Calender Roller Speed Control for Tyre Elongated Element Deposition
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Solution Overview
Problem
In existing tyre production methods, the deposition of a continuous elongated element of elastomeric material is prone to separation or adhesion issues between rollers, leading to increased cycle times and potential faults in the tyre component, especially during the starting of new application steps, which hampers productivity in automated tyre manufacturing plants.
Innovation Solution
The method involves retaining the continuous elongated element on one roller and guiding its head against the deposition surface, ensuring correct alignment and application without distortion or flaws, using a calender with a first roller rotating at a lower speed than a second roller to maintain control and prevent adhesion issues, and an actuating device to move the calender for easy purging and servicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the continuous elongated element is fed through a slit between two calender rollers, then the elastomeric material can be deposited onto the forming drum, but the element tends to separate from the rollers or adhere to one roller without control, causing increased cycle times and potential faults
Solution Approach 1:
The system performs preliminary routing of the continuous elongated element between the calender rollers before actual deposition onto the forming drum. This preliminary action ensures the element is properly positioned and controlled on the rollers before the critical deposition phase, preventing adhesion issues and separation during the main deposition process.
Solution Approach 2:
The calender rollers act as an intermediary mechanism between the extrusion system and the forming drum. The rollers provide a controlled interface that guides the continuous elongated element, ensuring stable transfer from the extrusion system to the deposition surface while preventing uncontrolled adhesion or separation.
2Ease of manufacture
If the continuous elongated element is routed between two calender rollers during deposition, then the material can be applied to the forming drum, but the element cools and widens between cycles, requiring elimination before new deposition
Solution Approach 1:
The system performs preliminary routing of the continuous elongated element between the calender rollers before actual deposition onto the forming drum. This preliminary action ensures the element is properly positioned and controlled on the rollers before the critical deposition phase, preventing adhesion issues and separation during the main deposition process.
Solution Approach 2:
The system dynamically adjusts the operation of the calender rollers, making them movable rather than fixed. The rollers can be positioned close to the forming drum during deposition and moved away during purging operations, enabling continuous operation without waiting for complete cooling and elimination of the element between cycles.
3Device complexity
If the calender rollers are fixed in position during deposition, then the structure is simple, but purging and servicing of the extruder becomes difficult
Solution Approach 1:
The system dynamically adjusts the operation of the calender rollers, making them movable rather than fixed. The rollers can be positioned close to the forming drum during deposition and moved away during purging operations, enabling continuous operation without waiting for complete cooling and elimination of the element between cycles.
Solution Approach 2:
The movable calender structure allows preliminary positioning of the rollers away from the deposition area before purging operations begin, providing easy access to the extruder for maintenance and servicing without requiring complete shutdown or complex disassembly.
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 ensures reliable and efficient deposition of the elastomeric material onto the forming drum, reducing cycle times, minimizing machine downtime, and enhancing productivity by preventing faults and allowing for easy purging of the extruder.
Implementation Method 1
The first roller is driven in rotation at a peripheral speed lower than a peripheral speed of the second roller... retaining the continuous elongated element on one roller
Data Source
AI summary
A method of controlling deposition of a continuous elongated element in building a tire for vehicle wheels, includes: feeding an initial end of a continuous elongated element of elastomeric material through a slit bounded by a first roller and a second roller of a calender; retaining the continuous elongated element against a peripheral surface of the first roller; laying the initial end of the continuous elongated element against a deposition surface; rotating the calender around an oscillation axis that is substantially coincident with a contact generatrix between the first roller and the second roller; and dragging along the continuous elongated element together with the deposition surface.