Linear Ball Bearing Support Track Element Embossing
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Solution Overview
Problem
The production of linear ball bearings with curved support track elements is expensive due to the need for bending and subsequent grinding, which increases the complexity and cost of manufacturing, while also risking deformation during the hardening process.
Innovation Solution
The use of web-like projections on the support track elements, which are embossed to create the necessary curvature, reduces production costs and maintains load-bearing capacity by distributing forces evenly and allowing for controlled material displacement during the embossing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support track elements are bent to create crowning, then misalignment compensation is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The crowning is integrated into the support track element blank before the final assembly, allowing the curvature to be pre-formed during the blanking process rather than requiring subsequent bending operations. This preliminary formation of the crowning reduces manufacturing steps and complexity.
Solution Approach 2:
The crowning formation is combined with the blanking process itself, merging two operations (blanking and crowning formation) into one integrated process. This eliminates the need for separate bending operations and reduces overall manufacturing complexity.
2Reliability
If the support track elements are bent to create crowning, then misalignment compensation is improved, but production cost increases
Solution Approach 1:
The crowning formation is merged with the blanking process, eliminating separate bending operations and reducing the number of manufacturing steps. This integration reduces production time and cost while maintaining the misalignment compensation function.
Solution Approach 2:
The blanking process itself is used to create the crowning, allowing the forming operation to serve dual purposes (creating the blank and forming the crowning). This self-service approach eliminates the need for additional dedicated crowning formation equipment and operations.
3Strength
If hardening of the bearing track elements is performed, then load-bearing capacity is improved, but deformation risk increases
Solution Approach 1:
The crowning is formed during the blanking process before hardening, allowing the curvature to be established while the material is still in its softer state. This preliminary formation avoids the risk of deformation during subsequent hardening operations, as the material can more easily accommodate the crowning shape before gaining its final hardness.
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 method allows for the cost-effective production of linear ball bearings with adequate misalignment compensation, reducing forming forces and minimizing the risk of deformation, thus enabling efficient and economic manufacturing while maintaining the necessary load-bearing capabilities.
Implementation Method 1
The at least one outer surface is formed by at least one web-like projection, which extends in the longitudinal direction of the supporting track element
Implementation Method 2
reduces forming forces and minimizing the risk of deformation
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates to a linear ball bearing (1) for longitudinally displaceable mounting of a shaft-shaped guide rail (2) in a part (3) surrounding the guide rail, with a sleeve-like cage (4) which has recesses (5) arranged one behind the other in the circumferential direction in which ball recirculations (9) are held, wherein each ball recirculation (9) has at least one support section with supporting balls (90) which are supported on the guide rail (2) in a rolling manner, wherein the supporting balls (90) of a ball recirculation (9) are additionally supported on a raceway of a support track element (8) which is inserted directly or indirectly into the cage (4) in a rolling manner, which (8) has at least one radial outer surface, curved outwards at least in one direction, for contact with an inner surface of the part (3) surrounding the guide rail (2).According to the invention, at least one outer surface (81) is formed by at least one rib-like projection (80) extending longitudinally along the support surface (8). This design makes it possible to produce the required crowning or curvature of the outer surface of the support surface (8) using a simplified manufacturing process (e.g., forming), without any significant reduction in the load-bearing capacity of the support surface (8). Furthermore, a cost-effectively manufactured support surface (8), a method for manufacturing the support surface, and a forming device for a blank of the support surface are presented.