Adjustable Molding System for Non-Pneumatic Wheels
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Solution Overview
Problem
The high cost and complexity of manufacturing non-pneumatic wheels are exacerbated by the need for multiple molds for different hub configurations, which increases production expenses.
Innovation Solution
An adjustable molding system that uses interchangeable removable mold elements within a single molding system to accommodate various hub configurations, allowing for the production of non-pneumatic wheels with different hub constructions without requiring separate molds for each configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate molds are used for different hub configurations, then each hub configuration can be manufactured with high precision, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The mold system is designed with interchangeable components that allow a single base mold to accommodate multiple hub configurations. The universal mold structure includes standardized mounting interfaces and modular elements that can be reconfigured for different hub types, eliminating the need for completely separate molds for each configuration while maintaining manufacturing precision.
Solution Approach 2:
The mold system is divided into separate, interchangeable components including the base mold, hub-specific inserts, and removable elements. This segmentation allows individual components to be swapped out based on the required hub configuration, reducing overall device complexity while preserving the ability to manufacture each configuration with high precision.
2Manufacturing precision
If multiple separate molds are used for different hub configurations, then each configuration can be optimized for its specific requirements, but manufacturing cost increases
Solution Approach 1:
The universal mold system allows a single investment to produce multiple hub configurations through interchangeable components. This reduces manufacturing cost by eliminating the need to create entirely separate molds for each configuration, while the modular design enables each configuration to be optimized for its specific requirements through targeted component selection.
Solution Approach 2:
Instead of discarding the mold after producing one hub configuration, the system recovers and reconfigures the same mold for subsequent configurations. The interchangeable components are removed, stored, and reused for different hub types, significantly reducing the cumulative manufacturing cost across multiple product variants.
3Ease of manufacture
If a single mold is used for different hub configurations, then manufacturing cost decreases, but the ability to accommodate different configurations requires increased mold complexity
Solution Approach 1:
The mold system is segmented into a simple base structure and interchangeable configuration-specific components. This segmentation allows the base mold to remain relatively simple while the complexity is isolated to individual inserts that can be swapped out, reducing the overall system complexity compared to a fully integrated complex mold.
Solution Approach 2:
The mold system transitions from a static, single-purpose design to a dynamic, reconfigurable system. The ability to interchange components based on the required hub configuration allows the mold to adapt its complexity only when needed, maintaining simplicity for the base structure while providing access to complexity through modular additions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs by enabling the use of a single molding system for multiple hub configurations, streamlining the production process and minimizing the need for multiple molds.
Implementation Method 1
The molding system includes an upper mold portion having a plurality of upper web forming elements spaced apart around the circumferential direction. A lower mold portion has a plurality of lower web forming elements spaced apart around the circumferential direction and are configured to receive the upper web forming elements when the molding system is in a closed position to form the tension transmitting web elements during the molding process.
Implementation Method 2
The upper mold portion and lower mold portion form an internal cavity when the molding system is in the closed position
Data Source
AI summary
A method and apparatus for molding non-pneumatic wheels is provided. The exemplary method and apparatus allow for the use of the same molding system to manufacture wheels with different hub constructions. Different configurations of removable mold elements are utilized within the same molding system to provide wheels with different hub constructions.