Bead forming system with dedicated setup area

Abstract

A bead forming system for forming tire beads can include a housing (110), a first bead former (102) configured to facilitate forming of the tire bead, and a base (118) secured to the first bead former, the first bead former having a bead-receiving surface rotatable relative to the base. The base can be adjustable to allow the first bead former (102) to move from a first position to a second position. The first position can be on a first side of the housing, and the second position can be on a second side of the housing. When the first bead former is positioned in the first position, a second bead former (104) can be positioned in the second position, and when the first bead former is positioned in the second position, the second bead former is positioned in the first position.

Description

[Background technology]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 981,221, filed February 25, 2020, which is incorporated by reference in its entirety.

[0002] Automobile tires typically have two annular bead rings at their innermost diameter that provide hoop strength and structural integrity to the tire. The beads also provide stiffness at the tire's attachment point to the rim. Beads are typically manufactured by winding metal wire within grooves on the periphery of a chuck or drum, often called a former. Beads may also be made from a single wire.

[0003] In many cases, a single manufacturing facility can produce several types of beads of various sizes and shapes. Existing equipment may not be capable of molding more than one type of bead, and therefore multiple machines, each associated with a specific type of bead, may be required at each of these facilities. While other equipment may be adjustable to accommodate different types of beads, the adjustment process can be tedious and require significant modifications to the machinery (thereby requiring downtime). For example, the formers typically associated with a particular bead type must be removed and replaced. Formers are typically heavy pieces of equipment and their removal and replacement can require significant time, thereby increasing costs and production time when adjusting machinery to accommodate different beads. Summary of the Invention [Problem to be solved by the invention]

[0004] Thus, what is desired is an improved bead forming system that includes a former that is both more efficient and easier to use. [Means for solving the problem]

[0005] According to one aspect of the present invention, there is provided a bead molding system for molding a tire bead, the bead molding system comprising: a housing; a first bead former configured to facilitate molding of the tire bead; and a base secured to the first bead former, the first bead former having a bead receiving surface that is rotatable relative to the base, the base being adjustable to allow the first bead former to move from a first position to a second position, the first position being on a first side of the housing and the second position being on a second side of the housing.

[0006] According to another aspect of the present invention, there is provided a bead molding system for molding a tire bead, the bead molding system including a housing, a first bead former configured to facilitate molding of the tire bead, and a base fixed to the first bead former, the bead former having a bead-receiving surface rotatable about a first axis relative to the base, and the base being rotatable about a second axis to enable the bead former to move from a first position to a second position.

[0007] According to yet another aspect of the present invention, there is provided a bead molding system for molding tire beads, comprising: a housing having a first side and a second side; and a base coupled to a first former and a second former, wherein the first former is located on the first side of the housing and the second former is located on the second side of the housing, and the base is rotatable so that the first former can move to and from the second side of the housing.

[0008] Embodiments of the present invention can be better understood with reference to the following drawings and description. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, throughout the drawings, like reference numbers indicate similar or identical features. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view of a bead molding system according to certain aspects of the present invention; [Figure 2] FIG. 2 is a plan view of the bead forming system of FIG. 1. [Figure 3] FIG. 2 is a front view of the bead forming system of FIG. 1. [Figure 4] 1 is a perspective view of the setup side of a housing for a bead molding system providing a setup area in accordance with certain aspects of the present invention; FIG. [Figure 5] 1 is a side view of the setup side of a housing for a bead molding system including automated setup equipment in accordance with certain aspects of the present invention; [Figure 6] FIG. 2 is a perspective view of a portion of the bead molding system of FIG. 1. [Figure 7] 2 is a side view of a portion of the bead forming system of FIG. 1 along with the path of travel of the bead former, illustrating the space through which the former passes during rotation of the base plate, in accordance with certain aspects of the present invention. [Figure 8] 1 is an exploded view of a housing for a bead molding system in accordance with certain aspects of the present invention; [Figure 9] FIG. 1 illustrates another embodiment of a bead molding system including multiple production areas in accordance with certain aspects of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] The present embodiment will be described with reference to the drawings, in which like elements are designated by like reference numerals. The relationship and function of the various components of the present invention will be better understood from the following detailed description. However, the embodiments of the present invention are not limited to the embodiments shown in the drawings. It should be understood that in certain cases, details not necessary for understanding the present invention, such as conventional manufacturing and assembly, have been omitted.

