Variable-Shape Auxiliary Drum for Uniform Tyre Belt Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The shaping of belt layers in ultra-high performance tyres, particularly for race car competitions, is hindered by increased structural rigidity and non-uniform expansion, leading to uncontrolled deformations and material selection limitations, which affect the control of the footprint area and overall performance.
Innovation Solution
A process involving the turning-up of the flaps of the first belt layer after shaping the annular assembly, combined with the use of a first auxiliary drum with variable shape and switching members, allows for uniform expansion and selection of materials with desired mechanical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional tyre building machines are used, then the construction of tyre carcasses and bead assemblies is possible, but the process requires separate machines for different tyre components and multiple manual operations
Solution Approach 1:
The patent combines multiple separate tyre building machines into a single integrated machine that can construct both the carcass assembly and bead assembly in one continuous operation. The integrated machine includes a first workstation for carcass construction and a second workstation for bead assembly, both controlled from a central location, eliminating the need for separate machines and manual transfer operations.
Solution Approach 2:
The integrated tyre building machine performs multiple functions that previously required separate specialized machines. It can construct the carcass assembly, construct the bead assembly, and apply different types of compounds (bulk compound and tread compound) all through a single machine system, making the equipment universal for various tyre building operations.
2Ease of manufacture
If separate machines are used for carcass and bead assembly, then each machine can be optimized for its specific function, but the overall process requires more floor space and coordination
Solution Approach 1:
The patent merges the carcass building function and bead assembly function into a single integrated machine footprint. The first and second workstations are positioned adjacent to each other within the same machine structure, allowing both functions to share the same floor space rather than requiring separate machine locations.
Solution Approach 2:
The bead assembly workstation is integrated within the overall structure of the tyre building machine, with the second bead assembly tool positioned to work in conjunction with the first carcass building tool. The components and tools are nested within a compact arrangement that minimizes the external footprint while maintaining functional separation.
3Ease of operation
If manual operations are used for tyre building, then flexibility in operation is maintained, but construction time and labour intensity increase
Solution Approach 1:
The system prepares materials and positions tools in advance for each construction step. The compound delivery system pre-positiones compound reservoirs and delivery mechanisms, while the bead assembly tool pre-positions the bead core and surrounding tools before the actual assembly operation begins, reducing construction time without sacrificing operational flexibility.
Solution Approach 2:
The integrated machine enables continuous operation where the bead assembly process can begin while the carcass is still being constructed. The first and second workstations operate in a coordinated continuous manner, eliminating idle time between operations and maintaining continuous useful action throughout the tyre building process.
4Device complexity
If traditional compound application methods are used, then simple equipment is required, but compound distribution uniformity and tyre quality suffer
Solution Approach 1:
The compound delivery system is integrated into the tyre building machine and serves multiple functions: it delivers bulk compound to the carcass, delivers tread compound to the bead assembly, and provides controlled distribution in both cases. This multi-functional system achieves precise compound distribution while being part of the unified machine structure.
Solution Approach 2:
The control system monitors the compound application process and adjusts delivery parameters to ensure uniform distribution. The centralized control location coordinates compound delivery timing and quantity based on the construction progress, providing feedback control that maintains manufacturing precision without requiring overly complex mechanical delivery mechanisms.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A plant (1) for building tyres (2) for vehicle wheels comprises a carcass structure building line (13), a crown structure building line (14) and an assembly station (15). The crown structure building line (14) comprises a first auxiliary drum (22) having shape variable between a cylindrical shape and a toroidal shape and comprising turning-up members (54). The plant implements a process in which an annular assembly (A) made on the first auxiliary drum (22) is shaped and subsequently subjected to a turning-up action while it is associated with the first auxiliary drum (22).