide surface that has been manufactured by gap profiling and gap profile bending, as described here. The radial rolling bearing is characterized by the use of bent gap profiles with a special profile cross-section in the inner and outer rings. Furthermore, the rolling bearing utilizes high strength and hardness in the gap-profiled flange area for the running surface of the rolling elements, such as balls.

[0108] The processes for manufacturing and assembling the rolling bearing are based on the proven feasibility of the production chain consisting of gap profiling, gap profile bending, and the utilization of flexibility and preload during assembly. In gap profiling, which is classified as a forming process,

[0109] Page 18 of 35 123-O188DE / 2024-24 23.09-2025 A flat sheet is upset at the strip edges in several passes, forming a flange on both sides. In exemplary embodiments, the resulting gap profile is bent around the vertical axis within the last forming pass to create a circular geometry. The resulting inner ring can then be joined, for example, by welding, and the outer ring can be bolted on after assembly and preloading of the bearing. Deviations in roundness have proven to be minimal. The methods enable the production of a rolling bearing with one ring and another ring, in particular an inner and an outer ring, whereby a preloading mechanism is used for assembly.

[0110] A key technical feature lies in the combination of the two manufacturing processes, gap profiling and bending, in a single step. This combination creates a stress state in the plastic bending zone that, on the one hand, enables the large strains required for bending and, on the other hand, drastically reduces the energy required for bending. Furthermore, the geometry of the bent ring can be precisely adjusted due to significantly reduced springback. Without this stress superposition, crack-free bending of the profiles with the tight radii required for bearing applications would not be possible, and springback would be very large and difficult to control at larger radii.

[0111] Some advantages of the presented rolling bearing and the presented methods for its manufacture and assembly can be described as follows.

[0112] The rolling bearing and the associated processes significantly simplify the production of lightweight large rolling bearings. This can drive new applications for large rolling bearings and lead to cost savings, even with low load-carrying capacity utilization. Furthermore, gap profiling and gap profile bending allow the use of harder materials than, for example, aluminum. Therefore, large rolling bearings can be produced in various shapes and from hard materials. The individual rings of the rolling bearing can also feature thin webs or other features relative to the width of the raceways.

[0113] Page 19 of 35 123-O188DE / 2024-24 23.09-2025

[0114] They feature ring disc sections, so that the large rolling bearings can be designed with a comparatively low weight despite high load capacity.

[0115] The benefits of using such large-diameter bearings based on bent gap profiles can therefore lie in cost and material savings. Necessary properties for raceways, such as shape, strength, and hardness, can arise inherently from the manufacturing process. The chipless, virtually waste-free production ensures resource-efficient material utilization and enables a high degree of environmental friendliness.

[0116] BRIEF DESCRIPTION OF THE FIGURES

[0117] The embodiments of the present invention are better understood with reference to the following detailed description and the accompanying drawings of the different embodiments, which, however, should not be understood as limiting the disclosure to the specific embodiments, but merely serve for explanation and understanding.

[0118] Fig. 1 illustrates a rolling bearing according to an embodiment of the present invention.

[0119] Fig. 2 shows features of an embodiment with a surrounding handle.

[0120] Fig. 3 shows features of an embodiment with a multi-row bearing.

[0121] Fig. 4 shows features of an embodiment with an inclined bearing.

[0122] Fig. 5 shows further features of an exemplary embodiment.

[0123] Fig. 6 illustrates further features of an exemplary embodiment.

[0124] Fig. 7 shows another embodiment of the rolling bearing according to the present invention.

[0125] Fig. 8 shows steps of a method for manufacturing a rolling bearing according to

[0126] Page 20 of 35 123-O188DE / 2024-24 23.09-2025 of the present invention.

[0127] Fig. 9 shows steps of a method for assembling a rolling bearing according to the present invention.

[0128] Fig. 10 shows steps of a further method for assembling a rolling bearing according to the present invention.

[0129] Fig. 11 shows further details of the methods for manufacturing and assembling a rolling bearing.

[0130] DETAILED DESCRIPTION

[0131] Fig. 1 shows two embodiments of a rolling bearing 100 with a rolling element 110 and a ring 120 as a guide, which comprises a ring disk section 125 as a flat section, wherein the ring disk section 125 has two flanges 131, 132 integrally connected to the ring disk section 125 at an edge 130, which are designed to form a running surface 135 for the rolling element 110.

[0132] Both embodiments show, in a cross-section, a further ring 150 next to the ring 120 for a radial rolling bearing configuration of the rolling bearing 100. The further ring 150 has a further ring disk section 155 and, at a further edge 160, further flanges 160, 161 integrally connected to the further ring disk section 155, forming a further running surface 165 for the rolling element 110.

