Braided Tire Bead Wire Folding for Precise Excess Wire Cutting
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Solution Overview
Problem
The existing methods for producing bead wires for pneumatic tires face challenges in accurately and efficiently positioning and cutting surplus lengths of braid wire, which can lead to improper assembly and reduced production efficiency.
Innovation Solution
A method involving a braiding step followed by a folding step, where the surplus braid wire is deformed to form an elbow, making it accessible for cutting and joining, ensuring precise manipulation and assembly without affecting the braided torus, and allowing for high production rates and robustness in the bead wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the excess section is left straight after braiding, then the braided torus structure is simple, but the excess section is difficult to position and manipulate for cutting operations
Solution Approach 1:
The excess section is folded during the braiding process itself, before the cutting operation. This preliminary folding action positions the excess section in an accessible location (protruding from the braided torus) while maintaining the overall simplicity of the braided structure. The folding is integrated into the braiding step, so no additional complex equipment is needed.
2Manufacturing precision
If cutting is performed immediately after braiding without folding, then the process is faster, but positioning accuracy and cutting precision are compromised
Solution Approach 1:
The excess section is folded during braiding to create an accessible position that enables precise cutting. This preliminary positioning ensures that when cutting occurs, the excess section is already in the optimal location, improving cutting precision without requiring significant additional time.
Solution Approach 2:
The folding creates a localized change in the excess section's position, making only the necessary portion accessible for cutting. The rest of the braided torus maintains its original structure, preserving production efficiency while achieving the required cutting precision.
3Ease of manufacture
If the excess section is made accessible by folding, then cutting and joining operations are facilitated, but the braiding process becomes more complex
Solution Approach 1:
The folding operation is merged with the braiding process. The same braiding machinery that creates the helical turns also performs the folding of the excess section by adjusting the winding path at the end of the braided torus. This integration eliminates the need for separate folding equipment, maintaining ease of manufacture while avoiding additional device complexity.
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 enables controlled and reproducible processing of bead wires, ensuring robustness and quality, while optimizing production infrastructure and flow by making the excess section easily accessible and manipulable, facilitating efficient cutting and sleeve-coupling operations.
Implementation Method 1
a folding step (S2) during which the excess section is deformed plastically by folding, so as to form an elbow which makes the excess section diverge with respect to the helical turns
Implementation Method 2
to act easily on the latter to provoke a slight local elastic flexing of a portion of the braid wire called 'end turn section', which links the winding section to the elbow, said local elastic flexing being, on the one hand, sufficient to make said end turn section accessible to a cutting tool then to a sleeve-coupling joining tool, and, on the other hand, sufficiently moderate to substantially allow an elastic return into place
Data Source
AI summary
The method comprises a braiding step during which a braiding wire is wound in helical turns about, and along, a generatrix line which is closed in a ring about a main axis, so as to form a bead wire element called “braided torus” within which the braid wire has, on the one hand, a winding section which corresponds to the helical turns and which occupies a braid volume, and, on the other hand, in an extension of said winding section, a surplus length of braid wire called “excess section”. After the braiding step, there is a folding step during which the excess section is plastically deformed by folding, preferably by means of a punch and an anvil, so as to form an elbow which makes the excess section diverge with respect to the helical turns and makes said excess section protrude at least partly with respect to the braid volume.