Segmented Plastic Roller Bearing Cage Assembly
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Solution Overview
Problem
Existing roller bearing cages face challenges in achieving dimensional accuracy and cost-effectiveness, particularly in large sizes, due to material limitations and the complexity of injection molding processes, which often result in high scrap rates and increased tooling costs.
Innovation Solution
The use of segmented cage designs, where individual segments are connected during assembly using circumferentially extending connecting elements, allowing for reduced shrinkage and improved accuracy, and enabling the use of smaller, more economical tools, with the option for reversible connections for cost-effectiveness and ease of replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If injection molding process is used to manufacture complete large roller bearing cages, then complex geometries can be reproduced, but dimensional accuracy deteriorates and scrap rate increases
Solution Approach 1:
The cage is divided into multiple segments that are manufactured separately using injection molding and then assembled together. Each segment is smaller and easier to mold with high precision, while the complete cage achieves complex geometry through the assembly of multiple precision-molded segments.
2Ease of manufacture
If injection molding process is used for large roller bearing cages, then complete cage can be produced, but tooling costs and manufacturing complexity increase
Solution Approach 1:
The manufacturing process is segmented into producing individual cage segments through injection molding, then assembling them. This reduces tooling size and complexity compared to molding a complete large cage, while still achieving complete cage production through systematic assembly of standardized segments.
3Productivity
If injection molding process is used for large roller bearing cages, then production can be scaled, but material loss and cavity formation increase
Solution Approach 1:
The cage is manufactured as multiple smaller segments through injection molding, which reduces material loss and prevents cavity formation compared to molding a complete large cage. The segments are then assembled to form the complete cage, maintaining production scalability while minimizing waste.
4Stability of the object's composition
If single-piece cage design is used, then structural integrity is maintained, but shrinkage and dimensional accuracy worsen
Solution Approach 1:
The cage is divided into multiple segments that are each manufactured with high dimensional accuracy through injection molding. The segments are then connected using connecting elements that maintain structural integrity while allowing each segment to be precisely manufactured independently, avoiding the shrinkage and accuracy issues of large single-piece molding.
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The segment (2,3) has a bar (4), which extends in an axial direction (8) and two side sections (14,16), which are connected with the bar and are arranged on the opposite sides of the bar in the axial direction. Another bar (6) has a slot (10) on the side opposite to the former bar for receiving a rolling body. A connecting element (18,20) is provided for connecting the segments with a further segment of the roller bearing cage. The segment is made of an injection-moldable plastic material of more than 50 percent by volume.