Superhard Roller Ball Support Assembly for Debris and Wear Resistance
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Solution Overview
Problem
Roller ball assemblies face issues such as point loading, surface spalling, corrosion, and fatigue leading to failure, along with contamination and reduced free rolling capability due to debris, especially in harsh environments like aerospace and downhole operations, where maintenance is time-consuming and disruptive.
Innovation Solution
The use of superhard materials like tungsten carbide, silicon carbide, and polycrystalline diamond for support elements in roller ball assemblies, eliminating small diameter support balls and enhancing load-bearing capacity, corrosion resistance, and debris clearance, while allowing for self-cleaning and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If small diameter support balls are used to support the primary roller ball, then the assembly can handle point loading, but the support balls are subject to surface spalling, corrosion, and fatigue leading to failure
Solution Approach 1:
The patent changes the material parameter of the support elements from conventional steel to superhard materials (tungsten carbide, silicon carbide, polycrystalline diamond). This material parameter change dramatically improves resistance to surface spalling, corrosion, and fatigue while maintaining load-bearing capacity, directly resolving the technical contradiction between strength and reliability.
Solution Approach 2:
The patent employs composite material solutions by using superhard materials either as coatings on support elements or as solid superhard support elements themselves. These composite or advanced material structures provide both the required mechanical strength for point loading and enhanced durability against surface degradation, corrosion, and fatigue.
2Reliability
If coatings or lubricants are used to overcome galling problems with direct cup surface engagement, then galling is reduced, but the coefficient of friction increases and free rolling capability is reduced
Solution Approach 1:
The patent extracts the support function from the cup surface directly and introduces discrete support elements (superhard balls or blocks) that carry the primary support function. This extraction eliminates the need for coatings or lubricants to prevent galling between the roller ball and cup surface, while maintaining low friction through the rolling contact of superhard support elements.
Solution Approach 2:
The patent uses solid superhard support elements that are inherently resistant to galling without requiring protective coatings or lubricants. These support elements serve as durable, maintenance-free replacements for coated or lubricated surfaces, eliminating the need for periodic re-coating or lubrication while maintaining free rolling capability.
3Ease of operation
If small debris evacuation openings are used in the cup structure, then the support balls are not interfered with, but the effectiveness in clearing contaminants is limited
Solution Approach 1:
The patent changes the geometry parameters of the debris evacuation openings by utilizing the larger spaces created by the superhard support element configuration. The support elements are positioned and sized such that larger openings can be provided in the cup structure, dramatically improving contaminant clearance effectiveness while maintaining proper support ball operation through the superhard elements.
4Reliability
If the primary roller ball surface contact area with the cup surface is increased to overcome galling, then galling is reduced, but the coefficient of friction increases and free rolling capability is reduced
Solution Approach 1:
The patent introduces superhard support elements as intermediary components between the primary roller ball and the cup surface. These support elements act as mediators that carry the contact loads, preventing direct contact between the roller ball and cup surface. This intermediary arrangement eliminates galling problems while maintaining low friction through the rolling contact of the superhard support elements.
Data Source
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 halls. Additionally, disclosed are system and apparatus incorporating the assembly, as well as to methods of making and using the same.