Single-Wire Bearing Cage Structure for Low-Friction Roller Support
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Solution Overview
Problem
Conventional bearing cages made from stamped materials have high friction and material usage, limiting their load-carrying capacity and efficiency.
Innovation Solution
A bearing cage formed from a single piece of wire, bent into shape with axial end rings, bridge portions, and circumferentially-extending connection portions, reducing material usage and friction through line contact engagement with rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional stamped material cages are used, then the cage structure is simple to manufacture, but friction is high and load-carrying capacity is limited
Solution Approach 1:
The invention changes the fundamental parameter of cage material form from stamped sheet material to wire-formed material. This parameter change enables line contact engagement with rollers instead of surface contact, significantly reducing friction and increasing load-carrying capacity while maintaining manufacturing feasibility through wire forming processes
Solution Approach 2:
The cage incorporates a low-friction coating applied to the wire surface, creating a composite structure with the wire base material. This composite approach reduces friction between the cage and rollers, further enhancing load-carrying capacity and reducing wear
2Weight of moving object
If stamped material cages are used, then the manufacturing process is straightforward, but material usage is high and weight is increased
Solution Approach 1:
The cage is constructed from discrete wire segments that are formed and joined together to create the complete cage structure. This segmentation allows for optimized material distribution, eliminating excess material used in stamped cages while maintaining structural integrity through wire-to-wire joining
Solution Approach 2:
Changing from stamped sheet material to wire-formed material fundamentally alters the material usage pattern. The wire form allows for precise material placement where needed, reducing overall material consumption and cage weight while maintaining necessary structural properties
3Productivity
If wire-formed cage is used, then friction is reduced and load-carrying capacity increases, but manufacturing complexity increases due to wire forming and joining
Solution Approach 1:
Multiple wire segments are joined together to form the complete cage structure. This merging approach allows each wire segment to be optimized for its specific function while combining to create the overall cage system, balancing structural complexity with manufacturing efficiency
Solution Approach 2:
The wire segments are designed to self-align and self-support during the wire forming and joining process, reducing the need for complex external fixtures or assembly operations. The inherent flexibility and geometry of the wire segments facilitate automatic positioning and joining
Data Source
AI summary
A bearing cage is formed from a single piece of wire bent into shape and includes a first axial end ring, a second axial end ring including a distal end of the single piece of wire, a plurality of axially-extending bridge portions between the first and second axial end rings, and a plurality of circumferentially-extending connection portions interconnecting adjacent bridge portions. The connection portions are alternately positioned adjacent the first and second axial end rings.