Modular Rolling Element Cage to Reduce Mold Costs and Material Waste
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Solution Overview
Problem
Existing rolling element cages for telescopic rails and linear guides require separate injection molds for each length and positioning, leading to high costs and resource wastage, especially in small-batch production, and lack flexibility in adapting to varying lengths and positioning needs.
Innovation Solution
A modular rolling element cage composed of base and extension modules with angled receiving legs and connecting sections, allowing for flexible assembly into desired lengths and configurations using compatible fastening means, such as tongue-and-groove connections, to position rolling elements efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate injection molds are used for each rolling element cage length and positioning, then manufacturing precision and adaptability are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The rolling element cage is divided into multiple modular segments that can be connected in series. Each segment contains standardized receiving legs with openings for rolling elements, and the segments can be assembled in different quantities and configurations to create cages of various lengths and positioning arrangements, eliminating the need for separate injection molds for each variant.
Solution Approach 2:
A universal base module design is created that can serve multiple functions. The standardized receiving legs and connecting sections can be configured in different arrangements to accommodate various cage lengths and positioning requirements, allowing a single mold design to produce adaptable components for multiple applications.
2Manufacturing precision
If separate injection molds are used for each rolling element cage length, then manufacturing precision is improved, but material waste increases
Solution Approach 1:
Instead of manufacturing complete cages of maximum length and cutting them to size, the cage is segmented into modular units that are connected in the required quantity. This eliminates material waste from cutting operations while maintaining precise length control through the standardized connection interfaces between segments.
3Adaptability or versatility
If separate injection molds are used for each rolling element cage configuration, then adaptability to positioning needs is improved, but production cost increases
Solution Approach 1:
The cage is segmented into standardized modules with receiving legs that can be arranged in different positioning configurations. By producing these standardized segments in high-volume production using a single mold, the cost per segment is reduced, and adaptability is achieved through flexible assembly of the segments in different patterns.
Solution Approach 2:
The positioning adaptability is achieved by changing the arrangement parameters of the receiving legs within the modular segments rather than creating entirely different cage designs. This allows various positioning configurations to be achieved through assembly variations rather than requiring separate injection molds for each configuration.
Data Source
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AI summary
Rolling element cage (1) for positioning a plurality of rolling elements between two rail elements of a telescopic rail or a linear guide which are mounted to be movable relative to each other, wherein the rolling element cage (1) is composed or composable from two or more module elements (2, 3a, 3b, 3c) comprising a base module (2) and one or more extension modules (3a, 3b, 3c), wherein each module element (2, 3a, 3b, 3c) has at least two receiving legs (4) each with one or more openings (6) for receiving rolling elements and at least one connecting section (5) connecting the two receiving legs (4), wherein the base module (2) and the one or more extension modules (3a, 3b, 3c) are fixedly or detachably connected in series in the longitudinal direction (A) of the rolling element cage (1) by means of fastening means (8a, 8b). are connected or connectable to each other.