A process capability evaluation method and system for evaluating tire green part assembly and roll out venting levels

Abstract

The present application relates to the field of tire production technology, and more particularly to a process capability evaluation method and system for evaluating the assembly and rolling degassing level of tire blank components. The method selects the formed tire blank as a sample, places it in a special low-temperature and low-pressure holding device to maintain the true interlayer state at the end of forming; then uses low-temperature water cutting to obtain the tire blank cross section and polish it flat. With the crown center reference line and the sub-port reference line as the reference, the positioning size of key components such as the belt, zero-degree belt, and carcass is measured and the centering degree is calculated, and the maximum width of the cross-sectional bubbles is measured; the data is recorded in the evaluation table and the tire blank forming state is evaluated according to the quantification rules to determine whether the assembly and rolling degassing process capability is qualified, and if not, the forming parameters are optimized according to the evaluation results and retested. The method can objectively reflect the assembly alignment and degassing effect before vulcanization, avoid the interference of vulcanization, and improve the defect tracing and process adjustment efficiency.

Description

Technical Field

[0001] This invention relates to the field of tire manufacturing technology, and in particular to a method and system for evaluating the process capability of tire blank component assembly and roll forming exhaust level. Background Technology

[0002] All-steel radial tires (also known as all-steel radial tires) have become the mainstream structure for heavy-duty vehicle tires due to their high load-bearing capacity, good durability, relatively low rolling resistance, and suitability for heavy-duty trucks and construction machinery. Their manufacturing process typically includes calendering / bonding, cutting and forming, vulcanization and shaping, and subsequent testing. Among these, the forming process is one of the key steps determining the stability and consistency of the tire structure. During the forming stage, various components such as the carcass ply, steel wire rings, belt layers, tread, steel sheath, and transition rubber need to be accurately assembled under specified geometric positions and tension conditions. This assembly is then repeatedly compacted using methods such as bladder inflation or mechanical rolling to ensure full interlayer bonding and expel residual air. If the assembly alignment is too large, the rolling air release is insufficient, or there is poor local bonding, defects such as interlayer porosity, air trapping channels, localized edge lifting, and eccentricity / misalignment often form in the tire carcass (green tire). These defects manifest after vulcanization as bulges, porosity, delamination risks, uniformity deterioration, and decreased durability, and in severe cases, can even affect driving safety.

[0003] Currently, the methods used in the industry to evaluate molding quality have certain limitations. A common practice is to vulcanize and shape the tire blank, then perform sectioning, X-ray examination, uniformity testing, or visual inspection on the finished tire to retrospectively assess molding quality. However, the vulcanization process is characterized by high temperature and high pressure: on the one hand, moisture or low-molecular-weight substances in the rubber compound system easily volatilize and generate gas under elevated temperatures; on the other hand, the pressure field causes residual air and generated gas to migrate, coalesce, or redistribute; simultaneously, mold closure and pressure application can induce component slippage or repositioning at the microscale. These factors mean that the defect morphology presented in the cross-section after vulcanization does not correspond one-to-one with the actual state of the tire blank at the end of molding, making it difficult to accurately trace the "source of defects." Process optimization requires more trial and error cycles, affecting machine setup efficiency and quality stability. Therefore, the industry has long hoped to conduct more direct, quantifiable, and repeatable process capability evaluations of "component assembly alignment accuracy" and "roller venting effect" before the tire blank is vulcanized in the mold.

[0004] Regarding quality inspection and measurement in the tire (especially green tire) manufacturing process, existing technologies mainly fall into two categories: one is online or offline geometric measurement based on sensing / optics; the other is defect detection or surface quality identification based on vision / point cloud / image algorithms.

[0005] In terms of geometry and dimensional measurement, US Patent 7909078B2 proposes a scheme for measuring the layup / forming state of green tire components. This scheme utilizes a laser sensor to form a "sensor sheet" that performs a comprehensive scan of the green tire carcass surface, thereby enabling the measurement and feedback control of parameters such as width and thickness to improve layup accuracy and consistency. This type of scheme emphasizes monitoring geometric parameters through non-contact measurement during the green tire stage, which helps reduce component layup deviations and improve consistency. However, its focus is more on "surface / geometric" indicators such as shape, thickness, or layup width, and it often struggles to directly characterize interlayer air trapping, internal pores, and the adequacy of venting at bonding interfaces.

[0006] Similarly, Korean patent KR101883255B1 discloses a green tire circumference measuring device, which can measure the circumference of green tires and further manage the tire quality level numerically through indicators such as roundness and standard deviation. Such devices are usually used for rapid detection of dimensional consistency (such as circumference and roundness) during the molding stage, and are suitable for process monitoring and statistical management. However, their core is still to evaluate the shape / dimensional consistency. They still have insufficient characterization of internal information that is closer to the assembly and roll forming air removal capabilities, such as "the alignment of components in the cross-sectional direction, the relative position between layers, and whether air is trapped at the local bonding interface".

[0007] In the area of ​​defect detection, Chinese patent CN115184364A discloses a method and system for detecting tire pore defects based on three-dimensional point clouds. This method achieves defect detection through steps such as tire point cloud data sampling, feature extraction, voting grouping, and proposal and refinement. This approach embodies the technical route of using three-dimensional data and algorithm models to identify pore defects, which can improve the automation and recognition rate of defect detection to a certain extent. However, this type of approach is usually geared towards defect identification on the tire surface or observable areas, or towards the detection of appearance / surface bulge defects in vulcanized tires. When defects are located at interlayer interfaces, buried internally, or require quantitative tracing using "cross-sectional component positioning dimensions + maximum pore width," relying solely on appearance / point cloud recognition often makes it difficult to establish a direct correspondence between the defects and molding assembly and roll forming venting parameters, thus limiting its support for molding adjustment and defect tracing.

