Curved Roller End Face Profile for Bearing Guidance
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Solution Overview
Problem
Existing roller bearings face challenges with low friction between the roller and the rim, leading to increased contact stresses and potential failures due to abrasion, especially when the roller tilts or twists.
Innovation Solution
The roller bearing features a curved approach section with specific constants (K1 and K2 between 10 and 50) and dimensions (h1 and h2 as a percentage of the roll diameter) that optimize the end face profile, minimizing contact stresses and ensuring better roller guidance, even with non-ideal contact surfaces, and includes a radially inner recess with a circumferential elevation to maintain optimal contact and reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat end face design is used for the roller, then manufacturing is simple, but contact stresses increase and roller guidance deteriorates when the roller tilts or twists
Solution Approach 1:
The patent applies curvature to the end face of the roller by introducing a curved approach section with a specific mathematical profile (parabolic or hyperbolic curve). This curved design replaces the traditional flat end face, allowing the roller to maintain optimal contact with the rim even when tilted or twisted, thereby improving roller guidance and distributing contact stresses more evenly without complicating manufacturing.
2Stress or pressure
If the contact surface area is increased to reduce contact stresses, then stress distribution improves, but frictional torque increases
Solution Approach 1:
The patent applies local quality by creating a non-uniform contact pressure distribution through the curved approach section. The curvature is designed to concentrate contact stresses toward the radially outer region of the end face, where the rim provides better support. This localized stress concentration reduces overall contact stresses while maintaining low frictional torque by avoiding excessive contact area in high-friction zones.
3Reliability
If the roller end face is designed with a curved approach section, then roller guidance improves and contact stresses reduce, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs parameter changes by defining the curved approach section through specific mathematical parameters (parabolic or hyperbolic equations with defined constants). This allows the complex curved profile to be manufactured using standard CNC machining processes with conventional tolerances, as the curve can be precisely controlled through programmed tool paths rather than requiring complex tooling or hand finishing.
Data Source
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AI summary
The roller (5) has a front side, where a section (27) of the front side (25) extends in a preset distance from a roller middle axis (23) up to an edge cutting region and is formed corresponding to a curve. The front side has an opening section radially lying relative to a contact section, and formed such that axial distance of the opening section to an axial contact surface is greater than axial distance of the contact section to the axial contact surface. The section of the front side is defined by a recess in a region of the middle axis.