Bead Wire Head Switching for Precise Cutting and Crimping
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Solution Overview
Problem
The existing methods for manufacturing bead wires for pneumatic tires are time-consuming, costly, and prone to errors due to the need for precise manual insertion and crimping of sleeves, leading to inefficiencies and material waste.
Innovation Solution
An automated installation that seamlessly transitions between cutting and crimping configurations, allowing for precise and reproducible adjustment and joining of bead wire ends using a receiving table, cutting tool, and crimping tool, with a configuration unit enabling automatic operation and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual insertion and crimping of sleeves is used, then positioning precision can be achieved, but the manufacturing process becomes time-consuming and labor-intensive
Solution Approach 1:
The system uses automatic detection and positioning mechanisms that guide the sleeve into the correct position without manual intervention. The detection device identifies the braid wire position and the actuator automatically positions and crimpes the sleeve, making the system self-servicing and eliminating manual labor while maintaining precision.
Solution Approach 2:
Manual mechanical positioning and crimping operations are replaced with an automated system comprising a detection device, actuator, and control unit. This substitution of manual mechanical operations with automated mechanical and electronic systems increases productivity while maintaining positioning precision through automated feedback control.
2Ease of operation
If manual crimping operations are performed, then flexibility in handling is maintained, but the process becomes costly and error-prone
Solution Approach 1:
The system automatically detects the braid wire position, positions the sleeve, and performs the crimping operation without manual intervention. The detection device and actuator work together to execute the entire process autonomously, eliminating manual operations while maintaining ease of use through automated control.
Solution Approach 2:
The detection device provides real-time feedback on the position of the braid wire and sleeve, allowing the control unit to adjust the actuator's movements accordingly. This feedback mechanism ensures precise positioning and crimping while simplifying the operator's role to merely initiating and monitoring the automated process.
3Manufacturing precision
If precise manual positioning is required, then joining accuracy is improved, but material waste increases due to incorrect sleeve placement
Solution Approach 1:
The detection device continuously monitors the position of the braid wire and sleeve during the positioning process, providing feedback to the control unit. This allows for real-time adjustments to ensure accurate sleeve placement, eliminating incorrect positioning that would lead to material waste and bead wire rejection.
Solution Approach 2:
The system performs preliminary detection and positioning of the sleeve before the actual crimping operation. The detection device identifies the correct position in advance, and the actuator pre-positions the sleeve accurately, ensuring that the subsequent crimping operation is performed at the correct location and preventing material waste from incorrect placement.
Data Source
AI summary
The installation for manufacturing a bead wire intended to reinforce a pneumatic tire, said installation comprising a receiving table which is adapted to receive a braided torus which comprises a braid wire which extends longitudinally from a first end section to a second end section, a cutting tool, a crimping tool adapted to crimp a sleeve around said first and second end sections, and a configuration unit which is adapted automatically to switch the installation from a cutting configuration in which the receiving table cooperates with the cutting tool so as to position the braided torus and the first and second end sections so that said first and second end sections are sectioned by the cutting tool to a crimping configuration in which the receiving table cooperates with the crimping tool.