Bearing Arrangement With Plastic Carrier And Sheet Metal Support
Solution Overview
Problem
Existing bearing arrangements for transmissions are costly to manufacture, require complex production processes, and often lack the mechanical strength and precision needed for stable operation, with the added disadvantage of requiring simultaneous assembly of shafts and shift rods, leading to high tool costs and weight.
Innovation Solution
A bearing arrangement produced using a plastic carrier part with injection molding, where linear bearing raceways are integrated during or after molding, combined with a sheet metal bearing support, allowing for precise mounting and high mechanical strength, simplified assembly, and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sheet metal bearing support is used to accommodate both bearings and shift rod guides, then the mechanical strength is sufficient, but the manufacturing cost increases and precision is compromised
Solution Approach 1:
The bearing support is divided into two separate components: a sheet metal bearing support for mechanical strength and a plastic carrier part for precise guide accommodation. This segmentation allows each component to be optimized for its specific function while reducing overall manufacturing complexity and cost.
Solution Approach 2:
The solution combines two different materials - sheet metal and plastic - each with complementary properties. The sheet metal provides mechanical strength and rigidity, while the plastic provides precision guidance and cost-effective manufacturing through injection molding.
2Ease of manufacture
If a plastic bearing support is used to reduce weight and cost, then manufacturing cost decreases, but mechanical strength is insufficient
Solution Approach 1:
The bearing support structure is segmented into load-bearing functions (handled by sheet metal) and guidance functions (handled by plastic). This allows the plastic component to be optimized for precision and cost while the metal component provides necessary structural strength.
Solution Approach 2:
Different regions of the bearing support system use different materials optimized for local requirements: plastic is used where precision guidance is needed and cost reduction is beneficial, while sheet metal is used where mechanical strength and rigidity are critical.
3Productivity
If shafts and shift rods are assembled simultaneously in known solutions, then assembly is completed in one step, but tool costs increase and assembly complexity increases
Solution Approach 1:
The plastic carrier part with shift rod guides is pre-assembled into the sheet metal bearing support before shaft installation. This preliminary action simplifies the subsequent assembly process by pre-positioning components, reducing the need for complex simultaneous alignment operations.
Solution Approach 2:
The assembly process is segmented into distinct stages: first assembling the plastic carrier part with shift rod guides into the bearing support, then separately installing the shafts. This segmentation of the assembly process reduces complexity and tooling requirements compared to simultaneous assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables cost-effective production with high precision, reduced tool costs, and easier assembly, while ensuring the mechanical strength and low weight of the bearing support, allowing for pre-assembly of shift linkages and improved manufacturing efficiency.
Implementation Method 1
producing a plastic carrier part (7) by means of injection molding, wherein a plurality of linear bearing raceways (8) of the second bearing (5) are connected to the plastic carrier part (7) by the injection molding process in situ
Data Source
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AI summary
The invention relates to a process for production of a bearing arrangement (1) which has a bearing carrier (2) which has at least one first bearing (3) to provide an at least radial bearing function for a shaft part (4) and at least one second bearing (5) to provide an at least radial bearing function for a rod-shaped component (6). A less expensive, lighter-weight design can be achieved by the process providing the following steps: a) production of a plastic carrier part (7) by means of injection moulding, where a plurality of linear bearing tracks (8) of the second bearing (5) are connected to the plastics carrier part (7) by the injection-moulding procedure in-situ or via a connecting process following the injection-moulding process; b) production of the bearing carrier (2) from intrinsically rigid material, where a receptacle (9) is formed into the bearing carrier (2) to receive the plastics carrier part (7) and where at least one receptacle (10) for a bearing ring (11) of the first bearing (3) is formed; c) placing and fixing of the plastics carrier part (7) in the receptacle (9) of the bearing carrier (2). The invention further relates to a bearing arrangement.