Full-Complement Strain Wave Bearing Assembly for Higher Load Capacity
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Solution Overview
Problem
Conventional strain wave gearing systems face issues with complex, one-piece machined cages that limit design flexibility, load capacity, and torque, leading to high manufacturing and maintenance costs, while conventional bearings are prone to failure due to space constraints and material constraints.
Innovation Solution
A full complement bearing assembly with rollers and idler rollers arranged circumferentially around the wave generator, eliminating the need for a cage, and incorporating grooves and conical ends to enhance load capacity and reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional one-piece machined cages are used in strain wave drives, then the bearing assembly can be manufactured with traditional methods, but the design flexibility is limited, load capacity is reduced, and manufacturing and maintenance costs increase
Solution Approach 1:
The bearing assembly is divided into multiple independent roller elements arranged in a full complement configuration, eliminating the need for a single complex machined cage. Each roller can be independently manufactured and assembled, providing greater design flexibility while reducing overall assembly complexity.
Solution Approach 2:
The bearing components are arranged in a circumferential pattern around the wave generator, utilizing the radial dimension to maximize load capacity. The conical ends of the wave generator create a three-dimensional bearing space that optimizes roller distribution and load bearing capability.
2Strength
If conventional bearings with cages are used, then the bearing assembly is easier to manufacture with traditional methods, but the load capacity and torque handling capability are limited
Solution Approach 1:
The bearing assembly uses multiple discrete roller elements instead of a single caged structure. This segmentation allows each roller to independently bear load, significantly increasing total load capacity while simplifying manufacturing through standardized roller components.
Solution Approach 2:
The bearing assembly parameters are optimized by arranging rollers in a full complement configuration with specific circumferential spacing. The conical geometry of the wave generator ends creates optimal load distribution angles, enhancing load capacity without requiring complex manufacturing processes.
3Productivity
If fewer bearing components are used to simplify assembly, then the manufacturing and assembly process is simpler, but the load capacity and reliability are reduced
Solution Approach 1:
The bearing assembly employs multiple discrete roller elements that can be independently assembled into the circumferential grooves of the wave generator. This modular approach maintains high reliability through load distribution across multiple components while simplifying assembly compared to installing a complex single-piece cage.
Solution Approach 2:
The full complement arrangement of rollers in the circumferential grooves creates a self-retaining structure where the rollers naturally maintain their positions through the groove geometry, eliminating the need for additional retention mechanisms and simplifying assembly while maximizing reliability.
4Device complexity
If conventional bearing arrangements are used, then the design is simpler, but friction is higher and efficiency is reduced
Solution Approach 1:
Multiple discrete roller elements are arranged circumferentially around the wave generator, creating multiple independent rolling contact zones. This segmentation distributes friction across numerous small contact points, reducing total friction loss and improving efficiency compared to conventional single-row arrangements.
Solution Approach 2:
The bearing arrangement parameters are optimized by positioning rollers at specific circumferential intervals and utilizing the conical geometry of the wave generator ends. This creates optimal rolling contact angles and load distribution, minimizing sliding friction and maximizing rolling efficiency.
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
The solution provides increased load capacity, reduced friction, improved efficiency, and lower manufacturing and maintenance costs, with enhanced positional accuracy and reliability.
Implementation Method 1
The bearing components may comprise a plurality of rollers which rotate about their own axis and a plurality of idler rollers located adjacent ones of said rollers, the idler rollers configured rotate in a direction opposite to the direction in which the rollers rotate about their own axis
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A bearing assembly for a strain wave drive, comprising a full complement of bearing components (200) arranged to be mounted closely adjacent each other around the peripheral extent of a wave generator (100), the number of bearing components being the maximum number of said bearing components that can be accommodated in the peripheral extent. Also provided is a strain wave drive comprising: a wave generator arranged to rotate about an axis and having an elliptical cross-section; a flex spline mounted around the wave generator; and a bearing assembly as described above, located around the wave generator between the wave generator and the flex spline.