Inner-Ring Roller Sleeve Flange Structure for Plastic Cage Retention
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Solution Overview
Problem
Existing inner-ring-fastened roller sleeves face issues with plastic bearing cages falling out due to gravity during assembly, leading to installation problems, and existing solutions like closed steel cages or durable locks are costly.
Innovation Solution
Designing the inner ring with a flange of larger diameter and an axially bent edge region to secure a cost-effective, axially slotted plastic bearing cage, using Z-shaped connecting webs for guidance and fixing the cage within the inner ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an axially slotted plastic bearing cage is used to reduce costs, then manufacturing cost is reduced, but the cage ends fall out due to gravity during assembly
Solution Approach 1:
The invention transitions from a symmetric two-flange design to an asymmetric design with a first flange and a second flange of larger outer diameter. The second flange extends further radially outward to provide an additional retention dimension that prevents the plastic bearing cage from falling out during assembly, while maintaining the cost-effective slotted plastic cage design.
Solution Approach 2:
The invention applies asymmetry by designing the second flange with a larger outer diameter than the first flange. This asymmetric configuration creates an uneven radial profile where the larger second flange provides enhanced retention for the bearing cage, preventing it from falling out during assembly operations.
2Reliability
If a closed steel bearing cage is used to prevent cage ends from falling out, then reliability is improved, but manufacturing cost and material cost increase
Solution Approach 1:
Instead of changing the cage material to steel, the invention adds a radial dimension by extending the second flange outward. This dimensional extension creates a physical barrier that retains the plastic cage ends without requiring a more expensive closed steel cage design.
Solution Approach 2:
The invention segments the flange structure into two distinct flanges with different functions: the first flange provides basic axial guidance, while the extended second flange specifically provides retention for the cage ends. This segmentation allows the use of a simple plastic cage with the retention function provided by the extended flange structure.
3Reliability
If a known cage lock is used to secure the plastic bearing cage, then reliability is improved, but durability for transmission requirements is insufficient
Solution Approach 1:
The invention extracts the retention function from the bearing cage itself and transfers it to the inner ring's flange structure. By extending the second flange to provide retention, the invention eliminates the need for separate cage locks or locking mechanisms, relying instead on the structural design of the inner ring to maintain durability.
4Reliability
If the second flange is extended radially outward to retain the cage, then cage retention is improved, but the radial overall height increases
Solution Approach 1:
The invention applies local quality by extending only the second flange radially outward while keeping the first flange at its original dimensions. This localized extension provides the necessary cage retention function without increasing the overall radial height of the entire bearing assembly, as the extension is confined to a specific region of the inner ring.
Data Source
AI summary
An inner-ring-fastened roller sleeve includes an inner ring and a roller-and-cage assembly. The inner ring is arranged for fastening on a shaft or axle and includes an outer lateral surface with an inner raceway, and first and second flanges extending radially outwards. The second flange includes a larger outer diameter than the first flange and an edge region bent axially towards the first flange. The roller-and-cage assembly is disposed on the inner ring and guided by the first flange and the second flange. The roller-and-cage assembly includes a bearing cage formed as an axially slotted plastic cage and a plurality of roller-type rolling elements inserted into the bearing cage and arranged to roll on the inner raceway. The bearing cage includes a first side ring radially surrounded by the edge region to fix the roller-and-cage assembly in the inner ring, a second side ring, and a plurality of connecting webs.