Abstract:
A roller-guided track apparatus is provided. The roller-guided track apparatus includes a support member and a track roller arrangement. The track roller arrangement includes an axle and a roller, with the axle having first and second axial ends thereof. The first axial end of the axle is attached to the support member in such a manner that the second axial end of the axle forms a distal end of the axle projecting away from the support member. The roller defines an inner side of the roller and an outer side of the roller and has an aperture formed therethrough configured for receiving the axle. The axle passes through the aperture of the roller such that the roller is rotatable about the axle, the inner side of the roller faces the support member, and the distal end of the axle extends beyond the outer side of the roller. The distal end of the axle is orbitally deformed to form a head for retaining the roller upon the axle.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention generally relates to roller-guided track apparatuses and, in particular, to a precision roller-guided track apparatus. 
       BACKGROUND OF THE INVENTION 
       [0002]    A conventional roller-type linear guide apparatus, such as disclosed in U.S. Pat. No. 5,820,269 to Ariga, is employed to guide a light weight structure along a linear path. However, the conventional roller-type linear guide apparatus only suitably carries a light weight structure and is not suitable for heavier loads. Therefore, the use of these types of guide apparatuses is limited. 
         [0003]    Other conventional roller-type linear guide apparatuses have components that are secured together by riveting. Because the riveting process generally relies on impacting an axial end of the rivet with a very large amount of force, the riveting process may cause damage to the roller assembly. For example, during impacting, components of the roller assembly might be prone to a form of brinelling, which is surface damage caused by repeated overload. If brinelling or other damage occurs, divots or notches may be formed in surface that the bearings travel over and along. If this occurs, operation of the roller-type linear guide is rather rough. 
         [0004]    To overcome these and other drawbacks, the industry has migrated toward using linear rail systems having a threaded roller assembly as depicted in U.S. Pat. Nos. 6,149,308 and 6,450,687 to Schroeder, et al., and U.S. Pat. No. 5,531,137 to Guilford. The threaded roller assembly has an axle with a threaded end. The threaded end is threadably driven into, for example, a slider body having mating threads. As such the roller assembly is well supported. 
         [0005]    While the threaded roller assemblies noted above work quite well for their intended applications, there are other applications where it would be desirable to eliminate the threads on the axle. In some circumstances, an axle bearing threads may be somewhat weakened compared to a non-threaded axle. This is because material it usually removed and the diameter of the axle is reduced when forming the threads. In addition, during the threading process, the hardening of the axle is partially stripped away. By removing the hardening from a portion of the axle, the benefits of that process are lost. As another drawback, an axle with threads may be more susceptible to cycle stress, fatigue, and vibration. Moreover, a threaded axle may be prone to over tightening, which will likely damage the axle and any threaded mating component. 
         [0006]    There exists, therefore, a need in the art for a tamper-proof roller mounting arrangement and method that overcomes one or more of the above-noted drawbacks. The invention provides such an arrangement and method. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    A roller-guided track apparatus is provided. The roller-guided track apparatus prevents or discourages tampering and is constructed using a process that is generally inexpensive and completely relatively quickly. The roller-guided track apparatus is also uniquely configured to prevent components of the apparatus from undesirably coming apart after they have been secured together. 
         [0008]    In one embodiment, a method of mounting a track roller arrangement to a support member is provided. The track roller arrangement includes an axle and a roller. The method includes the steps of attaching a first portion of the axle to the support member, passing a second portion of the axle through the roller, and orbitally deforming the second portion of the axle to secure the roller onto the axle. 
