Disc Brake Roller Bearing Cage Outer Shell Connection
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Solution Overview
Problem
The assembly of full complement needle roller bearings in disc brakes is problematic due to the need for the cage to be pivoted during assembly, leading to high production costs and material usage, as well as complex assembly processes.
Innovation Solution
A disc brake design featuring a roller bearing with a cage and outer shell connected via window sections and projections, allowing secure holding of rollers in all directions, enabling simple production and assembly without an inner shell, using bending or injection molding for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a full complement needle roller bearing is used to maximize load capacity, then the optimized load capacity is achieved, but the assembly becomes problematic and production costs increase
Solution Approach 1:
The bearing is divided into two main segments: the outer shell and the cage with needles. The cage assembly can be pre-formed as a separate unit and then installed into the outer shell, allowing the complex full complement needle bearing to be manufactured in modular sections that are easier to produce and assemble
Solution Approach 2:
The cage and needles are pre-assembled as a unit before being installed in the outer shell. This preliminary assembly allows the needles to be securely positioned in the cage structure beforehand, eliminating the need for complex assembly operations after the outer shell is in place and enabling pre-fabrication of the roller bearing
2Ease of manufacture
If an inner shell is added to connect the cage and outer shell to enable pre-assembly, then pre-assembly becomes possible, but production costs and material usage increase
Solution Approach 1:
The inner shell component is extracted/removed from the design. Instead of using an inner shell to connect the cage and outer shell, the invention directly connects the cage assembly to the outer shell through the cage's own structure and the projection-window section mechanism, eliminating unnecessary material usage while maintaining pre-assembly capability
Solution Approach 2:
The cage and outer shell are merged into a single integrated assembly through the projection-window section connection. The cage assembly serves both as the needle holder and as the component that directly interfaces with the outer shell, combining functions that would otherwise require separate components
3Ease of operation
If the cage is designed to be pivoted during assembly to accommodate needle positioning, then the needles can be held during pivoting, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The cage and needles are pre-assembled as a complete unit before installation in the outer shell. This preliminary action ensures that the needles are already securely positioned in the cage structure, eliminating the need for time-consuming assembly operations after the outer shell is in place and enabling the roller bearing to be pre-fabricated as a complete unit
Solution Approach 2:
The cage structure itself provides the needle retention function through its own geometry and the projection-window section mechanism. The cage does not require external assistance or additional components to hold the needles during assembly, as it is designed to securely hold them as part of its inherent structure
Data Source
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AI summary
A disc brake for a commercial vehicle, with a clamping device positioned in a brake caliper, which has a brake lever which is pivotably mounted in the brake caliper by means of at least one circular arc-shaped rolling bearing (7), wherein the rolling bearing (7) has an outer shell (11) and a plurality of adjacent rolling rollers (13) which support themselves on the concave inner surface (15) of the outer shell (11) and which are held in a cage (12) which is pivotable to a limited extent relative to the outer shell (11), is designed such that the cage (12) and the outer shell (11) are positively connected to each other.