Braided Tyre Bead Core Positioning With Optical End Tracking
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Solution Overview
Problem
The manufacturing of reinforcing rods for tires is hindered by the difficulty and slowness of adjusting and fixing the braiding wire ends, often resulting in incorrect placement and material waste.
Innovation Solution
A device with a positioning system that automatically adjusts the braided torus using a drive unit, spacer unit, and end section sensor to precisely position and cut the wire ends, ensuring accurate and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment and fixing of braid wire ends is performed, then flexibility in handling is maintained, but manufacturing speed decreases and positioning precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated positioning system that uses a sensor to detect the end section of the braid wire and a drive unit to automatically position it. This substitution of manual operation with an automated sensor-driven system resolves the contradiction by increasing manufacturing speed while maintaining positioning precision through optical detection rather than mechanical measurement.
Solution Approach 2:
The positioning system enables the braided torus to be automatically positioned and adjusted without continuous manual intervention. The sensor detects the wire end position and the system self-adjusts the positioning, reducing the need for operator skill and increasing production speed while maintaining consistency.
2Manufacturing precision
If manual cutting and assembly operations are performed, then adaptability to variations is maintained, but manufacturing precision deteriorates and time consumption increases
Solution Approach 1:
The patent employs an optical sensor system to detect the precise position of the braid wire end section, replacing manual visual inspection and measurement. This optical detection method provides superior positioning precision and immediately triggers the cutting and assembly operations, eliminating the time delay associated with manual measurement and adjustment.
Solution Approach 2:
The sensor provides real-time feedback on the position of the braid wire end section, enabling the control system to automatically adjust positioning and timing of cutting operations. This closed-loop feedback mechanism ensures high manufacturing precision while reducing assembly time through automated real-time adjustments.
3Reliability
If manual placement of crimp sleeves is performed, then flexibility in handling variations is maintained, but reliability deteriorates and material waste increases
Solution Approach 1:
The patent replaces manual sleeve placement with an automated system that uses sensor detection to precisely position the crimp sleeve on the braid wire end sections. The optical sensor ensures consistent and accurate positioning of the sleeve, eliminating the variability and errors associated with manual placement while the automated drive unit positions components with high reliability.
Solution Approach 2:
The positioning system automatically adjusts and positions the crimp sleeve without manual intervention, using sensor feedback to ensure correct placement. This self-service capability increases reliability by eliminating human error in sleeve placement while the integrated system manages the complexity of coordination between detection, positioning, and assembly operations.
4Productivity
If manual operations are used for cutting and assembly, then ease of operation is maintained, but productivity decreases and scrap rate increases
Solution Approach 1:
The positioning and cutting system operates automatically once initiated, with the sensor detecting the wire end position and the drive unit performing positioning and cutting operations without continuous manual intervention. This self-service automation dramatically increases manufacturing output while the standardized automated process actually simplifies operation by eliminating the need for skilled manual adjustment techniques.
Solution Approach 2:
The sensor provides continuous feedback on the position of the braid wire, enabling the automated system to make real-time adjustments for optimal cutting and assembly. This feedback mechanism increases productivity by enabling continuous automated operation while simplifying the operator's role to monitoring and initiation, rather than complex manual adjustments.
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 method allows for rapid, reliable, and reproducible production of reinforcing rods with reduced scrap rates, improving manufacturing yield.
Implementation Method 1
a spacing unit which is arranged to make the first and second end sections protrude, by elastic deformation, from the rest of the braided torus
Implementation Method 2
an end section sensor which is placed so as to be able to detect the presence or passage of the relevant protruding end section at a reference point
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a device (1) for producing an annular bead core element (2) intended to reinforce a pneumatic tyre, with a splicing station (10) which is designed firstly to receive a braided torus (3) with a central axis (Z3) comprising a braid wire (4), which extends in a longitudinal direction from a first end section (5) to a second end section (6), and which is interwoven in helical coils (7), and secondly to bring the first end section (5) and the second end section (6) together and attach them to each other, the device comprising a positioning system (20) which allows automatic adjustment of the position of the braided torus relative to the splicing station and which comprises a drive unit (30) for this purpose to move the braided torus (3) relative to the splicing station (10), a spacer unit (40) to make the first and second end sections (5, 6) project, by means of elastic deformation, relative to the body of the braided torus (3A), and an end section sensor (60) to detect the passage of the end section (5, 6) projecting into a tracking point (O60).