Cross-Roller Bearing Plug Manufacturing Process
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Solution Overview
Problem
Conventional cross-roller bearings face challenges in achieving high stiffness and smooth operation at high speeds without jarring or wobble, requiring complex adjustments and processes to minimize clearance and apply prestressed pressure.
Innovation Solution
A cross-roller bearing design with a plug that fits into a ringlike track, featuring V-shaped raceway surfaces and a depressed outside surface, allowing for precise manufacturing and prestressed roller placement, along with a production process that includes rough cutting, hardening, and precise finishing to ensure accurate assembly and high stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plug is made separately and fitted subsequently into the bore, then the manufacturing process is simpler, but the manufacturing precision and accuracy of the raceway surface are reduced
Solution Approach 1:
The plug and the race blank are merged into a single integrated component through simultaneous machining operations. The raceway surface on the plug and the raceway surface on the race blank are machined in the same setup, ensuring precise alignment and eliminating cumulative errors from separate manufacturing processes. This integration maintains manufacturing simplicity while achieving high precision.
Solution Approach 2:
The plug is positioned and clamped to the race blank before the final machining operations. This preliminary positioning allows the raceway surfaces to be machined simultaneously in the correct relative positions, ensuring accuracy while streamlining the manufacturing process by eliminating subsequent alignment operations.
2Stability of the object's composition
If the clearance between rolling element and raceway surface is minimized, then high stiffness is achieved, but complex adjustment processes are required
Solution Approach 1:
Prestressed rollers are pre-installed in the bearing assembly before final assembly. These prestressed rollers apply predetermined radial and axial forces to the raceway surfaces, minimizing clearance and ensuring high stiffness without requiring complex post-assembly adjustments. The prestressing is built into the design and assembly process itself.
Solution Approach 2:
The bearing design utilizes prestressed rollers with specific force parameters to achieve optimal clearance control. By carefully selecting the prestress forces and roller dimensions, the bearing achieves high stiffness with simplified assembly procedures, eliminating the need for complex adjustment mechanisms.
3Ease of operation
If the plug outside surface is depressed below the race circular surface, then smooth rolling operation is ensured, but additional machining steps are required
Solution Approach 1:
The depression of the plug outside surface below the race circular surface is achieved by simultaneously machining both surfaces in the same setup. This integrated machining approach ensures the correct depth and smooth transition without requiring separate operations, maintaining operational smoothness while simplifying the manufacturing process.
Data Source
AI summary
A cross-roller bearing with plug, which has the high stiffness enough to allow the cross-roller bearing to turn with causing no jar or wobble, and also the production process to realize the cross-roller bearing with plug with ease and accuracy. With the cross-roller bearing with plug, more than one roller fills the space between the outside and inside races through a loading bore cut in any one of the races, and then a plug fits into the loading bore. The plug experiences cutting on its outside surface at the same time with the cutting of the circular outside surface of the outside race at once. The inside surface of the plug is also worked together with the cutting of the raceway surface around the inside circular surface of the outside race at a time.