Omnidirectional Roller Wheel Assembly With Solid Bushings
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Solution Overview
Problem
Conventional omnidirectional wheels face challenges in assembly complexity, requiring split bushings that are weaker and prone to failure, or solid bushings that necessitate complex assembly steps, while also needing overmolding processes that are time-consuming and inefficient.
Innovation Solution
A wheel assembly design featuring symmetrical axles and solid bushings with interlocking faces, allowing for pre-roller assemblies to be overmolded with peripheral rollers and wheel hubs, forming cross roller sub-assemblies that can be easily assembled into a robust omnidirectional wheel with efficient production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If split bushings are used in conventional omnidirectional wheels, then assembly complexity is reduced, but structural strength and reliability deteriorate
Solution Approach 1:
The wheel is divided into modular components (wheel hub, cross rollers, peripheral rollers) that can be assembled separately and then overmolded together. This segmentation allows the use of solid bushings in the pre-assembled cross roller sub-assemblies while maintaining manageable assembly complexity through modular construction.
Solution Approach 2:
Cross roller sub-assemblies are pre-assembled with solid bushings and pre-roller assemblies before being integrated into the wheel hub. This preliminary assembly allows for robust construction with solid bushings while the overmolding process subsequently integrates these sub-assemblies into the final wheel structure.
2Strength
If solid bushings are used in omnidirectional wheels, then structural strength is improved, but assembly complexity increases
Solution Approach 1:
The patent combines multiple assembly steps into a single overmolding process. Cross roller sub-assemblies with solid bushings are placed in the mold and overmolded with the wheel hub in one operation, eliminating the need for separate assembly steps and reducing overall assembly complexity despite using solid bushings.
Solution Approach 2:
The overmolding material acts as an intermediary that bonds the pre-assembled cross roller sub-assemblies (with solid bushings) to the wheel hub. This intermediary material facilitates integration of robust sub-assemblies into the final wheel structure without requiring complex mechanical fastening or additional assembly operations.
3Ease of manufacture
If conventional overmolding processes are used, then wheel integration is achieved, but manufacturing time and efficiency deteriorate
Solution Approach 1:
Cross roller sub-assemblies are pre-assembled with solid bushings and pre-roller assemblies before being placed in the overmolding mold. This preliminary preparation allows the overmolding process to simply integrate these ready-made sub-assemblies with the wheel hub, significantly reducing the time and complexity of the final assembly operation.
Solution Approach 2:
The patent merges multiple components (wheel hub, cross rollers, peripheral rollers, and overmolding material) into a single integrated manufacturing step. By combining these elements into one overmolding operation, the process achieves both strong integration and manufacturing efficiency.
Data Source
AI summary
A wheel assembly is composed of multiple wheels, each featuring a hub with spokes and a main axle bore, and cross-roller sub-assemblies that include symmetrical axles and solid bushings, as well as peripheral rollers. The cross-roller sub-assemblies are overmolded with the wheel hub to form a peripheral axle ring. A method of assembling the wheel assembly involves creating the cross-roller sub-assemblies by overmolding the solid bushings with peripheral rollers, and then placing these sub-assemblies in a mold to form the peripheral axle ring. Alternatively, the pre-roller assemblies may be overmolded directly with the wheel hub to form the peripheral axle ring.