Composite Wheel Assembly for Precise Run-Out Control
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Solution Overview
Problem
Ensuring high precision and stability in the assembly of composite wheels, particularly in achieving a qualified overall run-out value, is a challenging problem for wheel manufacturers.
Innovation Solution
A composite wheel assembly device with a frame, oil cylinder, and rollers, along with a unique locking mechanism using a cylinder sleeve and locking sleeve, allows for precise alignment and connection of the rim, connecting ring, and spokes, ensuring high precision and stability during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wheel assembly methods are used, then the assembly process is simple, but the run-out value cannot be ensured to be qualified
Solution Approach 1:
The patent applies preliminary action by pre-positioning the spoke assembly on the flange using ring grooves and positioning holes before final tightening. The assembly device pre-aligns components using guide rails and positioning fixtures, ensuring correct spatial relationships before the actual assembly is completed. This preliminary positioning is critical for achieving the required run-out value qualification.
Solution Approach 2:
The patent changes key assembly parameters including the use of adjustable tightening forces on bolts, controlled insertion depths of spokes into ring grooves, and precise angular positioning of multiple spokes. The assembly device incorporates adjustable parameters for clamp positions and tightening sequences, allowing optimization of the assembly process to achieve qualified run-out values.
2Manufacturing precision
If high precision assembly is achieved through complex mechanisms, then the run-out value is qualified, but the structure becomes complicated
Solution Approach 1:
The patent segments the wheel assembly into distinct modular components: flange with ring grooves, multiple independent spoke assemblies, connecting ring, and rim. Each component has standardized interfaces and positioning features. The assembly device is also segmented into separate functional modules for positioning, clamping, and tightening, allowing each to be optimized independently while maintaining overall precision.
Solution Approach 2:
The patent introduces intermediary elements such as ring grooves that act as mediators between the flange and spoke assemblies, providing precise geometric constraints. Positioning holes and guide rails serve as intermediary features that transfer and maintain alignment information throughout the assembly process. These intermediaries simplify the overall structure by providing fixed reference relationships rather than requiring complex active control mechanisms.
3Manufacturing precision
If multiple positioning features are added to ensure precision, then the run-out value is controlled, but the manufacturing complexity increases
Solution Approach 1:
Positioning features such as ring grooves, positioning holes, and guide rails are incorporated into the component designs during the manufacturing stage. These features are pre-formed on the flange, spokes, and assembly device fixtures, so that during assembly they automatically provide the necessary geometric constraints without requiring additional complex operations. This preliminary incorporation of positioning features simplifies the actual assembly process.
Solution Approach 2:
The patent optimizes the parameters of positioning features including the dimensions of ring grooves, the locations and tolerances of positioning holes, and the geometries of guide rails. By carefully selecting and controlling these parameters, the design achieves the required run-out control while minimizing the complexity of manufacturing these positioning features. The parameters are optimized to provide sufficient constraint with simple geometric forms.
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
The solution achieves high size and shape precision, dynamic balance, fatigue strength, rigidity, light weight, and attractive appearance, while simplifying the assembly process and ensuring stable performance.
Implementation Method 1
an oil cylinder is fixed on the frame; an oil cylinder rod of the oil cylinder penetrates through a base fixed on the frame
Implementation Method 2
a top of each bracket is provided with an arc-shaped inclined plane, wherein the arc-shaped inclined plane is matched with a corresponding roller of the rollers
Implementation Method 3
the cylinder sleeve is provided with an inner hole spherical surface and a cylindrical surface from an outside to an inside in a radial direction of the cylinder sleeve, the cylinder sleeve is further inserted with a locking sleeve, and the locking sleeve includes a side wall spherical surface, an outer cylindrical surface and a threaded hole
Implementation Method 4
threaded holes penetrating through the two ring grooves are uniformly provided in the first axial surface and the second axial surface of the flange corresponding to the ring grooves, and multiple first mounting holes are inserted into the two ring grooves and connected by bolts passing through the first mounting holes and matching with the threaded holes
Data Source
AI summary
A composite wheel includes a rim, a connecting ring, a plurality of spokes and a flange all connected in sequence from the outside to the inside. One end of each spoke is provided with a thread, and the other end of each spoke is provided with a first mounting hole.