Spoke with Dual Flattened Sections for Torsion Absorption
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Solution Overview
Problem
Traditional spokes in wheel sets suffer from inadequate fatigue resistance due to insufficient resistance against torsion and incorrect angles, leading to frequent breaking during assembly and use, especially under cyclic stress.
Innovation Solution
A spoke design featuring a combination of a first flattened section to absorb torsion and a second flattened section to transfer tension and adjust bending angles, allowing for enhanced shock wave absorption and improved assembly alignment, thereby reducing the likelihood of breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional spoke with a fixed-angle bend section is used, then the manufacturing process is simplified and assembly is efficient, but the spoke has insufficient fatigue resistance and breaks easily under torsion and cyclic stress
Solution Approach 1:
The spoke is divided into multiple functional sections: a terminal section, a neck section, a first flattened section, and a second flattened section. This segmentation allows each part to perform its specific function - the flattened sections absorb torsion and adjust angles independently, while the neck section maintains structural integrity, resolving the contradiction between manufacturing simplicity and fatigue resistance.
Solution Approach 2:
Different sections of the spoke are given different geometric properties - the first flattened section has flats for absorbing torsion, the second flattened section has flats for angle adjustment, and the neck section has optimized geometry for strength. This local differentiation of properties allows the spoke to handle complex stress conditions while maintaining manufacturing feasibility.
2Reliability
If a single flattened bend section is used to improve fatigue resistance, then the spoke can absorb torsion better, but it becomes difficult to assemble to the wheel hub or causes abnormal angles with the wheel rim
Solution Approach 1:
The spoke includes two distinct flattened sections - the first flattened section for torsion absorption and the second flattened section for angle adjustment. This segmentation allows the spoke to maintain both fatigue resistance and assembly ease by separating the functions of stress absorption and alignment adjustment into different sections.
Solution Approach 2:
The second flattened section is designed to allow angular adjustment during assembly, providing dynamic adaptability to match different wheel rim configurations. This dynamic capability ensures proper alignment while the first flattened section maintains structural integrity under load.
3Productivity
If the bend section angle is fixed at the industry standard, then manufacturing is consistent and stock management is efficient, but the spoke cannot adapt to different wheel radii and angles, reducing fatigue resistance
Solution Approach 1:
The spoke is segmented into a fixed-angle neck section for manufacturing consistency and a second flattened section for angle adjustment. This segmentation allows the majority of the spoke to be manufactured with standard precision while providing adjustable geometry at the flattened section to adapt to different wheel configurations.
Solution Approach 2:
The second flattened section provides dynamic angle adjustment capability, allowing the spoke to adapt to different wheel radii and mounting angles. This dynamic feature maintains manufacturing efficiency for the standardized portions while providing versatility where needed.
4Reliability
If known spoke designs with flattened bend sections are used, then fatigue resistance may be improved, but they are extremely easily broken or show worse fatigue resistance than traditional spokes
Solution Approach 1:
The spoke is divided into four distinct sections with optimized geometry for each - the terminal section for mounting, the neck section for structural strength, the first flattened section for torsion absorption, and the second flattened section for angle adjustment. This comprehensive segmentation ensures that no single section is overloaded, preventing catastrophic failure while maximizing fatigue resistance.
Solution Approach 2:
Each section of the spoke is given specific geometric properties optimized for its function - the neck section has reinforced geometry for strength, the first flattened section has geometry for torsion absorption, and the second flattened section has geometry for angle adjustment. This local optimization ensures maximum strength where needed while maintaining fatigue resistance throughout.
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 spoke design significantly enhances fatigue resistance, withstanding up to 25,644 cycles under fatigue testing, compared to 11,632 and 6,472 cycles of traditional and known spokes, while ensuring correct assembly and reduced risk of breakage.
Implementation Method 1
the first flattened section absorbs torsion
Implementation Method 2
the second flattened section helps transfer tension
Implementation Method 3
the spoke body, when put into use, effectively absorbs or transfer shock waves transmitted thereto
Data Source
AI summary
A spoke includes a spoke body that has two ends respectively forming a terminal section and the threaded section and includes a neck section arranged below the terminal section; a first flattened section set at a location below the neck section; and a second flattened section set at a location below the first flattened section in such a way that the second flattened section and the first flattened section are at different horizontal plane. In assembling the spoke body to a wheel hub and a wheel rim, the combination of the first flattened section and the second flattened section helps set the spoke body at a correct position and direction for assembly and force taking, whereby the first flattened section may absorb torsion and the second flattened section helps transfer tension and allows for change of the angle of bending.