Forming Drum Outer Body Replacement via Radial Expansion
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Solution Overview
Problem
The existing methods for replacing forming drums in tyre building processes are costly, time-consuming, and require significant human resources, leading to inefficiencies and limitations in production flexibility due to the need for manual intervention and large storage of central bodies.
Innovation Solution
A method and system for automatically or semi-automatically replacing the outer bodies of forming drums within the cycle time, using a central body with radial expansion capabilities and quick coupling devices, allowing for efficient switching of outer bodies without modifying the central bodies, thus reducing downtime and resource requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If forming drums are replaced manually in traditional methods, then production changes can be implemented, but the process is time-consuming and requires significant human resources
Solution Approach 1:
The forming drum is divided into two separate components: a central body and an outer body. The outer body can be removed and replaced independently while the central body remains in place. This segmentation allows rapid replacement of the outer body without manual disassembly of the entire forming drum, significantly reducing replacement time while maintaining production flexibility.
Solution Approach 2:
The system enables automatic or semi-automatic replacement of outer bodies through mechanical interfaces and coupling devices. The central body with its radial expansion capability can automatically secure and release outer bodies without requiring manual intervention, reducing human resource requirements and accelerating the replacement process.
2Adaptability or versatility
If forming drums are replaced manually, then production changes can be made, but the process is costly and requires large storage of central bodies
Solution Approach 1:
By separating the forming drum into a reusable central body and replaceable outer bodies, the system reduces the need to store multiple complete forming drums. Only outer bodies need to be stored in various configurations, while the expensive central body is retained and reused across multiple production changes, reducing storage requirements.
Solution Approach 2:
The central body is designed as a universal component that can accommodate multiple different outer bodies through its radial expansion capability and standardized coupling interface. This multi-functionality allows a single central body to serve multiple production configurations, eliminating the need to store and manage multiple complete forming drum assemblies.
3Adaptability or versatility
If traditional forming drum replacement is used, then production changes are possible, but downtime increases and production efficiency decreases
Solution Approach 1:
Outer bodies are pre-configured and ready for installation on the central body. The quick coupling devices and radial expansion mechanism allow for rapid attachment without requiring time-consuming manual assembly or adjustment procedures. This preliminary preparation of replacement components minimizes downtime and maintains production efficiency.
Solution Approach 2:
The manual mechanical replacement process is replaced with an automated or semi-automated system using radial expansion mechanisms and quick coupling devices. This substitution reduces the time required for replacement operations and eliminates the productivity losses associated with manual intervention, while still allowing production flexibility.
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
This approach enables faster and more reliable replacement of forming drum outer bodies, maintaining production efficiency and flexibility by integrating the replacement process into the cycle time constraints, reducing the need for manual intervention and minimizing storage needs for central bodies.
Implementation Method 1
a central body with radial expansion capabilities
Data Source
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AI summary
A method for managing a production change in a building line (2) for at least one tyre component produced on a forming drum (10), said forming drum (10) comprising a central body (12) on which a first outer body (13) is fitted to define a forming surface (11) on which said at least one tyre component is produced, wherein there is provision for: separating said at least one component from said forming drum (10) in a final work station (3b) of said building line; modifying said forming surface of said forming drum by replacing, on said central body (12) and in a period of time equal to or less than the said cycle time, said first outer body (13) with a second outer body (13') different from said first outer body; moving said forming drum (10) comprising said second outer body (13') to an initial work station (3a) of said building line.