[0133] Ring 120 also has second flanges 141, 142 on a second edge 140 of the ring disk section 125. Likewise, the further ring 150 has further second flanges 171, 172 on a further second edge 170 of the further ring disk section 155. These flanges 141, 142, 171, 172 can each form corresponding second running surfaces, or be designed to connect ring 120 and the further ring 150, respectively, to a corresponding surrounding structure (not shown). For example, ring 120 can be connected to a stator via the second flanges 141, 142, and the further ring 150 can be connected to a stator via the further second flanges 171, 172.

[0134] Page 21 of 35 123-O188DE / 2024-24 23.09-2025, for example, connected to a rotor. The connection can be, for example, a material-bonded or a force-fit connection.

[0135] In particular, part (a) of the figure shows a first of the two embodiments. In this embodiment, the rolling element 110 is a sphere.

[0136] Part (b) of the figure shows a second of the two embodiments. In this embodiment, the rolling element 110 is a roller or barrel.

[0137] The running surface 135 and the further running surface 165 are each adapted to a geometry of the rolling element n. In exemplary embodiments, the flanges 131, 132 and the further flanges 161, 162 are produced by gap profiling and gap profile bending. The second flanges 141, 142 and the further second flanges 171, 172 can also be produced by gap profiling and gap profile bending. Due to the plastic deformation caused by gap profiling and gap bending, a region of the flanges exhibits a higher hardness than a region of the ring disc section away from the flanges.

[0138] Fig. 2 shows features of a radial rolling bearing 100 similar to that in Fig. 1, in which the two flanges 131, 132 are formed on the ring 120 (or on the ring disc section 125) to engage the two further flanges 161, 162 on the further ring 150 (or on the further ring disc section 155). For this purpose, a respective outer surface of the flanges 131, 132 may have been bent to form an engagement 133. This bending may involve incremental folding and can be carried out after gap profile bending or during assembly of the rolling bearing 100. The engagement 133 is designed to protect the rolling element engagement and to secure the position of the ring 120 relative to the further ring 150.

[0139] The bending or forming of the circumferential grip 133 can be carried out in the manufacture of the rolling bearing 100 shown here even before assembly of the

[0140] Page 22 of 35 123-O188DE / 2024-24 23.09-2025

[0141] The rolling bearing 100 or the rings 120, 150 are formed. This can offer the advantage of producing the circumferential section 133 during or immediately after gap profiling and gap profile bending for the formation of the flanges 131, 132 in a simpler and possibly more precise manner. During assembly, however, the rings 120, 150 must then be connected accordingly before preloading.

[0142] Alternatively or additionally, the forming of the circumferential grip 133 during the manufacture of the rolling bearing 100 shown here can only take place after the assembly of the rolling bearing 100 or the rings 120, 150. This can offer the advantage of initially arranging the rings 120, 150 only in an approximate position, then pre-clamping or clamping them, and only then securing the rings 120, 150 or the rolling elements 110 by the circumferential grip 133.

[0143] A circumferential element 133 as shown here can also be formed in other embodiments of the rolling bearing 100, for example in a roller guide. In particular, the guide rail of a roller guide can, for example, be designed as a profile rail.

[0144] Fig. 3 shows features of an embodiment with a multi-row bearing arrangement. In addition to ring 120 and the further ring 150, the rolling bearing 100 comprises at least one further pair of rings 12O', 15O' in a corresponding configuration. A connecting element 180 is arranged between ring 120 and a ring 12O' in the further pair of rings, connecting the ring disk section 125 of ring 120 to a ring disk section 125' of ring 12O' in the further pair of rings, so that ring 120 is fixed relative to ring 12O' in the further pair of rings. Similarly, between the further ring 150 and a further ring 15O' in the further ring pair, a further connecting element i8o' is arranged, which connects a ring disk section 155 of the further ring 150 with a ring disk section 155' of the further ring 15O' in the further ring pair, so that the further ring 150 is fixed relative to the further ring 15O' in the further ring pair. The connecting elements 180., i8o' can be trained either globally or locally. The.

[0145] Page 23 of 35 123-O188DE / 2024-24 23.09-2025

[0146] Connecting elements 180., i8o' can also be installed after the assembly of the ring pair 120, 150 and the further ring pair i2o', 15O'.

[0147] Between the rings 120, 12O', 150, 15O' of the two ring pairs, rolling elements 110, no' are arranged. These can be different; in particular, rolling elements 110 of the ring pair 120, 150 can also be different from rolling elements no' of the further ring pair 12O', 15O'.