[0011] In particular, in addition to the features described below (and variations thereof), the systems described herein may incorporate components from commercially available equipment and technology for forming annular bead rings, such as the SWS-6000 Single Wire Bead Winding System and / or the TDS-860 Bead Winder System, each manufactured by Bartell Machinery Systems, LLC, of ​​Rome, N.Y. Incorporating certain existing components can provide backward compatibility with certain machine parts, thereby reducing initial costs for a particular customer.

[0012] Referring now to the drawings, FIG. 1 is a perspective view of a bead molding system 100 for molding at least one tire bead. FIG. 2 is a plan view of the bead molding system 100. FIG. 3 is a front view of the same bead molding system. The bead molding system 100 shown in FIGS. 1-3, and variations thereof, can have the capability of producing tire beads of multiple sizes. Additionally, as described in detail below, the bead molding system 100 advantageously can rotate the first bead former 102 between an operating position and a loading or setup position. When the first bead former 102 is in a first position 106 (e.g., for bead manufacturing), the second bead former 104 can be in a second position 108, such that the second bead former 104 can be operated to subsequently manufacture a bead of a particular size. At an appropriate time, the first bead former 102 and the second bead former 104 may be interchanged so that beads of different characteristics (eg, different diameters) can be formed by the associated bead winding equipment.

[0013] Such a feature is advantageous in providing a quick and effective way to set up the bead forming system 100 to form beads of different characteristics (e.g., different sizes) while reducing machine run time for other systems. For example, while other systems must be shut down for significant periods (e.g., several hours in some cases) when changing bead sizes, the present embodiment provides a way to accomplish such setup with little or no machine downtime. For example, the only machine downtime required when the first bead former 102 and the second bead former 104 are swapping positions (which can occur in less than 15 seconds in certain exemplary embodiments). A system with this capability can also occupy relatively little space for its manufacturing capabilities (e.g., because the reduced downtime increases the output of each system).

[0014] As shown in FIGS. 1-3 , a housing 110 may occupy a substantial portion of the bead forming system 100. The housing may be formed, for example, from sheet metal. In the illustrated configuration, a first bead former 102 is positioned at a first position 106 on a first side 112 of the housing 110, and a second bead former is positioned at a second position 108 on a second side of the housing 110. The first position 106 may be the position at which the corresponding bead former engages the bead winding device 116. That is, when the first bead former 102 (and / or the second bead former 104) is positioned at the first position 106, the first bead former is positioned in appropriate proximity to the bead winding device 116 so that a bead can be formed on the first bead former 102. The second position 108 may be free of bead winding devices. Alternatively, the second location 108 may include setup equipment (described below) and / or floor space suitable for manual setup so that the bead former can be adjusted at this location for future production of beads with specific characteristics. In particular, the first bead wire 102 and the second bead wire 104 may be separately operable (e.g., actuation / rotation of one does not adversely affect the other) such that bead formation on the first bead former 102 does not adversely affect the setup procedure on the second bead former 104, and vice versa.

[0015] A base 118 may be fixed to the first bead former 102 and / or the second bead former 104. For example, during a bead winding operation in the illustrated orientation, the base 118 may remain substantially stationary (i.e., locked in place) while at least one tire bead is formed on the bead-receiving surface 120 of the first bead former 102. The first bead former 102 may rotate relative to the base 118 during this bead forming. At the same time, the second bead former 104 may be substantially stationary (and may not be adversely affected by at least the rotation of the first bead former 102) to allow the setup process to occur.

[0016] Once bead winding on the first bead former 102 is complete (and / or setup of the second bead former 104 is complete), the base 118 can be rotated or moved in a different manner so that the first bead former 102 and the second bead former 104 swap places. Once the swap occurs, the second bead former 104 can be positioned at a first position 106 on a first side of the housing 110 (for bead forming using the second bead former 104), and the first bead former 102 can be positioned at a second position 108 on a second side of the housing 110 (e.g., where the first bead former can be reconfigured to form a different type of bead, if desired).