[0008] In summary, existing technologies for quality monitoring in the green tire stage focus more on readily obtainable indicators such as external dimensions, circumference roundness, and laying geometry parameters, or on identifying defect targets using visual / point cloud methods. These technologies can improve the level of automation and consistency control to a certain extent, but they still have shortcomings for two particularly critical issues in the forming of all-steel radial tires: (1) Insufficient evaluation of the cross-sectional authenticity of assembly alignment: The relative positional deviation of the belt layer, steel cladding layer, and carcass layer of an all-steel radial tire in the cross-sectional direction will directly affect the mechanical properties and uniformity. It is difficult to fully reflect key cross-sectional indicators such as "left-right alignment deviation based on the crown center" and "bead positioning deviation based on the outer end of the wire bead" using only circumference, roundness, or surface geometry measurements. (2) Insufficient quantifiable traceability of roll forming degassing capability: The goal of roll forming degassing is to eliminate interlayer air and micro-gaps at the bonding interface, but the result is often reflected in the number / size / location distribution of internal pores. Relying solely on post-vulcanization sectioning or appearance defect identification is susceptible to interference from factors such as gas generation, migration, and redistribution during the vulcanization process, making it difficult to accurately reflect the gas-filled state at the end of molding. On the other hand, relying solely on surface visual / point cloud detection makes it difficult to obtain "cross-sectional quantitative information" such as the maximum width of pores at the internal interface, thus making the correspondence between "insufficient venting - defect morphology - process parameters" unclear.

[0009] Therefore, from the perspective of process optimization and quality traceability, the industry still urgently needs an evaluation technology that can be carried out before the tire blank enters vulcanization and has less disturbance to the actual state after molding: on the one hand, it should be able to establish a unified measurement method and recording standard for alignment dimensions based on the cross-sectional reference; on the other hand, it should be able to form comparable quantitative indicators for air-entrapment defects such as pores, and use the evaluation results to guide the adjustment of molding assembly and roll forming venting parameters, so as to shorten the machine adjustment cycle, reduce trial and error costs, and improve the stability of the molding quality of all-steel radial tires. Summary of the Invention

[0010] The technical objective of this invention is to provide a tire molding quality evaluation method that can be implemented before the tire blank is molded and vulcanized. By performing low-temperature and low-pressure holding, low-temperature water cutting sampling, and cross-sectional measurement and recording on the tire blank after molding, the alignment dimensions of each key component and the maximum width of interlayer pores are quantitatively obtained. This objectively evaluates the component assembly accuracy and roller pressing venting capability, avoids interference of the vulcanization process on the defect morphology and size, and thus provides a real and reliable basis for setting molding machine parameters and optimizing the process.

[0011] Firstly, in order to achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0012] A process capability evaluation method for assessing tire blank component assembly and roll-pressed exhaust levels includes the following steps:

[0013] S1, Sample preparation: Obtain the test embryo after the molding process, and select along the circumference of the embryo. The sampling section locations; among them. The number of cross sections and ;

[0014] S2, Low-temperature and low-pressure holding: The test embryo is placed in a sealed holding cavity and held at the holding temperature. With holding time The embryo is held in place while the internal pressure is controlled. external pressure of the cavity Satisfying pressure difference constraints To maintain the relative positions of the embryo layers and the morphology of residual pores at the end of molding; among which, , To the maximum allowable pressure difference;

[0015] S3, Low-Temperature Water Cutting Sampling and Section Shaping: At the cutting water temperature... With water jet pressure Under the conditions described above, the fixed embryo is subjected to... Water cutting was performed at each sampling section to obtain the embryo cross section, and the cross section was then ground smooth to obtain a measurable cross section.

[0016] S4, Cross-section Measurement and Evaluation Record: Based on the center baseline of the embryo crown. Using the horizontal measurement reference as the reference, the line connecting the outer ends of the left and right steel wire loops As the reference for sub-port measurement, for a preset set of components The distance from the endpoints of each component to the baseline was measured and the alignment was calculated. Simultaneously, the measurement points were set at the preset pore measurement points. The maximum pore width was measured and recorded in the evaluation table;

[0017] S5, Quantitative Evaluation and Closed-Loop Judgment: Calculate the total score based on the evaluation table. and the judgment threshold The comparison yields a pass / fail conclusion; when it fails, the set of molding parameters to be optimized is output. And return to S1 and repeat until it is successful; where It includes at least the component assembly alignment parameters and the roll extrusion parameters.

[0018] Preferably, the steps described in step S1 satisfy Furthermore, the sampling cross-sections are evenly distributed along the circumference of the embryo; wherein the circumferential angle between adjacent cross-sections is... .

[0019] Preferably, the holding temperature in step S2 satisfy The holding time satisfy And the maximum allowable pressure difference satisfy ;

[0020] And / or, in step S2, the holding cavity is provided with a tire blank annular support to define the tire blank's shape, and during the holding process, the tire blank undergoes circumferential deformation. Not greater than ; To allow the maximum circumferential deformation.

[0021] Preferably, the cutting water temperature mentioned in step S3 satisfy The water jet pressure satisfy The surface roughness after the cross-section is ground smooth Not greater than ; To allow the maximum roughness.

[0022] Preferably, the component assembly described in step S4 It includes at least a zero-degree belt layer, a first belt layer, a second belt layer, a third belt layer, a steel cladding layer, and a carcass layer; for any component any cross section The distance from its left endpoint to the measured point is 1000 meters. distance With the right endpoint to distance And will be for moderate Defined as: in: For components In cross-section The left endpoint to the center baseline of the coronal region The distance; For components In cross-section From the right endpoint to the center baseline of the crown The distance; For components In cross-section The degree of symmetry;

[0023] And / or, in step S4, for any pore measuring point any cross section The maximum width of the pores at the measuring point was measured. And the statistical width of the pore measuring point. Defined as: in: For measuring points In cross-section the maximum width of the air hole at the position; is the measured point the statistical air hole width; is the number of cross sections.

