Modular rolling element cage
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Solution Overview
Problem
The existing manufacturing methods for rolling element cages of different lengths are costly and resource-intensive, as they require individual injection molding tools and result in material waste when long cages are cut to size, limiting flexibility and increasing production costs, especially for small batches.
Innovation Solution
A modular rolling element cage design composed of base and extension modules with connecting sections, allowing for adjustable length and positioning of receptacles for rolling elements, which can be fixedly or detachably connected to achieve desired lengths and configurations, reducing the need for multiple tools and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual injection molding tools are used for each rolling element cage length, then manufacturing precision and adaptability are improved, but device complexity and production costs increase
Solution Approach 1:
The rolling element cage is divided into multiple standardized modules (e.g., 20mm, 40mm, 60mm length modules) that can be combined in series. Each module contains receiving legs and connecting sections that interface with adjacent modules, allowing flexible assembly of different total lengths using the same basic tooling for each module type.
Solution Approach 2:
The connecting sections are designed with universal interfaces (such as standardized attachment features) that allow the same module type to be used in various positions and combinations. This enables a single set of injection molding tools to produce modules that serve multiple configuration needs across different cage lengths.
2Adaptability or versatility
If long rolling element cages are cut to size, then adaptability to different lengths is improved, but material waste increases
Solution Approach 1:
Instead of manufacturing one long cage and cutting it to various lengths, the system segments the cage into discrete modular units. Each module is manufactured to its final length via injection molding without requiring post-manufacturing cutting, thus eliminating material waste while still providing flexibility to assemble different total lengths by combining appropriate numbers of modules.
3Reliability
If connecting sections are added to receive rolling elements, then reliability is improved, but device complexity increases
Solution Approach 1:
The connecting section performs multiple functions simultaneously: it structurally joins adjacent receiving legs to maintain cage integrity, provides attachment features for modular assembly, and positions receiving openings to guide rolling elements. By merging these functions into a single integrated component rather than separate elements, reliability is improved without proportionally increasing complexity.
Data Source
AI summary
A rolling element cage for positioning a plurality of rolling elements between two rail elements of a telescopic rail or a linear guide which are mounted so as to be movable relative to each other is provided. The rolling element cage is composed or can be composed of two or more module elements which include a base module and one or more extension modules. Each module element has at least two receiving legs, each having one or more openings for receiving rolling elements, and at least one connecting section connecting the two receiving legs, the base module and the one or more extension modules being fixedly or releasably connected or connectable to one another in series in the longitudinal direction of the rolling element cage via fasteners.