Embossed Bearing Contact Surface for Ring Migration Resistance
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Solution Overview
Problem
Existing methods for connecting bearing assembly components, such as rolling-element bearings or plain bearings, in a rotationally fixed and displacement-resistant manner face challenges like ring migration, material overload, and high costs due to the limitations of press-fitting, thermal expansion, and surface coating processes, which can lead to inaccuracies and material damage.
Innovation Solution
A bearing-assembly component with an embossed structure on its contact surface, which increases friction through mechanical roughening without adding or removing material, allowing for a positionally fixed friction-fit connection that is releasable and resistant to ring migration, achieved by deforming the surface to create protuberances and recesses that interlock with the counter-contact surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-fitting or thermal expansion methods are used to connect bearing rings to shafts or housings, then assembly is achieved, but the range of acceptable pressures is limited and material overload or insufficient friction can occur
Solution Approach 1:
The patent applies local quality by creating an embossed structure only on the contact surface of the bearing ring that interfaces with the shaft or housing. This localized embossing increases friction precisely where needed for connection reliability, while leaving the bulk material properties and other surfaces unchanged, thus avoiding material overload throughout the entire component.
2Reliability
If zinc layers are applied through spray processes to increase friction, then the friction coefficient increases, but layer accuracy is insufficient and mechanical post-processing is required
Solution Approach 1:
The patent replaces the spray coating process with a mechanical embossing process. Instead of applying a zinc layer that requires subsequent grinding to achieve accuracy, the embossed structure is created directly through mechanical deformation of the bearing ring surface, achieving the desired friction increase with inherent geometric precision without needing post-processing.
3Reliability
If zinc layers are applied to increase friction, then the friction coefficient increases, but additional masking and post-processing steps are required increasing complexity
Solution Approach 1:
The patent extracts and eliminates the unnecessary masking and post-processing steps from the manufacturing process. By using direct embossing of the bearing ring surface, the method removes the intermediate steps of masking non-coating areas, applying zinc spray, and performing mechanical grinding, thereby simplifying the overall manufacturing process while maintaining friction connection reliability.
4Reliability
If galvanic zinc-plating is used to increase friction, then the friction coefficient increases, but large bearing rings cannot be immersed in the plating bath
Solution Approach 1:
The patent replaces the immersion-based galvanic plating process with a mechanical embossing process that can be applied to bearing rings of any size. The embossing method uses direct contact with an embossing tool or roller that can traverse the surface of large rings, eliminating the size limitation imposed by plating bath immersion requirements.
5Reliability
If zinc lacquers are applied to increase friction, then the friction coefficient increases, but layer thickness fluctuation is too high for correct press fit
Solution Approach 1:
The patent replaces the lacquer application process with mechanical embossing. The embossed structure creates consistent geometric features with controlled dimensions through direct mechanical contact, eliminating the thickness fluctuation issues inherent in lacquer application where tolerances of 35+10/−5 μm are typical, thereby ensuring correct press fit and friction connection.
6Reliability
If sandblasting is used to roughen the surface and increase friction, then the friction coefficient increases, but material is removed and dimensional accuracy decreases
Solution Approach 1:
The patent inverts the approach of sandblasting. Instead of removing material to create surface roughness, the embossing process adds localized geometric features through plastic deformation of the surface material. This inversion maintains the original dimensional accuracy and roundness of the bearing ring bore while still achieving the desired friction increase through the embossed pattern.
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 embossed structure enhances the coefficient of friction, preventing ring migration and ensuring precise positioning without altering the component's dimensions or requiring additional coatings, thus providing a reliable and cost-effective solution for connecting bearing components.
Implementation Method 1
The friction force is determined by the friction value, assuming a maximum normal force or contact pressure force
Implementation Method 2
achieved by deforming the surface to create protuberances and recesses that interlock with the counter-contact surface
Data Source
AI summary
A first bearing assembly component, which is configured to be connected to a second bearing assembly component, has a contact surface configured to frictionally engage a counter-contact surface of the second bearing assembly component to secure the first bearing assembly component to the second bearing assembly component. The contact surface includes at least one embossed structure or embossed pattern. Also an assembly of the first and second bearing assembly components and a method of forming the first bearing assembly component.