Automated Elastomeric Reel Supply for Green Tire Manufacturing
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Solution Overview
Problem
The existing methods for supplying green tyre manufacturing machines with elastomeric products require operator intervention for reel changes, leading to reduced productivity and potential machine stoppages, especially when multiple reel changes are needed simultaneously.
Innovation Solution
A partially or fully automated supply facility with a preparation station equipped with a manipulator arm and motor, allowing for the precise positioning and handling of reels, and an autonomous handling apparatus to transfer reels without operator intervention, enabling parallel operations and reducing the need for operator involvement during reel changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reel changes are performed manually by operator intervention, then the process is simple and flexible, but productivity decreases and machine stoppages occur
Solution Approach 1:
The system performs preliminary actions by having the mobile platform and preparation station ready before reel changes are needed. The mobile platform can be positioned in advance, and the preparation station pre-processes reels (separating product from interleaf, positioning ends) before they are needed for machine operation, thus enabling rapid reel changes without stopping the laying process
Solution Approach 2:
The system implements self-service through automated operations where the mobile platform autonomously transports reels, the preparation station automatically separates and positions product ends, and the joining station autonomously connects product ends. These automated systems perform reel change operations without requiring manual operator intervention, thereby maintaining continuous machine productivity
2Reliability
If buffer stock is increased to allow reel changes, then machine stoppages are avoided, but product storage quantity increases
Solution Approach 1:
The preparation station performs preliminary actions by pre-separating the product from the interleaf and pre-positioning the product ends before reel changes occur. This advance preparation eliminates the need for large buffer stocks, as the system can quickly exchange reels and resume production without interruption, thereby ensuring continuous operation with minimal product storage
Solution Approach 2:
The system extracts the time-consuming operations (separating product from interleaf, positioning ends, joining product ends) from the critical path of machine operation by performing them in advance at the preparation station. This extraction allows rapid reel changes without requiring large buffer stocks to cover the time needed for these operations
3Productivity
If multiple reel changes are performed simultaneously, then productivity is maintained, but operator workload and complexity increase
Solution Approach 1:
The system segments the reel change process into distinct functional modules: mobile platform for transport, preparation station for separating and positioning, and joining station for connecting product ends. This segmentation allows multiple reel changes to be performed simultaneously at different stations without increasing overall system complexity, as each module operates independently and autonomously
Solution Approach 2:
The automated systems perform reel change operations autonomously without requiring operator coordination for multiple simultaneous changes. The mobile platform autonomously navigates and positions reels, the preparation station automatically separates and positions product ends, and the joining station autonomously connects product ends, thereby maintaining sustained productivity without increasing operational complexity
Data Source
AI summary
A method for supplying green tire manufacturing machines (14) with elastomeric products (12) by means of a supply facility (10) comprising a loading member (30) and at least one transfer member (34) comprising an unwinder (36) is disclosed. The supply facility comprises a preparation station (32), said preparation station comprising a manipulator arm (70), and at least one motor (53), the preparation station and the unwinder being distinct from the green tire manufacturing machine. The method comprises the following successive operations: loading the reel onto the unwinder; positioning the end of the product wound on the réel; arranging the end of the product in such a way that it is laid on a dispenser of the unwinder; and transferring the reel from the preparation station to the green tire manufacturing machine.