Method and apparatus for heating vehicle wheels
Inductor heating with a multi-turn toroidal inductor inside the rim addresses the inefficiencies of gas-heating methods, achieving uniform and cost-effective heating for vehicle wheels, enhancing environmental sustainability and quality.
Patent Information
- Application Number
- JP2024534223
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2021-12-22
- Filing Date
- 2022-12-21
- Publication Date
- 2025-02-04
AI Technical Summary
Existing methods for heating vehicle wheels for flow forming are energy-intensive, costly, and environmentally harmful due to the use of combustion gas, and can cause uneven heating leading to quality issues.
Inductor heating is used to heat vehicle wheels, specifically the rim, with a multi-turn toroidal inductor placed inside the rim, allowing for efficient, uniform heating and reduced energy consumption, while using renewable energy sources to minimize environmental impact.
Inductor heating provides efficient, uniform, and cost-effective heating of vehicle wheels, reducing energy consumption and emissions, ensuring high-quality processing for flow forming without overheating.
Smart Images
Figure 2025503401000001_ABST
Abstract
Description
[Technical field]
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority from German patent application No. 10 2021 134 233.3, the contents of which are incorporated by reference.
[0002] The present invention relates to a method for heating a vehicle wheel, in particular as a preparation for a subsequent forming process, and further to an apparatus for heating a vehicle wheel, in particular as a preparation for a subsequent forming process. [Background technology]
[0003] Various casting methods for manufacturing vehicle wheels are known from the state of the art.
[0004] Vehicle wheels cast by these methods can be further processed by so-called flow forming or flow forming process, i.e. rolling of the rim of the vehicle wheel. The flow forming process leads to a compaction of the material, which increases its stability and strength. Furthermore, the flow forming process saves material, so that lighter and more resistant vehicle wheels can be produced. Another advantage of this known method is that one and the same basic form of the vehicle wheel produced by casting can be used to produce a large number of wheels of different widths, which reduces the production costs of such vehicle wheels.
[0005] To carry out the flow forming process, the vehicle wheel must be heated to a certain temperature. Up to now, this has been done in suitable furnaces, which are usually gas-operated and therefore have a very high energy consumption. A further disadvantage of this method is the use of combustion gases in the furnaces, which not only leads to very high costs but also to a very high CO2 consumption. Furthermore, vehicle wheels manufactured in certain ways can cause problems if certain parts of the wheel are heated to excessive temperatures. Summary of the Invention [Problem to be solved by the invention]
[0006] It is therefore an object of the present invention to provide a method and apparatus for heating vehicle wheels that is capable of heating vehicle wheels in a simple, reliable and environmentally friendly manner. [Means for solving the problem]
[0007] According to the invention, this object is achieved by the features defined in claim 1.
[0008] The method according to the invention for heating at least a part of a vehicle wheel by induction heating using an inductor offers many advantages compared to previous methods.
[0009] For example, induction heating requires much less energy than known methods, since the required temperature is generated directly in the component itself and does not require much space, which also leads to a significant reduction in CO2 emissions, thus improving the environmental balance of the method according to the invention.
[0010] Another advantage is that the inductors used for induction heating can be powered by electric current, which not only contributes to environmental protection compared to the use of gas, but also provides economic advantages, which are further increased by the significantly greater efficiency of induction heating compared to heating in a furnace. Yet another advantage of using inductors for heating vehicle wheels is that the method is easy to implement.
[0011] Furthermore, induction furnaces take up less space than gas furnaces and therefore offer advantages in terms of space required.
[0012] As a very advantageous development of the invention, it can be provided that essentially only the rim of the vehicle wheel is heated. On the one hand, it is heated to a much lesser extent than in known solutions, which leads to even lower energy requirements. On the other hand, the inductors used to implement the method can thus be of simpler structural design and can be manufactured more cost-effectively. This embodiment will be particularly advantageous in the case of vehicle wheels manufactured by die casting, since, as far as possible, certain areas of the vehicle wheel should not be heated too much.
[0013] In a further advantageous embodiment of the method according to the invention, if the inductor is arranged on the inside of the rim, this leads to a more uniform heating of the vehicle wheel. Moreover, also in this case, a simpler structural design of the inductor is possible, which can therefore lead to reduced costs. The inside of the rim usually has a more uniform contour than the outside, so that the rotation of the inductor can be performed relatively easily. Furthermore, the movement of the inductor to arrange it on the inside of the rim is easier than in the case of an inductor arranged on the rim from the outside, which is not shown.
[0014] Additionally, the spokes and / or hub of the vehicle wheel may be cooled, which helps to keep certain areas of the vehicle wheel that should not become too hot within a desired temperature range whenever possible.
