Lightweight Wheel Hub Using Rigidly Joined Sheet-Metal Elements
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Solution Overview
Problem
Existing wheel hub assemblies are heavy, inefficient in material usage, and costly due to the reliance on hot-forging processes, which also have a significant environmental impact.
Innovation Solution
A lightweight wheel hub assembly is created by using multiple sheet-metal elements that are rigidly joined together through methods like welding or gluing, eliminating the need for hot-forging and optimizing material use, with steel only applied where necessary for structural and functional reasons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot-forging process is used to manufacture wheel hub, then structural strength is achieved, but weight is excessive and material usage is inefficient
Solution Approach 1:
The wheel hub is divided into multiple separate components (bearing support component, wheel mounting component, connecting component) that are rigidly joined together. This segmentation allows each component to be optimized independently for strength where needed and weight where not needed, resolving the contradiction between structural strength and weight reduction.
Solution Approach 2:
Steel material is applied only where necessary for structural and functional reasons, specifically on surfaces making contact with rolling bodies and in critical load-bearing areas. This local quality approach ensures structural strength is maintained in essential areas while reducing overall weight by eliminating unnecessary material in non-critical areas.
2Reliability
If hot-forging process is used, then wheel hub is manufactured as single piece, but production costs are high and environmental impact is significant
Solution Approach 1:
The wheel hub is manufactured as an assembly of multiple sheet-metal components rather than a single hot-forged piece. This segmentation enables the use of less resource-intensive manufacturing processes (sheet metal forming, welding, or gluing) while maintaining structural integrity through proper design of connection interfaces between components.
Solution Approach 2:
The wheel hub employs composite construction using multiple sheet-metal elements rigidly joined together, creating a composite structure that achieves the required structural integrity without relying on the hot-forging process. This approach reduces manufacturing costs and environmental impact while maintaining reliability.
3Weight of moving object
If multiple sheet-metal elements are used, then weight is reduced and material efficiency is improved, but structural strength may be compromised
Solution Approach 1:
The wheel hub is segmented into multiple sheet-metal components (bearing support component with bearing races, wheel mounting component with mounting holes, and connecting component) that are rigidly joined together. This segmentation reduces weight by using thin sheets only where material is needed, while the rigid connections between segments maintain overall structural strength.
Solution Approach 2:
Steel material is applied locally only where necessary for structural and functional reasons, specifically on surfaces making contact with rolling bodies and in critical load-bearing areas. This local quality approach ensures structural strength is maintained in essential areas while minimizing overall material usage and weight.
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
This approach results in a reduced weight, improved material efficiency, lower production costs, and a smaller environmental footprint while maintaining structural strength, suitable for various wheel hub configurations and applications.
Implementation Method 1
rigidly joined together through methods like welding or gluing
Implementation Method 2
rigidly joined together through methods like welding or gluing
Data Source
AI summary
Wheel hubs for a motor-vehicle wheel hub assemblies provided with a bearing unit in turn which include at least one row of rolling bodies, the wheel hub being provided with at least two sheet-metal elements which are rigidly joined together, wherein a first sheet-metal element forms a raceway for the at least one row of rolling bodies.