Sheet Metal Bearing Cage Segments for Lower-Material Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing methods for rolling bearing cages, particularly for large bearings, are costly and complex due to high material usage and require multiple machining processes, especially when using plastics or metals.
Innovation Solution
A cage segment for a rolling bearing is designed as a kit of flat sheet metal components that are assembled to form a multi-part cage segment, reducing material usage and eliminating the need for extensive machining by using laser cutting and bending to create functional elements that guide, retain, and connect the segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods (rolling and machining solid material) are used for large bearing cages, then the cages have sufficient strength and durability, but the material usage is high and manufacturing complexity increases
Solution Approach 1:
The cage is divided into multiple cage segments (first cage segment, second cage segment, etc.) that can be manufactured separately and assembled together. Each segment is formed from flat sheet metal components rather than solid material, significantly reducing material usage while maintaining structural integrity through the segmented architecture.
Solution Approach 2:
The invention uses flat sheet metal components to form the cage segments instead of solid material. The sheet metal is bent and joined to create the cage structure, which reduces material consumption compared to conventional rolling and machining of solid material, while still providing sufficient strength for large bearing applications.
2Strength
If plastic material (e.g., glass fiber reinforced PEEK) is used for bearing cages, then the cages have good temperature properties and strength, but the per-kilogram cost is high and material quantity required is large
Solution Approach 1:
The invention uses flat sheet metal components with reduced thickness compared to conventional plastic cages. The sheet metal is bent and joined to form the cage structure, significantly reducing the quantity of material required while maintaining structural integrity. This eliminates the need for expensive high-performance plastics like glass fiber reinforced PEEK.
Solution Approach 2:
The cage segments are formed from sheet metal components that can be joined together to create a composite cage structure. This approach allows the use of simpler, less expensive materials while achieving the required mechanical properties through the composite assembly of multiple segments.
3Strength
If metal cages are manufactured by rolling and machining solid material, then the cages have sufficient strength, but the manufacturing process is complex and costly
Solution Approach 1:
The invention uses flat sheet metal components that are bent and joined to form the cage segments. This process is simpler than rolling and machining solid material, as it requires fewer manufacturing steps and less complex equipment. The sheet metal can be easily formed into the required shapes and joined using standard fabrication techniques.
Solution Approach 2:
The cage is divided into multiple segments that can be manufactured separately and assembled together. This segmentation allows for simpler manufacturing of each individual segment from flat sheet metal, rather than requiring complex rolling and machining of a large solid block. The segments are joined using connecting elements to form the complete cage.
4Device complexity
If thicker cage segments are used to reduce the number of rolling elements, then the cage structure is simpler, but the distance between rolling elements increases reducing bearing performance
Solution Approach 1:
The cage is divided into multiple thin cage segments that can be closely spaced, allowing for a large number of rolling elements to be accommodated in the bearing. The segmented structure enables the use of thinner individual cage walls while maintaining overall structural integrity through the assembly of multiple segments.
Solution Approach 2:
The cage segments are formed from sheet metal components that are joined together to create a composite cage structure. This allows the use of thinner individual segments while maintaining sufficient strength through the composite assembly, enabling closer spacing of rolling elements and improved bearing performance.
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 reduces material and manufacturing costs while allowing for more rolling elements in large bearings, enhancing performance and eliminating the need for separate guides, thus increasing the service life of raceways and simplifying assembly.
Implementation Method 1
the sheet metal component (4) joined at a joint (6) to form a cage segment (1)... In a preliminary stage of production, the cage segment is supplied as a kit with one or more flat sheet metal components (4)... the sheet metal component is bent and joined at its two ends
Implementation Method 2
These sheet metal components are designed to be assembled to form the cage segment... by using laser cutting and bending to create functional elements
Implementation Method 3
the sheet metal component (4) joined at a joint (6) to form a cage segment (1)... joined at its two ends
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A cage segment (1) for a multi-part rolling bearing cage (30), in particular for large rolling bearings, is disclosed, wherein in a preliminary stage of production the cage segment (1) is available as a kit consisting of one or more flat sheet metal components (4), wherein the sheet metal components (4) are designed to be assembled to form the cage segment (1), wherein the cage segment (1) in its assembled form has at least one joining point (6) at which two ends of the sheet metal components (4) are joined to form a pocket (2) suitable for receiving at least one rolling element (32).