Contoured Raceway Joint Edges for Precise Ring Alignment
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Solution Overview
Problem
Existing methods for forming raceway elements from sheet metal struggle with precise alignment of joint edges during connection, leading to potential misalignment and increased manufacturing costs due to the need for additional surface treatments and complex processing steps.
Innovation Solution
A method involving a sheet metal panel with pre-configured alignment elements and laser cutting/punching techniques to form raceway elements, allowing for precise alignment and connection of joint edges, reducing material waste, and enabling efficient production of raceway elements with desired dimensions and surface treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deep drawing and rolling methods are used to form raceway elements, then the manufacturing process is well-established, but alignment precision of joint edges deteriorates leading to offset connections
Solution Approach 1:
The patent applies preliminary action by pre-forming contoured alignment features (such as protrusions and recesses) on the joint edges of the raceway blank before the final forming operations. These alignment features are created during intermediate stages of the deep drawing process, enabling precise self-alignment of joint edges before connection, thereby preventing offset connections while maintaining process simplicity.
2Manufacturing precision
If additional surface treatment steps are performed to achieve desired surface properties, then surface quality is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent merges the surface treatment function into the forming process itself by creating contoured joint edges and alignment features during the deep drawing operations. The forming process simultaneously achieves both the geometric shape and the surface properties required, eliminating the need for separate surface treatment steps and reducing manufacturing complexity while maintaining surface quality.
3Reliability
If traditional connecting methods are used for joint edges, then connection is achieved, but risk of displacement and misalignment increases
Solution Approach 1:
The patent applies self-service by designing joint edges with complementary contoured alignment features (protrusions and recesses) that automatically guide and constrain the relative positioning of connecting edges during the connection operation. The geometry itself provides the alignment function, making the connecting operation self-aligning and eliminating the need for external alignment devices or complex positioning procedures, thereby improving both reliability and ease of operation.
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
The method ensures precise alignment and connection of joint edges, reducing manufacturing costs and complexity, while allowing for the production of raceway elements with desired dimensions and surface treatments, enhancing the accuracy and efficiency of the raceway element manufacturing process.
Implementation Method 1
separating a strip of sheet metal from a sheet metal body by a combination of punching and laser cutting
Data Source
AI summary
A method includes separating a strip of sheet metal from a sheet metal body by a combination of punching and laser cutting, the strip having a first joint edge having at least one first alignment element and a second joint edge having at least one second alignment element complementary to the at least one first alignment element, folding a longitudinal edge portion of the strip to form a flange, bending the strip into a ring and materially bonding the first joint edge to the second joint edge, installing the ring on a radially inner circumferential surface or a radially outer circumferential surface and mounting a plurality of rolling-elements on the ring. The first joint edge and the second joint edge are formed by the punching, and side edges connecting the first joint edge and the second joint edge are formed by the laser cutting.