Segmental Bearing Cage Insert Layout for Thin-Walled Load Support
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Solution Overview
Problem
Existing rolling bearing cages, especially for large bearings, require significant material and are costly due to complex manufacturing processes and high material thickness needed to withstand large rolling element weights, making them difficult and expensive to produce.
Innovation Solution
A cage segment design featuring a pocket for rolling elements and a separate insert element that can be captively fastened, allowing for a thinner cage segment, made from sheet metal, which compensates for distance and weight differences using a distinct insert element that can be designed for specific contact zone requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick cage segment is used to withstand large rolling element weights, then the strength is improved, but the material usage increases and production costs rise
Solution Approach 1:
The cage segment is divided into two separate components: a thin-walled base cage segment and a separate thick insert element. The insert element is placed into a recess in the cage segment and securely fastened, combining to form the final load-bearing structure. This segmentation allows each component to be optimized independently - the cage segment for ease of manufacture and the insert element for strength.
Solution Approach 2:
The solution combines two different components (cage segment and insert element) made from potentially different materials to create a composite structure. The insert element can be made from a material with higher strength-to-weight ratio, while the cage segment uses a more cost-effective material, achieving overall strength improvement without proportional material increase.
2Reliability
If a thick cage segment is used to compensate for distance between rolling elements, then the reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The functional requirements are segmented between two components: the cage segment provides the basic structure and spacing, while the separate insert element provides the additional thickness needed for reliability. This allows the cage segment to be manufactured simply as a thin-walled structure.
Solution Approach 2:
The load-bearing thickness requirement is extracted from the cage segment design and implemented as a separate insert element. This allows the cage segment to be optimized for manufacturing simplicity while the insert element is optimized for providing the necessary structural reliability.
3Strength
If a thick cage segment is used to withstand rolling element weights, then the strength is improved, but the ease of manufacture deteriorates due to difficult forming
Solution Approach 1:
The difficult-to-form thick load-bearing structure is segmented into a thin cage segment (easy to form) and a separate insert element (which can be formed or machined independently). The cage segment can be manufactured using simple stamping or drawing processes, avoiding the high forces required to form thick sections.
Solution Approach 2:
The complex forming requirements for thick sections are extracted from the cage segment and assigned to a separate insert element. This allows the cage segment to be manufactured using simple, cost-effective processes while the insert element can be produced by specialized processes only where needed.
4Strength
If more material is used in the cage segment, then the strength is improved, but the weight increases
Solution Approach 1:
The composite structure of cage segment and insert element allows for optimized material distribution. The insert element provides the necessary strength with minimal material, positioned only where load-bearing is required, while the rest of the cage segment remains lightweight.
Solution Approach 2:
The thick load-bearing section is provided only locally where needed through the insert element, rather than throughout the entire cage segment. This localized reinforcement provides the necessary strength while minimizing overall weight increase.
Data Source
Figure 1~2
Figure 3~5
AI summary
A cage segment (2) for a segment cage, in particular for large rolling bearings, is disclosed, wherein the cage segment (2) forms a pocket (8) suitable for receiving at least one rolling element (32), wherein the cage segment (2) has at least one recess (16) designed to receive an insert element (4), wherein the insert element (4) can be secured in the recess (16) in a loss-proof manner.