[0024] As a preference, the total score described in step S5 is calculated by the following formula: and when it is judged as qualified, otherwise it is judged as unqualified; wherein:

[0025] is the average alignment degree of the component ;

[0026] is the component alignment degree limit; is the measured point air hole width limit;

[0027] is the component alignment degree weight and satisfies ; is the measured point air hole weight and satisfies ;

[0028] is the qualification threshold;

[0029] and / or, the molding parameter set described in step S5 at least includes:

[0030] component assembly alignment parameter , for adjusting the center positioning deviation and bonding tension of component bonding;

[0031] rolling and degassing parameter , for adjusting rolling pressure, rolling speed and number of rolling passes;

[0032] wherein .

[0033] In a second aspect, the present invention further provides a tire green tire assembly and rolling degassing level evaluation system for implementing the method, comprising: a holding module, a low-temperature water cutting module, a cross-section shaping module, a measurement module, an evaluation table generation module and an evaluation judgment module; wherein the evaluation judgment module is configured to: calculate the total score based on the alignment degree and air hole width data output by the measurement module and output a qualified / unqualified conclusion, and output the molding parameter set when unqualified for process optimization.

[0034] Preferably, the evaluation form includes at least the following fields: sample number, cross-section number, project name, standard value, measurement point name, left and right measurement values, centering or difference, pore width, and judgment result.

[0035] And / or, the system further includes a parameter sending interface for communicating with the molding machine controller, used to send... At least one parameter must be written into the molding machine formula or rolling program.

[0036] Thirdly, the present invention also provides a computer-readable storage medium having a computer program or instructions stored thereon, which, when executed by a processor, implement the steps of the method.

[0037] Fourthly, the present invention also provides a computer program product, including a computer program or instructions that, when executed by a processor, implement the steps of the method.

[0038] This invention, by employing the aforementioned technical solution, can maximize the preservation of the true interlayer structure and defect morphology of the tire blank after assembly and rolling, avoiding detection deviations caused by factors such as high-temperature volatilization gas generation, residual air migration and redistribution under high pressure, and component micro-displacement caused by mold closure in traditional post-vulcanization cross-sectional analysis. Utilizing a cross-sectional measurement method with the crown center baseline and the bead baseline as unified references, it can directly and quantitatively reflect the left-right alignment and positioning deviations of key components such as the belt layer, steel cladding, and tire carcass, significantly improving the traceability of component assembly accuracy. Simultaneously, it can also measure the maximum width of pores, etc. Standardized recording and statistical analysis of gas-related indicators can objectively characterize the rolling extrusion processing capability and quickly locate areas of concentrated air and weak process sections. Based on the quantitative evaluation results of the evaluation table, problems can be directly mapped to the optimization direction of parameters such as molding machine assembly alignment, rolling pressure / speed / number of passes, etc., forming a repeatable process capability closed loop. This shortens the machine adjustment and trial-and-error cycle, reduces rework and scrap caused by molding defects and subsequent vulcanization cost waste, and ultimately improves the uniformity, structural stability, durability and safety of finished tires, and enhances the consistency and comparability of quality control in mass production. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of cross-sectional measurement, illustrating the measurement of the positioning dimensions and pore width of each component with reference to the center baseline of the tire crown and the vent baseline.

[0040] Figure 2 This is a diagram illustrating the recording of an evaluation form, showing how measurement data is written into the evaluation form according to uniform fields for subsequent evaluation and judgment. Detailed Implementation

[0041] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present invention.

[0042] I. Terminology Explanation

[0043] For ease of understanding, the key terms used in this specification are explained as follows:

[0044] 1. Tire carcass (green tire): refers to the initial structure of a tire after the tire forming process is completed but before it enters the mold for vulcanization and shaping. The tire carcass is composed of multiple components such as the tire body, belt layer, steel wire ring, and tread, which are stacked together. The layers are bonded together with rubber and air is expelled under the action of rollers.

[0045] 2. Component assembly (alignment) accuracy: refers to the positioning deviation of each key component (such as zero-degree belt layer, first / second / third belt layer, carcass reverse wrap layer, steel cladding layer, tread, etc.) relative to the design center line or reference point during molding, especially the deviation in the cross-sectional direction (left and right direction, radial direction).

[0046] 3. Roller venting: This refers to the process by which the molding machine compacts each layer of the tire blank using rollers / pressure rollers / compacting devices, squeezing out or eliminating air, micro-gaps, and localized air-entrapment channels between layers. Insufficient venting can lead to interlayer porosity and poor local bonding, thus affecting the structural stability and durability after vulcanization.

[0047] 4. Low-temperature and low-pressure holding (curing): In this invention, the molded embryo is placed in a special holding cavity. Under low-temperature conditions, by controlling the pressure difference between the inside and outside of the embryo, the embryo is kept as consistent as possible with the interlayer relative position and pore morphology as it was at the end of molding before subsequent cutting and sampling. This avoids secondary displacement and changes in defect morphology caused by sudden changes in temperature or pressure or improper external support.

[0048] 5. Low-temperature water jet cutting: This refers to sampling the cross-section of the tire blank using a water jet within a certain temperature range. This avoids the softening, melting, volatilization, or interface dragging of the rubber material caused by hot cutting (such as hot blades, high-temperature friction of grinding wheels, etc.), thereby ensuring the authenticity and measurability of the cross-sectional contour and interface defects.

[0049] 6. Coronal center baseline: such as Figure 1 As shown, the cross-sectional centerline determined by the center positioning line of the tread component is used as a unified starting point for left-right symmetrical measurements; in this specification, it is referred to as... express.