[0017] The setup area 122 may be located on the second side 114 of the housing 110. In some embodiments (e.g., the fourth embodiment), the setup area 122 may simply include sufficient floor space for changing over the bead former, which may be occupied by tooling, bead former components, workstations, and / or other equipment usable by a skilled bead former setup operator. Additionally or alternatively, at least one robot or other automated changeover mechanism may be provided. In the illustrated embodiment of FIG. 5, a robotic arm 124 is provided. The robotic arm 124 may be configured to change the second bead former 104 between a first bead setting and a second bead setting, which bead settings are associated with different bead characteristics. For example, the robotic arm may resize (in the orientation shown) the second bead former 104 so that it can be moved to the first position 106 (described above and see FIG. 2) where it is ready to begin producing a bead with desired characteristics (which may be different from a bead previously produced on the second bead former 104). Illustratively, the robotic arm 124 has moved the chuck portion 125 into position in FIG. 5 (which may replace the previous chuck portion).

[0018] FIG. 6 illustrates a portion of the bead forming system 100 with the housing 110 (see FIG. 1) omitted. The base housing is also removed from view in FIG. 6, thereby revealing a base component 126 of the base. The base 118 may include actuators for actuating the first bead former 102 and the second bead former 104 (and it is noted that the second bead former 104 is shown with a small setup in this image). For example, a first actuator 128 may be provided for rotating the first bead former 102 about a bead former axis 132. A second actuator 130 may be provided for controlling the radial position of at least one bead receiving surface 120 (including grooves 136) of the first bead former 102 (e.g., so that the bead receiving surface 120 can move to engage and disengage from a bead). A similar or identical actuator may be associated with the second bead former 104. Optionally, the actuator associated with the first bead former 102 and the actuator associated with the second bead former 104 may be operable separately as a whole (as described above) so that operation of one bead former does not adversely affect the other.

[0019] The base 118 may also be rotatable (e.g., by attachment to a rotatable base plate 138, as described in more detail below). For example, the base 118 may be rotatable about a base axis 134 (shown in FIG. 7). Such rotation may be utilized to move the first bead former 102 and / or the second bead former 104 between an operating position and a setup position, as described above. As shown in FIGS. 6 and 7, the base axis 134 may be perpendicular to the bead former axis 132. In particular, the base axis 134 may be angled relative to true plumb (where "true horizon" is defined as the plane parallel to flat ground and defined by the Earth's gravity, and "true plumb" is defined as the direction perpendicular to "true horizon"). For example, the base axis 134 may form an angle of at least 5°, e.g., at least 15°, e.g., at least 30° (or more) with respect to true vertical. Such an angle prevents contact between the bead formers and the winding equipment during their movement. That is, referring to FIG. 7 (which shows the space 140 that may be occupied during former rotation), the path of the first bead former 102 does not obstruct any bead winding equipment 116 or other components. Such a feature is advantageous with respect to certain other embodiments, since the bead winding equipment 116 may remain fixed in place during bead former movement rather than being moved out of the way, thereby further reducing downtime and further increasing the efficiency of the bead-forming system 100.

[0020] 8 is an exploded view showing the housing 110 of the bead forming system 100 along with a base plate 138. The base plate 138, which may be rotatable relative to the illustrated housing components, may have a top surface 142 affixed to the base 118 (described above). The top surface 142 may be substantially flat and may remain in a plane as it rotates. Thus, the axis of rotation of the base plate 138 (which may define the base axis described above) may be perpendicular to the top surface of the base plate 138. Such an arrangement may be advantageous in providing predictable and stable rotation of the base plate 138 (and thus the base 118 and associated bead former described above).

[0021] Although not shown, the base plate 138 and / or another component coupled to the base 118 (FIG. 1) may be driven by an actuator, such as a pneumatic or hydraulic actuator, an electric motor, or the like. If an actuator is provided, the actuator may be fixed to the housing, for example. Alternatively, it is contemplated that the base plate 138 may be manually rotatable by a human operator. In such an embodiment, the base plate 138 preferably includes a locking device so that the base plate can be secured against rotation relative to the housing, at least when the bead is being formed.

