Axial Split Resin Cage for Taper Roller Bearing
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Solution Overview
Problem
The existing cages for taper roller bearings, particularly those made of resin, face challenges in manufacturing due to the need for complex mold designs that increase mold split surfaces, leading to difficulties in maintaining dimension accuracy and productivity.
Innovation Solution
A cage design featuring a small-diameter and large-diameter annular portion linked by column portions with specific inner surface configurations, including a second virtual taper surface and grooves, allowing for manufacturing using a half-split mold that moves in the axial direction, which simplifies the mold design and enhances productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a split mold is used to mold the pocket with a narrow shape on one axial side and wide shape on the other, then the pocket can be formed, but the number of split molds increases and mold split surfaces increase, making it difficult to manage dimension accuracy
Solution Approach 1:
The cage is divided into two separate moldable parts by introducing a parting line in the axial direction. The first mold forms the small-diameter annular portion and first column portions, while the second mold forms the large-diameter annular portion and second column portions. This segmentation allows each mold to work independently with simpler geometry, avoiding the need for complex multi-directional split molds while maintaining dimensional accuracy.
Solution Approach 2:
Instead of using split molds that move in the radial direction (adding radial dimension complexity), the invention introduces a parting line in the axial direction. This dimensional change allows the mold to open and close axially, simplifying the mold structure and making it easier to control dimension accuracy while still forming the complex tapered pocket shape.
2Ease of manufacture
If multiple split molds are used to accommodate the complex pocket shape, then the pocket can be molded, but the device complexity increases and management becomes difficult
Solution Approach 1:
The cage manufacturing is segmented into two independent molding operations using two separate molds that move in the axial direction. Each mold forms a portion of the cage with simpler geometry, avoiding the need for a single complex multi-directional split mold. This reduces device complexity while maintaining the ability to form the complete cage structure.
Solution Approach 2:
The mold parting line is positioned in the axial direction rather than radially, allowing the molds to open and close axially. This dimensional change simplifies the mold structure by eliminating the need for complex radial splitting mechanisms, making the molding process easier to manage and maintain.
3Ease of manufacture
If the cage is made of resin and molded with complex split molds, then the cage can be manufactured, but productivity decreases due to manufacturing complexity
Solution Approach 1:
The cage is segmented into portions that can be formed by two independent molds moving in the axial direction. This segmentation allows for simpler, faster molding cycles compared to complex multi-directional split molds, thereby improving manufacturing efficiency and productivity while still accommodating the resin material and complex pocket geometry.
Solution Approach 2:
By positioning the parting line in the axial direction, the molds can open and close more quickly and easily compared to radial splitting. This dimensional change simplifies the molding process, reduces cycle time, and improves overall productivity while maintaining the ability to manufacture resin cages with complex pocket shapes.
Data Source
AI summary
A cage made of a resin includes: a small-diameter annular portion on one side in an axial direction; a large-diameter annular portion on the other side in the axial direction; and a plurality of column portions which link the small-diameter annular portion and the large-diameter annular portion to each other. Spaces which are formed between the large-diameter annular portion and the small-diameter annular portion and between the column portions adjacent to each other in the circumferential direction are pockets which hold the taper rollers. A surface of the entire cage including the small-diameter annular portion, the large-diameter annular portion, and all of the column portions is configured by aggregating a surface viewed from the one axial side and a surface viewed from the other axial side.