Segmented Wheel Design for Endless Track Systems
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Solution Overview
Problem
Current drive wheels for endless track systems in agricultural vehicles are costly to manufacture due to the need for large and expensive tooling for elastomeric coatings, and they suffer from issues like debris trapping and localized wear, requiring the entire wheel to be replaced if damaged.
Innovation Solution
A segmented wheel design comprising multiple identical segments, each with a support portion, circumferential flange, and rim portion, allows for reduced tooling costs and easier localized strengthening. The segments can be bolted together, and the rim portion can be an elastomeric material for improved friction and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous sheet of steel is used to form drive wheels, then the wheel structure is simple and strong, but expensive tooling is required and it is difficult to hold close tolerances in larger sizes
Solution Approach 1:
The wheel is divided into multiple identical segments (typically 3-6 segments per wheel) that are manufactured separately and then assembled together. Each segment can be produced using smaller, less expensive tooling while maintaining close tolerances. The segments are joined using bolts or other fastening mechanisms to form the complete wheel assembly, achieving both structural strength and manufacturing economy.
2Reliability
If the entire wheel is enclosed in a mold to apply elastomeric surface, then the elastomeric coating is complete and uniform, but the mold size becomes very large and expensive
Solution Approach 1:
The wheel is segmented into multiple smaller sections that can each be individually coated with elastomeric material using smaller, more cost-effective molds. After the elastomeric coating is applied to each segment, the segments are assembled together to form the complete wheel. This approach maintains uniform and complete elastomeric coverage while significantly reducing mold size and manufacturing cost.
3Device complexity
If the wheel is made as a single piece, then the structure is simple, but if damage occurs to a localized portion, the entire wheel needs to be replaced
Solution Approach 1:
The wheel is constructed from multiple identical segments that can be independently replaced. If damage occurs to a localized portion affecting only one or a few segments, those damaged segments can be removed and replaced without replacing the entire wheel assembly. This significantly reduces repair costs and downtime while maintaining structural integrity through the modular design.
4Ease of manufacture
If conventional manufacturing techniques are used, then the process is established, but it is difficult to locally thicken and strengthen locations of a wheel
Solution Approach 1:
The segmented wheel design allows for localized thickening and strengthening at specific locations without requiring changes to the entire wheel manufacturing process. Each segment can be independently designed and manufactured with varying thicknesses and material properties tailored to specific load-bearing requirements. This enables optimization of structural strength at critical locations while maintaining cost-effective conventional manufacturing techniques for standard segments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The segmented wheel design reduces manufacturing costs by minimizing tooling requirements, allows for localized strengthening of high-stress areas, and improves durability and noise reduction through the use of elastomeric rim portions and debris ejection features.
Implementation Method 1
Some of the wheels are of such a diameter that the application of the elastomeric surface requires the entire wheel to be enclosed in a mold
Implementation Method 2
This elastomeric material allows for better friction characteristics between the drive wheel and the track carcass
Implementation Method 3
An elastomeric rim portion reduces damage to an endless track and dampens the noise of the system
Data Source
AI summary
A wheel for use with an endless track system includes at least three substantially identical segments. Each of the segments has a support portion, a circumferential flange, and a rim portion. The rim portion is affixed to an outer face of the circumferential flange. The segments are attached to each other to form the wheel. Methods of forming a wheel are also described.