Belt Member Production via Segmented Strip Overlap
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Solution Overview
Problem
The existing methods for producing belt members for tires require a wide variety of intermediate materials due to differences in tire sizes and cord angles, leading to inefficient production of small lot sizes and the need for multiple types of belt members, which complicates the process and increases stock requirements.
Innovation Solution
A method that involves cutting strip pieces of a predetermined width to a regular size, overlapping them on a conveyor to achieve the desired length and width of a belt member without changing the cutting angle, by calculating the necessary number of strip pieces and overlapping amount using specific equations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cutting angle of strip pieces is adjusted to obtain belt members of desired width and length, then the belt member dimensions can be matched to tire specifications, but the cutting angle determined by tire performance must be changed
Solution Approach 1:
The belt member is segmented into multiple strip pieces that are joined together. By dividing the belt member into Nint strip pieces with overlapping amount P, the patent achieves desired dimensions without changing the cutting angle, thus maintaining tire performance while obtaining precise dimensional control through the joining of multiple segments
Solution Approach 2:
The patent transitions from controlling belt member dimensions through a single parameter (cutting angle) to using multiple parameters including the number of strip pieces Nint, overlapping amount P, and strip piece width W. This dimensional expansion in the parameter space allows simultaneous achievement of desired dimensions and preservation of the performance-determined cutting angle
2Adaptability or versatility
If a wide variety of types of belt members are prepared as intermediate members to cope with different tire sizes and specifications, then various tire products can be produced, but extremely large number of types of belt members need to be stocked
Solution Approach 1:
The patent creates a universal belt member production system where a single type of strip material can be used to produce belt members for various tire sizes and specifications. By using the joining method with adjustable parameters (Nint, P, W), one strip material type serves multiple product purposes, eliminating the need to stock multiple specialized intermediate member types
Solution Approach 2:
The patent introduces dynamic adjustability in the production process through variable parameters (number of strip pieces Nint, overlapping amount P, strip piece width W). These dynamic parameters allow the same strip material to be adapted to different tire specifications on demand, replacing the static inventory of multiple pre-prepared belt member types
3Productivity
If belt members are cut to regular size and joined together to form desired width and length, then production efficiency can be improved, but the cutting angle must be adjusted which affects tire performance
Solution Approach 1:
The patent segments the belt member into multiple regularly-cut strip pieces that are joined together. This segmentation allows regular cutting (improving productivity) while the joining process with overlapping amount P compensates for any dimensional deviations, maintaining the required cutting angle for tire performance through the cumulative effect of multiple pieces
Data Source
AI summary
There is provided a belt member producing method including forming a strip piece 17 of a predetermined width W by cutting a strip material 12 including a plurality of reinforcement cords 11 to a regular size, conveying the strip piece 17 to a transfer conveyor 22 in such a manner that cut sides 19 of the strip piece 17 are in parallel with a traveling direction B of the transfer conveyor 22 and overlapping continuously an integral number Nint of strip pieces 17 on each other on the transfer conveyor 22 in such a manner that the strip pieces 17 are overlapped on each other by an overlapping amount P along non-cut sides 18 thereof, so as to produce a belt member 30 having a desired length equal to a predetermined length L of a belt layer of a pneumatic radial tire, the belt member producing method being characterized by including selecting a desired cutting angle θpre relative to a traveling direction A of the strip material 17 when the strip material 12 is cut to the regular size, calculating a number Ncal of strip pieces 17 necessary for forming a belt member 30 by the following equation (1), rounding up the number Ncal so calculated to the integral number Nint and calculating an overlapping amount P of the strip pieces 17 by the following equation (2), so as to determine the integral number Nint and the overlapping amount P.Ncal=(L/W)×sin θpre (1)P=W−L×sin θpre/Nint (2)