Cellular Wheel Production Using Segmented Sheet Metal Strips
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Solution Overview
Problem
Current methods for producing cellular wheels for pressure wave superchargers with small cell wall thicknesses of 0.2 mm or less are inefficient and costly, and existing techniques such as using Z-shaped profiles or erosion methods fail to achieve the required accuracy and dimensional stability.
Innovation Solution
A method involving sheet metal strips with lamellas, where the lamellas are positioned and welded or soldered to form concentric sleeves, allowing for the precise assembly of cellular wheels with wall thicknesses of 0.2 mm or less, using laser or electron beam welding, and optionally employing grinding rolls to align lamellas with the outer or inner sleeves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If erosion method is used to produce cellular wheel, then cell wall thickness can be reduced, but manufacturing precision and dimensional stability deteriorate
Solution Approach 1:
The cellular wheel is divided into multiple Z-shaped profiles that are arranged in rows. Each profile is a separate component that can be precisely manufactured and then assembled together, allowing for better control of individual component dimensions while achieving the overall thin wall thickness requirement
Solution Approach 2:
The Z-shaped profiles are pre-formed with precise dimensions before assembly. This preliminary manufacturing of individual components with high precision ensures that when assembled, the final cellular wheel maintains dimensional stability and accuracy despite the thin overall wall thickness
2Length of moving object
If Z-shaped profiles are used to form chambers, then cell wall thickness can be reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The cellular wheel is segmented into multiple Z-shaped profiles arranged in rows. This segmentation allows for standardized mass production of individual profiles, which can then be systematically assembled, reducing overall manufacturing complexity despite the intricate final structure
Solution Approach 2:
Multiple identical Z-shaped profiles are created as copies and arranged in rows. This replication approach allows for standardized manufacturing processes and simplifies quality control, as each profile unit is identical and can be produced using the same tooling and procedures
3Ease of manufacture
If erosion method is used, then material removal is simplified, but manufacturing cost increases
Solution Approach 1:
Instead of eroding the entire cellular wheel structure, the method segments the work into forming individual Z-shaped profiles and then assembling them. This approach reduces material removal to simple profile formation rather than complex three-dimensional erosion, significantly lowering machining costs
Solution Approach 2:
The invention replaces the mechanical erosion process with a combination of simpler forming operations on individual profiles followed by assembly. This substitution eliminates the need for expensive and time-consuming erosion machining while achieving the same thin wall thickness results
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 method enables the cost-effective and accurate production of dimensionally stable cellular wheels suitable for small gasoline engines, reducing material and machining costs while maintaining the required precision and performance.
Implementation Method 1
connect the lamellas to the sheet metal strip by welding or soldering
Implementation Method 2
connect the lamellas to the sheet metal strip by welding or soldering
Implementation Method 3
using laser or electron beam welding
Implementation Method 4
using laser or electron beam welding
Implementation Method 5
optionally employing grinding rolls to align lamellas with the outer or inner sleeves
Data Source
AI summary
In a method for producing a cellular wheel made of metal, the following steps are conducted consecutively: (a) providing a sheet metal strip (26) having a length (1) that corresponds at least to the length of a circumferential line of an intermediate sleeve and a width (b) that corresponds at least to the length of the cellular wheel; (b) placing disks (16) in predetermined locations in predetermined quantities on both sides of the sheet metal strip (26) perpendicular to the sheet metal surface and perpendicular to the longitudinal direction of the sheet metal strip (26) and connecting the disks (16) to the sheet metal strip (26) by welding or brazing; (c) bending the metal strip (26) equipped on both sides with the disks (16) and connecting the two ends of the sheet metal strip (26) by welding or brazing to form the intermediate sleeve; (d) placing a first tubular sleeve that is concentric to the intermediate sleeve as an outer sleeve, and a second tubular sleeve that is concentric to the intermediate sleeve as an inner sleeve, and connecting the free ends of the disks (16) to the outer sleeve or the inner sleeve by welding or brazing. The method allows cellular wheels to be produced which have material wall thicknesses of 0.2 mm and less for use in pressure wave superchargers.