Ventilated Wheel Disc Structure for Lightweight Load Capacity
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Solution Overview
Problem
Existing disc wheels for commercial vehicles face a trade-off between minimizing weight for improved driving behavior and fuel efficiency, while maintaining sufficient strength and load capacity, as reduced material thickness increases stress and compromises load-bearing capacity.
Innovation Solution
The introduction of ventilation holes in the transition region of the wheel disc, with a reduced material thickness of over 30% in the radially inner section and a drop- or egg-shaped design, distributes material thickness and stress effectively, allowing for a significant weight reduction while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the material thickness of the wheel disc is reduced to minimize weight, then weight decreases and fuel consumption improves, but stress in the material increases and load capacity deteriorates
Solution Approach 1:
The wheel disc features non-uniform material thickness distribution, with thinner material in the transition region (2-4mm) and thicker material at critical load-bearing locations (hub connection flange and disc rim, 4-6mm). This local quality variation optimizes weight while maintaining strength where needed. The ventilation holes are strategically positioned in the transition region where they reduce weight without compromising critical load paths.
Solution Approach 2:
The transition region is divided into multiple sections with different curvatures and material thicknesses. The ventilation holes segment the material continuity, creating a pattern that reduces overall mass while maintaining structural integrity through the distributed hole pattern extending from the first to second pitch circle.
2Weight of moving object
If the material thickness is uniformly reduced across the entire wheel disc, then weight decreases, but stress concentration increases at critical regions
Solution Approach 1:
Different regions of the wheel disc have different material thicknesses optimized for their specific functions. The transition region has reduced thickness (2-4mm) with ventilation holes for weight reduction, while the hub connection flange and disc rim maintain greater thickness (4-6mm) for strength. This localized quality differentiation prevents stress concentration while achieving weight reduction.
Solution Approach 2:
The material thickness parameter is varied continuously across different regions of the wheel disc. The thickness transitions from 4-6mm at critical load-bearing regions to 2-4mm in the transition region, with further reduction where ventilation holes are present. This parameter change optimizes the stress-weight ratio across the entire component.
Data Source
AI summary
A wheel disc for a wheel with a radially extending hub connection flange and a disc rim connected to a wheel rim and a transition region extending between the disc rim and the connection flange. The transition region is provided with ventilation holes. The holes extend in the radial direction from a first inner pitch circle located closer to the connection flange to a second outer pitch circle located closer to the rim. The transition region in the radial section in a first sectional area extending between the connection flange and the radially inner first pitch circle has a material thickness reduced by at least 30% compared to a material thickness of the connection flange and/or wherein the holes have a hole region with a hole width increasing in the circumferential direction of the disc from the radially inner, first pitch circle towards the radially outer, second pitch circle.