Sheet Metal Bearing Cage Segment for Lower-Cost Large Bearings
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Solution Overview
Problem
The manufacturing of rolling-element bearing cages is complex and costly, especially for large bearings, due to high material usage and the need for multiple manufacturing methods, with plastic cages being expensive and metal cages requiring extensive processing.
Innovation Solution
A sheet metal cage segment is designed as a preform of connected flat components, which can be easily and cost-effectively manufactured using techniques like cutting, laser cutting, and reshaping, reducing material usage and allowing for thinner designs that increase efficiency by housing more rolling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic cages are used, then the cages can be manufactured by injection molding, but the material cost is very high especially for large bearings
Solution Approach 1:
The patent changes the material parameter from plastic to sheet metal, fundamentally altering the material properties and enabling different manufacturing approaches. This substitution reduces material cost while maintaining manufacturability through cutting and forming operations
Solution Approach 2:
The patent employs sheet metal as a cheaper alternative material that can be easily processed and discarded or replaced, reducing the overall cost burden compared to expensive plastic materials required for large bearing cages
2Strength
If metal cages are manufactured by rolling and machining, then the cages have sufficient strength, but the material usage is high and manufacturing is complex
Solution Approach 1:
The patent divides the cage into multiple separate sheet metal components that are individually formed and then assembled together. This segmentation allows each component to be optimized independently and simplifies the manufacturing process compared to forming a complete cage as a single piece
Solution Approach 2:
The patent transitions from three-dimensional bulk metal forming to two-dimensional sheet metal processing. By working with flat sheets that are subsequently formed and assembled, the manufacturing process becomes simpler and more cost-effective while maintaining structural integrity
3Quantity of substance
If sheet metal components are used, then the cage can be made thinner and material usage reduced, but the manufacturing process requires precise cutting and joining
Solution Approach 1:
The patent incorporates preliminary forming of functional elements directly onto the sheet metal components before final assembly. This preliminary action ensures precise positioning and reduces the complexity of subsequent joining operations, as elements are already in their correct configurations
Solution Approach 2:
The patent combines multiple manufacturing operations into integrated processes, such as combining cutting with forming, or combining component fabrication with functional element creation. This merging reduces the number of separate precision operations required and streamlines the overall manufacturing process
Data Source
AI summary
A cage segment defines a single pocket of a multipart rolling-element bearing cage and includes first and second circumferentially spaced side walls connected by first and second end walls. The first and second side walls and the first and second end walls are formed by at least one sheet metal segment connected at at least one joint.