Bearing Unit with Segmented Outer Rings and Spacer Separator
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Solution Overview
Problem
Conventional bearing units require significant material processing and transportation of high-strength steel in regions not necessary for high-strength applications, increasing manufacturing complexity and cost.
Innovation Solution
A bearing unit comprising two outer rings connected by a separator, which can be preassembled and manufactured from different materials, including lighter plastics, to reduce material usage, weight, and processing costs, with spacers and base bodies designed to support and position the rings for optimal stability and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece outer ring is used to accommodate two bearings, then the bearing unit can be manufactured as a single component, but the material usage and weight increase significantly
Solution Approach 1:
The outer ring is divided into two separate outer rings (first outer ring and second outer ring) that are spaced in the axial direction. Each outer ring accommodates one bearing, eliminating the need for a single large outer ring. This segmentation reduces material usage and weight while maintaining structural integrity through the separator component.
2Adaptability or versatility
If a one-piece outer ring with large axial extension is used, then both bearings can be housed in a single component, but the processing and transportation costs increase
Solution Approach 1:
The bearing unit is segmented into modular components: first bearing, second bearing, separator, and two separate outer rings. This allows each component to be manufactured independently with optimized processing requirements, reducing overall manufacturing complexity and cost compared to a single large outer ring.
Solution Approach 2:
A separator component is introduced as an intermediary element between the two outer rings. The separator maintains the axial spacing and structural relationship between the separated outer rings, enabling the modular design to function as a unified bearing unit while simplifying manufacturing and assembly.
3Strength
If high-strength steel is used throughout the outer ring, then the bearing unit achieves required strength, but material costs and processing complexity increase in non-critical regions
Solution Approach 1:
Different materials are used for different components based on their specific functional requirements. The outer rings use high-strength steel where structural integrity is critical, while the separator uses a different material that is optimized for its specific function of maintaining axial spacing. This local optimization reduces overall high-strength material usage while maintaining necessary strength.
Solution Approach 2:
The bearing unit employs a composite structure with different materials for different components. The first and second outer rings are made from appropriate materials for load-bearing applications, while the separator is made from a different material optimized for its spacing and positioning function. This material differentiation reduces the quantity of high-strength material required.
Data Source
AI summary
A bearing unit configured to support a first component for rotary movement with respect to a second component includes a first bearing having an inner ring and an outer ring and a second bearing having an inner ring and an outer ring and a separator axially disposed between and connecting the outer ring of the first bearing and the outer ring of the second bearing in an interference fit manner or in a friction fit manner to form a preassembled unit. The separator may be annular and have a plastic base body with axial openings in which metal spacers, cylindrical rods, for example, are mounted.