Hub-Wheel Radially Outer Ring Toroidal Truncated Cone Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing hub-wheel assemblies with flanged radially outer rings are the heaviest and most bulky components, limiting design freedom to reduce size and weight while maintaining performance, and current forging technologies restrict significant material reduction without increasing production complexity and cost.
Innovation Solution
A new shape for the radially outer ring is designed with a first and second toroidal surface connected by a truncated cone, optimizing the trade-off between weight reduction and mechanical strength, allowing for a reduced weight without unnecessary material addition and maintaining performance, achieved by specific radius and angle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flanged radially outer ring is used in hub-wheel assemblies, then the structural strength and stability are improved, but the weight and bulk of the component increases
Solution Approach 1:
The patent applies curvilinear surfaces (toroidal surfaces) instead of flat or cylindrical surfaces to connect the flange portion and cylindrical portion of the radially outer ring. This curvature-based design optimizes material distribution, maintaining structural strength while reducing unnecessary material and overall weight.
Solution Approach 2:
The patent creates different surface geometries in different regions of the radially outer ring: a flange portion with holes for structural coupling, a cylindrical portion for bearing support, and curvilinear connecting surfaces. Each region has optimized local geometry that provides the necessary strength while minimizing weight.
2Weight of moving object
If material is removed to reduce weight of the radially outer ring, then the weight is reduced, but the mechanical strength may be compromised
Solution Approach 1:
The curvilinear (toroidal) surfaces are designed with specific radii (R1 and R2) that create optimal stress distribution patterns. The curvature geometry is specifically engineered to maintain mechanical strength while allowing material reduction compared to conventional flat or cylindrical connections.
Solution Approach 2:
The patent specifies particular parameter ranges for the curvilinear surfaces, including radius R1 between 1.5-7mm and radius R2 greater than twice R1, and connection angle α between 10°-20°. These optimized parameters ensure the right balance between weight reduction and mechanical strength maintenance.
3Ease of manufacture
If conventional forging technology is used to produce the radially outer ring, then the manufacturing process is simple, but significant material reduction is restricted
Solution Approach 1:
The curvilinear surfaces with specific radii and angles can be directly formed through forging operations, integrating complex weight-optimized geometry into a single-step manufacturing process. This eliminates the need for additional machining operations while achieving significant weight reduction.
Solution Approach 2:
The patent defines specific geometric parameters (radii R1, R2 and angle α) that can be controlled during the forging process, allowing weight optimization to be achieved through standard manufacturing techniques without requiring complex multi-step production.
4Weight of moving object
If additional machining operations are performed to remove material, then the weight is reduced, but the production complexity and cost increase
Solution Approach 1:
By defining specific parameter ranges for the curvilinear surfaces that can be directly formed during forging, the patent enables weight optimization to be achieved through process parameter control rather than post-forging material removal, thereby avoiding additional machining complexity.
Solution Approach 2:
The optimal geometry for weight reduction is built into the forging process itself through predetermined surface radii and connection angles, eliminating the need for subsequent machining operations. The weight optimization is performed in advance during the forming stage.
Data Source
AI summary
Radially outer ring of a bearing unit for a hub-wheel assembly for motor vehicles, the radially outer ring being provided with: a flange portion having a plurality of axial fixing holes that connect an element of the motor vehicle wheel to the radially outer ring, an almost cylindrical portion which with part of its radially internal surfaces defines raceways for rows of rolling bodies of the bearing unit, an axially internal or axially external surface of the flange portion and a radially external surface of the cylindrical portion connected to each other by a first portion of toroidal surface (St1) and of a second portion of toroidal surface (St2) defined by corresponding first radius (R1) and second radius (R2), a truncated cone surface (Stc) defined by an angle (a) formed with a rotation axis (X) of the radially outer ring is interposed between the first portion of toroidal surface (St1) and the second portion of toroidal surface (St2).