Test Wheel Locking Flange Layout to Prevent Bench-Induced Vehicle Movement
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Solution Overview
Problem
Existing test wheels for powertrain test benches cannot reliably prevent accidental locking of the rotating inner part against the stationary outer part during testing, leading to sudden and unintended translational movement of the vehicle, which can cause damage and safety hazards.
Innovation Solution
A test wheel design featuring a wheel rim, wheel bearing, locking device, wheel shaft, and wheel hub, where the wheel hub is connected to the locking device in a rotationally fixed manner via a third connecting flange, ensuring that the wheel shaft and wheel hub are non-rotatable, and the connection of the second connecting flange is dependent on the third connecting flange not being connected, preventing simultaneous engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wheel hub is rotatably mounted on the wheel shaft to allow relative rotation, then the test wheel can simulate actual vehicle wheel behavior during testing, but accidental locking of the rotating inner part against the stationary outer part may occur causing sudden translational movement
Solution Approach 1:
The test wheel is divided into distinct functional segments: a stationary outer part (wheel rim and locking device) and a rotating inner part (wheel hub and shaft). The locking device is further segmented into a locking element that can engage with positioning elements on the wheel rim. This segmentation allows the system to provide both rotational freedom during normal operation and positive locking when needed, preventing accidental locking while maintaining simulation capability.
Solution Approach 2:
Positioning elements are introduced as intermediary components between the wheel rim and wheel hub. These positioning elements extend radially inward from the wheel rim and can engage with corresponding features on the wheel hub to prevent accidental locking. The locking element on the shaft acts as another intermediary that can positively lock the assembly when engagement is required. These intermediaries mediate between the stationary outer part and rotating inner part to ensure reliable operation.
2Reliability
If a locking device is added to prevent accidental locking, then safety and reliability are improved, but the structural complexity of the test wheel increases
Solution Approach 1:
The locking device is merged with the existing wheel structure rather than being added as a separate complex subsystem. The locking element is integrated into the wheel shaft, and the positioning elements are integrated into the wheel rim. This merging approach provides the necessary locking functionality while minimizing additional structural complexity. The locking mechanism uses simple geometric features (protrusions, recesses, and engagement surfaces) rather than complex mechanical components.
3Reliability
If the wheel shaft and wheel hub are made non-rotatable relative to each other, then accidental locking is prevented, but the ability to simulate wheel rotation during testing is reduced
Solution Approach 1:
The connection between the wheel shaft and wheel hub is made dynamic rather than fixed. The locking element on the shaft can engage with positioning elements on the rim to prevent rotation when safety is concerned, but can also disengage to allow free rotation during normal testing. This dynamic capability allows the system to adapt between locked and unlocked states based on test requirements, maintaining both reliability and simulation fidelity.
Data Source
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AI summary
The invention relates to a test wheel (1) for a drive train test bench (2), comprising a wheel rim (7), a wheel bearing (8), a blocking device (9), a wheel shaft (10) and a wheel hub (17), wherein the wheel hub (17) is arranged on the wheel shaft (10) for rotation therewith, wherein the wheel shaft (10) and the wheel hub (17) are held rotatably in the wheel rim (7) via the wheel bearing (8), wherein the blocking device (9) is connected to the wheel rim (7) for rotation therewith, wherein the wheel shaft (10) is designed to be connected via a first connection flange (34) to an output shaft (5) of a drive train (44) to be tested, for rotation with said output shaft, and wherein the wheel hub (17) is designed to be connected via a second connection flange (22) to a drive shaft (23) of the drive train test bench, for rotation with said drive shaft. The test wheel (1) according to the invention is distinguished in that the wheel hub (17) is furthermore designed to be connected via a third connection flange (35) to the blocking device (9) for rotation therewith such that the wheel shaft (10) is blocked from being rotatable in relation to the wheel rim (7), wherein the third connection flange (35) is connectable only if the second connection flange (22) is not connected. The invention also relates to a corresponding drive train test bench (2).