Embossed Ramp Disc Bearing Unit for Uniform Hardening
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Solution Overview
Problem
Existing ramp actuators face issues with heat treatment due to large changes in wall thickness, leading to uneven hardness application, additional tolerances, relative movement, increased wear, and a bulky design, which results in high material loss and long machining times.
Innovation Solution
The use of sheet metal to produce a ramp actuator with a pivotable ramp disc that integrates a ramp mechanism and a stationary actuator disc, featuring specific ratios for axial width and ramp radius, and employing a single-row angular contact ball bearing without cutting, allowing for a compact design and reduced material usage through embossing and case hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part variant with a single-row angular contact ball bearing is installed with the sintered actuator disc, then the actuator can function, but additional tolerances are introduced and the design becomes bulky
Solution Approach 1:
The bearing outer ring is merged with the actuator disc to form a single integrated component. The outer ring serves dual functions as both the bearing outer ring and the actuator disc, eliminating the need for separate parts and reducing the tolerance chain while maintaining functional performance
2Manufacturing precision
If the actuator disc and bearing outer ring are machined as one piece, then additional tolerances are eliminated, but the design becomes bulky and material loss increases
Solution Approach 1:
The design parameters are optimized with specific ratio constraints: the axial width to support height ratio is between 2.9 and 4.1, and the ramp radius to support height ratio is between 0.7 and 1.3. These parameter changes enable a compact design that eliminates material loss associated with traditional machining while maintaining precision
3Strength
If thorough hardening is applied to the machining combination, then strength is improved, but hardening times increase significantly
Solution Approach 1:
Instead of thorough hardening of the entire component, only local case hardening is applied to the bearing raceway surfaces. This provides the necessary hardness and strength at the contact surfaces while avoiding the time-consuming thorough hardening of the entire actuator disc and bearing assembly
4Ease of manufacture
If sintered ramp discs are used, then production is simplified, but large changes in wall thickness occur during heat treatment leading to uneven hardness
Solution Approach 1:
The design incorporates specific ratio parameters (axial width to support height between 2.9 and 4.1, ramp radius to support height between 0.7 and 1.3) that control the geometry to minimize wall thickness changes during heat treatment, ensuring uniform hardness distribution while maintaining ease of manufacture
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
This solution prevents uneven hardness, reduces material loss, and achieves a compact, durable, and cost-effective design capable of handling high loads while eliminating the need for pre-assembly and extensive machining, thereby improving the efficiency and functionality of the ramp actuator.
Implementation Method 1
a pivotable ramp disc (2), in particular having at least one ramp (4) on a first end face (5) which is prepared for the rolling of a rolling body (7)
Implementation Method 2
employing a single-row angular contact ball bearing without cutting, allowing for a compact design and reduced material usage through embossing and case hardening
Data Source
AI summary
A ramp actuator has a pivotable ramp disc, which on a first end face has at least one ramp, which is prepared for the rolling of a rolling body and, spaced apart therefrom, has a raceway for bearing rolling bodies of a rolling bearing prepared to receive radial and axial forces. A bearing ring can be fixed on a shaft, wherein the ratio of the axial width of the ramp disc relative to the support height thereof is between 2.9 and 4.1 and the ratio between the ramp radius of the ramp of the ramp disc relative to the support height of the ramp disc is between 0.7 and 1.3. A method for producing a ramp disc for such a ramp actuator includes drawing, upset forging and embossing, preferably carried out in that order.