Insert-Molded Rolling Element Guide Member for Motion Systems
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Solution Overview
Problem
Conventional motion guide devices face challenges in manufacturing complex shapes at low costs and ensuring secure installation and guidance of rolling elements without deflection, particularly due to material limitations and high manufacturing costs associated with metal components and complex geometries.
Innovation Solution
A motion guide device featuring a rolling element guide member composed of a beam member made of metal for structural strength and an outer member made of resin for guiding the rolling elements, with insert-molding and optional connecting means such as screw holes and supporting shapes to secure the guide member to the moving block, allowing for adaptable and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rolling element guide member is made of resin, then manufacturing cost is reduced, but the guide member causes unwanted deflection due to external force when skew occurs
Solution Approach 1:
The rolling element guide member is constructed as a composite structure with a resin outer member providing the guiding surface and a metal inner member providing structural strength and rigidity. This composite construction allows the guide member to maintain low manufacturing cost while preventing deflection under external forces, as the metal core reinforces the resin structure without significantly increasing cost or complexity.
2Strength
If a rolling element guide member is made of metal, then structural strength is improved, but manufacturing cost increases and complex shapes cannot be manufactured at low cost
Solution Approach 1:
The guide member uses a composite construction where only the critical load-bearing portions are made of metal (inner member), while the outer shaping portions are made of resin. This allows the structure to achieve sufficient strength where needed while maintaining low manufacturing cost through resin molding for complex geometries.
Solution Approach 2:
The metal inner member is positioned specifically in regions requiring high strength and rigidity, while the resin outer member forms the complex guiding surfaces and external geometry. This local differentiation of material properties optimizes both strength and manufacturability by applying each material where it is most effective.
3Ease of manufacture
If a single material is used for the rolling element guide member, then manufacturing process is simplified, but the member cannot simultaneously achieve complex shape, low cost, and deflection-free operation
Solution Approach 1:
The guide member combines resin and metal materials in a integrated composite structure, where the resin outer member provides complex geometry and the metal inner member provides structural reinforcement. This composite approach enables the single component to simultaneously achieve complex shaping, cost-effectiveness, and deflection resistance that would be impossible with a single material.
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
Enables low-cost, complex shape manufacturing with secure and deflection-free installation and guidance of rolling elements, adaptable to various applications and specifications by selecting appropriate connecting means, thereby reducing manufacturing costs and enhancing the device's versatility.
Implementation Method 1
the beam member and the outer member are insert-molded
Data Source
AI summary
A motion guide device includes a plurality of rolling element guide members provided along the entire length of a rolling element rolling surface so as to guide the unloaded side of a plurality of rolling elements that perform a rolling movement under load between the rolling element rolling surface and a loaded rolling element rolling surface. The rolling element guide member includes a beam member an outer member including a rolling element guide surface for guiding the unloaded side of the rolling elements, and the beam member and the outer member are insert-molded. Such a structure provides the motion guide device including the rolling element guide member that enables low cost manufacturing of a complex shape and capability of secure installation and guidance of the rolling elements with no deflection and can be adapted for use in various types by optionally selecting a connecting means.