[0022] 8 also illustrates that the housing 110 can have various openings, as appropriate. For example, a first housing opening 144 can be provided in a first side 112 of the housing 110, and a second housing opening 146 can be provided in a second side of the housing 110. Thus, the first housing opening can accommodate the passage of a bead former when the bead former is in the first position 106 of FIG. 2, and the second housing opening 146 can accommodate the passage of a bead former when the bead former is in the corresponding second position 108. While only two openings are provided, additional openings are also envisioned (e.g., three or more bead formers attached to the base and / or multiple setup stations, for example).

[0023] FIG. 9 illustrates an alternative embodiment of a bead-forming system 200. In FIG. 9, two production stages are provided. For example, a set of bead winding devices 216 may be disposed on a first side of the housing 210, and a set of apex attachment devices 217 (which appear to be substantially the same as device 216, but may in fact be substantially different) may be disposed on a first side 212 of the housing 210. A base (similar or identical to base 118 described above) may be provided for interchanging the positions of the first bead former 202 and the second bead former 204 in a manner consistent with the above-described embodiment (and variations thereof). Advantageously, multiple specifications of the tire building process can be achieved without manual intervention. While only two stages are shown in this example, it is contemplated that more than two formers may be coupled to base 218, thus providing more than two production stages (and / or setup stages). If two formers are provided, a common drive shaft may rotate them (however, this feature is optional and the provision of separate actuators may be desirable).

[0024] While various embodiments of the present invention have been described, the scope of the present invention should not be limited except in light of the appended claims and their equivalents. Moreover, the advantages described herein are not necessarily the only advantages of the present invention, and it is not necessarily expected that every embodiment of the present invention will achieve all of the described advantages.

[0025] The scope of the present invention may also relate to, but is not limited to, one or more of the following aspects (and combinations thereof):

[0026] In a first aspect, a bead forming system for forming tire beads may include the following components: a housing; a first bead former configured to facilitate forming of the tire bead; and a base fixed to the first bead former, the first bead former having a bead-receiving surface rotatable relative to the base. The base may be adjustable to allow the first bead former to move from a first position to a second position. The first position may be on a first side of the housing, and the second position may be on a second side of the housing. When the first bead former is positioned in the first position, the second bead former may be positioned in the second position, and when the first bead former is positioned in the second position, the second bead former may be positioned in the first position.

[0027] The first bead former can engage one or more bead winding machine components when the first bead former is in the first position. The first bead former can be disposed within a setup area when the first bead former is in the second position. The setup area can include at least one robotic component configured to change the first bead former between a first bead setting and a second bead setting.

[0028] The bead receiving surface may revolve around a bead forming axis, and the first bead former may be rotatable relative to the base about a first bead former axis. The base may be rotatable about a base axis, and the base axis may be perpendicular to the first bead former axis. The base axis may be at an angle to the vertical.

[0029] The base can be fixed to a surface of a base plate, the surface of the base plate being rotatable to move the first bead former between a first position and a second position. The surface of the base plate can remain in a plane as the base plate rotates, the plane being angled relative to horizontal. Rotation of the base plate can be controlled via at least one actuator fixed to the housing.

[0030] The housing may have a first opening and a second opening, the first opening being located on a first side of the housing and allowing the bead to pass through when the first bead former is in a first position, and the second opening being located on a second side of the housing and allowing the bead to pass through when the first bead former is in a second position.

[0031] The base may have a first actuator that rotates the first bead former about the bead former axis, and the base has a second actuator that controls the radial position of the bead-receiving surface of the bead.

[0032] In a second aspect, a bead-forming system for forming tire beads can include the following components: a bead former configured to facilitate forming of the tire beads; and a base secured to the bead former, the bead former having a bead-receiving surface rotatable about a first axis relative to the base. The base can be rotatable about a second axis to enable the bead former to move from a first position to a second position.

[0033] The first axis may be perpendicular to the second axis.

[0034] The second axis may be at an angle to the true vertical.

[0035] The first location can be on a first side of the housing and aligned with a first housing opening, and the second location can be on a second side of the housing and aligned with a second housing opening.

[0036] The bead former may engage one or more bead winding machine components when the bead former is in the first position.

[0037] The bead former may be located within the set-up area when the bead former is in the second position.