         [0009]    In one embodiment, a roller-guided track apparatus is constructed according to the above noted method. The roller-guided track apparatus includes a support member and a track roller arrangement. The track roller arrangement includes an axle and a roller, with the axle having first and second axial ends thereof. The first axial end of the axle is attached to the support member in such a manner that the second axial end of the axle forms a distal end of the axle projecting away from the support member. The roller defines an inner side of the roller and an outer side of the roller and has an aperture formed therethrough configured for receiving the axle. The axle passes through the aperture of the roller such that the roller is rotatable about the axle, the inner side of the roller faces the support member, and the distal end of the axle extends beyond the outer side of the roller. The distal end of the axle is orbitally deformed to form a head for retaining the roller upon the axle. 
         [0010]    Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings: 
           [0012]      FIG. 1  is a partially exploded view of an exemplary embodiment of a roller-guided track apparatus in accordance with the teachings of the present invention, the roller-guided track apparatus oriented proximate a channel; 
           [0013]      FIG. 2  is a front elevation view of the roller-guided track apparatus of  FIG. 1 ; 
           [0014]      FIG. 3  is a side elevation view of the roller-guided track apparatus of  FIG. 1  prior to a free end of the axle being subjected to an orbital forming process; 
           [0015]      FIG. 4  is a side elevation view of the roller-guided track apparatus of  FIG. 1  after the free end of the axle has been orbitally formed; 
           [0016]      FIG. 5  is a top view of the roller-guided track apparatus of  FIG. 1  highlighting a set screw and a pair of wipers; and 
           [0017]      FIG. 6  is another embodiment of a roller-guided track apparatus formed by the orbital forming process. 
       
    
    
       [0018]    While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Referring to  FIG. 1 , a roller-guided track apparatus  10  is illustrated. As will be more fully explained below, the roller-guided track apparatus  10  is constructed in a manner that prevents or discourages tampering. In addition, the roller-guided track apparatus  10  is constructed using a process that is generally inexpensive and that can be completed relatively quickly. The roller-guided track apparatus  10  is also uniquely configured to prevent components of the roller-guided track apparatus from undesirably coming apart after they have been secured to each other. As shown in  FIG. 1 , the roller-guided track apparatus  10  comprises a support member  12  and a track roller arrangement  14 . 
         [0020]    In the illustrated embodiment of  FIG. 1 , the support member  12  is a slider body, which may also be described as a carriage or shuttle. As shown, the support member  12  includes a central aperture  16  disposed about an equal distance from each side  18 ,  20  and the top and bottom  22 ,  24  of the slider body  12 . The central aperture  18  generally passes through the slider body  12  from a front surface  26  to the back surface  28 . The particular configuration of the central aperture  18  will be more fully explained below. 
         [0021]    Spaced outwardly from the central aperture  18  toward the sides  18 ,  20  are two small round apertures  30 . The small round apertures  30  pass entirely through the slider body  12  from the front surface  26  to the back surface  28 . These apertures  30  are sized and dimensioned to receive a screw, bolt, or other suitable connector such that the slider body  12  may be secured to, for example, a drawer in a piece of furniture (not shown). 
         [0022]    Set outwardly from the two small apertures  30  toward the sides  18 ,  20  are two larger round apertures  32 . Like the small round apertures  30 , the large apertures  32  pass entirely through the slider body  12  from the front surface  26  to the back surface  28 . In the illustrated embodiment, a portion of slider body  12  around the large round apertures  32  is angled inwardly to form a countersink  34 . 
         [0023]    Each of the large round apertures  32  is sized and dimensioned to receive an axle  36  (a.k.a., spindle, shaft, etc.) from the track roller arrangement  14 . In the illustrated embodiment, each of the axles  36  includes an outwardly flared end  38 . When each of the axles  36  is inserted into one of the large round apertures  32 , the flared end  38  generally engages the countersink  34  in the slider body  12  to prevent the axle  36  from being pulled entirely through the slider body  12 . In the illustrated embodiment of  FIG. 1 , the flared ends  38  of the axles  36  are disposed slightly beneath the front surface  26  of the slider body  12 . In other words, in the illustrated embodiment the flared ends  38  are not flush with the front surface  26  of the slider body  12 . 
