Integral Duplex Bearing Manufacturing via Segmented Inner Rings
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Solution Overview
Problem
Conventional methods for manufacturing integral duplex bearings are inefficient due to the tedious process of matching separately-ground inner raceways, leading to increased costs and limited dimensionality, particularly for smaller dimensions.
Innovation Solution
The method involves forming and precisely matching inner and outer raceways while the inner rings are joined, allowing for simultaneous grinding of raceways, which reduces the need for separate matching and enhances dimension control, enabling the production of a wider variety of bearing sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inner rings are manufactured separately and then assembled, then manufacturing flexibility is improved, but matching precision and time consumption worsen
Solution Approach 1:
The inner ring is segmented into two separate inner rings (first inner ring and second inner ring) that are joined together, allowing each to have its own raceway formed independently while maintaining precise relative positioning through the joining structure
Solution Approach 2:
The two separately-manufactured inner rings are merged into a single assembled unit with precise raceway matching, eliminating the need for tedious matching operations while maintaining manufacturing flexibility
2Productivity
If inner rings are joined during raceway forming, then manufacturing time and cost are reduced, but process complexity increases
Solution Approach 1:
The inner rings are pre-joined together before the raceway forming operation, establishing the precise geometric relationship between raceways in advance and eliminating subsequent matching operations
Solution Approach 2:
A joining structure acts as an intermediary between the two inner rings, providing the mechanical connection that maintains precise relative positioning during the raceway forming process
3Ease of manufacture
If separate grinding operations are performed on inner raceways, then manufacturing flexibility is maintained, but dimension control and precision worsen
Solution Approach 1:
The inner ring is divided into two segments that can be manufactured independently with separate grinding operations, yet maintain precise dimensional control through their joined configuration
Solution Approach 2:
The two separately-ground inner rings are combined into a single assembled unit where the joining structure ensures precise dimensional relationships between the raceways
4Adaptability or versatility
If conventional matching processes are used, then adaptability to different bearing types is maintained, but time consumption and cost increase
Solution Approach 1:
The precise geometric relationship between raceways is established in advance through the joining structure, eliminating the need for time-consuming matching operations for different bearing types
Solution Approach 2:
The joined inner ring structure provides a universal solution that can be adapted to different bearing types without requiring separate matching procedures, as the precise geometry is built-in during assembly
Data Source
AI summary
In certain embodiments, a method for manufacturing an integral duplex bearing having an outer ring, a first inner ring, and a second inner ring includes forming a first outer raceway and a second outer raceway in an inner surface of the outer ring. The method further includes forming a first inner raceway in an outer surface of the first inner ring and a second inner raceway in an outer surface of the second inner ring while the first inner ring and the second inner ring are joined together. The first and second inner rings each have an outer surface diameter less than an inner surface diameter of the outer ring such that the first and second inner rings may be positioned inside the outer ring with the first inner raceway located adjacent to the first outer raceway and the second inner raceway located adjacent to the second outer raceway. The method further includes separating the first inner ring from the second inner ring.