Non-Pneumatic Wheel Spoke Assembly Guide
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Solution Overview
Problem
The assembly of non-pneumatic wheels, particularly aligning and attaching spokes to a hub with desired pretension, is challenging due to the complexity of manually aligning each spoke with the hub's slots, especially when mechanical attachment is required for support and disassembly.
Innovation Solution
A guide with frustoconically oriented slots is used to align and attach the spokes to the hub, allowing for simultaneous insertion and application of pretension, facilitated by a linear actuator and retainer system to simplify the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spokes are mechanically attached to the hub with desired pretension, then the wheel provides better support and reliability, but the assembly process becomes more complex and difficult to align
Solution Approach 1:
A conical alignment guide is introduced as an intermediary tool during assembly. The guide features conical slots that receive the spoke ends and guide them into proper alignment with the hub slots. The conical geometry provides self-centering action, automatically aligning the spokes with the hub while maintaining the desired pretension, thus eliminating the need for complex manual alignment procedures
Solution Approach 2:
The alignment guide is prepared in advance with conical slots positioned at the correct angles and orientations. The guide itself is pre-aligned with the hub before assembly begins. This preliminary preparation ensures that when spokes are inserted, they automatically follow the pre-established alignment path, simplifying the actual assembly operation
2Manufacturing precision
If individual spoke alignment is performed manually, then precise positioning can be achieved, but the assembly time increases significantly
Solution Approach 1:
Multiple alignment functions are merged into a single conical guide component. The guide simultaneously provides alignment for multiple spokes, maintains pretension, and guides insertion all in one operation. This consolidation allows all spokes to be aligned and attached in a single collective action rather than requiring sequential individual alignment, dramatically improving assembly speed while maintaining precision
Solution Approach 2:
The conical (curved) geometry of the alignment guide slots provides self-centering action through geometric constraints. As spoke ends are inserted into the conical slots, the converging walls of the cones automatically center the spokes radially, ensuring precise alignment without requiring complex adjustment mechanisms or manual positioning for each spoke
3Ease of repair
If the wheel is designed for disassembly for repairs, then maintenance becomes easier, but the structural integrity may be compromised
Solution Approach 1:
The wheel is segmented into distinct modular components: the hub, multiple spokes, and the outer band. Each spoke can be independently removed from the hub through the alignment guide mechanism, and each component can be separately inspected, repaired, or replaced. This segmentation enables easy disassembly for maintenance while maintaining the structural integrity of each individual component through proper design and material selection
Data Source
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AI summary
An apparatus and method of assembling a radially outer portion of a nonpneumatic wheel onto a hub (100) having a plurality of slots (150) extending along an axis, each of the slots (150) arranged in a frustoconical orientation extending from the first end (632) to the second end (634) such that the distance between the slots is greater at the first end than at the second end.