[0050] 7. Sub-mouth baseline: such as Figure 1As shown, a line connecting the outer ends of the left and right wire coils, or a reference line determined by the position of their outer ends, is used to measure the height / position of the ferrule area; in this manual, it is referred to as... express.

[0051] 8. Maximum width of air holes: refers to the maximum lateral dimension (maximum width) of the air holes (air-clamping cavities) visible along the cross-section at a specified measuring point or within a specified area, used to quantify the air extrusion effect of the roller pressing.

[0052] 9. Evaluation Form: This refers to a data carrier that records various measurement data, standard values, limits, judgment rules, and scoring results of the embryo cross-section in a unified field structure. It can be a paper form or an electronic form (such as Excel or MES form) and is used to form a traceable basis for process capability evaluation.

[0053] 10. Evaluation Model: The present invention preferably adopts a "rule-based quantitative scoring model", that is, a calculation rule consisting of centering, pore width and their weights and limits; in optional embodiments, a parameter recommendation model trained based on historical data can also be introduced to assist in outputting optimization suggestions for molding parameters.

[0054] II. System Structure

[0055] The method of this invention can be implemented by a system consisting of "tire embryo retention—low-temperature sampling—cross-sectional measurement—evaluation table generation—evaluation and judgment—parameter closed-loop control". Preferably, the system includes the following modules (which can be integrated into the same equipment platform or deployed separately):

[0056] 1. Holding module

[0057] The holding module includes a sealed holding cavity, a temperature control unit, a pressure control unit, and a tire support assembly. The sealed holding cavity is used to isolate external heat and pressure disturbances; the temperature control unit is used to stably control the temperature of the holding cavity to the holding temperature. The pressure control unit is used to control the internal pressure of the embryo. External pressure of the holding cavity And satisfy the pressure difference constraint ;in The tire blank support assembly is preferably a ring-shaped soft support or a multi-point evenly distributed support, used to limit the shape of the tire blank and reduce the deformation introduced during the holding process, and to avoid interlayer slippage or pore migration caused by local indentation at the support points.

[0058] 2. Low-temperature waterjet cutting module

[0059] This includes a waterjet cutting platform, nozzle assembly, cooling / thermostatic water tank, pressure pump, and positioning fixture. The cooling / thermostatic water tank controls the cutting water temperature to a specific value. The pressure pump provides the water jet pressure. The positioning fixture is used to fix the embryo and define the cross-sectional position (e.g., selecting along the circumference). (Each section position) ensures that the cutting plane is consistent with the measurement reference.

[0060] 3. Section shaping module

[0061] This includes a grinding platform, sandpaper / grinding disc, and flatness correction fixtures, used to lightly grind the cut surface to achieve a clear, repeatable interface profile. The surface shaping follows the principle of "not changing the actual interface position and defect morphology," and preferably employs a low-pressure, light grinding method with gradual refinement.

[0062] 4. Measurement Module

[0063] Manual measuring tools (rulers, vernier calipers, depth gauges) and / or digital measuring tools (2D image measurement, laser displacement sensors, profilometers) can be used. The measurement module is used to: establish a baseline at the center of the coronal region. With the baseline of the sub-mouth Measure the positioning dimensions of the endpoints of key components; measure the maximum width of vents in a specified area. Output measurement data to the evaluation table generation module.

[0064] 5. Evaluation Form Generation Module

[0065] This is used to establish the field structure of the evaluation table, write sample information (fetal number, machine, work order number, date, specifications, etc.), write measurement results, write standard values / limits / tolerances, and generate traceable records. The evaluation table can correspond to... Figure 2 The record format shown should include at least the following fields: "Location / Sampling Point / Distance / Item / Standard Value / Measured Value / Difference or Alignment / Stomach Width / Judgment / Remarks".

[0066] 6. Evaluation and Judgment Module

[0067] Used to calculate the moderate index, stomatal index, and total score based on the evaluation form data. and with threshold The comparison outputs "Pass / Fail". When it fails, the evaluation and judgment module outputs a set of molding parameters to be optimized. (Including at least assembly alignment and roll venting parameters), and can be linked with the molding machine controller to provide suggested parameters to process engineers or automatically write them into the formula (optional).

[0068] 7. Data Management and Interface Module (Optional)

[0069] It is used to upload evaluation forms and evaluation results to the MES / quality system to achieve cross-batch statistics, process capability index analysis and trend early warning; it can also be used to form historical datasets to provide data sources for training optional parameter recommendation models.

[0070] III. Specific Technical Route for Implementing the Method of the Invention

[0071] Step S1: Preparation of embryo samples

[0072] 1. Sample selection principles

[0073] Test blanks completed during the molding process are selected as samples, preferably blanks of the same specification, from the same machine, on the same shift, or under the same formulation conditions, to facilitate comparative evaluation of process capability. The sample size can be [number missing]. Strip embryo, For process verification or parameter optimization, the preferred method is... To reduce the influence of chance.

[0074] 2. Determining the location of the cross-section

[0075] Select along the circumference of the embryo Each cross-sectional location is used for sampling. In a preferred embodiment, Samples of 2 to 6 were taken and evenly distributed around the circumference to facilitate evaluation of circumferential consistency. The cross-sectional positions could be assisted by marking strips or locating pins to ensure consistent sampling locations for different samples.

[0076] 3. Identification and Recording

[0077] Record information such as sample number, cross-section number, molding machine number, molding process number, and date on the outer surface of the embryo; establish corresponding fields in the evaluation table for subsequent traceability.

