Grounded Bearing Carrier Assembly for Stray Current Protection
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Solution Overview
Problem
Rolling-element bearings in modern electric machines face damaging current flows, which can be mitigated by using non-conductive ceramic elements, but this increases manufacturing costs.
Innovation Solution
A bearing assembly with a bearing carrier made from non-conductive materials, such as thermoplastics or thermosets, incorporating an electrically conducting element for grounding and current dissipation, allowing for both rotational and axial fixation while preventing harmful current flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic rolling elements are used to prevent damaging current flows, then bearing reliability is improved, but manufacturing costs increase
Solution Approach 1:
The patent introduces a bearing carrier as an intermediary component between the bearing unit and the housing. This carrier includes an electrically conducting element that serves as a mediator to provide electrical contact with the housing, thereby protecting the bearing from damaging current flows without requiring expensive ceramic rolling elements. The conducting element acts as a bridge that dissipates electrical charges away from the bearing.
Solution Approach 2:
The patent replaces the mechanical solution of using ceramic rolling elements (which rely on material properties) with an electrical/conductive solution. Instead of changing the bearing materials to prevent current damage, the invention uses a conductive bearing carrier to actively manage electrical charges, substituting a passive material-based approach with an active electrical management system.
2Reliability
If a bearing carrier with electrically conducting element is used, then protection against current flows is improved, but device complexity increases
Solution Approach 1:
The patent merges the bearing carrier function with the electrical protection function into a single integrated component. The bearing carrier simultaneously supports the bearing unit mechanically and provides electrical protection through its integrated conducting element. This combination eliminates the need for separate protection mechanisms, thereby reducing overall device complexity despite adding electrical protection capabilities.
Solution Approach 2:
The bearing carrier is designed as a multi-functional component that performs both mechanical support (holding the bearing unit) and electrical protection (providing conductive path to housing). This universal component approach consolidates multiple functions into one element, reducing the number of separate parts needed and simplifying the overall device structure.
3Ease of operation
If bearing assembly is provided as preassembled unit, then ease of installation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the bearing unit with the bearing carrier in a factory setting before installation. The bearing unit is inserted into the bearing carrier and secured during manufacturing, creating a pre-assembled unit that simplifies field installation. This preliminary assembly ensures proper positioning and tolerance alignment that would be difficult to achieve during final installation.
Solution Approach 2:
The patent segments the bearing assembly into modular components (bearing unit and bearing carrier) that can be manufactured separately and then pre-assembled. This segmentation allows each component to be optimized and manufactured independently, then combined into a pre-assembled unit that balances manufacturing complexity with installation ease.
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 solution provides a cost-effective and lightweight bearing assembly that effectively prevents damaging current flows and facilitates easy installation by integrating an electrically conducting element for grounding, ensuring secure fixing and weight reduction.
Implementation Method 1
the bearing carrier includes at least one electrically conducting element. This electrically conducting element can on the one hand provide an electrically conducting contact with the stationary component, and thus serve for current dissipation and grounding
Implementation Method 2
The bearing carrier can preferably be formed from a non-conducting material, in particular from thermoplastic and/or from thermoset
Data Source
AI summary
A bearing assembly includes a bearing unit configured to support a rotating component relative to a stationary component and having a first stationary bearing ring configured to be connected to the stationary component in a rotationally fixed manner by a bearing carrier and a second rotatable bearing ring configured to be connected to the rotating component. The bearing carrier includes at least one electrical conductor configured to make electrical contact with the bearing unit and to make electrical contact with the stationary component or to be electrically connected to the stationary component when the bearing carrier is mounted to the stationary component.