Segmented Ball Bearing Outer Ring for Automated Assembly
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Solution Overview
Problem
The assembly of ball bearings, particularly the introduction of the ball cage between the inner and outer rings, is complex and expensive due to the need for precise alignment with minimal play between the running grooves, making automated assembly challenging.
Innovation Solution
The design features two outer partial rings connected via radial overmolding with a reduced diameter shoulder and notches for axial fixation, allowing for simplified and automated assembly by forming an outer ring with a common running groove and using identically designed rings to minimize production complexity and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a traditional outer ring with a complete running groove is used, then the ball bearing structure is simple, but the assembly of the ball cage between inner and outer rings is complex and expensive due to precise alignment requirements
Solution Approach 1:
The outer ring is segmented into two outer partial rings (32a, 32b) that are connected via overmolding. This segmentation allows the ball cage (4) to be easily introduced between the inner ring and the segmented outer partial rings during assembly, eliminating the complex precise alignment requirements of traditional single-piece outer rings while maintaining structural integrity through the overmolded connection.
2Productivity
If automated assembly is implemented, then productivity increases, but precise positioning of the ball cage between running grooves becomes difficult
Solution Approach 1:
The two outer partial rings (32a, 32b) are pre-formed with specific geometries including guide surfaces and connection features before assembly. This preliminary preparation enables automated assembly systems to easily position and connect the ball cage between the inner ring and outer partial rings without requiring complex real-time alignment adjustments, thus maintaining high positioning precision while enabling full automation.
3Reliability
If different outer partial rings are used to achieve precise fixation, then assembly reliability improves, but production complexity and storage requirements increase
Solution Approach 1:
While the outer partial rings are connected asymmetrically to achieve precise fixation and positioning, the patent employs symmetric design elements where applicable (such as identical guide groove patterns on both partial rings) to simplify manufacturing and storage. The asymmetric connection features are strategically placed only where needed for fixation, balancing reliability requirements with production simplicity.
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
Enables efficient, fully automated assembly of ball bearings with reliable fixation and reduced production costs, facilitating easier integration of the ball cage and minimizing position maintenance.
Implementation Method 1
The two outer partial rings (32a, 32b) are connected to one another via an overmolding (5)
Data Source
AI summary
The bearing (1) has an outer ring (3) coaxially arranged on an inner ring (2). The outer ring is formed with running grooves that lie opposite to each other. Balls (41) are inserted between the running grooves. The outer ring is formed by two identical outer part rings, which are connected with each other by a radially rotating overmold part (5). One of the outer part rings comprises an outer diameter-reduced outlet in an outer side, where the outer diameter-reduced outlet is engaged with the overmold part. Notches are arranged offset to each other at an angle of 120 degree. An independent claim is also included for a method for manufacturing a ball bearing.