[0015] If a cooling medium is applied to the spokes and / or the hub during heating, a particularly simple possibility is offered for cooling the spokes and / or the hub of the vehicle wheel.
[0016] Another advantageous embodiment of the method according to the invention is to heat at least a portion of the vehicle wheel for a period between 20 seconds and 5 minutes, preferably between 40 seconds and 3 minutes, which has proven to be particularly advantageous in terms of uniform heating of the area of the vehicle wheel to be heated.
[0017] In order to be able to carry out the subsequent forming process, in particular the so-called flow forming, in the desired manner, a further advantageous embodiment of the invention is to heat at least a part of the vehicle wheel to a temperature of 250-400°C, preferably 300-360°C.
[0018] Furthermore, the vehicle wheel and / or the inductor may be rotated during heating, which results in a very uniform heating of the vehicle wheel and prevents potential excessive heat generation in certain areas, thus maintaining the high quality of the vehicle wheel treated by the method according to the invention.
[0019] In a further advantageous embodiment of the method according to the invention, if the temperature of at least a part of the vehicle wheel is monitored during heating, not only is overheating of the vehicle wheel avoided but also a constant quality of the wheel is ensured.
[0020] A further advantageous embodiment of the method according to the invention is to use power from renewable energy sources for the operation of the inductor, which ensures a CO2-neutral process and helps protect the environment.
[0021] The device for heating a vehicle wheel is defined in claim 11.
[0022] The device according to the invention can be used particularly advantageously in the method according to the invention and ensures that the method can be carried out easily. Furthermore, the device according to the invention is simply and cost-effectively manufactured.
[0023] A very advantageous embodiment of the device according to the invention is that the inductor is formed as a toroidal inductor, in particular a multi-turn toroidal inductor, adapted to the inner area of the rim of the vehicle wheel, which ensures uniform heating of the entire rim of the vehicle wheel and can have a relatively simple structural design and can therefore be manufactured more cost-effectively.
[0024] Furthermore, the device according to the invention may comprise a device for supplying a cooling medium to the spokes and / or the hub of the vehicle wheel, which makes it very easy to cool the spokes and / or the hub of the vehicle wheel and to keep these areas at a desired temperature despite heating.
[0025] A further advantageous embodiment of the device according to the invention is that a device for rotating the vehicle wheel and / or the inductor is provided, by means of which a uniform heating of the vehicle wheel can be achieved.
[0026] In a further advantageous embodiment, if a device for monitoring the temperature of the vehicle wheels is provided, a simple possibility is obtained for avoiding potential overheating of the vehicle wheels.
[0027] The principles of exemplary embodiments of the present invention will now be described with reference to the drawings. [Brief description of the drawings]
[0028] [Figure 1] 1 is a highly schematic view of an installation used in a method for manufacturing vehicle wheels, part of which is a device according to the invention for heating the vehicle wheels; [Diagram 2] 1 is a side view of an apparatus according to the invention for heating a vehicle wheel; [Diagram 3] FIG. 3 is a cross-sectional view taken along line III-III in FIG. [Figure 4] 4 is a view taken along arrow IV in FIG. 2. [Diagram 5] 1 is a perspective view of an apparatus according to the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] In Fig. 1 an installation 1 for heating vehicle wheels 2 is shown, also very diagrammatically. The installation 1 comprises a casting device 3 for producing the vehicle wheels 2 by casting, a device 4 for heating the vehicle wheels 2 and a forming device 5, in particular for carrying out a flow forming process on the vehicle wheels 2. All devices 3, 4 and 5 are shown only very diagrammatically in Fig. 1.
[0030] The installation 1 likewise also has a handling device 6, shown only diagrammatically, by means of which the vehicle wheels 2 can be transported between the devices 3, 4, 5. In this case the handling device 6 is a multi-axis robot.
[0031] The casting device 3 and the forming device 5 can be of a design known per se, so that the devices and the method steps performed with them will not be described in more detail below, but the device 4 capable of performing the method for heating a vehicle wheel will be described in more detail below.
[0032] An apparatus 4 for heating a vehicle wheel 2 is shown in the various views of Figures 2 to 5. The apparatus 4 comprises an inductor 7 which is at least partially adapted to the shape of the vehicle wheel 2. In the present example, the inductor 7 is a multi-turn toroidal coil inductor, the design of which can be seen in particular from Figures 3 and 5 and will be explained in more detail later.
[0033] The vehicle wheel 2, best seen in the representation of Figure 3, comprises, in known manner, a circumferential rim 2a, a hub 2b forming a central region of the vehicle wheel 2, a number of spokes 2c connecting the hub 2b to the rim 2a, and two rim flanges 2d forming the lateral boundaries of the rim 2a.
