Composite Wheel Rim Architecture for Simpler Automated Manufacturing
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Solution Overview
Problem
Current composite wheel rims are expensive and time-consuming to manufacture due to their complex geometry, making them inaccessible to a wider market and limiting their use to high-end vehicles.
Innovation Solution
A new composite rim architecture is proposed where certain functions are dissociated, simplifying the manufacturing process and allowing for automation. This architecture includes a drum, web, and flange made of composite materials, with the option of hybrid rims combining metallic and composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to manufacture wheel rims, then weight is reduced and aerodynamic performance is improved, but manufacturing complexity increases and production costs rise
Solution Approach 1:
The wheel rim is divided into multiple separate components (drum, web, flange) that are manufactured independently and then assembled. This segmentation allows each component to be produced using optimized processes suitable for its specific geometry and functional requirements, reducing overall manufacturing complexity while maintaining the weight benefits of composite materials.
Solution Approach 2:
The drum component is designed to serve multiple functions: it provides the structural foundation for mounting the tire, serves as a mounting surface for the web and flange, and contributes to the overall aerodynamic profile. This multi-functionality reduces the number of separate parts needed, simplifying the assembly process while maintaining weight reduction benefits.
2Weight of moving object
If composite materials are used to manufacture wheel rims, then weight is reduced, but manufacturing time increases and automation becomes difficult
Solution Approach 1:
By segmenting the rim into drum, web, and flange components, each part can be manufactured using high-speed, automated composite manufacturing processes such as resin transfer molding or automated fiber placement. The simplified geometries of individual components are more amenable to automation than a complete integrated rim, thereby increasing production speed while maintaining weight benefits.
Solution Approach 2:
Components are pre-manufactured as separate units with standardized interfaces and connection features built in during the initial manufacturing process. This preliminary preparation of connection elements enables rapid assembly through automated joining processes, significantly reducing total manufacturing time while preserving the weight advantages of composite construction.
3Weight of moving object
If composite materials are used to manufacture wheel rims, then weight is reduced, but material waste and manufacturing costs increase
Solution Approach 1:
Segmenting the rim into separate components allows each part to be optimized for its specific function and geometry, enabling more efficient material utilization during manufacturing. Each component can be sized and shaped precisely to requirements, reducing excess material usage and waste compared to manufacturing a complete integrated rim as a single piece.
Solution Approach 2:
The modular component design facilitates easier recovery and potential reuse of composite materials from individual parts if defects occur during manufacturing or inspection. Rather than wasting entire complex integrated structures, only specific components need to be discarded or reworked, reducing overall material loss while maintaining the weight benefits of composite construction.
Data Source
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AI summary
The invention relates to a composite rim (1) for a vehicle wheel, comprising a drum (2) having a rim band (3) for receiving a tire, and a disc (4) having a central hub (5) for mounting on a vehicle axle and a plurality of connecting elements (6) extending between the central hub and the drum. The rim, comprising a composite flange (7) which is attached, at least partially covers said disc, forms the outer face of the rim, and has a central opening (8) at the center of the central hub. The flange is designed to conform, in whole or in part, to the shape of the disc (4), and to be secured to the connecting elements (6) and the central hub (5) of the disc, as well as to the peripheral edge of the drum (2), to form a reinforced, one-piece structural rim.