Spoke Manufacturing with Variable Cross-Section Forming
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Solution Overview
Problem
Existing methods for producing spokes from wire materials lack precision and consistency in achieving tight tolerances, leading to optical differences and increased effort in selecting spokes for wheels, resulting in waste and suboptimal performance.
Innovation Solution
A method involving a molding tool with synchronized opposing tool units that changes the relative position of the wire material using different positioning movements to shape and reduce cross sections, ensuring precise dimensional accuracy and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional reducing machines are used to produce spokes with different thickness sections, then a wide variety of spoke types can be produced, but the manufacturing precision and tolerance consistency deteriorate, leading to optical differences and increased selection effort
Solution Approach 1:
The forming process is divided into multiple discrete forming sections along the spoke length, each with independently controllable positioning movements. This allows different shaft sections to be formed with precise control over transition areas, achieving tight tolerances while producing various spoke types through configuration changes of the forming tool and positioning parameters
Solution Approach 2:
The feed device employs dynamically adjustable positioning movements that can be precisely controlled during the forming process. The positioning movements are adaptable to different spoke types and can be adjusted in real-time to maintain tight tolerances across various shaft sections and transition areas, resolving the contradiction between versatility and precision
2Ease of manufacture
If traditional forming processes are used, then production is simpler, but the dimensional accuracy and reproducibility of cross sections deteriorate, requiring pre-selection of spokes
Solution Approach 1:
The forming process incorporates feedback control through synchronized positioning movements and tool unit coordination. The control system monitors and adjusts the positioning movements to maintain precise dimensional accuracy of cross sections, eliminating the need for post-production selection while keeping the manufacturing process straightforward
Solution Approach 2:
The system achieves high dimensional accuracy by precisely controlling and changing positioning parameters during forming. Different positioning movements with specific parameters are applied to form various cross sections with tight tolerances, improving reproducibility without complicating the manufacturing process
3Manufacturing precision
If tighter tolerances are achieved through improved positioning movements, then optical differences are eliminated, but the device complexity increases
Solution Approach 1:
The positioning movements are merged with the existing feed device structure, utilizing the same mechanical components for both feeding and positioning functions. This integration achieves tight tolerances without proportionally increasing device complexity, as the positioning control is combined with the feeding mechanism rather than being a separate system
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 achieves significantly tighter tolerances and improved precision in spoke production, eliminating the need for pre-selection and reducing waste, while enhancing the mechanical properties and visual appeal of the spokes.
Implementation Method 1
the wire material is shaped and/or reduced at least in sections with the shaping tool or by embossing
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a method and a device (1) for manufacturing spokes (100) from a wire material (3), in particular for at least partially muscle-powered two-wheeled vehicles (200). The spokes (100) have a spoke shaft (101) with at least two shaft sections (111, 121). The shaft sections (111, 121) differ in at least one cross-section (103). To form the cross-sections (103), the wire material (3) is formed at least section by section with a forming tool (4). The relative position (43) of the wire material (3) with respect to the forming tool (4) is changed in the axial direction during the forming process. In order to shape the cross-sections (103) in the two shaft sections (111, 121), the relative position (43) of the wire material (3) in relation to the forming tool (4) is changed with different positioning movements (7).