[0078] Step S2: Low temperature and low pressure fixation

[0079] The core of step S2 is to maintain the relative position of the layers and the defect morphology of the blank at the end of molding by using a low temperature environment and pressure difference constraint before the blank enters the cutting process. This avoids interlayer slippage, pore migration / expansion / collapse caused by changes in ambient temperature, improper external force support or excessive internal and external pressure difference, thereby ensuring that the subsequent cross-section reflects the "true state at the end of molding".

[0080] 1. Fixed operating condition settings

[0081] The embryo is placed in a sealed holding cavity, and the holding temperature is set. With holding time Preferred for ~ More preferably ~ Duration The optimal time is 10–120 min. The role of low temperature is to improve the morphological stability of the rubber system, reduce the slow flow and secondary displacement tendency caused by interfacial viscoelasticity, and at the same time avoid the disturbance of the pore state caused by gas generation induced by high temperature.

[0082] 2. Differential Pressure Constraint Control

[0083] Controlling the internal pressure of the embryo during fixation External pressure of the holding cavity To make the pressure difference satisfy: ;in: , To the maximum allowable pressure difference.

[0084] In a preferred embodiment, The pressure range is 0–10 kPa, more preferably 0–5 kPa. The technical advantages of this pressure differential constraint are:

[0085] like Excessive internal pressure (significantly higher than external pressure) may cause the embryo to swell, the interface to open, the original micropores to expand, and the pore width to be "enlarged".

[0086] like If the pressure is too low or the external pressure is significantly higher than the internal pressure, the embryo may be crushed, the interface may be squeezed, and the pore morphology may be "compressed" or even closed, resulting in distorted evaluation.

[0087] Therefore, by controlling Within a smaller window, the "secondary impact" of fixation on the geometry and defect morphology of the embryo is minimized.

[0088] 3. Support and Deformation Restriction

[0089] The embryo should be supported in a ring or multi-point uniformly distributed manner within the holding cavity to avoid interlayer displacement caused by localized stress points. Circumferential deformation can be used as a reference. Characterize and control the shape changes introduced by the fixation process: ;in: To allow for the maximum circumferential deformation (e.g., 0.5% to 2%), in one possible implementation, a flexible support ring is provided at the equator of the tire blank, and limiting retaining rings are provided on both sides of the tire blank. This ensures positioning while preventing hard contact that could damage the rubber surface.

[0090] 4. Adhere to completion criteria

[0091] After the holding period ends, record the holding curve (temperature). ,pressure and (Changes over time), and confirm in The internal pressure differential constraint is met. After fixation is completed, the embryo is transferred to S3. During the transfer, a low temperature environment (e.g., a refrigerated transfer box) is maintained to avoid temperature rise causing shape rebound.

[0092] Step S3: Low-temperature water jet sampling and section shaping

[0093] The core of step S3 is to use low-temperature water cutting to obtain the cross-section, avoiding the softening of the rubber material, interface dragging, volatilization and gas generation and melting deformation caused by thermal cutting, thereby ensuring that the cross-section contour and defect morphology are measurable and repeatable.

[0094] 1. Waterjet cutting operating condition settings

[0095] Set the cutting water temperature With water jet pressure Preferred for ~ ; The preferred pressure is 150–400 MPa. The role of low-temperature water is to reduce the heat introduced during the cutting process; a suitable… To ensure cutting efficiency and cut surface quality, avoid tearing and burrs caused by insufficient pressure, and also avoid local erosion caused by excessive pressure, resulting in unnecessary gaps at the interface.

[0096] 2. Section positioning and cutting path

[0097] For each embryo, as determined by S1 Cut at specific cross-sectional locations. The preferred cutting path is a radial plane passing through the center of the embryo, to facilitate the subsequent establishment of the crown center baseline. and the baseline of the sub-mouth In one possible implementation, an adjustable clamp is used to keep the blank concentrically positioned on the cutting platform, with the clamp scale corresponding to the section number (1~). This ensures that different samples have consistent cross-sectional comparability.

[0098] 3. Section shaping and flatness control

[0099] After cutting, the cut surface is lightly sanded to smooth it. To avoid secondary interface movement caused by sanding, the following is preferred:

[0100] 1) Grind coarsely first, then finely, using low pressure and light grinding;

[0101] 2) Only remove burrs and waterjet textures without changing the position of the interfaces between layers;

[0102] 3) Control the surface roughness (For example (or smaller) to ensure consistent gauge fit and reading.

[0103] 4. Defect Protection

[0104] For areas with visible pores in the cross-section, grinding should avoid directly crossing the pore boundaries to prevent damage. Partial masking or bypassing the pores can be used to ensure that the maximum width of the pores can be accurately measured.

[0105] Step S4: Cross-section measurement and evaluation record

[0106] The core of step S4 is to quantify and record "component alignment" and "pore width" using a unified measurement baseline and a unified field structure, forming a traceable, statistically verifiable, and scoreable evaluation table data.

[0107] 1. Establishment of measurement benchmarks (in conjunction with...) Figure 1 )

[0108] Crown center baseline :like Figure 1 As shown, the center positioning line of the tread component is used as the crown center reference line. In actual operation, the tread center mark, the tread pattern center symmetry line, or the tread geometric center line can be used to determine the crown center reference line. And use a ruler / marker to extend it in the cross-sectional plane to form a measurement reference.

[0109] Sub-mouth baseline :like Figure 1 As shown, the outer ends of the left and right steel wire rings are used as reference points to connect or project to form the sub-mouth reference line, which is used to measure the height and positioning dimensions of the sub-mouth area.

[0110] 2. Component Assembly and Measurement Item Definition

[0111] The set of components to be tested is defined according to the tire structure. Preferably, it includes at least: a zero-degree belt layer, a first belt layer, a second belt layer, a third belt layer, a steel cladding layer, a carcass layer, a tread base layer / abrasion-resistant rubber end, and an inner liner layer. For each component... Define measurement items, for example:

[0112] component outer end point to The left and right distances;

[0113] Belt layer width (distance between left and right endpoints);

[0114] The gaps between layers (e.g., the gap between the zero-degree zone and the third zone);

[0115] The relative area of ​​the ferrule (height of steel wire wrapping, height of tire body reverse wrapping, etc.) The distance.

