Cutting Band-Like Rubber Members with Embedded Cords
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Solution Overview
Problem
The existing methods for cutting band-like members with embedded reinforcing cords often result in a variable number of cords in the cut members, leading to non-conforming products that cannot be used as structural components, such as tire reinforcing layers, and are subsequently discarded.
Innovation Solution
A method and device that set specific cutting positions in the band-like member to produce (N + 1) band-like cut members by cutting along the length direction, adjusting the number of reinforcing cords in each cut member to ensure they conform to specifications, using a combination of fixed and variable cutting positions based on the total number of cords and allowable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting positions are set based on fixed intervals of reinforcing cords, then the cutting process is simple and efficient, but the number of reinforcing cords in cut members varies and specifications are not met
Solution Approach 1:
The cutting position determination is made dynamic by adjusting the number of reinforcing cords to exclude based on the actual total number of cords detected. Instead of using a fixed predetermined number, the system calculates the exclusion number dynamically using the formula: (total number of reinforcing cords - target number of cords) ÷ 2, ensuring specification compliance while adapting to variations in the original band-like member.
Solution Approach 2:
The system incorporates feedback by detecting the actual total number of reinforcing cords in the band-like member before cutting, then using this information to adjust the cutting position calculations. This closed-loop approach ensures that even when cord density varies, the final cut members will contain the correct target number of cords.
2Adaptability or versatility
If the total number of reinforcing cords in the band-like member varies, then flexibility in material supply is maintained, but the cut members may not meet specification requirements
Solution Approach 1:
The system performs preliminary detection of the total number of reinforcing cords in the band-like member before the cutting process begins. This advance knowledge allows the system to pre-calculate the correct cutting positions that will ensure the target number of cords in each cut member, preventing specification violations before they occur.
Solution Approach 2:
The system changes the parameter of cutting position based on the detected total number of reinforcing cords. By adjusting the number of cords to exclude from each end according to the formula provided, the system adapts the cutting parameters to match the actual material being processed, ensuring specification compliance regardless of variations in the original band-like member.
3Productivity
If cutting is performed without adjusting for varying cord numbers, then the manufacturing process is simple and fast, but non-conforming products are produced and discarded
Solution Approach 1:
The system performs preliminary detection and calculation of cutting positions before the actual cutting process. By detecting the total number of reinforcing cords and calculating the appropriate number of cords to exclude from each end in advance, the system ensures that all cut members will meet specifications, eliminating material waste from producing non-conforming products.
Solution Approach 2:
The system makes the cutting process self-adjusting by automatically detecting the total cord count and calculating the correct cutting positions without requiring manual intervention or adjustment. This self-service capability maintains manufacturing speed while ensuring all produced members conform to specifications, preventing material waste.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
(N + 1) band-like cut members is manufactured by cutting a band-like member, in which a plurality of reinforcing cords are arranged mutually parallel and embedded in rubber, N times along the length direction of the reinforcing cords. At such time, cutting positions are set at a plurality of locations in the width direction of the band-like member from a first end toward a second end, and cuts are made in the band-like member on the basis of the cutting positions. Setting the cutting positions includes: a step A in which cutting positions of the band-like member are set M times (where M is a natural number less than N) for every fixed first number of reinforcing cords; and a step B in which a second number of the reinforcing cords is set within an allowable number range, and the cutting positions are set at (N - M) locations using the second number such that band-like cut members having the second number of reinforcing cords are continuously produced.