[0148] Fig. 4 shows features of an embodiment with an inclined (multi-row) bearing arrangement. Similar to Fig. 3, the rolling bearing 100 comprises, in addition to the ring 120 and the further ring 150, at least one further ring pair 12O', 15O' in a corresponding configuration. However, the further ring pair 12O', 15O' is arranged at a different angle relative to the ring pair consisting of ring 120 and the further ring 150. Depending on the design of the surrounding structure, an X-bearing or an O-bearing can thus be achieved.

[0149] Fig. 5 shows further features of an embodiment of the rolling bearing 100. This can be, in particular, an embodiment according to part (a) in Fig. 1. A perspective view of the ring 120, which in this embodiment is an inner ring, and the further ring 150, which in this embodiment is an outer ring, is shown. A plurality of rolling elements 110 are arranged between the ring 120 and the further ring 150. The rolling bearing 100 can be a full complement bearing, i.e., without any further holding device that fixes the rolling elements 110 in their position between the raceway 135 and the further raceway 165. However, the rolling bearing 100 can also be designed with such a holding device, for example, with a chain or a cage.

[0150] Fig. 6 illustrates further features of an embodiment of the rolling bearing 100. This can be, in particular, an embodiment according to Fig. 5. The figure consists of two images, each showing a part of ring 120 and the other ring 150. In this embodiment, ring 120 and the other ring 150 are made of steel.

[0151] Page 24 of 35 123-O188DE / 2024-24 23.09-2025 can be high-strength overall, and especially in an area of ​​the connection line of the flanges 131, 132, 161, 162.

[0152] Fig. 7 shows an embodiment of the rolling bearing 100 in a roller guide 200, or an embodiment of the roller guide 200 with a rolling bearing 100 of the type disclosed herein. In this embodiment, the rolling element 110 is configured as a wheel 213 of a carriage 210. The roller guide 200 comprises a guide rail 120, which has a web 125 as a flat section. At a first edge of the web 125, the web 125 has two flanges 131, 132 integrally connected to the web 125, which form a running surface 135 for the rolling element 110. The carriage 210 has further rollers 213' or rolling elements n1', which together with the guide rail 120 form further rolling bearings n10' of the type presented. In particular, the guide rail 120 also has flanges 131 / , 132' produced on a second edge by gap profiling and gap profile bending, which form a second running surface 135'.

[0153] In further embodiments of this type, the flanges 131, 131?, 132, 132' of the guide rail 120 can also have grips 133 (not shown here). The guide rail 120 can be designed as a profile rail, for example with a C-profile.

[0154] In further embodiments of this type, the rollers 213, 213' may also include webs or rings which have flanges produced by gap profiling and gap profile bending to form running surfaces for rolling elements.

[0155] Fig. 8 shows steps of a method for manufacturing a rolling bearing 100 according to the present invention. The method comprises providing S110 a flat sheet. The method then comprises gap profiling S120 of the sheet to produce two flanges 131, 132 on one edge of the sheet; and gap profile bending S130 of the sheet to produce a guide 120, for example a ring or a guide rail. The guide 120 then comprises a flat section 125 which, on one of its edges 130, forms the two

[0156] Page 25 of 35 123-O188DE / 2024-24 23.09-2025 with the flat section 125 integrally connected flanges 131, 132 which are designed to form a running surface 135 for a rolling element 110.

[0157] In exemplary embodiments, the gap profile bending can be carried out, for example, using a roller arranged transversely to a feed direction of the sheet metal to effect edge bending or bending about a vertical axis (perpendicular to the edge of the sheet metal or the edge 130 of the flat section 125). In exemplary embodiments, minimum bending radii of, for example, 600 mm can be produced using rollers.

[0158] The gap profiling S120 and the gap profile bending S130 are carried out in direct temporal succession. This process allows the production of rings 120, 120', 150, and 150', as shown in the preceding figures.

[0159] Fig. 9 shows steps of a method for assembling a rolling bearing 100 according to the present invention. The method comprises providing S210 an open ring 120 and an open further ring 150. The method further comprises a preliminary closing S220 of the ring 120 and / or the further ring 150, leaving a gap. The method also comprises arranging S230 the ring 120 and the further ring 150. The arranging S230 can, in particular, take place after the preliminary closing S220. Once the rings 130 and 150 are arranged, the method comprises inserting S240 at least one rolling element 110 between the ring 120 and the further ring 150. The insertion S240 utilizes the flexibility caused by the gap as well as the elasticity of the material of the ring 120 and the further ring 150.

