Superhard Roller Ball Assembly for Load and Debris Handling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Roller ball assemblies in material handling and equipment applications face issues such as point loading, surface spalling, corrosion, fatigue, and contamination, leading to failure, especially in harsh environments like aerospace and downhole operations, where maintenance is disruptive and access is limited.
Innovation Solution
A roller ball assembly using a primary roller ball supported by superhard polycrystalline diamond elements within a cup, eliminating the need for small diameter support balls, which provides higher load bearing capacity, corrosion resistance, smoother operation, and effective debris clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small diameter support balls are used to support the primary roller ball, then the assembly can handle point loading and reduce surface spalling, but the debris evacuation openings must be small which limits their effectiveness in clearing contaminants
Solution Approach 1:
The invention extracts the support function from small steel balls and transfers it to the cup surface itself, which is hardened with a superhard coating. This eliminates the constraint of small debris openings while maintaining support ball functionality through the hardened surface contact.
Solution Approach 2:
The invention changes the material parameter of the cup surface by applying a superhard coating (such as diamond-like carbon or ceramic), transforming it from a soft steel surface to a hard, wear-resistant surface that can support point loads without spalling, while allowing larger debris openings.
2Reliability
If coatings or alternative roller ball materials are used to overcome galling problems, then galling is reduced, but the increased surface contact area increases the coefficient of friction and reduces free rolling capability
Solution Approach 1:
The invention replaces the mechanical ball-on-ball support system with a ball-on-hard-surface system, where the primary roller ball rolls directly on the superhard-coated cup surface. This substitution maintains low friction and high rolling capability while the superhard coating prevents galling.
3Force
If the roller ball assembly is designed for high load bearing capacity, then it can handle heavy loads in aerospace and downhole applications, but it becomes more susceptible to fatigue loading and failure over time
Solution Approach 1:
The invention uses composite construction by applying a superhard coating (such as diamond-like carbon or ceramic) onto a metal cup substrate. This composite structure combines the high strength and toughness of the metal substrate with the extreme wear and fatigue resistance of the superhard coating, enabling the assembly to handle heavy loads while resisting fatigue failure over time.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A roller ball assembly is provided. The assembly includes a primary roller ball supported by a support element that is composed of a superhard material. The assembly includes a cup defining a cavity within which the support element is positioned. A cap is coupled with the cup and positioned to retain the primary roller ball within the cavity. Also, a cup is disclosed for supporting roller balls. Additionally, disclosed are system and apparatus incorporating the assembly, as well as to methods of making and using the same.