Multipiece Road Wheel Structure for Lightweight Load Resistance
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Solution Overview
Problem
Existing road wheel designs face challenges in balancing weight reduction with structural integrity and manufacturing complexity, particularly in resisting deflection and strain under loading while maintaining vehicle clearance and ease of manufacturing.
Innovation Solution
A multipiece road wheel assembly comprising two rim halves connected via fasteners, with a hollow cavity and a dovetail connection, using additive manufacturing and machining to create a lightweight yet strong structure that resists deformation and supports elastomeric pads with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece road wheel design is used, then structural integrity is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The road wheel is divided into multiple separate components including a rim assembly with first and second rim halves, a hub assembly, and a disc assembly. These segments are connected through fasteners and interference fits, allowing each component to be optimized independently for weight while maintaining overall structural integrity through the segmented architecture.
2Strength
If a single-piece road wheel design is used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The road wheel is divided into multiple separate components including a rim assembly with first and second rim halves, a hub assembly, and a disc assembly. These segments are connected through fasteners and interference fits, allowing each component to be optimized independently for weight while maintaining overall structural integrity through the segmented architecture.
Solution Approach 2:
Multiple rim halves are merged together to form the complete rim structure, and the hub assembly is merged with the disc assembly through interference fits and fasteners. This merging of separate components creates a unified structure that achieves structural integrity comparable to single-piece designs while enabling simplified manufacturing of individual parts.
3Strength
If material is added to resist deflection and strain, then structural strength is improved, but weight increases
Solution Approach 1:
The rim assembly includes localized thickening at the cantilevered end region where the elastomeric pad is mounted, providing increased strength and resistance to deflection and strain exactly where needed. The rest of the rim structure maintains a lighter gauge, optimizing the weight-strength ratio by concentrating material only in the critical load-bearing area.
Solution Approach 2:
The road wheel employs composite construction combining different materials and structures: the rim assembly uses aluminum alloy with localized thickening, the hub assembly uses a different aluminum alloy composition, and the elastomeric pad provides additional damping and strain absorption. This composite approach allows each material to be optimized for its specific function, reducing overall weight while maintaining strength.
4Strength
If radial stiffening ribs are added, then structural strength is improved, but device complexity increases and debris accumulation occurs
Solution Approach 1:
The traditional radial stiffening ribs that extend into the hollow interior of the road wheel have been removed. Instead, structural strength is achieved through the segmented rim and hub assemblies connected by fasteners and interference fits, which provide stiffness without the complexity and debris-trapping issues of internal ribs.
5Strength
If undercuts are created for wear ring support, then structural strength is improved, but manufacturing difficulty increases
Solution Approach 1:
A separate wear ring component is introduced as an intermediary element that provides the necessary support structure without requiring difficult undercut geometries. The wear ring is mounted in a simple recess in the rim assembly and secured with fasteners, eliminating the need for complex undercut areas while still providing adequate support for the elastomeric pad and resistance to external loads.
Data Source
AI summary
A road wheel for a tracked vehicle includes a first rim half and a second rim half operatively connected to the first rim half. The first rim half includes at least a first portion that is angled away from the second rim half. The second rim half includes at least a first portion that is angled away from the first rim half. A hollow cavity is formed between the first portion of the first rim half and the first portion of the second rim half.