Cellular Wheel Production Using Segmented Z-Profile Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing cellular wheels with thin cell wall thicknesses for pressure wave superchargers are inefficient, costly, and lack precision, making it difficult to achieve the required tolerances and dimensions for small engines, especially with high heat resistance and low material usage.
Innovation Solution
A method involving a tool with a cylindrical inner face to fix fins in angular position, using a fire-resistant molding material mixture that hardens thermally, and subsequent welding or brazing with sleeves, allowing for precise and cost-effective production of cellular wheels with cell wall thicknesses less than 0.5 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cellular wheel diameter is reduced to 100 mm or less for small engine supercharging, then engine displacement is reduced for lower fuel consumption and emissions, but manufacturing precision and dimensional stability become extremely difficult to achieve
Solution Approach 1:
The cellular wheel is divided into multiple separate Z-shaped profiles that are assembled together. Each profile is manufactured independently with standard tolerances, then joined to form the complete cellular wheel. This segmentation allows the large-diameter precision requirement to be broken down into smaller, more manageable manufacturing units.
Solution Approach 2:
Multiple Z-shaped profiles are merged together through overlapping and joining to form the complete cellular wheel structure. The profiles are positioned adjacent to one another and fixed in their angular positions, then joined by welding or brazing to create a dimensionally stable assembly that achieves the required precision through combination rather than single-piece manufacturing.
2Weight of moving object
If cell wall thickness is reduced to 0.5 mm or less for weight reduction and maximum cell volume, then weight is reduced and cell volume is maximized, but manufacturing feasibility and dimensional stability are compromised
Solution Approach 1:
The thin-walled cellular structure is segmented into multiple Z-shaped profiles rather than attempting to manufacture as a single thin-walled component. This allows each profile to be manufactured with standard wall thicknesses using conventional processes, avoiding the extreme difficulty of producing dimensionally stable 0.5 mm or thinner walls in a complete cellular wheel.
Solution Approach 2:
The Z-shaped profiles are pre-formed with their fins positioned in predetermined angular orientations before assembly. The profiles include oversize fins that are later trimmed to final dimensions. This preliminary positioning and pre-forming allows precise angular alignment during assembly without requiring extreme precision in the final trimming operation.
3Shape
If Z-profiles are placed next to one another and fixed in accurate position, then cellular wheel structure is formed, but production time increases and positioning precision is difficult to achieve
Solution Approach 1:
The Z-shaped profiles are pre-formed with fins positioned in predetermined angular orientations during the profiling process. This preliminary positioning eliminates the need for time-consuming manual alignment during assembly. The profiles are designed with oversize fins that can be easily trimmed later, allowing rapid assembly without precise positioning requirements during the joining operation.
Solution Approach 2:
The cellular wheel is segmented into a small number of standardized Z-shaped profiles rather than attempting to machine the entire structure from a solid block or assemble many small components. This segmentation into optimal units reduces the number of assembly operations required while maintaining structural integrity and precision.
4Manufacturing precision
If molding pieces are inserted between fins to fix angular position during welding, then fins are positioned in predefined angular position, but molding pieces become jammed and cannot be removed without damage due to thermal stresses
Solution Approach 1:
The angular positions of the fins are predetermined and established during the pre-forming of the Z-shaped profiles rather than during the welding operation. The profiles are designed with built-in positioning features that maintain angular relationships without requiring removable molding pieces during welding, eliminating the jamming problem entirely.
Solution Approach 2:
The problematic molding pieces that cause jamming during welding are completely removed from the process. Instead, the angular positioning function is integrated into the Z-shaped profile design itself through predetermined fin orientations and positioning features that remain during welding but do not interfere with the welding operation or require removal afterward.
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
Enables the production of dimensionally stable and highly precise cellular wheels suitable for small gasoline engines, reducing production costs and improving precision, while maintaining heat resistance and mechanical stability.
Implementation Method 1
using a fire-resistant molding material mixture that hardens thermally
Implementation Method 2
it is welded by means of a laser beam to the free end edges of the fins which lie beneath it, by means of a bead on plate weld
Data Source
AI summary
A method for producing a cellular wheel, wherein a tool having a cylindrical inner shell, the diameter of which corresponds to the inner diameter of the subsequent sleeve, is placed on the free end edges of the fins for fixing the angular orientation of the fins. A molding material mixture is applied in the cells bounded by the inner shell of the tool and the fins and cured. After removing the tool, the subsequent sleeve is placed on the free end edges of the fins fixed in place by the cured molding material mixture. The free end edges of the fins are joined to the subsequent sleeve to the cells. The cured molding material mixture is thermally treated and is removed from the cells.