Continuous Tyre Base Layer Manufacturing With Folded Bead Wires
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Solution Overview
Problem
Existing tyre manufacturing processes are inefficient and labor-intensive, particularly in forming bead wires and integrating them into tyre base layers, leading to increased time and cost.
Innovation Solution
A method for manufacturing a continuous belt of tyre base layer by folding lateral edge portions over stiffening elements, such as bead wires, and securing them to a central portion, allowing for a continuous production process that can be cut to desired lengths, and incorporating a puncture protection layer for enhanced strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch process with manual labor is used for tyre manufacturing, then flexibility in handling different tyre sizes is maintained, but productivity is low and time consumption is high
Solution Approach 1:
The tyre base layer manufacturing is divided into discrete sequential steps: providing the sheet material, laying stiffening elements at specific positions, folding lateral edge portions over the stiffening elements, and securing them together. This segmentation enables automated processing of each step while maintaining the ability to handle different tyre sizes by adjusting parameters for each segment.
Solution Approach 2:
Stiffening elements are positioned and secured to the sheet material before the folding operation. This preliminary positioning ensures proper alignment and structural integrity before the lateral edge portions are folded over, enabling continuous automated processing without manual intervention during critical assembly steps.
2Productivity
If manual placement of bead wires and materials is used, then quality control is possible, but labor costs increase and production time extends
Solution Approach 1:
Manual mechanical placement operations are replaced with automated systems that lay stiffening elements and fold lateral edge portions according to predetermined patterns. The automation maintains precision through controlled positioning mechanisms while dramatically increasing production speed and eliminating manual labor requirements.
Solution Approach 2:
The manufacturing process uses adjustable parameters such as the positioning coordinates of stiffening elements, folding angles, and securing forces that can be modified through control systems to maintain precision across different tyre sizes without requiring manual adjustment for each product variant.
3Productivity
If discrete tyre base layers are manufactured individually, then each tyre can be customized, but manufacturing time and cost increase
Solution Approach 1:
The manufacturing process is designed as a continuous operation where sheet material is continuously fed, stiffening elements are continuously positioned and secured, and lateral edge portions are continuously folded. This continuous production flow eliminates idle time between discrete manufacturing cycles while maintaining the capability to produce base layers for different tyre sizes through parameter adjustment.
Data Source
AI summary
A method of manufacturing a continuous belt of tyre base layer, the method comprising providing a sheet of material having a first lateral edge portion, and a second lateral edge portion, wherein the first lateral edge portion is separated from the second lateral edge portion by a central portion, laying a first stiffening element on the sheet where the first lateral edge portion and central portion meet, and laying a second stiffening element on the sheet where the central portion and second lateral edge portion meet, folding the first lateral edge portion over the first stiffening element, folding the second lateral edge portion over the second stiffening element, and securing the first lateral edge portion and the second lateral edge portion to the central portion.