Multi-hub Wheel Assembly with Intermediate Hub for Structural Integrity
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Solution Overview
Problem
Conventional wheel assemblies in motor vehicles lack sufficient structural integrity to prevent penetration of the passenger compartment during external loading conditions, such as shallow offset frontal loads, and do not provide adequate styling freedom while maintaining radial and transverse stiffness.
Innovation Solution
A multi-hub wheel assembly comprising a rigid outer wheel made from a lower strength material like cast aluminum and an intermediate hub made from high-strength low-alloy steel, with an oblique deflection rim and convex mounting base, is integrated into the wheel unit to enhance structural support and control movement under external loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional single-material wheel assembly is used, then manufacturing is simpler and cost is lower, but structural integrity is insufficient to prevent penetration during external loading
Solution Approach 1:
The wheel assembly uses a composite structure combining an outer wheel made from cast aluminum (lower strength material) and an intermediate hub made from HSLA steel (higher strength material). This composite material approach provides the necessary structural integrity to prevent penetration during external loading while maintaining manufacturing feasibility.
Solution Approach 2:
The wheel assembly is divided into multiple segments: an outer wheel, an intermediate hub, and a central hub. This segmentation allows each component to be optimized for its specific function - the outer wheel for styling and basic structure, the intermediate hub for high-strength load management, and the central hub for suspension component mounting.
2Strength
If a higher strength material is used throughout the wheel assembly, then structural integrity improves, but styling freedom is reduced and manufacturing cost increases
Solution Approach 1:
The intermediate hub is specifically engineered with local geometric features including an oblique deflection rim and convex mounting base. These localized high-strength features are positioned precisely where external loading occurs, providing structural integrity only where needed rather than throughout the entire wheel assembly.
3Ease of manufacture
If the outer wheel is made from lower strength material for styling freedom, then manufacturing ease and styling freedom improve, but radial and transverse stiffness may be insufficient
Solution Approach 1:
The combination of cast aluminum outer wheel with HSLA steel intermediate hub creates a composite structure where the lower strength material provides styling freedom and manufacturing ease, while the higher strength intermediate hub compensates for and provides the necessary radial and transverse stiffness.
4Strength
If a multi-hub configuration is implemented, then structural integrity and stiffness are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The wheel assembly is divided into multiple segments: an outer wheel, an intermediate hub, and a central hub. This segmentation allows each component to be optimized for its specific function - the outer wheel for styling and basic structure, the intermediate hub for high-strength load management, and the central hub for suspension component mounting.
Solution Approach 2:
The intermediate hub is nested within the outer wheel structure, with the outer wheel positioned around the intermediate hub. This nested configuration allows the high-strength intermediate hub to provide structural support while being protected by and integrated with the outer wheel, creating a compact multi-functional assembly.
Data Source
AI summary
Disclosed are wheel assemblies for motor vehicle powertrains, methods for making and methods for using wheel assemblies, and motor vehicles with wheel units each composed of a tire and a wheel assembly. For example, a multi-hub wheel assembly for a motor vehicle is disclosed. The motor vehicle includes a tire and a suspension component, such as a hub-and-bearing assembly, mounted to the vehicle body. The wheel assembly includes an outer wheel with an annular rim well attached to a central hub. The central hub mounts onto the vehicle's suspension component, e.g., via lugs and bolts, while the tire mounts onto the rim well. The wheel assembly also includes an intermediate hub with a deflection annular rim attached to a mounting base. The mounting base is attached to the outer wheel. The intermediate hub mounts inside a hollow core of the outer wheel, interposed between the central hub and the suspension component.