One-Piece Ball Screw Diverter for Low-Noise Assembly
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Solution Overview
Problem
Existing ball screw diverter designs are complex, costly, and prone to assembly errors, contributing to operational noise and inefficiency due to the need for multiple components and intricate constructions.
Innovation Solution
A simplified ball return system featuring two structurally identical, one-piece diverters with a positioning element and a deflection element, configured to guide balls from the ball channel into a diverting channel without forming closed tubes, ensuring reliable operation and reduced noise through flexible material selection and design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-component ball diverter designs are used, then ball guidance function is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functional elements (diverging channel, positioning elements, deflection surfaces) into a single integrated diverter component. This merging eliminates the need for separate parts that would otherwise be required to perform these functions, thereby reducing device complexity while maintaining the ball guidance function.
Solution Approach 2:
The single-piece diverter is designed to perform multiple functions simultaneously: guiding balls out of the ball channel, positioning itself within the nut, deflecting balls into the return channel, and maintaining structural integrity. This multi-functionality reduces the overall number of components needed in the system.
2Reliability
If traditional multi-component ball diverter designs are used, then ball guidance function is achieved, but assembly complexity and time increase
Solution Approach 1:
By integrating all diverter functions into one component, the assembly process is simplified from installing multiple separate parts to installing a single pre-assembled unit. This eliminates the time required for aligning and fastening multiple components together.
Solution Approach 2:
The diverter is designed as a complete, ready-to-install unit with all functional features already integrated. This preliminary preparation of the diverter as a single assembly reduces on-site assembly time and complexity during the ball screw assembly process.
3Reliability
If rigid closed-tube diverting channels are used, then ball recirculation path is formed, but operational noise increases
Solution Approach 1:
The patent replaces rigid closed-tube structures with flexible wall structures in the diverting channel. These flexible walls can adapt to ball passage, reducing impact noise and vibration while still maintaining the recirculation path. The flexibility allows the structure to accommodate ball movement without creating the noise associated with rigid impacts.
4Reliability
If multiple separate diverter components are used, then ball guidance is achieved, but manufacturing cost increases
Solution Approach 1:
consolidating multiple diverter components into a single molded part eliminates the need for separate manufacturing processes, inventories, and quality inspections for multiple parts. This integration reduces overall manufacturing cost despite the increased complexity of the single component.
Data Source
AI summary
A diverter for a ball return of a ball screw configured for lifting in and lifting out balls from a ball channel between the spindle nut and the threaded spindle. The diverter is configured in one piece and has 3 functional units, specifically a positioning element, a deflection element having a spade-like lifting-out region and a diverting surface for balls out of or into the ball channel. All surfaces of the diverter that are provided for guidance of balls are configured as circumferentially open grooves (not closed in the manner of a tunnel). A method for assembling such a ball return includes providing two single-piece, structurally identical diverters; providing a pre-assembled module with a spindle nut and a threaded spindle, the spindle nut having two inwardly fitted apertures; inserting the diverters into the apertures; introducing balls; and securing the ball return by attaching a covering sleeve to the spindle nut.