This project was developed in collaboration with Fersa Bearings, with the goal of redesigning the cage of a tapered roller bearing used in the differential of electric vehicles. The initiative required a complete review of the component’s geometry and material selection, integrating both structural optimization and industrial design considerations.
Our briefing was to maintain the original dimensions and compatibility of the bearing, while rethinking the internal structure of the cage. At the same time, it was necessary to evaluate different high-performance polymers, ensuring mechanical resistance, thermal stability, and reduced friction under demanding operating conditions.
For this project, it was crucial to validate the design through FEM simulations, vibration analysis, and benchmarking with current market solutions. The focus was also on simplifying the manufacturing process, optimizing the geometry to reduce material waste and improve assembly precision, while guaranteeing long-term reliability in real driving conditions.
To ensure the feasibility of the redesign, a physical prototype of the cage was produced and tested under real operating conditions. This phase allowed us to validate the FEM predictions and verify key aspects such as dimensional stability, assembly precision, and resistance to dynamic loads. The results confirmed the improvements in performance and reliability, demonstrating that the new design could successfully meet the demanding requirements of electric vehicle applications.