[0034] Preferably, the inductor 7 is designed such that substantially only the rim 2a of the vehicle wheel 2 is heated. During the process of inductive heating of the vehicle wheel 2, which is carried out by means of the inductor 7, the inductor 7 is arranged inside the vehicle wheel 2 in the illustrated exemplary embodiment, thereby heating the rim 2a from its inside. To this end, the inductor 7 fits into the inner area of the rim 2a of the vehicle wheel 2.
[0035] As shown above, the inductor 7 formed as a multi-turn toroidal inductor has a number of turns 7a arranged inside the rim 2a and one turn 7b assigned to the rim flange 2d oriented away from the spokes 2c. The diameter of the individual turns 7a may decrease in the direction of the spokes 2c if, as in this example, the rim 2a has a particular conical shape. The other components of the inductor 7 are generally known and will not be described in more detail here.
[0036] Preferably, the vehicle wheel 2 or at least a part of the vehicle wheel 2, specifically the rim 2a, is induction heated for 20 seconds to 5 minutes, preferably for 40 seconds to 3 minutes. Furthermore, the temperature to which the vehicle wheel 2 or the rim 2a is induction heated by the inductor 7 is 250 to 400° C., preferably 300 to 360° C. The temperature to which the rim 2a is heated can be set by an inverter (not shown) connected to the inductor 7.
[0037] The temperature of the vehicle wheel 2 during heating can be monitored by a device (not shown) for monitoring the temperature of the vehicle wheel 2. This device is, for example, an infrared camera or a pyrometer.
[0038] The vehicle wheel 2 and / or the inductor 7 can be rotated during heating, for which purpose the device 4 can comprise a device for rotating the vehicle wheel 2 and / or the inductor 7, which is likewise not shown.
[0039] Furthermore, in order to cool the spokes 2c and / or the hub 2b of the vehicle wheel 2 during induction heating, a device may be provided for supplying a cooling medium to the spokes 2c and / or the hub 2b of the vehicle wheel 2. For example, this device may be formed as a cooling spray. By means of the cooling medium, the temperature of the hub 2b and / or the spokes 2c can be set to a desired level.
[0040] In a manner known per se, in induction heating eddy currents are induced in the rim 2a of the vehicle wheel 2 by the alternating electromagnetic field of the inductor 7 and are converted into heat. Due to the good heat conducting properties of the aluminium material, the desired area, in this example the rim 2a, is heated in a comparatively short time. The coupling distance between the inductor 7 and the vehicle wheel 2 may be, for example, 2-6 mm. To operate the inductor 7, electricity from a renewable energy source is preferably used.
Claims
1. 1. A method for heating a vehicle wheel, in particular in preparation for a subsequent forming process, characterized in that at least a part of said vehicle wheel is heated by induction heating using an inductor.
2. 2. The method of claim 1, wherein substantially only the rim of the vehicle wheel is heated.
3. 2. The method of claim 1, wherein the inductor is disposed inside the rim.
4. 4. A method according to claim 1, 2 or 3, characterized in that the spokes and / or the hub of the vehicle wheel are cooled.
5. 5. The method of claim 4, characterized in that a cooling medium is applied to the spokes and / or the hub during the heating.
6. 6. A method according to any one of claims 1 to 5, characterised in that at least a part of the vehicle wheel is heated for a period of between 20 seconds and 5 minutes, preferably between 40 seconds and 3 minutes.
7. 7. A method according to any one of claims 1 to 6, characterised in that at least a part of the vehicle wheel is heated to a temperature of from 250 to 400°C, preferably from 300 to 360°C.
8. 8. A method according to any one of claims 1 to 7, characterised in that the vehicle wheel and / or the inductor are rotated during heating.
9. 9. A method according to any one of claims 1 to 8, characterized in that the temperature of at least a part of the vehicle wheel is monitored during said heating.
10. 10. The method according to claim 1, characterized in that the inductor is powered with electricity from a renewable energy source.
11. 1. A device for heating a vehicle wheel, in particular in preparation for a subsequent forming process, characterized by an inductor that at least partially conforms to the shape of said vehicle wheel.
12. 12. The arrangement according to claim 11, characterized in that the inductor is formed as a toroidal inductor, in particular a multi-turn toroidal inductor, and fits into an inner area of the rim of the vehicle wheel.
13. 13. An arrangement according to claim 11 or 12, characterised by a device for supplying a cooling medium to the spokes and / or to the hub of the vehicle wheel.
14. 14. Apparatus according to claim 11, 12 or 13, characterized by a device for rotating the vehicle wheels and / or the inductor.
15. 15. Apparatus according to any one of claims 11 to 14, characterized in that it is a device for monitoring the temperature of the vehicle wheel.