[0116] These fields can correspond to Figure 2The evaluation form has a "Location / Sampling Point / Distance / Item" structure: "Location / Sampling Point" is used to mark the measurement points (e.g., crown center, driving surface edge, sub-end point, etc.), "Distance" is used to record the standard distance or design value relative to the reference point, and "Item" is used to record the name of the specific measurement item.

[0117] 3. For moderate calculations

[0118] For any component In cross-section At that point, the distance from the left endpoint to... distance With the right endpoint to distance This will affect moderate Defined as: in: For components In cross-section The left endpoint to the baseline The distance; For components In cross-section The right endpoint to the baseline The distance; The centering of the component at this cross section. The smaller the value, the better.

[0119] In a preferred embodiment, to reduce random errors, the same cross-section can be measured repeatedly. For example The average value is taken as the final measurement; this repeated measurement structure can also be corresponding to... Figure 2 The field format is "1, 2, 3, average".

[0120] 4. Measurement and statistics of maximum pore width

[0121] In the preset set of pore measurement points In the middle, for each measuring point , section Measuring the maximum width of the pores and take the statistical width The maximum values ​​for each cross-section:

[0122] ;

[0123] in: For measuring points In cross-section The maximum width of the pores at that location; For measuring points Statistical pore width; This refers to the number of cross-sections.

[0124] In practice, the maximum width of the pores is preferably measured by using a ruler or a transparent scale sheet along the cross-sectional plane to measure the maximum span of the visible boundary of the pores. When the pore shape is irregular, the maximum chord length is used as the standard, and the pore location is noted in the evaluation table (e.g., "near the end of the belt layer", "the interface between the tread base layer and the belt layer").

[0125] 5. Evaluation form records (combined with...) Figure 2 )

[0126] Write all the above measurement data into the evaluation form. The evaluation form should include at least:

[0127] Basic information: sample number, specifications, machine type, molding process number, time, analyst, etc.

[0128] Measurement fields: Location / sampling point, project name, standard value or design value, measured value (may include multiple measurements 1~). (and average), median / difference, stomatal width;

[0129] Tolerance / Limit Field: For medium-range limits Pore ​​width limit Operational tolerances, etc.;

[0130] Judgment fields: Individual judgment, Overall judgment, Remarks.

[0131] The evaluation form can be an electronic form that is automatically calculated. , , It also generates judgment results, reducing errors from manual calculations.

[0132] Step S5: Quantitative evaluation and closed-loop determination

[0133] The core of step S5 lies in: establishing repeatable quantitative evaluation rules (scores / thresholds / weights) based on the evaluation table data, outputting a pass / fail conclusion, and forming a set of closed-loop optimization suggestions for the molding parameters when the parameters fail. This guides the alignment of components and the adjustment of roll extrusion parameters.

[0134] 1. Evaluation Indicators and Feature Composition

[0135] The preferred quantitative evaluation model of this invention consists of two types of core indicators:

[0136] Alignment-related indicators: average alignment of components Represented by endpoint differences, critical interlayer gaps, etc.;

[0137] Exhaust parameters: width of exhaust vents (or the number of pores, the maximum width distribution) indicates this.

[0138] Among them, components average median It can be defined as:

[0139] ;

[0140] in: Number of cross sections; For components In cross-section The degree of neutrality.

[0141] 2. Total Score Calculation and Threshold Determination (The "Computational Layer" of the Rule-Based Model)

[0142] In a preferred embodiment, the total score Calculate using the following formula:

[0143] ;

[0144] And when If it is qualified, it is deemed qualified; otherwise, it is deemed unqualified.

[0145] in: For components The centering limit; For measuring points Pore ​​width limit; For the positional weight, satisfying ; For exhaust-related weights, satisfying ; The passing threshold (e.g., 90 points, 95 points, etc., can be set according to the company's quality standards).

[0146] The technical effectiveness of this scoring model is as follows:

[0147] 1) When a component exceeds the limit, a penalty is applied to the score, and the more it exceeds the limit, the greater the penalty.

[0148] 2) When the width of the vent at a certain measuring point exceeds the limit, a penalty item is generated for the score, reflecting insufficient exhaust;

[0149] 3) Through weights and This allows for focused attention on critical components (such as the end points of the belt layer and the sub-gate region), making the scoring more closely reflect actual failure risks.

[0150] 3. Individual Decision-Making and Defect Localization (The "Interpretation Layer" of the Rule Model)

[0151] In addition to the overall score, the system can also output individual evaluation results:

[0152] If it exists Then determine "component" Insufficient ability to match up;

[0153] If it exists Then determine "measuring point" "Insufficient exhaust / risk of air trapping";

[0154] Locate the corresponding section number in the evaluation table. The corresponding measurement point locations enable process engineers to quickly locate the problem (e.g., "right deviation of the third belt layer", "height deviation of the steel wire wrapping", "excessive air trapping in the end area of ​​the belt layer").

[0155] 4. Set of closed-loop output molding parameters

[0156] When a defect is detected, the present invention outputs a set of molding parameters to be optimized. At least including:

[0157] 1) Component assembly alignment parameters Such as component center positioning deviation correction amount, bonding tension setting, material feeding correction parameters, bonding start point calibration, etc.

[0158] 2) Roller extrusion parameters Such as rolling pressure, rolling speed, number of rolling passes, rolling trajectory coverage, and rolling sequence (from the center to both sides / from the vent to the crown), etc.

