Braided Tire Bead Core Folding for Precise Wire End Positioning
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Solution Overview
Problem
The existing methods for manufacturing reinforcing rods for tires face challenges in efficiently and accurately positioning excess braid wire sections for cutting, leading to potential imprecise assembly and reduced production efficiency.
Innovation Solution
A method involving a braiding step where the braid wire is wound in helical turns around a closed ring, followed by a folding step that deforms the excess wire section to form an elbow, making it accessible for cutting and joining, thereby ensuring precise assembly and reproducible production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the excess section of braid wire is left protruding after braiding, then it is accessible for cutting and joining operations, but it may interfere with the braided torus structure and cause positioning difficulties
Solution Approach 1:
The excess section is folded during the braiding process itself, before cutting and joining operations. This preliminary folding action positions the excess section in a controlled manner that facilitates subsequent operations while maintaining precision.
Solution Approach 2:
The braid wire is divided into distinct sections: the main braided torus and the folded excess section. This segmentation allows the excess section to be treated separately, making it accessible for cutting and joining while keeping the main structure intact.
2Productivity
If the braiding operation is performed at high production rates, then productivity increases, but it becomes more difficult to position and treat the braided torus accurately
Solution Approach 1:
The folding of the excess section is performed during or immediately after the braiding operation, before the torus needs to be positioned for cutting and joining. This preliminary action ensures that even at high production rates, the excess section is already in the correct position, maintaining precision without slowing down production.
Solution Approach 2:
The folding operation is integrated into the continuous braiding process, eliminating separate positioning steps. This continuous action allows high production rates to be maintained while ensuring accurate treatment of the braided torus.
3Manufacturing precision
If the excess section is folded to form an elbow, then cutting and joining operations become easier and more precise, but additional processing steps are required
Solution Approach 1:
The folding operation is merged with the braiding process, so that the excess section is folded as part of the main manufacturing flow rather than as a separate post-processing step. This integration adds minimal complexity while achieving the precision benefits.
Solution Approach 2:
The folding is performed in advance of cutting and joining operations, preparing the excess section for these operations. This preliminary preparation simplifies the subsequent cutting and joining steps, offsetting the added folding step with reduced complexity in later operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for controlled and reproducible braiding, cutting, and sleeving operations, resulting in robust and high-quality rods with optimized production flow and machine layout.
Implementation Method 1
a folding step (S2) during which the excess section is plastically deformed by folding, so as to form an elbow which causes the excess section to diverge with respect to the helical turns and at least partly protrude said excess section with respect to the braid volume of the braided torus
Data Source
Figure 1~4
Figure 5A~5C
Figure 6~7
AI summary
The invention relates to a method for producing a bead wire for a pneumatic tyre, said method comprising a braiding step (S1) during which a braiding wire (1) is wound in helical coils (2) around and along a generatrix line (L3) which is closed in the form of ring around a main axis (Z3), such as to form a bead wire element, known as a "braided torus" (4), inside which the braiding wire (1) includes a winding segment (5) which corresponds to the helical coils (1) and which occupies a braiding volume (V5), and, extending from said winding segment (5), a surplus length of braiding wire, known as the "surplus segment" (6). The invention also relates to a facility for producing bead wires for reinforcing a tyre.