[0160] If the rolling bearing 100 is a radial rolling bearing, then, for example, ring 120 can be an inner ring and the other ring 150 an outer ring.

[0161] The preliminary closing of S220 and / or a subsequent (final) closing of the rings 120, 150 can also be carried out before the ring(s) 120, 150 are attached to a predetermined storage position (of an assembly).

[0162] Page 26 of 35 123-O188DE / 2024-24 23.09-2025 of the warehouse in the narrower sense).

[0163] In the embodiment shown here, both ring 120 and the further ring 150 have been produced based on steps S110, S120, and S130 shown in Fig. 7. The steps of the method shown here can follow the steps shown in Fig. 7 directly or at a later time interval. In particular, the provision S210 of the open ring 120 and the open further ring 150 shown here can be understood as comprising or completing steps S110, S120, and S130 of the method from Fig. 7.

[0164] Fig. 10 shows steps of a further method for assembling a rolling bearing 100 according to the present invention. The method again comprises providing S210 of the open ring 120 and the open further ring 150. The method further comprises closing S250 of the ring 120, inserting S260 of at least one rolling element 110 onto a running surface 135 of the closed ring 120, arranging S270 of the open further ring 150, for example around the closed ring 120, and pre-tensioning S280 of the further ring 150. The pre-tensioning S280 of the further ring 150 can comprise wrapping the entire further ring 150, for example with a band, a strap or a clamping sleeve, and based on this, tightening the further ring 150.

[0165] If the rolling bearing 100 is a radial rolling bearing, then, for example, ring 120 can be an inner ring and the other ring 150 an outer ring.

[0166] The closing S250 and / or the preloading S280 can also take place before the ring(s) 120, 150 are attached in a predetermined bearing position (a mounting of the bearing in the narrower sense).

[0167] As in Fig. 8, in the embodiment shown here, both ring 120 and the further ring 150 were produced based on the steps S110, S120, S130 shown in Fig. 7. The steps of the here

[0168] Page 27 of 35 123-O188DE / 2024-24 23.09-2025 The procedures shown can follow the steps shown in Fig. 7 directly or at a later time interval. In particular, the provision S210 of the open ring 120 and the open further ring 150 shown here can again be understood as comprising or completing steps S110, S120, S130 of the procedure from Fig. 7.

[0169] Fig. 11 shows a method for manufacturing and assembling a rolling bearing 100. The method combines embodiments of the steps shown in Figures 7 to 9. Overall, it can be understood as an embodiment of the method for manufacturing a rolling bearing (as in Fig. 7).

[0170] As in Fig. 7, the method includes providing S110 of the flat sheet metal. The method then includes a preliminary process 115, for example, straightening, to prepare the following steps. Subsequently, the method includes gap profiling 120 of the sheet metal to create the two flanges 131, 132 on one edge of the sheet. During and after this step, the method includes a decision S125 as to whether a desired profile cross-section has been achieved. If the desired profile cross-section has not yet been achieved, the gap profiling S120 is repeated. This can be done at one or more locations where the gap profiling S120 has already been carried out previously. However, the repeated gap profiling S120 can also be carried out at additional locations or edges of the sheet metal than before.Once the desired profile cross-section is achieved, the sheet metal is slit-profile bent (S130) shortly after the final slit profiling (S120) to produce a ring (120, 150). Two profiles or flange pairs (131, 132, 161, 162) can be produced on the same sheet metal, forming the two running surfaces (135, 165). In exemplary embodiments of the method, both an inner and an outer ring can be produced simultaneously in one step. The produced profiles are then cut (S140), providing (S210) an open ring (120) and another open ring (150).

[0171] The process now includes joining and in particular closing S250 of the ring 120 to form an inner ring of the radial rolling bearing 100.

[0172] Page 28 of 35 123-O188DE / 2024-24 23.09-2025. The method then comprises mounting or inserting S260 rolling elements 110 onto a running surface 135 of the closed ring 120.

[0173] Following this step, the additional ring is joined as the outer ring of the radial rolling bearing; this includes arranging S270 of the initially unclosed additional ring 150 and preloading S280 of the additional

[0174] Rings 150, in order to subsequently fix it to a corresponding surrounding structure by means of an joining connection.

[0175] The features of the invention disclosed in the description, claims and figures may be essential for the realization of the invention, either individually or in any combination.

