Aluminum Alloy Wheel Correction for Runout and Rim Deformation
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Solution Overview
Problem
The existing manufacturing process for aluminum alloy wheels, involving two procedures with secondary positioning and clamping, leads to issues like wheel runout, balance out of tolerance, and safety problems due to decentraction and rim deformation, necessitating correction of semi-finished products.
Innovation Solution
A wheel correcting device composed of a hub positioning unit, a hub feed unit, and a tool correction unit, utilizing a rotating standard correction cutter head to correct decentraction and rim bulges, improving hub positioning and radial expansion for precise centering and correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If secondary positioning and clamping is adopted in two-procedure machining, then production efficiency is improved, but wheel runout and balance precision deteriorate due to decentraction
Solution Approach 1:
The device performs preliminary correction of the wheel hub before final machining operations. The correction device pre-adjusts the hub position and eliminates deformation in advance, preventing decentraction issues that would otherwise require repositioning between machining procedures.
Solution Approach 2:
A specialized correction device serves as an intermediary between the two machining procedures. This device includes correction rollers and positioning mechanisms that mediate the transition between procedures, ensuring the hub maintains accurate positioning without decentraction.
2Speed
If front casting lip positioning is used in first procedure, then machining speed is improved, but rim deformation and bulges occur due to casting deformation
Solution Approach 1:
The device converts the harmful casting deformation into a correctable condition by using correction rollers that apply controlled pressure to the rim bulges. The deformation that initially causes problems is transformed into an opportunity for precise geometric correction through the correction mechanism.
Solution Approach 2:
The correction device changes the physical state of the deformed rim by applying mechanical pressure through correction rollers. This alters the geometric parameters of the rim, eliminating bulges and restoring the intended shape while maintaining the benefits of fast machining.
3Loss of time
If rapid feed movement is implemented, then production cycle time is reduced, but positioning precision deteriorates
Solution Approach 1:
The feed movement is segmented into multiple phases: rapid approach movement followed by precise positioning movement. The feed mechanism divides the total displacement into a fast initial phase and a slow final phase, allowing both speed and precision requirements to be met.
Solution Approach 2:
The positioning system uses dynamic control where the feed speed automatically adjusts based on the positioning stage. During rapid approach, high speed is used; during final positioning, speed reduces automatically to ensure precision, creating a dynamic rather than static speed profile.
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 device enhances the runout and balance qualified rate of products, simplifies operation, and addresses decentraction and rim deformation issues in the manufacturing process, ensuring efficient and practical correction in a flow production line.
Implementation Method 1
the expansion cylinder drives the expansion core to complete radial positioning of the hub, the hub is fixed while being expanded
Implementation Method 2
the feed motor drives the feed sliding plate to move up and down through the ball screw structure
Implementation Method 3
the four positioning cylinders are respectively connected with the four positioning sliding blocks to drive the four sliding blocks to move synchronously so as to control synchronous centering of the four positioning rods
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention provides a device for correcting an aluminum alloy wheel, which is composed of a frame (1), an expansion cylinder (4), a correction motor (10), a feed motor (23) and the like. A hub positioning unit (13, 14, 15, 16, 17) initially positions a hub to prepare for positioning a center hole expansion sleeve (6); a hub feed unit (3, 4, 5, 6, 7, 18, 19, 20, 21, 22, 23) performs precise center hole positioning on the hub and completes upward feed movement of the hub; and a tool correction unit (8, 9, 10, 11, 12) completes hub correction through a rotating standard correction cutter head (8). The device can meet the process requirements of wheels in flow production, improve the runout and balance qualified rate of products, and solve the problems of decentraction of the outer diameter and deformation of rim bulges, which are the result of manufacturing the wheel hub by means of a first procedure and a second procedure.