Segmented Rolling Element Cage Welding Reduces Material Waste
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Solution Overview
Problem
The existing manufacturing process for rolling body guide cages generates a significant amount of waste material when punching out ring elements from sheet metal, leading to high production costs.
Innovation Solution
The solution involves producing rolling body guide cages from sheet metal ring elements composed of flat material segments joined in succession and welded together, reducing waste by using a 120° segment configuration that requires only three weld points, allowing for efficient punching and welding with minimal material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If ring elements are punched out from sheet metal material as complete circles, then the ring elements can be formed into spherical cap pockets, but a relatively large amount of waste material is generated
Solution Approach 1:
The ring element is divided into multiple flat material ring segments (e.g., three 120° segments) that are punched out from the sheet metal material. These segments are then joined together to form the complete ring element, significantly reducing waste material compared to punching out complete circular ring elements.
Solution Approach 2:
The invention changes the geometric parameters of the ring element from a complete circle to segmented arcs (e.g., 120° segments). This parameter change allows the segments to be arranged and joined in a way that minimizes material waste while maintaining the functional requirements of the ring element.
2Loss of substance
If flat material ring segments are joined and welded together before forming, then cutting waste is significantly reduced, but additional welding steps are required
Solution Approach 1:
The flat material ring segments are joined together and welded in advance before the forming step that creates the spherical cap pockets. This preliminary action allows the segments to be pre-assembled into a complete ring element, reducing material waste while organizing the additional welding step in an optimal sequence.
Solution Approach 2:
Multiple flat material ring segments are merged and welded together to form a complete ring element. This combining of segments reduces the overall material waste compared to punching out complete circles, while the welding process joins the segments into a structurally sound component.
3Quantity of substance
If 120° ring segments are used to form the ring element, then only three weld points are required and material saving is achieved, but the segments must be precisely positioned and welded
Solution Approach 1:
The joint contours of the 120° ring segments are designed with specific geometric profiles that create adequate coupling with as short as possible weld seam length. The joint contours are configured to taper with obtuse angles towards the ring element edges, concentrating the welding requirements at specific locations and facilitating precise positioning.
Solution Approach 2:
The patent employs a rotary plate with annular grooves to position and hold the ring segments during the welding process. This mechanical positioning system ensures precise alignment of the 120° segments before welding, reducing the complexity of achieving accurate segment positioning.
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 approach significantly reduces production costs by minimizing cutting waste and forming strong, high-strength welds with low distortion, making it suitable for various types of rolling body guide cages, including radial and axial bearing cages.
Implementation Method 1
the flat material ring segments are joined to one another in succession in the circumferential direction and are connected, in particular welded, to one another in a production step which precedes the formation of the axial profiling
Implementation Method 2
these are punched out from a sheet metal material and formed in a forming tool such that they obtain the axial profiling required to form the ball guide pockets
Data Source
AI summary
A rolling element guide cage having a ring element which is made from a sheet material and has an axial profiling produced using forming techniques and forms a plurality of successive rolling element guide structures in the circumferential direction. The ring element is composed of at least two flat material ring segments joined to one another successively in the circumferential direction, said segments being joined together in a manufacturing step which precedes the formation of the axial profiling.