Segmented Wheel Core Laser Welding Around Free Rollers
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Solution Overview
Problem
Existing wheel manufacturing methods for omnidirectional mobile devices face difficulties in welding annular core segments with free rollers attached, as it is challenging to access the pipe material for effective TIG welding due to the presence of free rollers, hindering the formation of a seamless core body.
Innovation Solution
A wheel manufacturing device equipped with a holder and a laser welder that uses a center jig to align and butt segments, and a manipulator to position the laser welder orthogonally or inclined relative to the segment's surface, allowing for reliable welding along the entire circumference while avoiding interference with the free rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If TIG welding is used to weld pipe material segments, then welding strength is improved, but accessibility to the pipe material is hindered by the presence of free rollers
Solution Approach 1:
The patent replaces traditional mechanical TIG welding with laser welding technology. The laser welder (23) uses a laser beam to melt and join the pipe material segments (7) without requiring physical access to the welding area, thus maintaining welding strength while overcoming the accessibility problem caused by free rollers (3).
Solution Approach 2:
The patent introduces a laser welder (23) as an intermediary device that can perform welding through the space occupied by free rollers (3). The laser beam acts as a mediator that transfers energy to the pipe material segments (7) without being blocked by the free rollers, enabling welding in previously inaccessible areas.
2Adaptability or versatility
If free rollers are attached to pipe material, then wheel functionality is improved, but welding access to pipe material is blocked
Solution Approach 1:
The patent attaches free rollers (3) to the pipe material segments (7) before the welding process. This preliminary action allows the segments to be prepared and positioned in advance, and then welded using laser technology that can access the joints even with free rollers present, thereby maintaining both functionality and manufacturability.
3Manufacturing precision
If laser welder positions optical axis orthogonal to segment surface, then welding precision is improved, but interference with free rollers occurs near central axis
Solution Approach 1:
The patent makes the laser welder's optical axis orientation dynamic rather than fixed. The welder can adjust the optical axis angle depending on the welding location: orthogonal to the segment surface for most areas to maintain precision, and inclined away from the central axis when welding near the center to avoid interfering with free rollers (3).
Solution Approach 2:
The patent applies different optical axis orientations for different locations on the segment. For areas away from the central axis, the optical axis is orthogonal to the surface for maximum precision. For areas near the central axis where free rollers are present, the optical axis is inclined to avoid interference, thus optimizing for local conditions rather than using a single fixed orientation.
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
Enables efficient and interference-free welding of annular core segments with free rollers, facilitating the production of wheels with a robust and seamless core structure, suitable for omnidirectional mobile devices like electric wheelchairs and personal mobility vehicles.
Implementation Method 1
a laser welder (23) that welds adjacent segments by irradiating a laser
Data Source
AI summary
A wheel manufacturing device for manufacturing a wheel having an annular core body configured by multiple segments and multiple free rollers rotatably provided around an annular axis of the core body includes: a holder that includes a center jig having a circular outer contour; and a laser welder that welds adjacent segments. The laser welder sets an optical axis of the laser in a direction orthogonal to an outer peripheral surface of the segment when welding a portion of the outer peripheral surface of the segment away from a central axis of the annular axis, and sets the optical axis in a direction inclined away from the central axis with respect to the direction orthogonal to the outer peripheral surface of the segment when welding a portion of the outer peripheral surface of the segment close to the central axis.