Omnidirectional Roller Wheel Overmolding With Symmetrical Axles
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Solution Overview
Problem
Conventional omnidirectional wheels require complex and time-consuming assembly processes, often using split or clamshell-style bushings that are weaker and more prone to failure under extreme loading conditions, necessitating a more robust and efficient manufacturing method.
Innovation Solution
A solid bushing, precision assembly, and advanced overmolding technique are used to produce a robust omnidirectional wheel by pre-assembling symmetrical axles and solid axle bushings into pre-roller assemblies, which are then overmolded into a completed wheel, simplifying the assembly process and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional omnidirectional wheels use split or clamshell-style bushings with multiple sub-assemblies, then the assembly process becomes complex and time-consuming, but the structural integrity and strength are reduced
Solution Approach 1:
The patent combines multiple separate components (bushing halves, axles, rollers) into a single integrated solid bushing structure. The solid bushing is formed as one piece that simultaneously supports multiple axles and rollers, eliminating the need for separate bushing halves and reducing assembly steps while increasing structural strength.
Solution Approach 2:
The solid bushing is pre-formed with integrated features for multiple axles and rollers before final assembly. The bushing is manufactured as a complete unit with all necessary bores and mounting features already in place, allowing for more efficient final assembly compared to assembling multiple separate components.
2Productivity
If conventional omnidirectional wheels use multiple sub-assemblies brought together at final assembly, then the manufacturing process becomes more complex, but the production time increases
Solution Approach 1:
The patent merges multiple sub-assemblies into a single solid bushing component that integrates support structures for all axles and rollers. This reduces the number of parts that need to be handled and assembled, directly improving production efficiency while reducing assembly complexity.
Solution Approach 2:
The wheel is divided into modular sections with each solid bushing serving as an independent module that can be manufactured separately and then installed. This segmentation allows for specialized manufacturing of each module while simplifying the overall assembly process.
3Ease of manufacture
If split bushings are used in omnidirectional wheels, then the assembly is easier to manufacture, but the bushings are weaker and more prone to failure under extreme loading
Solution Approach 1:
The solid bushing combines multiple functions into a single monolithic structure that eliminates weak points associated with joined bushing halves. The integrated design removes seams and joints that could fail under load, significantly improving reliability while maintaining manufacturability through advanced forming processes.
Data Source
AI summary
A wheel and a method for its manufacture are disclosed herein. The wheel includes a wheel hub including a main axle bore rotatable around a main axis. The wheel also includes a plurality of cross roller sub-assemblies comprising a plurality of pre-roller assemblies. The pre-roller assemblies include a plurality of symmetrical axles, and a plurality of axle bushings, each axle bushing configured to receive one symmetrical axle in a central longitudinal bore. The cross roller sub-assemblies also include a plurality of peripheral rollers, each pre-roller assembly overmolded with one peripheral roller. The wheel also includes a peripheral axle ring adapted about the wheel and radially spaced from the main axis, the wheel having the plurality of cross roller sub-assemblies overmolded with the wheel hub, where the overmolded cross roller sub-assemblies form the peripheral axle ring.