Automated Needle Roller Bearing Assembly Device
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Solution Overview
Problem
The manual assembly of needle roller bearings in mechanical systems with relative rotary motion is labor-intensive and costly, as it requires precise fitting of the outer casing and central pin, making automation challenging.
Innovation Solution
A device with truing and moving means is used to align and insert rollers between the outer casing and central element, allowing for automated assembly by arranging rollers in groups and moving them simultaneously into position, eliminating the need for traditional bearings and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly of needle roller bearings is performed, then precise fitting of outer casing and central pin can be achieved, but labor intensity and cost increase significantly
Solution Approach 1:
The assembly process is segmented into distinct stages: positioning the outer casing, inserting the central pin, and then adding rollers in groups. This segmentation allows each component to be precisely positioned independently, maintaining fitting precision while enabling automated handling of each segment through the device's structured approach
Solution Approach 2:
The outer casing and central pin are pre-positioned and secured in the device before roller insertion. This preliminary action establishes precise reference positions that guide the subsequent automated roller insertion, ensuring fitting precision is maintained while enabling automation of the most complex part of the assembly process
2Reliability
If traditional bearing assembly methods are used, then reliable rotation can be achieved, but assembly time and labor resources are excessively consumed
Solution Approach 1:
The device uses gravity and self-aligning mechanisms to automatically position rollers between the outer casing and central pin without requiring manual adjustment or complex alignment procedures. This self-service approach maintains rotational reliability through proper roller positioning while dramatically reducing assembly time and labor requirements
Solution Approach 2:
Multiple rollers are inserted and positioned simultaneously in groups rather than individually. This merging of operations maintains the reliable rotational function through proper roller distribution while reducing the number of discrete assembly steps and overall assembly time
3Productivity
If automation of roller insertion is attempted, then productivity increases, but device complexity increases due to alignment requirements
Solution Approach 1:
The device creates a gravity-based reference frame where rollers naturally align themselves along the vertical axis during insertion. This equipotential approach uses gravitational force as a universal reference, simplifying the alignment mechanism while enabling automated high-speed roller insertion without complex positioning systems
Solution Approach 2:
A specialized insertion device acts as an intermediary between the roller supply and the bearing assembly. This intermediary component handles the complex alignment and positioning functions, allowing the main assembly system to remain simple while achieving automated precise roller insertion through the mediator's specialized mechanisms
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
This approach automates the assembly of mechanical systems with relative rotary motion, significantly reducing time, labor, and costs, while reducing friction between moving parts through the use of rollers.
Implementation Method 1
round bodies arranged between the surfaces in relative rotatary motion, in such a way that dynamic friction is reduced by means of the round bodies rolling without sliding
Data Source
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Figure 1(b)
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AI summary
A device is proposed for assembling mechanical systems. These systems comprise an external casing (20) defining a cavity (22), for example a through hole, a central element (30) having at least one portion housed in said cavity (22) of said external casing (20) and a plurality of needle rollers (40), each of the needle rollers (40) housed between the external casing (20) and the portion of central element (30) housed in the cavity (22) of the external casing (20). The external casing and the central element are free to rotate with respect to each other. The device (1000) comprises truing means (200) adapted to arrange each needle roller (40) in such a way that each needle roller (40) has longitudinal axis parallel to a predefined axis (R) and that the needle rollers (40) are arranged in one or more groups (40a, 40b, 40c, 40d). Each group of rollers is arranged at a corresponding level along the predefined axis (R). The needle rollers (40) belonging to each group (40a, 40b, 40c, 40d) are arranged in a reciprocal position substantially corresponding to their final reciprocal position inside the mechanical systems (10) to be assembled. The device (1000) further comprises moving means (300) adapted to simultaneously move the groups (40a, 40b, 40c, 40d) of needle rollers (40) along a direction substantially parallel to the predefined axis (R), so as to position at least one of the groups of needle rollers (40) in a predefined position in which the group of needle rollers (40) is assembled with the external casing (20) and the central element (30) of the mechanical system (10).