Controllable Gas Spring Wheel Assembly for Run-Flat Load Management
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Solution Overview
Problem
Existing wheel technologies, particularly for large construction and mining vehicles, face challenges with high replacement costs and downtime due to tire deformation, punctures, and rapid tread wear, which are not adequately addressed by pneumatic or non-pneumatic tire solutions.
Innovation Solution
A wheel assembly featuring an inner and outer rim with gas springs operatively coupled between them, including a local controller to manage the gas springs' response based on sensors, providing a controllable gas pressure and volume, and a disk for mechanical support, enabling a run-flat capability and field-serviceable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pneumatic tires are used to absorb forces during vehicle operation, then the tire can provide cushioning and comfort, but the tire and rim may deform, puncture, or blowout under excessive forces
Solution Approach 1:
The wheel assembly is divided into multiple independent gas spring units distributed around the circumference, with each gas spring providing independent force absorption. This segmentation allows the load to be distributed across multiple elements, preventing any single point from experiencing excessive stress that could lead to deformation or failure.
Solution Approach 2:
The gas springs provide adjustable and controllable operating response with variable gas pressure and volume, allowing the suspension characteristics to be optimized for different load conditions. This parameter adjustability enables the system to maintain reliable structural integrity while adapting to varying force requirements.
2Reliability
If non-pneumatic wheels with mechanical springs are used instead of pneumatic tires, then run-flat capability is improved, but the complexity of the mechanical spring system increases
Solution Approach 1:
The patent employs gas springs (pneumatic elements) instead of complex mechanical spring systems to achieve run-flat capability. The gas springs provide the necessary suspension and load-bearing functions through gas pressure rather than complex mechanical linkages, significantly reducing system complexity while maintaining reliability.
Solution Approach 2:
The gas springs provide dynamic response to varying loads and road conditions, allowing the wheel assembly to adapt its characteristics in real-time. This dynamic capability enables run-flat operation while maintaining ride comfort and handling characteristics without requiring complex mechanical adjustment mechanisms.
3Strength
If traditional wheel assemblies are used, then structural integrity is maintained, but operational costs and downtime increase due to tire wear and replacement
Solution Approach 1:
The gas spring units are designed to be individually replaceable and serviceable in the field. When a gas spring becomes worn or depleted, it can be replaced without replacing the entire wheel assembly or tire, allowing recovery and continuation of operation with minimal downtime. This selective replacement strategy significantly improves productivity while maintaining structural integrity.
Solution Approach 2:
The wheel assembly incorporates sensors and controllers that monitor the condition of each gas spring and can detect when service is needed. This self-monitoring capability allows for proactive maintenance scheduling, preventing failures that would cause unplanned downtime and enabling optimized replacement intervals that maximize operational efficiency.
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 reduces operational costs and downtime by providing a durable, field-serviceable wheel assembly with improved load management and reduced wear, enhancing the lifespan of the wheel and vehicle, while maintaining structural integrity and fuel efficiency.
Implementation Method 1
The gas spring may include a double-acting gas cylinder and associated piston. In other embodiments, the gas spring may have a controllable operating response, for example, a controllable gas pressure and/or a controllable gas volume.
Data Source
AI summary
A wheel assembly to be coupled to a hub of a vehicle may include an inner rim to be coupled to the hub of the vehicle and an outer rim surrounding the hub. The wheel assembly may also include gas springs operatively coupled between the inner rim and the outer rim. At least one gas spring may have a controllable operating response.