Bearing Unit Swaging Layout for Compact, Low-Energy Assembly
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Solution Overview
Problem
The existing bearing unit manufacturing devices are excessively large in height due to the arrangement of the swaging mechanism, hydraulic cylinder, and rotating mechanism, making them inefficient in terms of size and energy consumption.
Innovation Solution
A revised manufacturing device with a rotating mechanism positioned below the processing area and a swaging mechanism above, utilizing an electric motor and linear actuator for thrust generation, which reduces the device's height and energy consumption by minimizing standby power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the swaging mechanism, hydraulic cylinder, and rotating mechanism are arranged above the processing area, then the processing function is achieved, but the device height becomes excessively large
Solution Approach 1:
The patent inverts the conventional arrangement by placing the rotating mechanism below the processing area instead of above. The rotor rotates the inner shaft from below while the swaging mechanism presses from above, achieving the swaging function with a compact vertical profile and eliminating the need for tall overhead structures.
Solution Approach 2:
The patent reorganizes the spatial arrangement of components by utilizing the vertical dimension differently. The rotor is positioned below the processing area and rotates horizontally, while the swaging mechanism operates vertically from above, creating a layered three-dimensional arrangement that minimizes overall device height.
2Force
If a hydraulic cylinder is used for thrust generation, then sufficient pressing force is achieved, but energy consumption increases due to standby power usage
Solution Approach 1:
The patent replaces the hydraulic cylinder with a direct-drive motor that generates thrust through electromagnetic force. This eliminates the hydraulic fluid system and standby power consumption associated with hydraulic pumps, while providing sufficient pressing force for swaging operations through controlled motor output.
Solution Approach 2:
The motor directly generates the required thrust force for swaging without needing a separate hydraulic power supply system. The motor can be activated only during actual swaging operations, eliminating continuous standby power consumption and providing force on-demand.
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 effectively reduces the manufacturing device's height, making it more compact and energy-efficient while maintaining the capability to perform swaging operations, thus addressing the size and energy consumption issues of the existing devices.
Implementation Method 1
a punch which is brought into contact with the swaged portion to plastically deform the swaged portion
Data Source
AI summary
A manufacturing device manufactures a bearing unit including an inner ring member outwardly fitted onto an end portion of a shaft main body of an inner shaft on one side in an axial direction and fixed by a swaged portion extending from the end portion. The manufacturing device includes: a rotating mechanism including a rotor which holds the other side of the inner shaft in the axial direction from below and rotates the inner shaft about a center axis of the inner shaft while the center axis is aligned with an up-down direction, the rotor being mounted below a processing area of the bearing unit; and a swaging mechanism mounted above the processing area and including a punch which is brought into contact with the swaged portion to plastically deform the swaged portion.