Split Sandwich Bearing Ring for Insulation Without Load Loss
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Solution Overview
Problem
Existing bearing components face challenges in balancing load-bearing capacity with additional functionalities such as electrical insulation and weight reduction, as optimizing for one often compromises the other.
Innovation Solution
A bearing ring with a sandwich structure comprising a first layer forming the running surface, a second interlayer providing additional functionalities, and a third split layer that can be easily assembled, allowing for the use of different materials for each layer to meet various requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bearing component is produced from an insulating material, then electrical insulation is improved, but load-bearing capacity deteriorates
Solution Approach 1:
The bearing component is constructed as a composite structure with a metal base layer providing load-bearing capacity and an insulating coating layer providing electrical insulation. This composite material approach allows both electrical insulation and load-bearing capacity requirements to be satisfied simultaneously by combining materials with complementary properties.
Solution Approach 2:
The bearing component is divided into functionally distinct layers: a metal base layer for mechanical strength and an insulating coating layer for electrical insulation. This segmentation of functions into separate layers allows each layer to be optimized for its specific purpose without compromising the other.
2Weight of moving object
If a bearing component is produced from a lightweight material, then weight is reduced, but load-bearing capacity deteriorates
Solution Approach 1:
The bearing component uses a composite structure combining a lightweight metal alloy base layer that provides both reduced weight and adequate load-bearing capacity, topped with a functional coating layer. This allows weight reduction while maintaining necessary mechanical strength through the lightweight base material.
3Reliability
If a coating is applied to the outer surface of a bearing ring, then electrical insulation is improved, but load-bearing capacity deteriorates
Solution Approach 1:
The bearing component structure is designed with local quality differentiation: the base layer is optimized for mechanical strength and load-bearing capacity, while the surface coating layer is optimized for electrical insulation. Each layer performs its specific function locally without compromising the overall performance.
Solution Approach 2:
A composite structure with a metal base layer for load-bearing capacity and an insulating coating layer for electrical insulation allows both requirements to be met simultaneously. The coating is designed to be thin enough to not significantly affect mechanical properties while providing sufficient electrical insulation.
4Ease of manufacture
If a bearing component is made from a single material, then manufacturing simplicity is improved, but functional versatility deteriorates
Solution Approach 1:
The bearing component is segmented into multiple layers with different materials, each optimized for specific functions. The base layer provides mechanical properties while the coating layer provides electrical insulation or other surface functions. This segmentation enables functional versatility while maintaining manufacturing efficiency through standardized multi-layer fabrication processes.
Solution Approach 2:
The multi-layer structure allows the bearing component to perform multiple functions simultaneously: the base layer provides load-bearing capacity and the coating layer provides electrical insulation, corrosion resistance, or other surface functions. This multi-functionality is achieved within a single integrated component structure.
Data Source
AI summary
A bearing ring includes a first ring portion, a second ring portion and a third ring portion, and the second ring portion is radially sandwiched between the first ring portion and the third ring portion. At least a portion of the first ring portion forms a running surface for a rolling-element. The second ring portion is disposed on the first ring portion, the third ring portion is disposed on the second ring portion, and the third ring portion comprises an axially split ring or a radially split ring.