         [0024]    As shown in  FIG. 2 , the axle  40  seated in the central aperture  18  has a generally rectangular end  42 . In the illustrated embodiment, the long side of the rectangular end  42  progresses toward each of the sides  18 ,  20  of the slider body  12 . The short side of the rectangular end  42  has a length that is somewhat less than the side dimension of the central aperture  18 . Therefore, as will be more fully explained below, the axle  40  is able to move vertically (i.e., up and down) within the central aperture  18  relative to the top and bottom surfaces  22 ,  24  of the slider body  12 . 
         [0025]    As shown in  FIG. 2 , the rectangular end  42  of the axle  40  seats against an inner surface  44  of a back wall  46  of the slider body  12 . The inner surface  44  of the back wall  46  is the surface that generally opposes the back surface  28  shown in  FIG. 1 . The back wall  46  of the slider body  12  forms a rectangular slot  48  oriented with a long side progressing toward the top and bottom  22 ,  24  of the slider body  12 . Therefore, the rectangular slot  48  is oriented about ninety degrees away from the rectangular end  42  of the axle  40 . Therefore, when the axle  40  is disposed within the central aperture  18 , the axle passes through the rectangular slot  48  and the rectangular end  42  engages the inner surface  44  of the back wall  46  in the slider body  12  and prevents the axle  40  from being pulled entirely through the central aperture  18 . 
         [0026]    Because the inner surface  44  of the back wall  46  is spaced further away from the front surface  26  of the slider body  12  than a thickness of the rectangular end  42  of the axle  40 , the rectangular end of the axle is disposed slightly beneath the front surface of the slider body. In other words, in the illustrated embodiment the rectangular end  42  is not flush with the front surface  26  of the slider body  12 . 
         [0027]    While the rectangular and flared ends  36 ,  42  of the axles  38 ,  40  are quite different from each other, the central portion  50  and free end  52  of each of the axles  36 ,  40 , represented in  FIG. 3  generally has the same cylindrical or axial shape. While the axles  36 ,  40  may be formed from a hollow cylinder, the axles in the illustrated embodiment of  FIG. 1  are solid. As depicted in  FIG. 1 , some of the central portion  50  and a free end  52  of each of the axles  36 ,  40  project away, and extend outwardly, from the back surface  28  of the slider body  12 . Therefore, the free ends  52  form a distal end. As will be more fully explained below, the distance that the axles  36 ,  40 , and particularly the free ends  52 , extend from the slider body  12  depends on the size and dimension of a roller  54  and, if one is included, a washer  56  (a.k.a., a spacer) of the track roller arrangement  14 . 
         [0028]    Before any work is performed on them, the free ends  52  are sized and dimensioned to pass through a central aperture  58  of the washer  56 . Once the washer  56  has been placed on the axle  36 ,  40 , the free end  52  is inserted through a central aperture  60  of an inner race  62  of the roller  54  such that the free end  52  is press fit to the inner race  62 . Therefore, as depicted in  FIG. 3 , the free end  52  projects out of the central aperture  60  of the inner race  62 . Also, the inner race  62 , the washer  56 , and the slider body  12  are engaged with each other. Even so, the outer race  64  and roller wheel  66  are still able to freely rotate. 
         [0029]    As those skilled in the art know, and as shown in  FIG. 1 , the inner race  62  of the roller  54  is engaged with an outer race  64  by, for example, bearings (not shown). Therefore, due to the bearings, the inner and outer races  62 ,  64  are able to move relative to one another. As a result, when the inner race  62  is secured in place, the outer race  64  is still able to rotate about the axle  36 ,  40 . When a roller wheel  66  having, for example, a central groove  68  is fitted to or around the outer race  64 , the roller wheel  66  rotates along with the outer race  64  and relative to the inner race  62 . 
