Insert-Molded Bearing Retainer Unit for Electric Motor
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Solution Overview
Problem
The existing methods for producing bearing retainer units with metal bearing bushings face challenges in precision forming, leading to issues such as canted rotation, noise, and reduced bearing lifespan due to the stress and complexity of press-forming processes, which compromise the roundness and accuracy of the cylindrical bearing liner.
Innovation Solution
The use of an insert molding method with a pair of mold dies to form a metal bearing bushing and a molded part with a cylindrical surface and communicating holes, allowing for precise positioning and anchoring of bearings, thereby improving the precision and reliability of the bearing retainer units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press-forming operation is used to form the projecting part and bearing liner, then the bearing retainer unit can be manufactured, but the precision of the bearing liner components deteriorates
Solution Approach 1:
The invention changes the manufacturing method from press-forming to injection molding, which fundamentally alters the process parameters and forming mechanism. Injection molding allows for better material flow control, reduced stress concentration, and improved dimensional accuracy of the bearing liner and projecting part, thereby resolving the precision issue while maintaining ease of manufacture
Solution Approach 2:
The invention replaces the mechanical press-forming process with an injection molding process that uses molten material injection. This substitution eliminates the excessive stress that acts on the bearing liner during press-forming, preventing compromise of the cylindrical roundness and improving the overall precision of the bearing components
2Ease of manufacture
If press-forming operation is used to form the projecting part, then the bearing retainer unit can be manufactured, but the roundness of the cylindrical bearing liner deteriorates
Solution Approach 1:
The invention changes the forming process parameters by transitioning from press-forming to injection molding. This allows the bearing liner to be formed without excessive radial stress, maintaining its cylindrical roundness and geometric accuracy while still enabling efficient manufacturing through the injection molding process
Solution Approach 2:
The invention substitutes the press-forming mechanical system with an injection molding system that injects molten material under controlled pressure. This replacement eliminates the excessive stress that compromises the bearing liner's roundness, ensuring precise cylindrical geometry is maintained throughout the manufacturing process
3Ease of manufacture
If press-forming operation is used to form the projecting part, then the bearing retainer unit can be manufactured, but the precision of motor rotation deteriorates
Solution Approach 1:
The invention changes the manufacturing process parameters from press-forming to injection molding, which provides better control over the geometry and positioning of the bearing liner and projecting part. This improvement in component precision directly translates to improved motor rotation precision, eliminating canted rotation and bearing misalignment issues
Solution Approach 2:
The invention replaces the press-forming mechanical system with injection molding, which produces more precise bearing liner components with better dimensional tolerances. This substitution eliminates the excessive stress and deformation associated with press-forming, ensuring that the bearings and stator are installed correctly and the motor rotates with high precision
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
This approach enables high-precision and reliable bearing retainer units, ensuring accurate installation of bearings and enhancing the rotational precision and lifespan of motors by reducing stress and maintaining the roundness of the bearing bushing.
Implementation Method 1
the first die, which has a circumferential surface shaped to correspond to at least part of the inner circumferential surface of the bearing positioning portion, and the second die, which has an abutment lent a form to correspond to an axial end face of the first die, are closed, readying the mold. Then, a molten material is injected into the internal space to form the molded part
Data Source
AI summary
A bearing retainer unit is formed by an insert-molding technique to cast a molded component of the bearing retainer unit utilizing a bearing bushing. A first mold die, having a circumferential surface shaped to correspond to at least a portion of the inner circumferential surface of a bearing-positioning portion of the molded component, and a second mold die, having an abutment that abuts against an axial end face of the first die, are readied. A molten material is then injected into the mold to form the molded part, thereby forming the die-parting line on the inner circumferential surface of the component's bearing positioning portion, positioned at the radially outer side of the abutment.