Idler Wheel Three-Member Welded Design
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Solution Overview
Problem
Conventional idler wheels for heavy-duty applications have welded portions that are subjected to high loads when a force is exerted in the axle direction, leading to increased weight and cost due to the need for thicker and longer welded legs to ensure strength.
Innovation Solution
The idler wheel is designed with a configuration of three members (first, second, and third members) and corresponding welded portions that distribute the load more evenly, reducing the stress on the welded areas by forming the first, second, and third welded portions between the support portions, allowing for a more efficient welding process and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the welded portions are provided at the end of the side plate, then the connection strength is improved, but the thickness of members and welded leg length must be increased, resulting in increased weight and cost
Solution Approach 1:
The boss is divided into two separate parts (first boss part and second boss part) that are welded to opposite sides of the side plate. This segmentation distributes the connection points along the side plate, reducing the load concentration at any single welded portion while maintaining overall connection strength.
Solution Approach 2:
The welded portions are arranged in the axial direction of the side plate rather than only at the ends. By distributing welds along the length of the side plate, the load is spread across multiple locations, reducing the stress on each individual welded portion and allowing for thinner members and shorter welded legs.
2Strength
If the welded portions are provided at the end of the side plate, then the connection strength is improved, but the thickness of members and welded leg length must be increased, resulting in increased cost
Solution Approach 1:
The boss is divided into two separate parts (first boss part and second boss part) that are welded to opposite sides of the side plate. This segmentation distributes the connection points along the side plate, reducing the load concentration at any single welded portion while maintaining overall connection strength.
Solution Approach 2:
The welded portions are arranged in the axial direction of the side plate rather than only at the ends. By distributing welds along the length of the side plate, the load is spread across multiple locations, reducing the stress on each individual welded portion and allowing for thinner members and shorter welded legs.
3Reliability
If the boss is divided into two parts with five welded locations, then the connection reliability is improved, but the manufacturing complexity and welding time are increased
Solution Approach 1:
The boss is divided into two separate parts (first boss part and second boss part) that are welded to opposite sides of the side plate. This segmentation distributes the connection points along the side plate, reducing the load concentration at any single welded portion while maintaining overall connection strength.
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
This configuration reduces the load on the welded portions when a force is applied in the axle direction, resulting in a lighter and less costly idler wheel while maintaining the required strength, and allows for easier manufacturing with reduced welding complexity.
Implementation Method 1
The first welded portion is formed between the second support portion and the third support portion and connects the second support portion and the third support portion. The second welded portion is formed between the first support portion and the third support portion, and connects the first support portion and the third support portion.
Data Source
AI summary
With an idler, a first member includes a first boss portion, a first rim portion, and a side plate. A second member includes a second boss portion, a second rim portion, and a side plate. A third member includes a third boss portion having a third axle hole portion configured to allow insertion of an axle. The third boss portion is disposed between the first boss portion and the second boss portion. A first welded portion is formed between the second boss portion and the third boss portion and connects the second and third boss portions. A second welded portion is formed between the first boss portion and the third boss portion and connects the first and third boss portions. A third welded portion is formed between the first rim portion and the second rim portion and connects the first and second rim portions.