Roller Spring Perch Assembly With Integrated Bearing Housing
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Solution Overview
Problem
Existing spring perches with roller bearings have large, separate bearing housings that are difficult and expensive to manufacture, requiring improved design for simplicity and cost-effectiveness.
Innovation Solution
A method involving a steel bracket with integrated bearing housing and snap rings, where a single tube is spot-welded through the bracket to accommodate roller bearings, reducing material and labor costs, and a process to convert existing perches by removing rubber bushings and replacing them with a new tube and bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate bearing housings are used to accommodate roller bearings, then the spring perch provides free rotation, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent integrates the bearing housing function directly into the bracket by forming counterbores within the bracket structure itself, eliminating the need for separate bearing housing components. This merging of functions reduces the number of parts and simplifies manufacturing while maintaining the free rotation capability through roller bearings.
Solution Approach 2:
The bracket is designed to serve multiple functions: it provides structural support, mounting surfaces, and integrated bearing housing through counterbores. This multi-functionality eliminates the need for dedicated bearing housing components, reducing manufacturing complexity while maintaining operational performance.
2Reliability
If separate bearing housings are used, then roller bearings are accommodated, but manufacturing time and expense increase
Solution Approach 1:
The counterbores for roller bearings are formed directly within the bracket structure during the bracket manufacturing process, combining the bracket fabrication and bearing housing creation into a single operation. This eliminates separate manufacturing steps for bearing housings, significantly improving manufacturing efficiency while ensuring reliable roller bearing accommodation.
3Ease of manufacture
If a single tube is spot-welded through the bracket, then material and labor costs are reduced, but the structural integrity must be maintained
Solution Approach 1:
Holes are pre-formed in the bracket sidewalls before the tube is installed, allowing the tube to be spot-welded in place through these predetermined locations. This preliminary preparation enables simple spot-welding construction while maintaining structural integrity at the critical connection points.
Solution Approach 2:
The patent replaces traditional extensive welding or mechanical fastening systems with spot-welding, substituting a complex mechanical connection system with a simpler thermal joining process that achieves sufficient structural integrity with minimal material and labor input.
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 new design significantly reduces manufacturing costs by at least 50% and simplifies the production process while maintaining functionality, offering a more economical and efficient roller spring perch.
Implementation Method 1
spot welding the bearing housing to the sidewalk of the steel bracket
Implementation Method 2
two of the four bearings pressed onto each of the two bearing lands and the bearings fit into the counterbores of the bearing housing
Data Source
AI summary
A method for creating a roller spring perch has steps for making a steel frame bracket, procuring snap rings, procuring four bearings, machining a steel cylindrical bearing housing, machining a bearing shaft, assembling the bearing shaft to the bearing housing with the four bearings pressed onto each of two bearing lands, assembling the snap rings in snap ring grooves of the bearing shaft, placing the bearing housing with the bearing shaft and bearings centered through holes in sidewalls of the steel bracket; and spot welding the bearing housing to the sidewalls of the steel bracket.