Extruder Head Permittivity Sensing for Tire Building Synchronization
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Solution Overview
Problem
Existing methods for detecting the output of a continuous elongated element from an extruder in tire manufacturing are unreliable due to sensitivity to environmental conditions like fumes and dust, and the physical constraints of the process make it difficult to position optical sensors effectively.
Innovation Solution
A capacitive sensor system that utilizes a resonant circuit formed by the extruder head and conductive elements to detect changes in electrical permittivity, allowing precise detection of the elongated element's output without being affected by environmental conditions, and can be easily integrated into the extruder head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical sensors are used to detect the output of the continuous elongated element, then detection can be performed, but the system becomes sensitive to environmental conditions like fumes and dust, reducing reliability
Solution Approach 1:
The patent replaces optical sensors with electromagnetic sensors that detect the presence of the continuous elongated element through electromagnetic field interactions. This substitution eliminates sensitivity to fumes and dust while maintaining detection capability, as electromagnetic sensors measure electrical permittivity changes rather than relying on optical paths that can be blocked or scattered by environmental contaminants.
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary between the sensor and the elongated element. Instead of direct optical detection that is blocked by fumes and dust, the electromagnetic field penetrates through the environment to interact with the dielectric material of the elongated element, enabling indirect but reliable detection through permittivity measurements.
2Measurement precision
If optical sensors are positioned near the extruder head for effective detection, then detection precision improves, but the physical constraints of the process make positioning difficult
Solution Approach 1:
The electromagnetic sensor system is designed to be universally applicable to the extruder head structure. The sensor can detect the elongated element through the head wall material, making the specific positioning less critical. This multi-functionality allows the same sensor design to work with different extruder head configurations without requiring precise custom positioning.
Solution Approach 2:
The patent changes the detection parameter from optical properties to electrical permittivity. This parameter change allows detection through non-conductive materials like the extruder head wall, eliminating the need for complex positioning arrangements and enabling simpler integration into the existing extruder structure.
3Reliability
If a resonant circuit with conductive elements is integrated into the extruder head, then detection reliability improves, but the device complexity increases
Solution Approach 1:
The patent merges the sensor system with the extruder head structure by integrating conductive elements directly into the head. This combining of functions reduces the number of separate components and simplifies the overall system, as the extruder head itself becomes part of the sensing mechanism rather than requiring separate sensor housings and mounting structures.
Solution Approach 2:
The resonant circuit uses the extruder head's own conductive elements and structure to create the electromagnetic field necessary for detection. The system serves itself by utilizing existing structural components for their dual purpose of both extrusion support and sensor functionality, eliminating the need for additional external field-generating components.
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
Ensures optimal synchronization of the forming drum rotation with the extruder output, maintaining precision and reliability over time without the need for frequent adjustments or large investments, and allows for effective use of the extruder head as part of the sensor system.
Implementation Method 1
detection of a variation of electrical permittivity characteristics in a region of space including the head, the aforesaid variation being caused by the presence of the continuous elongated element outgoing from the aperture of the extruder
Implementation Method 2
a resonant circuit (31) positioned at the head (23) to generate an electromagnetic field in a portion of space surrounding the head (23)
Implementation Method 3
detection of a variation of the natural resonant frequency of the resonant circuit (31) as a function of the presence or absence of the continuous elongated element (21) from the aperture (24)
Data Source
Figure 1
Figure 2~4
Figure 5a~6
AI summary
A process for building a tyre, comprising : - energizing a resonant circuit (31) of an electromagnetic sensor (30; 30'; 30"), in such a way that the resonant circuit (31) generates an electromagnetic field in a region comprising a head (23) of an extruder (20), - measuring a parameter (V) of the resonant circuit, produced in response to the energizing of the resonant circuit, this parameter being a function of the electrical permittivity characteristics of the region, - starting to extrude a continuous elongated element (21) made of elastomeric material through an aperture (24) formed in the head (23) of the extruder, in such a way that the electrical permittivity characteristics of the region are modified, - detecting a variation of the parameter (V) caused by the modification of the electrical permittivity characteristics, thus determining the presence of the continuous elongated element (21) outgoing from the aperture, - putting a forming drum (2) into rotation about its axis of rotation (X), at the end of a predetermined time interval after the detection of the variation of the parameter, - distributing the continuous elongated element (21) along a radially outer surface (3) of the forming drum (2), thereby forming at least a portion of a component of a tyre by winding on turns which are in side by side relationship and/or at least partially overlapping. An apparatus arranged to operate according to this process is also described.