Vehicle Wheel Rim and Disc Welding via High Energy Beam Inserts
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Solution Overview
Problem
Existing methods for assembling vehicle wheels, such as rivets or welding, lack an efficient and stable connection between the metal rim and light alloy disc, which can compromise the structural integrity and durability of the wheel.
Innovation Solution
A method involving a metal sheet rim and a light alloy disc with a connection part featuring recesses for metal sheet inserts, where a high energy beam is used to weld the inserts to the rim, creating deep welds and a stable mechanical connection between the rim and disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mechanical connection systems (rivets) or welding techniques are used to connect the rim and disc, then the wheel can be assembled, but the structural integrity and durability are compromised due to insufficient connection strength
Solution Approach 1:
The connection part of the disc is divided into multiple segments corresponding to individual rim portions, with each segment containing a recess for an insert. This segmentation allows the high energy beam to weld each insert independently to its corresponding rim portion, ensuring comprehensive and reliable connection across the entire interface between disc and rim, thereby resolving the contradiction between connection strength and structural integrity.
Solution Approach 2:
The patent replaces conventional mechanical connection systems (rivets) and traditional welding techniques with high energy beam welding. This substitution enables deep penetration welds that create strong metallurgical bonds between the inserts and rim, significantly improving both connection strength and structural integrity compared to mechanical fastening methods.
2Ease of manufacture
If shallow welding is used to connect the rim and disc, then the manufacturing process is simpler, but the connection stability is insufficient
Solution Approach 1:
The patent changes the welding parameters by using high energy beam welding instead of conventional welding, which enables deep penetration welds. This parameter change transforms the welding process from shallow surface bonding to deep structural bonding, achieving stable connections while maintaining manufacturing feasibility through automated beam application.
3Manufacturing precision
If the insert is positioned below the rim thickness to enable deep welds, then weld penetration is improved, but the positioning precision and alignment become more difficult
Solution Approach 1:
The inserts are pre-positioned in recesses formed in the connection part of the disc before the welding process. This preliminary action ensures proper alignment and positioning of the inserts relative to the rim, facilitating deep weld penetration while reducing positioning complexity during the actual welding operation. The recesses act as guides that maintain precise insert placement.
4Duration of action of stationary object
If deep welds are applied to connect the insert to the rim, then the connection durability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent replaces complex multi-step welding procedures with high energy beam welding, which achieves deep penetration welds in a single continuous process. This substitution improves connection durability through deep metallurgical bonds while actually simplifying the manufacturing process by eliminating the need for multiple welding passes or complex fixture arrangements.
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
This method provides a strong, stable, and durable connection between the rim and disc, enhancing the structural integrity and rotational fixing of the wheel, while allowing for deep welds that penetrate through the rim thickness.
Implementation Method 1
applying a high energy beam to an area of the rim respectively superimposing the insert of the connection part to weld the insert to the rim
Implementation Method 2
weld the insert to the rim
Data Source
Figure 1~2
Figure 3
AI summary
Method for manufacturing a vehicle wheel, comprising the following steps: providing a rim (2) of metal sheet, comprising on its axially outer side an outer flange (27), an outer bead seat (26) and a retaining hump (25), as well as a rim well (24) connected to the outer bead seat (26) through the retaining hump (25), providing a disc (3) of light alloy material, comprising a cover part (31) and a connection part (32) protruding axially from the cover part (31), wherein the cover part (31) comprises a plurality of angularly spaced spokes, extending radially outwards from a central portion of the cover part (31), wherein at least one recess (34) is formed on the connection part (32), a respective insert (35) of metal sheet being arranged into said at least one recess (34), fitting the connection part (32) of the disc (3) to a radially inner surface of the rim (2), and applying a high energy beam to an area (28) of the rim (2) respectively superimposing the insert (35) of the connection part (32) to weld the insert (35) to the rim (2).