Radially Contracting Annular Elements for Tyre Carcass Ply Building
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Solution Overview
Problem
Conventional tyre manufacturing processes face challenges in achieving high regularity and uniformity of the carcass ply, particularly in single-station first-stage building processes, where annular support elements facilitate deposition but hinder subsequent positioning and turning operations of the annular anchoring structure, leading to irregular joint quality and reduced production efficiency.
Innovation Solution
The use of radially expandable and contractable annular elements that can be moved away from the forming drum to allow for precise positioning and turning of the carcass ply, with the annular elements' radially outer surface positioned inside inflatable bladders to provide structural stiffening and eliminate gaps, ensuring uniform deposition and improved joint quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If annular support elements are used to facilitate deposition of the carcass ply, then deposition regularity is improved, but positioning and turning operations of the annular anchoring structure are hindered
Solution Approach 1:
The annular support element is designed to be movable rather than fixed, allowing it to be positioned during deposition to ensure regularity, then moved away to enable subsequent positioning and turning operations of the annular anchoring structure. This dynamic repositioning resolves the contradiction between maintaining deposition precision and enabling ease of operation.
2Manufacturing precision
If the annular element remains in position during turning operations, then deposition uniformity is maintained, but production efficiency is reduced
Solution Approach 1:
The annular support element is dynamically repositioned based on process stage: positioned during deposition to maintain uniformity, then moved away during turning operations to enable efficient production. This time-dependent positioning strategy resolves the contradiction between precision and productivity.
3Extent of automation
If radially expandable and contractable annular elements are used, then automated building process is enabled, but device complexity increases
Solution Approach 1:
The annular support element incorporates radially expandable and contractable capabilities through pneumatic or hydraulic mechanisms, enabling automated control of the building process. While this increases device complexity, it achieves high-level automation that improves overall manufacturing efficiency and precision.
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 enables high regularity and uniformity of the carcass ply, automates the building process, and enhances the quality of tyre joints while maintaining compactness and reducing installation costs, allowing for efficient production of high-quality tyres in single-station processes.
Implementation Method 1
radially contracting said annular element until it is set at a predetermined second diameter smaller than said first diameter
Implementation Method 2
turning said axial end edge around said annular anchoring structure by inflating said inflatable bladder
Data Source
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AI summary
The present invention relates to a process and apparatus for producing a tyre for vehicle wheels, the process comprises building a carcass structure on a forming drum (50). At each of the opposite axial end portions of said forming drum (50), a radially expandable and contractable annular element (60) having a radially outer surface (62) is arranged inside an inflatable bladder (70) and supporting said inflatable bladder (70) when it is deflated. It is initially arranged in a first operating position axially adjacent to said forming drum (50) and is set at a predetermined first diameter (D1) for supporting an axial end edge (2a) of at least one carcass ply (2) being deposited on said forming drum (50). The annular element (60) is then radially contracted to allow positioning an annular anchoring structure (10) on said axial end edge (2a). Then said axial end edge (2a) is turned around said annular anchoring structure (10) by inflating said inflatable bladder (70).