Cycle Hub Spoke Mount Structure for Lower Mass Distribution
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Solution Overview
Problem
Existing cycle hub assemblies are overly heavy due to oversized spoke mounting elements, which are a result of production method limitations, and there is a need for a lighter alternative with optimal mass distribution for required strength.
Innovation Solution
The cycle hub assembly employs topology optimization and 3D printing to design spoke mounting elements with bridge pieces that are narrower than the elements themselves, allowing for efficient force distribution and reduced material usage, with the spoke mounting elements and bridge pieces being made from lightweight materials like Scalmalloy or polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional production methods are used to manufacture spoke mounting elements, then manufacturing simplicity is maintained, but the spoke mounting elements become oversized and heavy
Solution Approach 1:
The patent changes the manufacturing parameters by transitioning from traditional machining methods to additive manufacturing (3D printing). This enables the creation of complex, optimized geometries with narrow bridge pieces and hollow spoke mounting elements that would be impossible or extremely difficult to produce with conventional methods, thereby reducing weight while maintaining structural integrity
Solution Approach 2:
The spoke mounting elements are segmented into hollow sections with internal cavities rather than being solid structures. This segmentation reduces material usage and weight while maintaining the necessary strength and stiffness to withstand spoke forces, directly addressing the weight reduction goal
2Strength
If spoke mounting elements are made larger to ensure strength, then structural reliability is improved, but the overall mass of the hub assembly increases
Solution Approach 1:
The patent applies local quality by varying the wall thickness and material distribution within the spoke mounting elements. The hollow sections have strategically placed walls that provide localized strength where forces are applied, while reducing material in areas where less strength is needed. This optimized material distribution maintains required strength while minimizing overall mass
Solution Approach 2:
The patent utilizes composite material structures by combining different material properties within the spoke mounting elements. The hollow sections and bridge pieces create a composite structure that leverages the strength-to-weight ratio advantages, achieving high strength with reduced mass compared to solid homogeneous structures
3Strength
If more material is used in spoke mounting elements to withstand spoke forces, then structural strength is improved, but material efficiency and production cost worsen
Solution Approach 1:
The patent changes the material quantity parameter by using hollow spoke mounting elements with internal cavities instead of solid structures. This reduces the volume and mass of material required while maintaining the necessary strength to withstand spoke forces, directly improving material efficiency and reducing production costs associated with material consumption
Data Source
AI summary
The invention relates to a cycle hub assembly and a method of producing such cycle hub assembly. The cycle hub assembly includes a wheel hub and a plurality of spoke mounting elements. The spoke mounting elements are present in two axially spaced rows positioned around the circumference of the wheel hub. Each spoke mounting element includes at least one spoke mounting hole for receiving at least part of at least one spoke. At least two adjacent spoke mounting elements are interconnected in an efficient manner such that an optimal design of the cycle hub assembly is obtained.