Segmented Bearing Cage Assembly for Large Roller Bearings
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Solution Overview
Problem
Large tapered roller bearings with diameters over 1 m face challenges in installation due to high manufacturing and acquisition costs, critical tolerance requirements, and mass-related guiding issues, necessitating the separation of inner and outer rings during assembly, which is difficult with traditional one-part cages.
Innovation Solution
The use of bearing cage segments with sliding surfaces and support elements allows for the assembly of rolling-element bearings by supporting band clamps at different radial positions, enabling the separation of inner and outer rings during installation, reducing costs and tolerance issues, and facilitating overhead installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a one-part steel-bolt cage or steel cage is used to receive all rolling elements, then the inner ring and outer ring can be separated during installation, but the cage mass is high and manufacturing costs are very cost-intensive
Solution Approach 1:
The cage is divided into multiple cage segments (first cage segment, second cage segment, etc.) that can be assembled separately and then joined together to form a complete cage structure. This segmentation reduces the mass of individual components and simplifies installation by allowing the inner ring with cage segments and rolling elements to be separated from the outer ring, while avoiding the high mass and cost of traditional one-part steel-bolt cages.
2Ease of operation
If a one-part steel-bolt cage or steel cage is used to receive all rolling elements, then the inner ring and outer ring can be separated during installation, but the manufacturing and acquisition costs are very cost-intensive
Solution Approach 1:
The cage is divided into multiple cage segments that can be manufactured separately using cost-effective materials and processes, then assembled together with rolling elements to form a complete bearing assembly. This segmentation avoids the high manufacturing costs associated with traditional one-part steel-bolt cages while maintaining the ability to separate the inner ring with cage segments from the outer ring during installation.
3Quantity of substance
If one-part very large cages (XXL cages) are used, then all rolling elements can be received, but high demands with respect to guiding are required to avoid cage deformations and tolerances are extremely critical
Solution Approach 1:
The cage is divided into multiple smaller cage segments that can be manufactured with more relaxed tolerances compared to a single large cage. Each segment can be precisely fabricated and then assembled together to form the complete cage structure, reducing the criticality of tolerances and eliminating guiding problems associated with very large one-part cages while maintaining the capacity to receive all rolling elements.
4Quantity of substance
If one-part cages are used, then all rolling elements can be received, but the cage clearance must grow with the diameter due to roller-/cage-guiding problems and speed differences of the rolling elements
Solution Approach 1:
The cage is segmented into multiple sections that can accommodate rolling elements with reduced clearance requirements. Each cage segment can be optimized for its specific location and function, allowing for tighter tolerances and reduced cage clearance compared to a single large one-part cage, while still maintaining the capacity to receive all rolling elements across the entire bearing structure.
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
This solution enables cost-effective assembly of large rolling-element bearings with reduced mass and improved tolerance management, allowing for efficient installation of bearings in applications like wind turbines, using band clamps and tension cables to secure the cage segments and rolling elements.
Implementation Method 1
at least one sliding surface (in particular at least one first and one second, which in particular are both circumferentially outer sliding surfaces), on which a surface of at least one rolling element of the rolling-element bearing is rotatable about an axial direction
Implementation Method 2
a first support element at a first radial position for supporting a first band section of the band clamp during a clamping/assembling of the rolling-element bearing; at least one second support element, at a second radial position different from the first radial position, for supporting a second band section of the band clamp
Data Source
AI summary
A bearing cage segment for a rolling-element bearing includes at least one sliding surface on which a surface of at least one rolling element of the rolling-element bearing is rotatable, a first support element, such as an axial projection on an axial side of the cage segment having a radially open radially facing channel, at a first radial position for supporting a first band section of a band clamp during an assembling of the rolling-element bearing, and at least one second support element at a second radial position different from the first radial position for supporting a second band section of the band clamp.