Segmented Wheel Frame Axle Molding for Precision
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Solution Overview
Problem
Existing multi-directional wheels face limitations in molding techniques due to integrally formed polyaxled rings, which restrict the range of molding methods and result in inconsistent and less accurate axle and roller components, leading to reduced strength and increased play between moving parts.
Innovation Solution
A wheel design featuring peripheral axles molded in a single process without longitudinal mold parting lines, with a head and axle shaft configuration that allows for accurate and consistent formation, enabling a continuous ring of rollers with improved strength and reduced play, using materials like high-strength plastic or composite materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If integrally formed polyaxled rings are used, then the wheel structure is simplified, but the molding technique range is restricted and component precision deteriorates
Solution Approach 1:
The wheel is divided into separate components: the wheel frame and the polyaxled rings are manufactured independently rather than as a single integral structure. This segmentation allows each component to be optimized for its specific manufacturing requirements, enabling higher precision in the molded axles and rollers while maintaining structural simplicity through modular assembly.
2Ease of manufacture
If integrally formed polyaxled rings are used, then manufacturing process is simplified, but component strength deteriorates and play between parts increases
Solution Approach 1:
By separating the wheel frame from the polyaxled rings and manufacturing them independently with specialized molding techniques, each component can be optimized for strength. The axles and rollers can be molded with precise fits and reinforced structures, eliminating the compromises required by integral forming while maintaining ease of manufacture through modular assembly.
Solution Approach 2:
The patent combines multiple axles into polyaxled rings that can rotate independently within the wheel frame. This merging of multiple functional elements into integrated rings reduces the number of separate components and assembly steps, maintaining manufacturing simplicity while achieving high component strength through optimized ring structures and bearing arrangements.
3Ease of manufacture
If traditional molding techniques are used for polyaxled rings, then manufacturing is easier, but accuracy and consistency of components deteriorates
Solution Approach 1:
The manufacturing process is segmented into specialized molding operations for different components. The polyaxled rings are molded separately from the wheel frame using techniques specifically suited for each component type, allowing for high accuracy and consistency in axle and roller dimensions while maintaining overall manufacturing efficiency through modular production.
Data Source
AI summary
A method of assembling a wheel rotatable about a main axis and having a plurality of peripheral rollers mounted on peripheral axles aligned tangentially about the wheel and radially spaced from the main axis, each peripheral axle joined to adjacent other peripheral axles to form a continuous ring comprising the peripheral axles, the method including the steps of: molding each peripheral axle in a die having a cylindrical cycle for forming the axle shaft of the peripheral axle without longitudinal separation tines, the peripheral axles each having a receiving head portion for receiving a free end of the axle shaft of an adjacent peripheral axle; mounting a roller on each axle shaft; joining the peripheral axles together to form a continuous ring of peripheral axles; and molding a wheel body including a support structure around the continuous ring.