Creel Bobbin Layout for Compact Tire Wire Feeding
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Solution Overview
Problem
The increasing complexity, cost, and footprint of creels used in tire manufacturing due to the growing number of creel bobbins required for wider tires with more reinforcement wires necessitate a reduction in these aspects.
Innovation Solution
A creel design featuring a unique arrangement of creel bobbins and guiding tubes, where the lower half of the bobbins feed wires to guiding tubes at the upper end and the upper half feed wires to guiding tubes at the lower end, optimizing the fleet angle and minimizing the overall height, thereby reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of creel bobbins is increased to support wider tires with more reinforcement wires, then the productivity and tire width capability are improved, but the device complexity, costs and footprint increase dramatically
Solution Approach 1:
The patent combines multiple braking functions into a single brake unit that can control multiple creel bobbins simultaneously. The brake unit is positioned to engage with multiple bobbins through their respective guiding tubes, allowing one brake mechanism to perform the function of multiple individual brakes, thereby reducing overall device complexity while supporting increased numbers of bobbins for wider tires.
Solution Approach 2:
The brake unit is designed as a universal component that can serve multiple creel bobbins with different wire types and tensions. This multi-functional brake unit can be adjusted to accommodate various bobbin configurations, reducing the need for multiple specialized braking systems and thereby simplifying the overall creel structure while maintaining productivity for wider tires.
2Productivity
If the number of creel bobbins is increased to support wider tires with more reinforcement wires, then the productivity and tire width capability are improved, but the costs increase dramatically
Solution Approach 1:
The patent merges multiple brake mechanisms into a single brake unit that controls multiple creel bobbins. This consolidation reduces the total number of components required, lowering manufacturing costs while enabling the creel to handle the increased number of bobbins needed for wider tires with more reinforcement wires.
Solution Approach 2:
The universal brake unit design allows a single component to perform the function of multiple individual brakes, reducing the bill of materials and manufacturing complexity. This multi-functional approach enables cost-effective scaling of the creel system to accommodate wider tires without proportionally increasing costs.
3Productivity
If the number of creel bobbins is increased to support wider tires with more reinforcement wires, then the productivity and tire width capability are improved, but the footprint increase dramatically
Solution Approach 1:
The patent combines multiple braking functions into a single compact brake unit that serves multiple creel bobbins. This consolidation reduces the spatial footprint required for braking mechanisms, allowing the creel to accommodate more bobbins for wider tires without proportionally increasing the overall footprint.
Solution Approach 2:
The universal brake unit provides space-efficient multi-functionality, allowing a single component to control multiple bobbins. This reduces the horizontal and vertical space required compared to having separate brakes for each bobbin, enabling the creel to support wider tires with more bobbins while minimizing footprint expansion.
4Reliability
If individual brakes are provided for each creel bobbin to ensure uniform tension, then the wire tension uniformity is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple individual brake functions into a single brake unit that can simultaneously control multiple creel bobbins. This unified brake unit maintains uniform wire tension across all bobbins by providing centralized braking control, while reducing device complexity by eliminating the need for multiple separate brake mechanisms and their associated control systems.
Data Source
AI summary
Disclosed is a creel including a plurality of creel bobbins, a plurality of guiding tubes located at the lower end of the creel and a plurality of guiding tubes located at the upper end of the creel, wherein each guiding tube is arranged for receiving a wire from an individual creel bobbin, wherein the lower half of the creel bobbins are arranged to feed their wires to the guiding tubes at the upper end of the creel, while the upper half of the creel bobbins are arranged to feed their wires to the guiding tubes at the lower end of the creel.