Load-Variable Rolling Bearing With Adaptive Contact Geometry
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Solution Overview
Problem
Conventional rolling bearings face inefficiencies due to fixed rated capacities, leading to oversized designs for varying load conditions, which result in increased weight, torque, and potential failures under extreme loads, especially in applications like vehicle transmissions and wind turbine generators.
Innovation Solution
A load-variable rolling bearing design featuring an outer and inner ring with concave arch sections and cylindrical variable contact portions, along with rolling elements having convex spherical surfaces, allowing for adaptive contact configurations to adjust rated capacity based on applied loads, thereby optimizing size and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bearing is designed with a large rated capacity to handle extreme loads, then the reliability under extreme loads is improved, but the weight and rotating torque increase
Solution Approach 1:
The patent applies the dynamics principle by enabling the bearing's rated capacity to change dynamically based on operating conditions. The variable contact portion allows the bearing to transition between different contact configurations, adjusting its load capacity in real-time. This resolves the contradiction by making the bearing lightweight for normal operation (low stages) while maintaining reliability when extreme loads occur (high stages), rather than being permanently oversized.
Solution Approach 2:
The patent employs parameter changes by modifying the contact configuration between rolling elements and raceway surfaces. The variable contact portion changes the contact area and load distribution parameters based on applied loads. This allows the bearing to optimize its effective rated capacity according to actual operating conditions, reducing weight and torque during light loads while maintaining reliability under extreme loads.
2Reliability
If the bearing is designed with a large rated capacity to handle extreme loads, then the reliability under extreme loads is improved, but the rotating torque increases
Solution Approach 1:
The dynamics principle resolves this contradiction by making the bearing's effective rated capacity dynamic rather than fixed. During normal operation at low stages, the bearing operates with a smaller effective rated capacity, minimizing rotating torque. When extreme loads occur at high stages, the variable contact portion activates to increase the rated capacity, ensuring reliability without the penalty of continuously high torque.
Solution Approach 2:
The parameter changes principle is applied by varying the contact configuration parameters between rolling elements and raceway surfaces. The variable contact portion modifies contact area, contact pressure, and load distribution parameters based on applied loads. This dynamic parameter adjustment reduces rotating torque during light loads while maintaining the reliability needed for extreme loads.
3Reliability
If the diameters of the balls are enlarged to increase the rated capacity, then the reliability is improved, but the bearing size increases unnecessarily
Solution Approach 1:
The patent applies parameter changes by modifying the contact configuration rather than simply enlarging the rolling elements. The variable contact portion changes the contact area and load distribution parameters, allowing the bearing to achieve higher effective rated capacity without increasing the physical size of the balls or overall bearing dimensions. This resolves the contradiction by decoupling rated capacity from physical size through parameter optimization.
4Object-generated harmful factors
If a ball bearing is used instead of a roller bearing, then the rotating torque is reduced, but the support capability against applied load becomes weaker
Solution Approach 1:
The patent applies the dynamics principle by enabling the ball bearing to dynamically adjust its effective support capability. The variable contact portion allows the bearing to operate with lower contact resistance (like traditional ball bearings) during normal operation, minimizing rotating torque. When extreme loads are applied, the contact configuration changes to increase the effective rated capacity, providing the strength needed to match roller bearings when required.
Data Source
AI summary
A load-variable rolling bearing includes: an outer ring having an outer ring raceway surface with spherical surface contact portions having concave arch sections and a variable contact portion having a shape of a cylinder in such a manner as to be adjacent to the spherical surface contact portions in an axial direction of the spherical surface contact portions; an inner ring having an inner ring raceway surface with spherical surface contact portions having concave arch sections and a variable contact portion having a shape of a cylinder in such a manner as to be adjacent to the spherical surface contact portions in an axial direction of the spherical surface contact portions; and a plurality of rolling elements each having a cylindrical variable contact portion and spherical surface portions formed with convex spherical surfaces on both sides of the variable contact portion.