[0159] In one possible implementation, the rule can be defined as: if the bandgap layer exceeds the limit, priority should be given to adjustment. The terms "belt layer center positioning" and "bonding tension" are relevant; if there are pores near the endpoints of the belt layer... Exceeding limits, priority adjustment. The settings include "endpoint area rolling pressure / number of passes" and "rolling coverage range"; if the height deviation of the sub-mouth area exceeds the limit, priority should be given to adjusting the wire ring positioning, reverse wrapping height control and sub-mouth rolling strategy.

[0160] IV. Specific Application Examples

[0161] (a) Test materials, equipment and general conditions

[0162] 1. Test Subjects and Specifications

[0163] Tire type: All-steel radial truck tire blank (green tire).

[0164] Example specification: 11R22.5 (can be replaced with the actual specification of the enterprise without affecting the implementation of this invention).

[0165] Key components: carcass layer, bead wire, belt layer (first, second, and third belt layers), zero-degree belt (crown belt / 0° belt), steel-clad layer, tread (base layer / abrasion-resistant rubber), inner liner, etc.

[0166] 2. Main Equipment

[0167] Low-temperature and low-pressure holding device for embryo (specific to this invention): sealed holding cavity, temperature control unit, internal and external pressure difference control unit, annular flexible support, and differential pressure sensor.

[0168] Low-temperature waterjet cutting equipment: including a constant temperature water tank (controllable) ), high-pressure pump (controllable) ), nozzle and positioning fixture.

[0169] Section shaping equipment: low-speed grinder / sandpaper table (for light section shaping).

[0170] Measuring tools: steel ruler, vernier caliper / digital caliper (accuracy 0.01 mm), depth gauge (optional), magnifying glass / industrial microscope (optional).

[0171] Comparative testing equipment (comparative example): vulcanizing machine, vulcanizing cutting tool, X-ray (optional), uniformity tester (optional).

[0172] 3. General process window (can be optimized according to the actual situation of the enterprise)

[0173] Holding temperature: (can be found) (Select from the range).

[0174] Duration of hold: (can be found) (Select from the range).

[0175] Intracytoplasmic pressure / external pressure: control , Make the pressure difference satisfy: in This example takes .

[0176] Water cutting water temperature: .

[0177] Water jet pressure: .

[0178] Number of cross-sections: taken along the circumference There are three cross-sections (sections 1, 2, and 3), which can be increased to more if necessary. Used for circumferential consistency evaluation.

[0179] 4. Measurement reference (corresponding to) Figure 1 )

[0180] Coronal center baseline: The center positioning line of the tread components is used to determine the left and right distances of all crown components. Measure to the left and right of the starting point.

[0181] Sub-mouth baseline: Determined by the outer ends of the left and right steel wire rings, the relevant height / positioning dimensions of the sub-mouth are based on... Measure upwards.

[0182] Pore ​​measurement: Measure and record the maximum width (maximum chord length) of the visible pores in the cross-section.

[0183] (II) Evaluation Indicators and Judgment Rules

[0184] 1. For medium-precision calculations (component assembly alignment)

[0185] For any component In cross-section At that point, the distance from the left endpoint to... distance With the right endpoint to distance Define the degree of neutrality:

[0186]

[0187] in: The smaller the value, the better.

[0188] It can also calculate the average symmetry:

[0189] ;

[0190] 2. Statistics on pore width (roller extrusion effect)

[0191] measuring points of pores In cross-section The maximum pore width was measured at [location]. , Take the statistical width:

[0192] ;

[0193] 3. Limit Settings

[0194] To facilitate laboratory validation, the following "executable limits" are set:

[0195] 1) Belt layer / zero-degree zone alignment limit: ;

[0196] 2) Tire body reverse wrapping / steel cladding centering limit: ;

[0197] 3) Stomatal width limits in the crown / shoulder / belt end region: ;

[0198] 4) Pore width limit in the sub-mouth region: .

[0199] 4. Qualification Criteria

[0200] Any critical component satisfies And any key measuring point satisfies If the process is deemed "qualified", it is judged as "unqualified"; otherwise, it is judged as "unqualified" and the set of parameters to be optimized is output. (Alignment parameters and rolling parameters).

[0201] (III) Application Example 1: Consistency Verification of Pre-Vulcanization Evaluation and Post-Vulcanization under Normal Operating Conditions

[0202] 1. Experimental Objective

[0203] The present invention verifies that, under normal molding parameters, it can objectively evaluate the alignment and venting level of the tire blank before vulcanization, and the results are consistent with those after vulcanization, with small dispersion in repeated measurements.

[0204] 2. Experimental Procedures (corresponding to S1–S5 of this invention)

[0205] S1: Continuous production of embryo buds using the same machine. Each item is taken One cross section (cross section 1 / 2 / 3).

[0206] S2: Hold: , ;control .

[0207] S3: Low-temperature waterjet cutting: , Light reshaping after cutting.

[0208] S4: Press Figure 1 Establish , And measure; write data Figure 2 The evaluation table fields are shown.

[0209] S5: Determine compliance based on the limit value, and repeat the measurement at the same measuring point. The mean was taken twice, and the standard deviation was calculated for repeatability assessment.

[0210] 3. Key Measurement Data

[0211] Table 1 Example 1: Key components to moderate (mm) and average value ( )

[0212]

[0213] Table 2 Example 1: Statistical width of pores (mm)

[0214]

[0215] 4. Comparison and verification of repeatability and "sulfidation interference"

[0216] Repeatability: Repeated measurements at the same cross-section and the same measuring point Next, the typical standard deviation of moderate measurement points Pore ​​width measuring point This indicates that the cross-section is clear and the measurement is stable.