         [0030]    Once the axles  36 ,  40  have been placed in the slider body  12  and the free ends  52  passed through the washer  56  and the roller  54  as shown in  FIG. 3 , an axial center of the free ends are located and the free ends are subjected to an orbital forming process  70  (a.k.a., radial riveting, spin riveting, etc.). Orbital forming is a cold forming process whereby an orbiting tool  72  held at a fixed angle  74 , typically three to six degrees, is used to progressively transform malleable material into a desired, predetermined shape. 
         [0031]    Advantageously, the orbital forming process  70  may be used to head, swage, crown, flare or draw a column or projection of material. The orbital forming process  70  is used to produce a high quality head without disrupting the component material grain structure. While similar in nature to impact or compression forming and riveting in that a compressive axial load  76  is applied to the part being formed, the axial load  76  is greatly reduced due to the mechanical advantage of the angular orbiting tool  72  and progressive forming action  78 . The axial load  76  required for forming is reduced up to eight percent (80%) with the orbital forming process  70  due to this mechanical advantage. 
         [0032]    The drastic reduction in compressive axial load  76  when using the orbital forming process  70  as opposed to an impact forming process has several distinct advantages: For one, most of the work during the orbit forming process  70  occurs at the orbiting tool&#39;s line of contact  80 . Internal stress loads, caused by a high compressive axial load  76  applied to the assembled components, are greatly reduced. Forming work is focused and the component being deformed sees less stress. In addition, mating parts experience less stress as well. Therefore, there is no brinelling or other damage to the components being worked upon. 
         [0033]    In addition, the orbital forming process  70  is able to produce a smoothly finished surface on the free ends  52 . In some cases, the orbital forming process  70  is able to eliminate cracks that could not be avoided with impact riveting. Also, cold head forming without bending or swelling of a column is achieved since the effective forming load does not typically exceed the column strength. Further, less axial load (up to 80% reduction) required for forming results in much lighter press requirements. On larger parts, equipment tonnage, floor space and cost are greatly reduced. 
         [0034]    Because of the lower forming force requirements with the orbital forming process  70 , less rigid fixturing is required, which reduces initial tooling costs. Also, due to lower forming forces, tool and fixturing life are much longer and expendable tooling costs are greatly reduced. In addition, as one of the orbital forming process  70  synonyms (noiseless riveting) implies, the orbital forming process is much quieter than other cold forming processes such as impact forming or peening. 
         [0035]    Cycle time for the orbital forming process  70  (i.e., the time needed to complete the progressive forming action  78 ) can vary greatly depending on the application. Typical cycle time to advance, form and retract is about one and a half to about three seconds (1.5 to 3.0 s). Cycle time is generally determined by the type of material being formed, material diameter, formed head configuration, and stroke required. 
         [0036]    Referring now to  FIG. 3 , during the orbital forming process  70  used to form the roller-guided track apparatus  10 , the free end  52  of the axles  36 ,  40  is deformed from a generally cylindrical shape  82  as shown in  FIG. 3  to a deformed shape  84  (a.k.a., a head) as depicted in  FIG. 4 . Despite the deformed shape  84  being a generally cylindrical shape in  FIG. 4 , the deformed shape may be any of the shapes noted above. 
         [0037]    As shown in  FIG. 4 , after having been worked on, the free end  52  of the axle  36 ,  40  extends radially outwardly further than the central portion  50  ( FIG. 3 ) of the axles. In order to accept such deformation, the axles  36 ,  40  are generally formed from a malleable material including, but not limited to, mild steel, most alloys such as stainless steel, heat-treated steels, case hardened materials and non-ferrous metals such as aluminum, brass, copper. In addition, the axles  36 ,  40  may also be formed from other suitable materials such as, for example, plastic. 
         [0038]    After the orbital forming process  70  has been performed, the washer  56 , slider body  12 , and the inner race  62  are tightly engaged with each other. As such, relative movement between these components is prevented. However, the outer race  64  and roller wheel  66  are still able to rotate about the axle  36 ,  40 . The nature of the orbital forming process  70  permits the amount of deformation of the free ends  52  and the axial length of the axles  36 ,  40  to be precisely controlled. 
