Concentric Part Insertion for Double-Walled Hole Punching
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Solution Overview
Problem
Existing methods for punching holes in plates using a punch nipple are energy-intensive and result in unpredictable mechanical characteristics, leading to material wastage and inefficiencies, especially in manufacturing high-end spoke wheels.
Innovation Solution
The method involves punching a hole in one plate, creating a concentric part that is then inserted into a second plate to form a widened hole, enhancing mechanical and stress characteristics while reducing material waste and allowing for faster, more cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the punch nipple is pushed through to widen the hole in the first plate, then a widened hole is formed, but a lot of energy is consumed and the mechanical characteristics become unpredictable
Solution Approach 1:
The invention extracts the concentric part including the hole from the first plate as a separate component. This punched-out concentric part is then inserted into the second plate to form the widened hole structure. By separating the hole-forming process from the widening process, the method avoids the energy-intensive pushing through operation while achieving the desired widened hole configuration with predictable mechanical characteristics.
2Shape
If the punch nipple is pushed through to widen the hole, then the hole is widened, but the mechanical characteristics and stress characteristics become unpredictable and the side of the hole may become carved
Solution Approach 1:
The concentric part is punched out as a separate component with controlled geometry, ensuring predictable mechanical characteristics. This extracted component is then inserted into the second plate, providing a reliable and consistent structure without the unpredictable carving effects that occur during the pushing through process.
Solution Approach 2:
The concentric part is punched out in advance with precise dimensional control before being inserted into the second plate. This preliminary formation of the concentric part ensures that the mechanical and stress characteristics are predetermined and consistent, avoiding the unpredictable results of in-situ widening operations.
3Ease of manufacture
If the punched out material disc is discarded, then the process is simple, but material is wasted and cost price increases
Solution Approach 1:
Instead of discarding the punched-out concentric part as waste material, the invention recovers and reuses it by inserting it into the second plate to form the widened hole structure. This transforms what would be waste material into a valuable structural component, eliminating material waste while maintaining process simplicity.
Solution Approach 2:
The invention converts the potentially harmful effect of material waste into a beneficial outcome. The punched-out concentric part, which would normally be discarded, is instead utilized to strengthen the second plate structure, turning material that would be lost into a value-adding component that improves the overall product.
4Strength
If additional strength is added to the rim at the spoke insertion place, then stress characteristics improve, but the rim weight increases
Solution Approach 1:
The invention applies local quality by concentrating the additional strength exactly where it is needed - at the spoke insertion place in the second plate. The inserted concentric part provides localized reinforcement without adding material throughout the entire rim structure, thereby improving stress characteristics at the critical location while minimizing overall weight increase.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
It is described a method of making holes in a first plate (1) and in a second plate (2) situated at a distance (3) from the first plate. The method comprises the steps of punching a hole in the first plate by means of a punch nipple (5); punching a concentric part (CP) which includes the hole out of the first plate (1); punching a hole in the second plate by means of the punch nipple (5); and pushing the punched out concentric part (CP) onto the hole into the second plate (2). This results in increased strength and stress characteristics especially around the hole in the second plate (2), which in turn may result in material savings, especially if the method is applied to a hollow rim of a wheel winch is to be provided with spokes by means of spoke nipples attached to the rim.