Compact Bearing with Segmented Roller Modules
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Solution Overview
Problem
Existing ball bearings with high load capacity requirements are often large and bulky, leading to frequent wear and replacement in environments where load capacity is near or slightly lower than the maximum, necessitating a compact and long-lasting bearing solution.
Innovation Solution
A compact bearing design featuring small diameter rollers with non-helical teeth engaging compatible grooves on an outer and inner race assembly, which increases load capacity and lifespan, allowing for easy assembly and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of ball bearings is increased to achieve high load capacity, then the load capacity is improved, but the bearing size becomes large and bulky
Solution Approach 1:
The invention divides the bearing into multiple modular units, each containing a small number of ball bearings (e.g., two ball bearings per unit). These modular units are stacked axially to achieve the desired load capacity without requiring a single large bearing, thus maintaining compact dimensions while scaling load capacity through controlled stacking of standardized modules.
Solution Approach 2:
The invention transitions from increasing load capacity by enlarging bearing diameter (two-dimensional scaling) to increasing load capacity by stacking multiple thin bearing units in the axial direction (one-dimensional scaling). This dimensional shift allows high load capacity to be achieved through axial stacking of compact units rather than radial expansion, resolving the contradiction between load capacity and bearing size.
2Force
If larger ball bearings are used to increase load capacity, then the load capacity is improved, but the bearing lifespan decreases due to frequent wear
Solution Approach 1:
The bearing system is segmented into multiple identical modular units with standardized ball bearing configurations. This segmentation allows for easier maintenance and replacement of individual modules, and the standardized design ensures consistent load distribution across all units, reducing premature wear and extending overall bearing lifespan while maintaining high load capacity.
Solution Approach 2:
The invention changes the operational parameters by using multiple small ball bearings in each module rather than fewer large ball bearings. This parameter change optimizes the contact stress distribution and reduces individual bearing wear rates, thereby extending bearing lifespan while achieving the required load capacity through the cumulative effect of multiple modules.
3Force
If multiple ball bearings are stacked to achieve high load capacity, then the load capacity is improved, but the assembly complexity increases
Solution Approach 1:
The bearing assembly is segmented into pre-assembled modular units that can be manufactured and tested independently. Each module contains a standardized configuration of ball bearings, races, and retaining structures. This segmentation simplifies the overall assembly process, as modules can be stacked and secured in a systematic sequence rather than requiring complex individual assembly of numerous ball bearings.
Solution Approach 2:
The modular bearing units are designed with universal interfaces and standardized dimensions, allowing the same module design to be used across different bearing configurations and applications. This universality simplifies assembly procedures, as the same assembly techniques and fastening methods can be applied to all modules, reducing assembly complexity despite the increased number of components required for high load capacity.
Data Source
AI summary
A high load capacity bearing that includes a cylindrical outer sleeve that fits around a separable cylindrical outer race assembly. The outer race assembly includes a set of non-helical grooves formed on its inside surface that mesh and engage teeth formed on the outside surface of a plurality of rotating rollers that are longitudinally and axially aligned inside the outer race assembly. The rollers are longitudinally aligned and evenly space apart and rotated as a unit inside the outer race assembly. Located inside the rollers is an inner race with non-helical grooves formed on its outside surface that mesh and engage the teeth on the rollers. The inner race includes a smooth inside bore that fits around the support surface on a shaft. During use, the inner race is becomes fixed on a support surface on a shaft and the outer sleeve and outer race assembly are mounted on a part.