[0217] Post-vulcanization verification: After normal vulcanization, cross-sectional sampling was performed on the same batch of tire blanks. It was found that the alignment of the belt layer after vulcanization was consistent with the cross-sectional measurements before vulcanization (the deviation was usually...). Furthermore, there were no cases where the product was deemed "qualified" by this invention but developed severe air inclusion defects after vulcanization.

[0218] Conclusion: Example 1 demonstrates that the present invention can objectively reflect the alignment and exhaust level of the tire embryo before vulcanization, and the data is stable and reproducible, providing a reliable basis for subsequent parameter adjustment.

[0219] The foregoing description of embodiments of the present invention, through which those skilled in the art are able to implement or use the present invention, will be readily apparent to those skilled in the art. Various modifications to these embodiments will be readily apparent to those skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novelty disclosed herein.

Claims

1. A method for evaluating the process capability of tire blank component assembly and roll forming exhaust level, characterized in that, The method includes the following steps: S1, Sample preparation: Obtain the test embryo after the molding process, and select along the circumference of the embryo. The sampling section locations; among them. The number of cross sections and ; S2, Low-temperature and low-pressure holding: The test embryo is placed in a sealed holding cavity and held at the holding temperature. With holding time The embryo is held in place while the internal pressure is controlled. External pressure of the cavity Satisfying pressure difference constraints To maintain the relative positions of the embryo layers and the morphology of residual pores at the end of molding; among which, , To the maximum allowable pressure difference; S3, Low-Temperature Water Cutting Sampling and Section Shaping: At the cutting water temperature... With water jet pressure Under the conditions described above, the fixed embryo is subjected to... Water jet cutting was performed at each sampling section to obtain the tire carcass cross-section, and the cross-section was then ground smooth to obtain a measurable cross-section; S4, Cross-section measurement and evaluation record: based on the center baseline of the tire carcass crown. Using the horizontal measurement reference as the reference, the line connecting the outer ends of the left and right steel wire loops As the reference for sub-port measurement, for a preset set of components The distance from the endpoints of each component to the baseline was measured and the alignment was calculated. Simultaneously, the measurement points were set at the preset pore measurement points. The maximum pore width was measured and recorded in the evaluation table; S5, Quantitative evaluation and closed-loop determination: The total score was calculated based on the evaluation table. and the judgment threshold The comparison yields a pass / fail conclusion; when it fails, the set of molding parameters to be optimized is output. And return to S1 and repeat until it is successful; where It includes at least the component assembly alignment parameters and the roll extrusion parameters.

2. The method as described in claim 1, characterized in that, The steps described in step S1 satisfy Furthermore, the sampling cross-sections are evenly distributed along the circumference of the embryo; wherein the circumferential angle between adjacent cross-sections is... .

3. The method as described in claim 1, characterized in that, The holding temperature mentioned in step S2 satisfy The holding time satisfy And the maximum allowable pressure difference satisfy ; And / or, in step S2, the holding cavity is provided with a tire blank annular support to define the tire blank's shape, and during the holding process, the tire blank undergoes circumferential deformation. Not greater than ; To allow the maximum circumferential deformation.

4. The method as described in claim 1, characterized in that, The cutting water temperature mentioned in step S3 satisfy The water jet pressure satisfy The surface roughness after the cross-section is ground smooth Not greater than ; To allow the maximum roughness.

5. The method as described in claim 1, characterized in that, The component assembly described in step S4 It includes at least a zero-degree belt layer, a first belt layer, a second belt layer, a third belt layer, a steel cladding layer, and a carcass layer; for any component any cross section The distance from its left endpoint to distance With the right endpoint to distance And will be for moderate Defined as: in: For components In cross-section The left endpoint to the center baseline of the coronal region The distance; For components In cross-section From the right endpoint to the center baseline of the crown The distance; For components In cross-section The degree of the middle; And / or, in step S4, for any pore measuring point any cross section The maximum width of the stomata at the measuring point was measured. And the statistical width of the pore measuring point. Defined as: in: For measuring points In cross-section Maximum width of the pores at that location; For measuring points Statistical pore width; This refers to the number of cross-sections.

6. The method as described in claim 1, characterized in that, The total score mentioned in step S5 Calculate using the following formula: ; and when it is determined to be qualified, otherwise it is determined to be unqualified; in: For components Average symmetry; For components The centering limit; For measuring points Pore ​​width limit; For components Medium weight and satisfy ; For measuring points The pore weight and satisfy ; The acceptable threshold; And / or, the set of molding parameters described in step S5 At least including: Component assembly alignment parameters It is used to adjust the center positioning deviation and bonding tension of the parts; Roller extrusion parameters It is used to adjust the rolling pressure, rolling speed, and number of rolling passes; among which .

7. A tire blank assembly and roll forming exhaust level evaluation system for implementing the method of any one of claims 1 to 6, characterized in that, include: The module includes a holding module, a low-temperature water jet cutting module, a section shaping module, a measurement module, an evaluation table generation module, and an evaluation and judgment module. The evaluation module is configured to calculate a total score based on the centering and stomatal width data output by the measurement module. It outputs a pass / fail conclusion, and outputs a set of molding parameters when the result is non-passable. Used for process optimization.

8. The system as described in claim 7, characterized in that, The evaluation form shall include at least the following fields: sample number, cross-section number, project name, standard value, measurement point name, left and right measurement values, centering or difference, pore width, and judgment result. And / or, the system further includes a parameter sending interface for communicating with the molding machine controller, used to send... At least one parameter must be written into the molding machine formula or rolling program.

9. A computer-readable storage medium having a computer program or instructions stored thereon, characterized in that, When the computer program or instructions are executed by a processor, they implement the steps of the method according to any one of claims 1-6.

10. A computer program product, comprising a computer program or instructions, characterized in that, When the computer program or instructions are executed by a processor, they implement the steps of the method according to any one of claims 1-6.

Images