It is officially called, “automatic air replacement device for bicycle tires.” It is indeed an astonishing hub (central axis of a wheel) which does not need air replenishment at all. Inside the hub is a rotation air pump which slowly provides the air to the air valves placed in front and back through special tubes only by the movement of pedals. It also constantly maintains the most comfortable air pressure for bicycle tires, 3.0 atmospheric pressure. The device not only removes the trouble of air pumping but also protects the tires from wear, lengthening their life by 20%. It remarkably reduces the probability of tire puncture closely linked with the air pressure, and thus widely gathering attention to its safety and comfort. The air hub developed by them has been applied to wheelchair tires, and wider application to various fields is expected.
Nakano Iron Works Co., Ltd. http://www.nakano-iw.co.jp/japanese.html
Founded in 1948, the company specialized in manufacture and sales of bicycle hubs. From 1960, they also began production of machining tools and engines. Along with the transfer of their factory to the current location in Osaka, they promoted factory automation of hub production and achieved a complete unmanned line system, gathering the attention from the industry circle. The development of Air Hub is part of their unchanging approach to creation of new added value. They are the only manufacturer specializing in the production of bicycle hubs, a precious asset to Japanese manufacturing.
Mr. Nakano, now known as “Edison of Naniwa (Osaka),” took up this challenge in December 2001. He was prompted by the repeated complaints of “troublesome tire puncture” from bicycle users. After all, 70% of the causes for puncture is related to inappropriate air pressure inside the tire. The recommended pressure is “3” whereas most of the bicycles are actually used under 2.0. Under such a condition, the tube is pressured as it gets pushed hard against the rim (frame of wheels), or the friction between the tire and tube increases the possibility of puncture. The characteristics of rubber tire are such that the air deflates as time passes, but periodical air pumping is a nuisance. Considering these, Mr. Nakano thought to himself whether he could install a pump inside the hub so that the air is constantly pumped.
Carrying his handcrafted prototype, he visited Bridgestone Corporation six months later. When bluntly told, “You brought something really strange with you,” Mr. Nakano responded, “You have nothing to lose. Please just take a look at it.” When they tested the product, it was indeed strange but innovative. Thereafter, he repeated severe tests on its running durability, its resistance against raining conditions, and so on, and made modifications accordingly. In the process, he had to experience deep sense of futility at times, but he never gave up. It took him another year to finally succeed in developing an air pump that operates by rotational movement caused by a uniquely designed cam in the hubs of the front and rear wheels. Until reaching a mass production stage through pilot sales activities, it was a long path extending over two years altogether. The unyielding persistence of Mr. Nakano realized the world’s first maintenance-free bicycle.
By way of training for succeeding the bicycle hub business, Mr. Nakano spent a lot of time since his childhood learning how to remodel and improve machines and tools, which is now his specialty. He promoted factory automation of the hub production ahead of the competitors in the industry circles, and later completed an unmanned line system. The machining tools and facilities in the factory were developed by Mr. Nakano himself, and they are therefore as if his own children. Part of his daily routine is to come to the office around 6:30 AM, earlier than anyone else, and to take an inspection tour of all equipment in the factory. His “craftsmanship” does not overlook any small changes.
In the factory, there is a section marked out particularly for the development of new products where a number of prototypes are made and examined. It is like a secret workshop. Since he is quite busy during the regular office hours with discussions with customers, formulation of sales strategies, designing of new products, etc., Mr. Nakano comes to the workshop after work to have an unrushed time for discussion with the development staff to freely exchange ideas with them.
The starting point of innovative ideas is “to ask ‘why,’ ‘why’ about anything.” Ideas and challenging issues never escape from his head. Some good brainstorming ideas come to his mind out of nowhere particularly when he is in bed at home. So, a notebook is always at his bedside to jot them down.
The peak of the bicycle parts production came around 1990 when close to 8 million bicycles were manufactured yearly. The demand declined continuously after that, and also the market has been occupied by imported products nowadays. The bicycle hub manufacturing is no exception. During the severe competition with Chinese makers, the 10 Japanese makers specializing in bicycle hubs disappeared from the market one by one, and now, Nakano Iron Works is the only Japanese hub producer. In the face of the ever-losing price competition with China, Mr. Nakano was determined to “Develop products having absolute added values which no one else can produce.” Under such a circumstance, a “miraculous hub” was born, and it was also Mr. Nakano’s fight for survival.
It has been a never-ending challenge for new products: the development of a unit hub which outdated the molded hub, labor saving by means of factory automation with sizable investment, and the latest development of Air Hub. Each new development accompanies birth pain, but it does not impose suffering or stress on Mr. Nakano. That is because he has richly acquired the technical ability and spirit of monodzukuri for nearly 50 years devoted to bicycle hubs. He says with a face-full of smile, “The joy of developing something only you have accomplished is so overwhelming that on one can understand it except you yourself.”
The Air Hub has been already applied to wheelchairs, and the first commercial model was released in April 2005. When the air pressure in tires drops, the brake does not work properly and that can result in a fall. The Air Hub, on the other hand, constantly keeps a desired level of air pressure and thus enables driving with less power, which in turn contributes to the safety of the wheelchair users. At present, development is being promoted for “internally equipped 3-step gear hub” incorporating a gearshift, “dynamo hub” with electricity generation function for safety ride during nighttime, and so on. The idea is to pack the small hub with additional new functions one after another. The conventional “image of bicycles” will surely continue to be updated.
The set in front is the new hub, and in the back is the conventional hubs. Complete transformation.
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