Wheel Nut Wrench Nested Sleeve Design

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Solution Overview

Problem

The existing single-ended L-shaped wheel nut wrenches made from carbon steel tubes face challenges in achieving sufficient strength and cost reduction due to the thinning of the nut socket portion under torsional pressure, which complicates the manufacturing process and hinders effective cost reduction.

Innovation Solution

A wheel nut wrench design featuring a tube-shaped steel tube with a hexagonal nut socket shell portion and a sleeve made from a bent steel plate, where the sleeve is pressed into the nut socket shell portion to unify and strengthen the nut socket portion, and the process includes forming a hexagonal shape by cold pressing and heat treatment to enhance strength and simplify manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a tube made of carbon steel is used as material and cold forging is applied to form the nut socket portion, then manufacturing cost is reduced compared to conventional round bar processing, but the nut socket portion thickness becomes insufficient and strength is compromised

Engineering Contradiction:

Improvemanufacturing costVSAvoidnut socket portion strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

A thick-walled tube is inserted into the nut socket portion formed by cold forging, creating a nested structure where the tube reinforces the thinner forged portion. This allows the use of cold forging (reducing cost) while maintaining strength through the inserted thick-walled tube.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The wrench combines two different manufacturing methods in one component: cold-forged portions for the handle and body, and a thick-walled tube for the nut socket portion. This composite approach allows each part to be optimized for its specific function while maintaining overall cost efficiency.

Inventive Principle:

Principle #40Composite materials

2Strength

If the nut socket portion thickness is increased to prevent thinning and maintain strength, then strength is improved, but additional processes are required which increases manufacturing time and reduces cost reduction effectiveness

Engineering Contradiction:

Improvenut socket portion strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Instead of increasing the thickness of the cold-forged nut socket portion through additional processing steps, a pre-manufactured thick-walled tube is inserted into the forged portion. This nesting approach achieves the required strength without adding complex manufacturing steps to the forging process.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The nut socket portion is segmented into two functional layers: the cold-forged base structure providing shape and basic strength, and the inserted thick-walled tube providing enhanced strength and torsional resistance. This segmentation allows each component to be manufactured independently using optimal processes.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a single-ended L-shaped wheel nut wrench is manufactured as a single component, then the number of wrenches required per vehicle is reduced, but the complexity of manufacturing each wrench increases

Engineering Contradiction:

Improvenumber of wrenches per vehicleVSAvoidmanufacturing process complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The handle, body, and nut socket portion are merged into a single integrated component formed through cold forging and tube insertion, eliminating the need for multiple separate wrenches per vehicle while using relatively simple manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

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 design enhances the strength of the nut socket portion while reducing manufacturing complexity and costs, allowing for a more robust and cost-effective wheel nut wrench that can withstand torsional pressure effectively.

Implementation Method 1

a portion of the nut socket shell portion is deformed toward the sleeve to thereby achieve unification of the nut socket portion and the sleeve

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

a sleeve made of a steel plate and having a cross section of a hexagonal shape is pressed into the nut socket shell portion

Methodology Applied

Scientific EffectCold-forming: Cold-forming

Data Source

PatentUS8327739B2Wheel nut wrench and manufacturing process thereof

Publication Date: 2012.12.11 RIKENSEIKO

AI summary

In order to provide a wheel nut wrench in which strength of a nut socket portion is allowed to be increased even though processes are facilitated under a situation where a tube made of carbon steel such as S45C is used as a material, and a manufacturing process thereof, an embodiment to implement the present invention is a wheel nut wrench made with a tube-shaped steel tube and provided with a nut socket portion at least one end, a nut socket shell portion whose inner and outer peripheries are both formed in a hexagonal shape is provided at an end portion of the steel tube, a sleeve made of a steel plate and having a cross section of a hexagonal shape is pressed into the nut socket shell portion, and a portion of the nut socket shell portion is deformed toward the sleeve to thereby achieve unification of the nut socket portion and the sleeve.