         [0039]    As shown in  FIGS. 1 ,  2  and  5 , either before or after the orbital forming process takes place, wipers  86  can be added to either side  18 ,  20  of the slider body  12 . The wipers  86  are linearly aligned with the rollers  54  and employed to wipe clean the channel  88  ( FIG. 1 ) when the slider body  12  is inserted therein. When the slider body  12  is disposed in the channel  88 , the groove  68  of each of the rollers  54  is aligned with one of the rims  90  on the channel and the slider body is positioned between the inner top and bottom surfaces  92 ,  94  of the channel  88 . Therefore, the slider body  12  generally travels within the channel  88 . 
         [0040]    To facilitate the insertion and removal of the slider body  12  from within the channel  88 , in the illustrated embodiment of  FIGS. 1 and 5  the slider body  12  includes an adjustment mechanism  96  that operates in conjunction with the axle  40  of the centrally located track roller arrangement  14 . The adjustment mechanism  96  may be, for example, one of the adjustment mechanisms disclosed in U.S. Pat. Nos. 6,149,308 and 6,450,687 to Schroeder, et al., each of which is incorporated herein in its entirety. 
         [0041]    In the illustrated embodiment, the adjustment mechanism  96  includes a pair of set screws  98  threaded into apertures  100  formed through the top and bottom  22 ,  24  of the slider body  12  as shown in  FIGS. 1 and 5 . By threadably driving the set screws  98  into or out of the slider body  12 , the central track roller arrangement  14  is moved vertically upwardly or downwardly. As a result, the axle  40  moves upwardly or downwardly within the rectangular slot  48 . In addition, the roller wheel  66  associated with that track roller arrangement  14  moves upwardly and downwardly with the axle  40 . 
         [0042]    When the slider body  12  is placed in the channel  88 , the roller wheel  66  of each outside track roller arrangement  14  is seated on the bottom rim  90  of the channel. Thereafter, the set screws  98  are manipulated to move the roller wheel  66  on the central track roller arrangement  14  upwardly until the roller wheel contacts the upper rim  90  of the channel  88 . If the set screws  98  are properly positioned, the outside roller wheels  66  exert a downward force on the bottom rim  90  of the channel  88  and the inside roller wheel  66  exerts an upward force on the upper rim  90 . In this manner, the slider body  12  is held within the channel  88 . To remove the slider body  12  from the channel  88 , the set screws  98  are backed off until the roller wheel  66  of the inner track roller arrangement  14  pulls away from the upper rim  90 . 
         [0043]    In one embodiment as shown in  FIG. 6 , the support member  102  is a rail. In this embodiment, several of the track roller assemblies  14  are secured to the support member  102  in opposing directions by the orbital forming process  70  described above. Thereafter, stops  104  are secured to the support member  102  and the track roller assemblies  14  are engaged with bumpers  106  disposed on either side of the support member  102 . The roller wheel  66  of each track roller arrangement  14  generally rides in the channel  108  of the bumper  106 . In other words, the support member  102  is sandwiched between the bumpers  106 . When assembled, the support member  102  slides relative to each of the bumpers  106 . Therefore, when attached to, for example, a drawer in a piece of furniture, the drawer may be easily and fluidly moved between open and closed positions. 
         [0044]    From the foregoing, those skilled in the art will recognize that the roller-guided track apparatus  10  disclosed herein provides prevents or discourages tampering. In addition, the roller-guided track apparatus  10  is constructed using a process that is generally inexpensive and that can be completed relatively quickly. The roller-guided track apparatus  10  is also uniquely configured to prevent components of the roller-guided track apparatus from undesirably coming apart after they have been secured to each other. 
         [0045]    All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. 
         [0046]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0047]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.