Cross-Head Die Assembly for Rapid Cord Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ply constructions for tires require significant downtime and loss of productivity when a reinforcement cord breaks, as the entire assembly must be disassembled to replace it, disrupting the remaining cords.
Innovation Solution
A cross-head die assembly with removably connected support blocks, flow passages, and a cassette system that allows for the easy replacement of cords without disrupting the elastomer flow, enabling quick replacement of broken cords and maintaining alignment and spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the guide insert is made as a fixed integrated component, then the structural integrity and stability are improved, but the time required to replace broken cords increases significantly
Solution Approach 1:
The guide insert is divided into multiple removable individual guides that can be independently accessed and replaced. Each guide is a separate component within the cross-head die assembly, allowing broken guides to be replaced without disassembling the entire assembly or affecting other guides.
Solution Approach 2:
The guide insert transitions from a fixed static structure to a dynamic modular structure where individual guides can be quickly removed and replaced. The removable design allows the system to adapt to cord breakages by enabling rapid guide replacement while maintaining operational flexibility.
2Ease of repair
If the guide insert is disassembled to replace broken cords, then cord replacement becomes possible, but productivity is significantly reduced due to the complexity of rethreading
Solution Approach 1:
The guide insert is segmented into individual removable guides, each accessible through the cross-head die assembly. This segmentation allows operators to replace only the specific broken guide without affecting other guides, dramatically reducing replacement time and maintaining productivity.
Solution Approach 2:
Broken guides can be extracted and replaced individually from the cross-head die assembly without removing the entire guide insert or disrupting the extrusion process. This extraction capability enables rapid replacement while minimizing production interruption.
3Loss of time
If individual cord guides are made removable and accessible, then cord replacement time is reduced, but the device complexity increases
Solution Approach 1:
The guide insert is segmented into standardized individual guides that are uniformly designed and easily accessible. This segmentation, while adding modularity, uses simple repetitive components rather than complex mechanisms, balancing accessibility with manageable complexity.
Solution Approach 2:
The guide insert incorporates dynamic removable elements within a stable cross-head die assembly framework. This dynamic design allows individual guides to be accessed and replaced without complicating the overall structure, as the modular guides fit into predetermined locations within the assembly.
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 rapid replacement of broken cords within minutes without rethreading the remaining cords, minimizing production downtime and maintaining cord alignment and spacing, while allowing for easy maintenance and flow channel modifications.
Implementation Method 1
an inlet section having an inlet for receiving flow from the extruder, a first flow passage being located between the upper support block and the interior section and being in fluid communication with the inlet
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cross-head die assembly (100) for use with an extruder is disclosed. The cross-head die assembly (100) comprises an inlet section (160) having an inlet for receiving flow from the extruder; an upper support block (130) removably connected to a first side of the interior section (150); a lower support block (140) removably connected to a second side of the interior section (150); a first flow passage (170) being located between the upper support block (130) and the interior section (150) and being in fluid communication with the inlet;and a second flow passage (180) being located between the interior section (150) and the lower support block (140) and being in fluid communication with the inlet. The cross-head die assembly (100) further comprises a removably mounted die (200) located at an outlet end of the assembly (100). The first (170) and the second (180) flow passage are in fluid communication with an inlet of the die (200). The interior section (150) further comprises an interior slot (402, 451) which extends from a first side of the assembly (100) to the inlet of the die (200). The first and second flow passage each have an inlet end and a raised center rib (310, 312) positioned at the inlet end.