Wheel Hub-Bearing Assembly with Deformation-Buffer Ring
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Solution Overview
Problem
The existing hub-bearing assemblies for motor vehicles experience stress concentration, deformation, and reduced service life due to the orbital roll forming process, which affects the flanged hub's interaction with the toothed sleeve and radial ball bearings, leading to coupling issues and premature fatigue.
Innovation Solution
Incorporating a rectangular section ring between the rolled edge of the flanged hub and the toothed sleeve to absorb deformations and a radially inner spacer to provide an axial shoulder for the radial ball bearings, allowing for a different internal shape of the flanged hub and reducing stress concentrations, while maintaining the internal geometry and structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If orbital roll forming is used to deform the flanged hub material onto the inner toothed sleeve, then axial preloading and clamping of components is achieved, but stress concentration and deformation occur leading to reduced service life
Solution Approach 1:
A rectangular section ring is introduced as an intermediary component between the flanged hub and the toothed sleeve. This ring absorbs the deformations induced by orbital roll forming, preventing direct stress concentration on the toothed sleeve and hub interface. The ring acts as a buffer that maintains the clamping function while protecting the structural integrity of the connected components.
2Force
If the flanged hub is deformed directly onto the toothed sleeve through roll forming, then axial preloading is achieved, but coupling problems occur due to expansion of the toothed sleeve profile
Solution Approach 1:
The rectangular section ring serves as a mediator that decouples the deformation process from the toothed sleeve. During orbital roll forming, the ring absorbs the expansive forces that would otherwise distort the toothed sleeve profile. This ensures that the toothed sleeve maintains its original geometry, preventing coupling problems between the sleeve and ring gear while still achieving the necessary axial preloading through the ring.
3Stability of the object's composition
If orbital roll forming is applied to the flanged hub, then component clamping is achieved, but the bearing seat contracts causing positioning and preloading problems
Solution Approach 1:
The rectangular section ring acts as a protective intermediary that isolates the bearing seat from the contracting effects of orbital roll forming. By positioning the ring between the deformed hub material and the bearing seat, the deformation forces are absorbed by the ring rather than being transmitted to the bearing seat. This maintains the bearing seat's original dimensions and geometry, ensuring accurate bearing positioning and preloading without the adverse effects of material contraction.
Data Source
AI summary
A hub-bearing assembly includes a stationary radially outer ring, a flanged hub extending into an interior of the radially outer ring and configured to rotate relative to the radially outer ring, and a radially inner ring mounted on the flanged hub and axially abutting a portion of the flanged hub. A toothed sleeve is mounted to the hub axially inward of and adjacent to the radially inner ring and is rotationally fixed relative to the flanged hub. An auxiliary ring is mounted on the flanged hub in contact with the toothed sleeve. The flanged hub includes an axially inner rolled edge in contact with the auxiliary ring and configured to maintain a preload on the radially inner ring, and the auxiliary ring is configured to accommodate deformations induced by the formation of the rolled edge.