Bearing Assembly Alignment Using Exposed Ring Surfaces
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Solution Overview
Problem
The precision of rolling-element bearings is compromised when the stationary bearing ring is overmolded to a bearing carrier, leading to a loss of positional accuracy when mounted on a stationary component.
Innovation Solution
A method involving a bearing assembly with a bearing carrier and a bearing unit, where the bearing unit includes a stationary and a rotatable bearing ring. The bearing carrier has notches that expose sections of the stationary bearing ring, allowing for precise alignment and centering with the stationary component using highly precise manufactured surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stationary bearing ring is overmolded to the bearing carrier, then the bearing assembly can be attached to the stationary component, but the positional accuracy is significantly reduced
Solution Approach 1:
The bearing carrier is segmented with notches that expose specific sections of the stationary bearing ring. This segmentation allows the precise bearing ring surface to remain accessible for alignment while still providing the protective and attachment functions of the bearing carrier, thus resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The bearing carrier acts as an intermediary component with notches that selectively expose the bearing ring. This intermediary structure allows the system to benefit from both the ease of attaching a carrier and the precision of the exposed bearing ring surface for alignment, maintaining positional accuracy while enabling easy manufacture.
2Ease of operation
If surfaces of the bearing carrier are aligned with the stationary component, then the bearing assembly can be installed, but the alignment precision is insufficient
Solution Approach 1:
The notches extract or expose specific sections of the stationary bearing ring from behind the bearing carrier. This allows the precise bearing ring surfaces to be used for alignment instead of the less precise bearing carrier surfaces, thereby improving alignment precision while maintaining ease of installation.
Solution Approach 2:
Instead of aligning the bearing carrier surfaces with the stationary component as in conventional methods, this invention inverts the approach by aligning the exposed bearing ring surfaces. This inversion leverages the superior precision of the bearing ring surfaces while still using the bearing carrier for attachment.
3Strength
If the bearing carrier completely surrounds the stationary bearing ring, then the bearing unit is protected, but the precise surfaces of the bearing ring are inaccessible for alignment
Solution Approach 1:
The bearing carrier is divided by notches that create gaps in the surrounding structure. This segmentation maintains the protective function of the bearing carrier while selectively exposing the precise bearing ring surfaces needed for alignment, thus resolving the contradiction between protection and alignment precision.
Data Source
AI summary
A method for installing a bearing assembly on a stationary component where the bearing assembly includes a bearing carrier, a stationary bearing ring rotationally secured to the bearing carrier and a rotatable bearing ring supported for rotation relative to the first bearing ring. The method includes inserting a portion of the bearing carrier into an opening in the stationary component or inserting a portion of the stationary component into the bearing carrier, using an alignment tool to position at least two exposed radial surface portions of the stationary bearing ring with a surface of the stationary component to produce a temporary alignment of a rotational axis of the stationary bearing ring with a central axis of the stationary component, after producing the temporary alignment, attaching the bearing carrier to the stationary component in a manner that maintains the alignment, and removing the alignment tool from the bearing ring.