Ball Bearing Ring Recesses for Lower Mass and Better Lubrication
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Solution Overview
Problem
The existing ball bearing selection process often results in the use of larger and heavier bearings than necessary to support the designated load, particularly in applications like electric vehicles where size and weight reduction are critical to minimize energy consumption.
Innovation Solution
A ball bearing design optimized for electric vehicles, featuring an inner and outer ring with specific radial thicknesses and annular recessed surfaces, along with a selected number and size of balls that satisfy specific equations to optimize the pitch diameter and reduce overall bearing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional ball bearing selection process is used, then the bearing can support the designated load, but the bearing becomes larger and heavier than necessary
Solution Approach 1:
The patent applies parameter changes by modifying the bearing configuration parameters - specifically using a higher contact angle (45 degrees versus conventional 30 degrees), changing the cage design, and adjusting the ball-to-inner-ring clearance. These parameter changes enable the bearing to support the same load with reduced outer diameter (from 80mm to 68mm) and weight, resolving the contradiction between load support capability and bearing weight.
2Strength
If a conventional ball bearing selection process is used, then the bearing can support the designated load, but the bearing becomes larger than necessary
Solution Approach 1:
The patent uses parameter changes to reduce bearing volume while maintaining load support. By increasing the contact angle to 45 degrees, the bearing achieves better axial load capacity with a smaller outer diameter (68mm versus 80mm). The optimized cage design and ball clearance adjustments further contribute to compact dimensions, reducing the bearing volume by approximately 29% compared to conventional designs.
3Strength
If the radial thickness of inner or outer ring is increased, then structural integrity is improved, but mass increases
Solution Approach 1:
The patent applies local quality by creating annular recessed surfaces at specific locations on the inner and outer rings - particularly at the axial ends where the radial thickness is greatest. These recesses remove material from regions experiencing lower stress, maintaining structural integrity where needed while reducing overall mass. This localized material removal resolves the contradiction between structural integrity and mass reduction.
4Use of energy by moving object
If the bearing size is reduced, then energy consumption decreases, but load support capability may be compromised
Solution Approach 1:
The patent uses parameter changes to achieve a smaller bearing size (68mm outer diameter versus 80mm) while maintaining or improving load support capability. The 45-degree contact angle provides superior axial load capacity, and the optimized cage design with increased ball-to-inner-ring clearance improves rolling element distribution. These parameter changes enable the smaller bearing to support the same load, reducing energy consumption without compromising strength.
Data Source
AI summary
An optimized ball bearing for an electric vehicle having an inner ring or an outer ring with a radial thickness at least equal to the diameter of the balls is provided with at least one annular recessed surface to reduce the mass of the ring. Each annular recessed surface may be formed as chamfer, a fillet or a groove. The annular recessed surfaces may be provided on both the inner and outer rings to improve lubrication flow.