[0176] Page 29 of 35 123-O188DE / 2024-24 23.09-2025

[0177] REFERENCE MARK LIST

[0178] 100 rolling bearings

[0179] 110 rolling elements

[0180] 120 guide, e.g. ring

[0181] 125 flat section

[0182] 130 (first) edge

[0183] 131, 132 (first) flanges

[0184] 135 tread area

[0185] 140 second edge

[0186] 141, 142 second flanges

[0187] 150 more guided tours, e.g., another ring road

[0188] 155 more flat section

[0189] 160 more (first) edge

[0190] 161, 162 further (first) flanges

[0191] 165 additional running surface

[0192] 170 more second edges

[0193] 171, 172 further second flanges

[0194] 180 connecting element

[0195] 200 roller guides

[0196] 210 trolleys

[0197] 213 Roller

[0198] S110, S120, S130, S200, S220, ..., S280 Steps of a procedure

[0199] Page 30 of 35

Claims

123-O188DE / 2024-24 09 / 23-2025 REQUIREMENTS 1. A rolling bearing (100), comprising: a rolling element (110); and a flat section (125) having at an edge (130) two flanges (131, 132) integrally connected to the flat section (125), which are designed to form a running surface (135) for the rolling element (110).

2. The rolling bearing according to claim 1, wherein the flat section (125) is part of one of the following devices: - a guide rail (220) of a roller guide (200), - a roller (213) of a carriage (210) of a roller guide (200), - of a ring (120) of the rolling bearing (100), wherein the flat section (125) is a ring disk section of the ring (120).

3. The rolling bearing according to one of the preceding claims, wherein the hardness of the running surface is increased by plastic deformation.

4. The rolling bearing according to claim 3, wherein the plastic deformation has been caused by gap profiling and gap bending.

5. The rolling bearing (100) according to one of the preceding claims, wherein the edge (130) is a first edge of the flat section (125) and the two flanges (131, 132) are first flanges, and wherein the flat section (125) has a second edge (140) with two second flanges (141, 142) integrally connected to the flat section (125).

6. The rolling bearing (100) according to one of the preceding claims, comprising a further flat section (155), wherein the further flat section (155) has two edges (160) connected to the further Page 31 of 35 123-O188DE / 2024-24 23.09-2025 flat section (155) has integrally connected further flanges (161, 162) which form a further running surface (165) for the rolling element (110).

7. The rolling bearing (100) according to claim 6, wherein at least one of the two flanges (131, 132) is formed on the flat section (125) to partially encompass at least one of the two further flanges (161, 162) on the further flat section (155).

8. The rolling bearing (100) according to any one of the preceding claims, wherein the rolling bearing (100) is one of the following: - a ball bearing, - a roller bearing, - a needle bearing, - a split swivel bearing, - a segmented warehouse, - a single-row radial rolling bearing, - a multi-row radial rolling bearing, - an employed warehouse, - a standing camp, - a bearing for a roller guide.

9. A method for manufacturing a rolling bearing (100), comprising: Providing (S110) a flat sheet; Split profiling (S120) of the sheet metal to produce at least one flange (131, 132) at one edge of the sheet metal; and Split profile bending (S130) of the sheet to produce a flat section (125) of the rolling bearing (100), wherein the flat section (125) has at an edge (130) the at least one flange (131, 132) integrally connected with the flat section (125) which is designed to form a running surface (135) for a rolling element (110). Page 32 of 35 123-O188DE / 2024-24 09 / 23-2025 10. The method according to claim 9, wherein the edge is a first edge of the sheet, the sheet has a second edge and the method comprises: further gap profiling of the sheet to produce at least one second flange (141, 142) on the second edge of the sheet.

11. A method for mounting a rolling bearing (100), comprising: Providing (S210) an open ring (120) and an open further ring (150); provisionally closing (S220) the ring (120) and / or the further ring (150) so that a gap remains; Arranging (S230) the ring (120) and the further ring (150); and Insertion (S240), based on a flexibility caused by the gap, of a rolling element (110) between the arranged ring (120) and the arranged further ring (150).

12. A method for mounting a rolling bearing (100), comprising: Provision (S210) of an open ring (120) and an open further ring (150); Closing (S250) of the ring (110); Insertion (S260) of a rolling element (110) onto a running surface (135) of the closed ring (120); Arranging (S270) the unclosed further ring (150); and Pre-tensioning (S280) of the further ring (150). Page 33 of 35 123-O188DE / 2024-24 09 / 23-2025 13. The method according to claim 12, wherein the pre-tensioning (S280) of the further ring (150) comprises encircling the entire further ring (150) and contracting the further ring (150).

14. The method according to one of claims 11 to 13, further comprising a pre-tensioning of the ring (120) based on a spreading of the Rings (120) are included.

15. The method according to any one of claims 9 to 14, further comprising bending an outer surface of at least one flange (131, 132) to form a circumferential (133). Page 34 of 35

Images