Bead Wire Tool Switching for Precise Cutting and Crimping
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Solution Overview
Problem
The existing methods for manufacturing reinforcing rods for tires are cumbersome, prone to errors, and costly due to the complexity of positioning and crimping specialized sleeves, leading to inefficiencies and material waste.
Innovation Solution
An automated installation that seamlessly transitions between cutting and crimping configurations, using a configuration unit to precisely and reproducibly adjust and join the ends of braided torus rods with a sleeve, ensuring quick, reliable, and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized tubular sleeves with internal central stops and chamfered positioning jaws are used, then the reliability of crimping is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent uses simple, standard crimping sleeves without complex internal features like central stops. The positioning is achieved through the automated tooling system rather than through specialized sleeve geometry, allowing the use of simpler, more economical sleeves that can be easily replaced.
Solution Approach 2:
The automated switching mechanism and positioning system perform the complex positioning and crimping operations automatically without requiring manual intervention. The system self-regulates the transition between cutting and crimping configurations, eliminating the need for complex manual positioning jaws and specialized sleeve features.
2Manufacturing precision
If manual positioning and insertion operations are performed, then the precision of sleeve placement is improved, but the production time and labor intensity increase
Solution Approach 1:
The patent replaces manual mechanical positioning operations with an automated switching mechanism that transitions between cutting and crimping configurations. This automated system maintains precision while dramatically increasing production speed by eliminating manual intervention in the positioning and crimping operations.
Solution Approach 2:
The system dynamically switches between different working configurations (cutting and crimping) through an automated mechanism. This dynamic reconfiguration allows the same equipment to perform multiple operations in sequence without manual intervention, maintaining precision while improving productivity.
3Reliability
If complex specialized sleeves are manufactured, then the crimping reliability is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent employs simple, standard crimping sleeves that are easier and less expensive to manufacture. The reliability is maintained through the precision of the automated crimping tooling rather than through complex sleeve design, allowing the use of simpler, more readily available components.
Solution Approach 2:
The simple crimping sleeves used in the patent can serve multiple purposes and are compatible with standard crimping operations. Their simplicity makes them easier to manufacture and less prone to manufacturing defects, while the automated tooling ensures reliable crimping performance.
4Productivity
If automated switching between cutting and crimping configurations is implemented, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The system uses a dynamic switching mechanism that automatically transitions between cutting and crimping configurations. This dynamic reconfiguration enables continuous automated operation without manual intervention, significantly improving productivity while the modular design of the switching mechanism helps manage the complexity.
Solution Approach 2:
The automated system is divided into distinct functional modules (cutting configuration and crimping configuration) that can switch between states. This segmentation allows each module to be optimized independently while the overall system achieves high productivity through automated sequential operation.
Data Source
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AI summary
The invention relates to an apparatus (1) for manufacturing a bead wire (9) intended to reinforce a pneumatic tyre, the apparatus comprising a receiving table (2) which is designed to receive a braided torus (3) which comprises a braid wire (4) which extends longitudinally from a first end section (5) to a second end section (6), a cutting tool (20), a crimping tool (30) designed to crimp a sleeve (14) around the first and second end sections (5, 6), and a configuration unit (40) which is designed to automatically switch the apparatus (1) from a cutting configuration (C20) in which the receiving table (2) cooperates with the cutting tool (20) so as to position the braided torus (3) and the first and second end sections (5, 6) so that said first and second end sections (5, 6) are sectioned by the cutting tool (20), to a crimping configuration (C30) in which the receiving table (2) cooperates with the crimping tool (30).