Conductive Roller Sensor for Wild Wire Detection in Tire Manufacturing

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Solution Overview

Problem

Automated tire manufacturing struggles with detecting and preventing 'wild wires' – partially separated metallic wire cords that can penetrate the innerliner, leading to air loss in tires, as existing equipment lacks a reliable detection system for these occurrences.

Innovation Solution

A method and apparatus using closely spaced electrically conductive rollers to detect exposed and partially separated metallic wire cords by closing an electrical circuit when the cord contacts both rollers, signaling equipment to stop and allowing for removal or reattachment, thereby preventing wild wires from entering the tire.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated assembly equipment is used for tire manufacturing, then productivity and consistency are improved, but the ability to detect wild wires deteriorates

Engineering Contradiction:

Improvemanufacturing speedVSAvoidwild wire detection capability

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces manual visual inspection with an automated electrical detection system. Conductive rollers sense the presence of wild wires through electrical contact, substituting human sensory capability with an automated electrical sensing mechanism that can operate at high speeds without compromising detection accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces conductive rollers as an intermediary detection device between the cutting mechanism and the tire building process. These rollers serve as a mediator that detects wild wires through electrical conductivity, enabling automated detection without interfering with the high-speed manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If manual inspection methods are used, then wild wire detection capability is improved, but productivity and consistency deteriorate

Engineering Contradiction:

Improvewild wire detection capabilityVSAvoidmanufacturing speed

Core Design Contradiction:

Difficulty of detecting and measuringVSProductivity

Solution Approach 1:

The patent replaces manual inspection with an automated electrical sensing system using conductive rollers. This substitution maintains the high detection capability of manual inspection while eliminating its limitations in speed and consistency, allowing the system to operate at full manufacturing throughput.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If conductive rollers are used for detection, then wild wire detection precision is improved, but device complexity increases

Engineering Contradiction:

Improvewild wire detection precisionVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the detection function from complex automated inspection systems and implements it through simple conductive rollers. By isolating the essential detection mechanism to basic electrical conductivity sensing, the system achieves high precision without requiring complex sensors, processors, or control systems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses simple, inexpensive conductive rollers that can be easily replaced if needed. These basic components provide reliable detection precision without the high cost and complexity of sophisticated sensing systems, aligning with the principle of using simple, cost-effective solutions for detection tasks.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Enables reliable in-line detection and prevention of wild wires, ensuring consistent tire quality and preventing air loss by integrating a sensor system into the tire manufacturing process.

Implementation Method 1

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS7441318B2Method for detecting exposed metal cords in an elastomeric strip

Publication Date: 2008.10.28 THE GOODYEAR TIRE & RUBBER CO

AI summary

A method and apparatus for detecting exposed and partially separated metal cords 17 in a cut end of a metallic cord reinforced strip 17 includes the steps of conveying and cutting the strip 17 and separating the cut ends and passing the conveyed cut strip 17 past a sensor means 40 for detecting any exposed partially separated metal cords or filaments. The preferred sensor means 40 includes a pair of closely spaced electrically conductive rollers 41, 42, a power source connected to one of the other rollers 41 or 42. When an exposed wire 26 touches both rollers 41 and 42 a circuit is closed giving indication of an exposed wire cord condition.