Single Piece Wheel Rim Press Forming and Welding
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Solution Overview
Problem
Existing methods for manufacturing wheel rims for very large vehicles, such as those used in mobile cranes and quarry excavation, are inadequate as they require multi-piece rims with loose parts in contact with the pneumatic tire, which are not robust enough for off-road use and cannot efficiently produce rims of the necessary large diameter.
Innovation Solution
A method involving press forming of cylindrical blank components to create a single-piece wheel rim with axially outer and inner rim portions, followed by machining and welding a press-formed disc to the rim base, allowing for thicker material usage and eliminating loose parts in contact with the tire, enabling the production of robust wheel rims with greater depth and asymmetry accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If multi-piece rims are used for very large vehicles, then the wheel rim can be produced with large diameter, but loose parts are in contact with the pneumatic tyre reducing robustness
Solution Approach 1:
The wheel rim is divided into two separate cylindrical blank components (inner and outer rim portions) that are formed independently through press forming and then joined together. This segmentation allows each component to be manufactured with optimal thickness and structural integrity for large diameter applications, while the joining process creates a unified structure that eliminates loose parts contact with the tyre.
Solution Approach 2:
The inner and outer rim portions are joined together through a combination of press fitting and welding to form a single integrated wheel rim structure. This merging eliminates the loose parts problem associated with multi-piece rims while maintaining the ability to manufacture large diameter rims through the segmented forming process.
2Ease of manufacture
If conventional circular rolling techniques are used, then manufacturing process is simple, but rim material thickness is insufficient for very large vehicle applications
Solution Approach 1:
The conventional circular rolling technique is replaced with press forming technology. Press forming allows for the formation of thick-walled cylindrical components from blank materials through controlled compression forces. This substitution enables the production of rim portions with sufficient material thickness for very large vehicle applications while maintaining manufacturing efficiency through standardized press forming processes.
3Reliability
If single-piece rim is manufactured, then no loose parts contact the tyre improving robustness, but manufacturing large diameter rims with required thickness is difficult
Solution Approach 1:
The single-piece rim is segmented into two manufacturable components (inner and outer rim portions) that can be formed using press technology. This segmentation makes the manufacturing of large diameter rims with required thickness feasible, while the subsequent joining process creates a unified structure that provides the robustness of a single-piece rim without loose parts contact.
Solution Approach 2:
The inner and outer rim portions are pre-formed using press forming technology to achieve the required thickness and structural integrity before joining. This preliminary action allows each component to be manufactured with optimal properties, and the subsequent joining process combines them into a robust single-piece equivalent structure.
4Adaptability or versatility
If multi-piece rim construction is used, then manufacturing flexibility is improved, but assembly complexity and time increase
Solution Approach 1:
The inner and outer rim portions are pre-formed using press forming technology to achieve the required thickness and structural integrity before joining. This preliminary action allows each component to be manufactured with optimal properties, and the subsequent joining process combines them into a robust single-piece equivalent structure.
Solution Approach 2:
The wheel rim is divided into two independent cylindrical blank components that can be manufactured simultaneously or in parallel through press forming. This segmentation provides manufacturing flexibility for large diameter rims while the standardized joining process (press fitting and welding) ensures efficient assembly, maintaining productivity.
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 method enables the production of robust, single-piece wheel rims with improved depth and accuracy, suitable for large pneumatic tires, enhancing manufacturing efficiency and suitability for both off-road and highway use without loose parts in contact with the tire.
Implementation Method 1
press forming the first blank component to form a one piece, axially outer rim portion; press forming the second blank component to form a one piece, axially inner rim portion
Implementation Method 2
welding the press-formed disc to the rim base at the machined inside diameter
Implementation Method 3
press fitting the press-formed disc to the rim base at the machined inside diameter
Data Source
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AI summary
A method of manufacturing a wheel sub-assembly (2) for a wheel of a very large vehicle, such as those used for mobile cranes, quarry excavation or transport of mined material. The method comprises the steps of: providing first and second cylindrical blank components and an annular disc blank; press forming the first blank component to form a one piece, axially outer rim portion (6); press forming the second blank component to form a one piece, axially inner rim portion (4); circumferentially joining the outer and inner rim portions to form an annular wheel rim having a base; machining the inside diameter of the wheel rim base; press forming the disc blank (8) to form a press-formed disc; machining the outside edge of the press-formed disc; press fitting the press-formed disc to the wheel rim base at the machined inside diameter; and welding the press-formed disc (8) to the wheel rim base (4,6) at the machined inside diameter.