Thrust Bearing Washer Manufacturing Overlap Rigidity

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Solution Overview

Problem

The existing method of manufacturing washers from a single blank for suspension bearings, which reduces the radius of one washer to avoid damage from axial forces, compromises the overlap between outer and inner diameters, leading to reduced rigidity and maintenance issues in thrust bearings.

Innovation Solution

A method involving the production of a first washer with a rolling track, followed by cutting to separate it and recover a ring with the same outside diameter, then reducing the inside diameter of the ring to produce a second washer with a smaller inside diameter, allowing for significant overlap and improved rigidity by forming washers in the same blank.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the radius of one washer is reduced to avoid damage from axial forces, then the reliability of the bearing is improved, but the overlap between outer and inner diameters is reduced, leading to worsened rigidity

Engineering Contradiction:

Improveprotection of rolling elements from axial force damageVSAvoidrigidity of the thrust bearing

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention divides the manufacturing process into distinct segments: first producing the outer washer with its complete raceway, then separately producing the inner washer with a reduced inside diameter. This segmentation allows each washer to be optimized independently - the outer washer maintains full structural integrity while the inner washer is specifically designed with reduced diameter to provide the necessary overlap for rigidity, thus resolving the contradiction between reliability and rigidity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies local quality by giving each washer different dimensional characteristics suited to its specific function. The outer washer has a standard outside diameter for load distribution, while the inner washer has a reduced inside diameter specifically at the region that contacts the outer washer, creating the overlap necessary for rigidity without compromising the overall reliability of the bearing assembly.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If washers are manufactured from the same blank with reduced inner diameter, then material saving and production simplification are achieved, but the overlap between diameters is limited, worsening the maintenance of rolling bodies

Engineering Contradiction:

Improvesimplification of production processVSAvoidmaintenance of rolling bodies between rolling tracks

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention applies preliminary action by first producing the outer washer with its complete raceway geometry from the blank, then using the remaining material to form the inner washer with the pre-determined reduced inside diameter. This preliminary formation of the outer washer allows the subsequent inner washer to be precisely sized to provide the optimal overlap for rolling body maintenance, thereby achieving both manufacturing simplicity and reliable rolling body maintenance.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the inside diameter of the crown is reduced, then the overlap between washers is increased, improving rigidity, but the manufacturing complexity increases

Engineering Contradiction:

Improverigidity of the suspension thrust bearingVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention merges the production of both washers into a single integrated manufacturing process using one blank. The outer washer is formed first, then the inner washer is formed from the remaining material with the reduced inside diameter. This merging approach achieves the necessary overlap for rigidity while actually simplifying the overall process compared to separate manufacturing, as it eliminates the need for additional joining operations or complex multi-step procedures.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2517805B1Method for manufacturing two washers each comprising a raceway

Publication Date: 2014.01.01 NTN SNR ROULEMENTS

Figure 1(a)~1(h)
Figure 2

AI summary

The method involves manufacturing a washer (1) in a blank of material, where the washer comprises a raceway (1a). The blank is cut for separating the washer from the blank along outer diameter (D1ext) of the blank and for retrieving a crown of material whose inner diameter is equal to the outer diameter. The inner diameter of the crown is reduced by pre-stamping, and another washer (2) is formed in the crown, where the latter washer includes a raceway (2a) and inner diameter (D2int) less than the outer diameter of the former washer. The blank and a ring are stamped. An independent claim is also included for a bump stop of a motor vehicle.