Segmented Bearing Cage Assembly for Large-Diameter Accuracy
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Solution Overview
Problem
Traditional integral injection molding of large-diameter bearing cages results in dimensional accuracy issues, limited adaptability to different bearing diameters, difficult assembly, poor lubrication leading to pressure erosion and noise, and inadequate vibration and noise reduction.
Innovation Solution
The use of arc-shaped segments with a specific radian angle range to form a segmented bearing cage, allowing for flexible assembly and adaptation to different bearing diameters, while incorporating ellipsoidal pockets and lubrication structures for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If integral injection molding is used to manufacture large-diameter cages, then the cage structure is simple, but the manufacturing difficulty increases and dimensional accuracy deteriorates
Solution Approach 1:
The cage is divided into multiple arc-shaped segments that can be manufactured separately using injection molding and then assembled together. Each segment is smaller and easier to manufacture with high dimensional accuracy, while the complete cage achieves the required large diameter and structural complexity.
2Device complexity
If integral injection molding is used for large-diameter cages, then the cage structure is simple, but the assembly difficulty increases
Solution Approach 1:
The cage is segmented into multiple manageable arc-shaped sections that can be assembled in a step-by-step manner. Each segment can be independently handled and positioned, making the overall assembly process much easier compared to handling a single large integral cage.
Solution Approach 2:
The arc-shaped segments are designed with flexible connection features that allow for dynamic adjustment during assembly. The segments can be temporarily positioned and adjusted before final fixation, enabling easier assembly operation.
3Device complexity
If integral injection molding is used, then the cage structure is simple, but the adaptability to different bearing diameters deteriorates
Solution Approach 1:
The segmented design allows the cage to be adapted to different bearing diameters by adjusting the number of arc-shaped segments or modifying the arc angle of each segment. This provides versatility while maintaining a relatively simple basic structure for each segment.
Solution Approach 2:
The arc-shaped segments are designed as universal components that can be used in different cage configurations. By varying the number of segments or their geometric parameters, the same basic segment design can accommodate multiple bearing diameters and applications.
4Device complexity
If traditional cage design is used, then the structure is simple, but the lubrication performance deteriorates
Solution Approach 1:
The cage structure incorporates localized lubrication features such as lubricant channels and storage cavities at specific positions where lubrication is most needed. This provides improved lubrication performance in critical areas while maintaining overall structural simplicity.
5Device complexity
If traditional cage design is used, then the structure is simple, but the noise and vibration deteriorate
Solution Approach 1:
The cage incorporates localized vibration reduction features such as damping materials or structural modifications at specific high-stress positions. This reduces noise and vibration generation at critical locations while maintaining overall structural simplicity.
Data Source
AI summary
An arc-shaped segment (1) for assembling a segmented bearing cage. An arc length L and a radian angle θ of the arc-shaped segment (1) satisfy the following relationship: 360L/πD−20°≤θ≤360L/πD+30° with D being a diameter of the segmented bearing cage. The arc length L refers to an arc length corresponding to the radian angle θ of the arc-shaped segment (1). A segmented bearing cage comprising a plurality of arc-shaped segments (1). A bearing comprising the segmented bearing cage. After being assembled in the bearing, a plurality of arc-shaped segments abut on or connect with each other, to form a complete cage.