Composite Spoke Star Forming with Adjustable Fibre Deflection
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Solution Overview
Problem
Existing methods for producing spoked wheels from fibre/plastic composite materials require costly preshaped form elements, limiting flexibility in producing different types of spoke stars and wheels, and resulting in suboptimal fibre utilization.
Innovation Solution
A production method using a device with rim-side and hub-side deflection devices to wind and deform a fibre coil into a spoke star, allowing for the production of various shapes and sizes without the need for preshaped forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If preshaped form elements are used to give the rim its shape, then the spoked wheel can be produced with proper shape, but the production cost increases and flexibility to produce different types of spoke stars is reduced
Solution Approach 1:
The patent applies the dynamics principle by using movable and adjustable deflection devices instead of fixed preshaped forms. The deflection devices can be repositioned along the fibre coil path, allowing the same production device to create different spoke star configurations (different numbers of spokes, different shapes) by dynamically adjusting the deflection device positions during the winding process
Solution Approach 2:
The patent segments the shaping function into multiple independent deflection devices rather than requiring a single preshaped form. Each deflection device can be independently positioned and adjusted, enabling flexible creation of different spoke star geometries. The fibre coil itself is segmented into portions that are deflected by different devices to form individual spokes
2Ease of manufacture
If preshaped form elements are used to produce spoked wheels, then the production process can be simplified, but fibre utilization becomes suboptimal
Solution Approach 1:
The patent applies preliminary action by winding the fibre coil in a controlled manner around the deflection devices before the actual shaping occurs. The fibre is pre-positioned and pre-tensioned during winding, allowing for optimal fibre path planning that maximizes utilization. The deflection devices are positioned in advance to guide the fibre along the desired spoke star geometry, ensuring efficient fibre usage from the start of the process
Solution Approach 2:
The patent changes the parameter of fibre path geometry by using adjustable deflection devices that can alter the winding radius and deflection angles. This allows the fibre to be routed optimally through the spoke star structure, maximizing the length and distribution of fibres in load-bearing positions while minimizing waste
3Productivity
If preshaped forms are used for production, then production speed can be maintained, but the device complexity increases due to costly forms
Solution Approach 1:
The patent applies self-service by allowing the fibre coil itself to define the spoke star shape through the action of deflection devices, rather than requiring external preshaped forms. The fibre coil is wound and deformed in-place within the production device, and the same device can produce different configurations by repositioning its own components. This eliminates the need for separate, costly preshaped form elements while maintaining production efficiency
Data Source
AI summary
Production method for a spoke star (5) with one or more continuous fibre bundles (111),during which a production device (100) is used for winding a fibre coil (3) and for deforming the fibre coil (3) into a spoke star (5),wherein the production device (100) comprises a plurality of deflection devices (2) at the rim side and a plurality of deflection devices (4) at the hub side,wherein the deflection devices (2) at the rim side and the deflection devices (4) at the hub side are arranged around an interior of the arrangement (10) of the deflection devices (2, 4),wherein in a first step a continuous fibre bundle (111) is wound around at least a portion of the rim-side deflection devices (2) as a fibre coil (3),and in a second step, after this winding, at least a portion of the hub-side deflection devices (4) are shifted in the direction of the interior of the arrangement (10), the fibre coil (5) being deformed into a star, so that between the hub-side deflection devices (4) and the rim-side deflection devices (2) spokes (12) are formed from portions of the fibre coil (3), which form at least a portion of a closed spoke star (5). Further, the invention relates to a production device (100), a spoke star (5) and a spoked wheel (11).