Vehicle Wheel Disc Lightener Pockets for Lower Mass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle wheels are heavy, which negatively impacts fuel economy, and reducing their mass increases manufacturing complexity and cost, necessitating a balance between weight reduction and cost complexity.
Innovation Solution
The implementation of lightener pockets in the wheel disc, which are recesses or voids formed by removing material from the hub portion, reducing the wheel mass by 0-2% and alternating with lug bolt holes around the circumference, formed through machining, milling, piercing, or laser cutting, allowing for a reduction in wheel mass while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If material is removed from the hub portion to create lightener pockets, then wheel mass is reduced, but manufacturing complexity increases
Solution Approach 1:
The hub portion is segmented by creating lightener pockets that divide the solid material into separated regions. These pockets are positioned between lug bolt holes and break the continuous material structure, reducing overall mass while maintaining structural integrity through the segmented design.
Solution Approach 2:
The hub portion is transformed from solid material to a porous structure by introducing lightener pockets. This creates a controlled porosity that reduces density and mass while preserving the necessary mechanical strength and structural function of the wheel disc.
2Weight of moving object
If material is removed from the hub portion to create lightener pockets, then wheel mass is reduced, but manufacturing cost increases
Solution Approach 1:
The lightener pockets are designed to be created during the initial wheel manufacturing process rather than as a subsequent modification. By incorporating pocket formation into the primary manufacturing steps (casting, forging, or machining), the mass reduction is achieved without requiring additional manufacturing operations or steps.
3Use of energy by moving object
If lightener pockets are added to the wheel disc, then fuel economy improves, but structural integrity may be compromised
Solution Approach 1:
The lightener pockets are strategically positioned in specific regions of the hub portion where material can be removed without compromising critical load-bearing areas. The pockets are located between lug bolt holes and designed with specific dimensions and spacing to maintain local structural quality while reducing overall mass for improved fuel economy.
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 solution effectively reduces the wheel mass by 0-2% without significantly increasing manufacturing complexity or cost, thereby enhancing fuel economy while maintaining the wheel's structural integrity and manufacturing efficiency.
Implementation Method 1
the material is removed from the hub portion by machining, milling, piercing, laser cutting, or water cutting
Data Source
AI summary
A fabricated vehicle wheel comprises a wheel disc and a wheel rim. The wheel disc has an annular hub portion, a center hub hole in the hub portion, opposite inboard and outboard faces of the hub portion, a plurality of circumferentially spaced lug bolt holes in the hub portion, a plurality of lightener pockets in the hub portion, and an extension portion. The lug bolt holes and the lightener pockets alternate around a circumference of the hub portion. An axis extends through the hub hole. The inboard face is planar and configured to mount to a vehicle. The inboard face is perpendicular to the axis and the extension portion extends from the hub portion along the axis. The wheel rim is secured to the extension portion.