Tolerance-ring mounts bearing in cast housing
A
Rencol Tolerance Rings product story
Edited by the Engineeringtalk editorial team
Mar 20, 2009
Engineers at Saint-Gobain Performance Plastics Rencol have developed a method that uses a tolerance ring to accurately and rigidly mount an alternator bearing in a cast housing.
The new approach presents a simple and cost-effective alternative to the more traditional mounting technologies of plastic/rubber boot and glue.
Alternators typically turn twice as fast as the car's engine to improve current output, particularly when the engine is idling.
These high speeds can cause the bearings to run at a high temperature and, in the case of a rubber boot being used, the heat is trapped within the assembly.
This excess heat can cause the grease within the bearing to breakdown and can ultimately shorten bearing life.
In addition, automotive engineers have measured significant variations in the durometer readings of the rubber boot, which can affect its spring rate.
This can allow unwanted side movement of the bearing under heavy-load conditions.
Designers have considered using adhesive as an alternative to rubber boots.
Although gluing the bearing into the cast housing looks attractive, it is difficult to accurately and consistently position it there.
Out-gassing of particulate to the electronics, especially at high temperature, can also cause problems.
With the introduction of the Waste Electrical and Electronic Equipment (WEEE) Directive at the beginning of 2007, OEMs are now turning their focus on the ability to rework or recycle component parts within their end equipment, in particular the alternator.
The customary use of adhesives makes it virtually impossible to dismantle the alternator into its constituent parts.
Tolerance rings are now being used to successfully overcome the problems associated with rubber boots or gluing.
They are easy to assemble, allow rework and offer excellent thermal expansion qualities.
Airflow around the tolerance ring allows the bearing to run as much as six degrees cooler when compared with the rubber boot mount.
The consistent spring rates allow for better centring of the bearing to minimise movement under side loads.
In addition, the sprung nature of the coupling between bearing and housing improves NVH properties of the overall assembly and brush life is extended as vibration is dampened under worst-case conditions.
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