[0038] In a third aspect, a bead molding system for molding tire beads can include one or more of the following components: a housing having a first side and a second side; and a base coupled to a first former and a second former. The first former can be located on the first side of the housing, and the second former can be located on the second side of the housing. The base can be rotatable so that the first former can move to and from the second side of the housing.

[0039] In addition to the features mentioned in each of the independent aspects listed above, some embodiments may also include optional features, either alone or in combination, mentioned in the dependent aspects and / or disclosed in the description above and shown in the drawings.

Claims

1. A bead molding system for molding a tire bead, comprising: Housing and a first bead former configured to facilitate the forming of a first tire bead having a first size; a base fixed to the first bead former, the first bead former having a bead receiving surface rotatable relative to the base, the base being adjustable to allow the first bead former to move from a first position to a second position; the first location is on a first side of the housing and the second location is on a second side of the housing; a second bead former is disposed at the second position when the first bead former is disposed at the first position; the second bead former is configured to facilitate the forming of the tire bead having a second size, the second size being different from the first size; A bead forming system, wherein the second bead former moves from the second position to the first position when the first bead former moves from the first position to the second position.

2. The bead forming system of claim 1 , wherein the first bead former engages one or more bead winding machine components when the first bead former is in the first position.

3. The bead forming system of claim 2 , wherein the first bead former is positioned inside a setup area when the first bead former is in the second position.

4. The bead forming system of claim 3 , wherein the setup area includes at least one robotic component configured to change the first bead former between a first bead setting and a second bead setting.

5. The bead forming system of claim 1 , wherein the bead receiving surface revolves around a bead forming axis, and the first bead former is rotatable relative to the base about the first bead former axis.

6. The bead forming system of claim 5 , wherein the base is rotatable about a base axis, the base axis being perpendicular to an axis of the first bead former.

7. The bead forming system of claim 6 , wherein the base axis is angled relative to true plumb line.

8. 2. The bead forming system of claim 1, wherein the base is secured to a surface of a base plate, the surface of the base plate being rotatable to move the first bead former between the first position and the second position.

9. The bead forming system of claim 8 , wherein the surface of the base plate remains within a plane as the base plate rotates, the plane being angled relative to horizontal.

10. The bead forming system of claim 8 , wherein rotation of the base plate is controlled via at least one actuator secured to the housing.

11. 2. The bead forming system of claim 1, wherein the housing has a first opening and a second opening, the first opening being located on the first side of the housing and allowing the first bead former to pass through when the first bead former is in the first position, and the second opening being located on the second side of the housing and allowing the first bead former to pass through when the first bead former is in the second position.

12. 2. The bead molding system of claim 1, wherein the base includes a first actuator that rotates the first bead former about a bead former axis, and the base includes a second actuator that controls a radial position of the bead receiving surface of the tire bead.

13. A bead molding system for molding a tire bead, comprising: a first bead former configured to facilitate the forming of a first tire bead having a first size; a second bead former configured to facilitate forming a second tire bead having a second size different from the first size; a base fixed to the first bead former and the second bead former, the first bead former having a bead receiving surface rotatable about a first axis relative to the base; the base is rotatable about a second axis such that when the first bead former is disposed at a first position, the second bead former is disposed at a second position, and when the first bead former is disposed at the second position, the second bead former is disposed at the first position; the first bead former engages one or more bead winding machine components when the first bead former is in the first position, and the first bead former is positioned within a setup area when the first bead former is positioned in the second position.

14. The bead molding system of claim 13 , wherein the first axis is perpendicular to the second axis.

15. The bead forming system of claim 13 , wherein the second axis is at an angle to the vertical.

16. 14. The bead forming system of claim 13, wherein the first location is on a first side of a housing that includes a first housing opening through which the first bead former passes when the first bead former is in the first location, and the second location is on a second side of the housing that includes a second housing opening through which the first bead former passes when the first bead former is in the second location.

17. A bead molding system for molding a tire bead, comprising: a housing having a first side and a second side; a base coupled to the first former and the second former; the first former is configured to form a first tire bead located on the first side of the housing and having a first size; the second former is configured to form a second tire bead located on the second side of the housing and having a second size different from the first size; The bead forming system, wherein the base is rotatable such that the first former and the second former interchange between a first position on the first side of the housing and a second position on the second side of the housing.

Images