Dual Bead Former System for Rapid Tire Bead Changeover
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Solution Overview
Problem
Existing bead forming systems require substantial downtime and multiple machines to accommodate different bead sizes and shapes, with cumbersome adjustment processes that increase production costs and times.
Innovation Solution
A bead forming system with a dual-bead former setup that allows for quick switching between operational and setup positions, utilizing a housing with separately operable bead formers and robotic retooling, enabling efficient production of multiple bead sizes with minimal downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple machines are used to produce different bead types, then each machine can be optimized for a specific bead type, but the facility requires more machines and increases capital costs
Solution Approach 1:
The bead forming machine is designed with adjustable components including the former, wire guide, and tensioning mechanisms that can be modified to accommodate different bead sizes and types. This allows a single machine to perform multiple functions and produce various bead types without requiring separate dedicated machines for each bead variety.
Solution Approach 2:
The machine incorporates adjustable and reconfigurable components rather than fixed structures. The former can be changed in size and configuration, wire guides can be repositioned, and tensioning mechanisms can be adjusted to adapt to different production requirements, enabling dynamic adaptation to various bead types.
2Adaptability or versatility
If the former is removed and replaced to accommodate different bead types, then the machine can be adjusted for different bead sizes, but the process requires substantial time and causes downtime
Solution Approach 1:
Multiple formers of different sizes and configurations are pre-prepared and stored in ready-to-use positions near the machine. When a change in bead type is required, the pre-prepared former can be quickly installed without requiring time-consuming manufacturing or extensive preparation, significantly reducing changeover time.
Solution Approach 2:
The machine setup is divided into modular, independently replaceable components including the former, wire guides, and tensioning mechanisms. This segmentation allows specific components to be changed without affecting the entire machine system, enabling rapid replacement of only the necessary parts for different bead productions.
3Adaptability or versatility
If the former is removed and replaced, then different bead types can be produced, but the heavy equipment requires substantial time to handle and install
Solution Approach 1:
Multiple formers are pre-prepared and staged in accessible locations before production runs. This preliminary preparation ensures that when a former change is needed, the replacement component is already ready for immediate installation, eliminating delays associated with preparing heavy equipment on-site.
Solution Approach 2:
Standardized former designs and configurations are created as reusable templates or copies. These standardized formers can be manufactured in advance and stored, allowing rapid replacement without custom fabrication time. The copying approach enables multiple identical or variant formers to be produced efficiently.
4Adaptability or versatility
If adjustable equipment is used to accommodate different bead types, then one machine can produce multiple bead types, but the adjustment process is burdensome and complex
Solution Approach 1:
The adjustment system is divided into discrete, independently adjustable modules including the former mounting mechanism, wire guide positions, and tensioning components. Each module can be adjusted separately through simple procedures, making the overall adjustment process more manageable and less complex than adjusting a monolithic system.
Solution Approach 2:
The machine incorporates adjustable parameters such as former size, wire guide positioning, and tensioning forces that can be modified to accommodate different bead types. These parameter changes are designed to be straightforward adjustments rather than complex reconfigurations, simplifying the adaptation process.
Data Source
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AI summary
A bead forming system for forming a tire bead may include the following: a housing (110), a first bead former (102) configured to facilitate the formation of the tire bead, and a base (118) secured to the first bead former, where the first bead former includes a bead-receiving surface that is rotatable relative to the base. The base may be adjustable such that the first bead former (102) is movable from a first position to a second position. The first position may be on a first side of the housing, and the second position may be on a second side of the housing. A second bead former (104) may be located in the second position when the first bead former is located in the first position, where the second bead former is located in the first position when the first bead former is located in the second position.