Automated Green Tyre Assembly Apparatus with Rotating Drums
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Solution Overview
Problem
Traditional tyre manufacturing processes are inefficient due to manual or semi-automatic steps, leading to long production times, high costs, safety risks, and high rejection rates, requiring significant operator intervention and storage space.
Innovation Solution
A fully automated apparatus comprising three tyre processing assemblies and an unloading station that automatically transfers and assembles tyre components, eliminating the need for manual intervention and optimizing production cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automatic processes are used for tyre manufacturing, then operator flexibility and adaptability are maintained, but production time increases and productivity decreases
Solution Approach 1:
The system enables self-service through automatic drum rotation and component positioning. The first drum automatically rotates to position the carcass, and the second drum automatically positions the belt package, eliminating the need for manual loading and positioning operations.
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems. The patent introduces automated drum rotation mechanisms, automatic component transfer systems, and coordinated mechanical actuators that replace manual loading, positioning, and assembly operations.
2Productivity
If manual loading and unloading operations are performed, then adaptability to different tyre types is maintained, but production efficiency decreases and costs increase
Solution Approach 1:
The apparatus achieves universality through adjustable drum configurations and programmable control systems that can accommodate different tyre types and sizes. The same automated system handles various tyre specifications by modifying operational parameters rather than requiring dedicated equipment for each tyre type.
Solution Approach 2:
The system utilizes parameter changes to adapt to different tyre manufacturing requirements. Control parameters such as drum rotation speed, component positioning coordinates, and assembly timing are programmably adjusted to accommodate different tyre types without changing the fundamental automation architecture.
3Loss of time
If automated transferring means are introduced, then production time is reduced, but device complexity and initial costs increase
Solution Approach 1:
The system merges the transferring function with the existing drum structures. The first and second drums serve dual purposes: they are both the forming tools for the tyre components and the transferring mechanisms that move components between stations, eliminating the need for separate transferring equipment.
Solution Approach 2:
The drums are designed with multi-functionality, serving as both forming tools and transferring mechanisms. This universal design reduces overall system complexity by combining multiple functions into single components rather than adding separate dedicated equipment for each function.
4Reliability
If fully automated assembly is implemented, then productivity and repeatability improve, but initial investment and system complexity increase
Solution Approach 1:
The control unit implements feedback mechanisms to ensure repeatable and accurate assembly operations. The system monitors and adjusts operational parameters based on real-time conditions, ensuring consistent positioning and assembly quality across production cycles while maintaining manageable system complexity through intelligent control.
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
The apparatus significantly reduces production time, costs, and rejection rates, ensuring high repeatability and reliability while maintaining flexibility with traditional tyre technology.
Implementation Method 1
a first drum, rotatable about a first axis, suitable for automatically positioning said carcass or inner section
Implementation Method 2
a second drum, rotatable about a second axis, suitable for automatically positioning said belt package or outer section
Data Source
AI summary
An apparatus (10) for producing green tyres (13) consisting of a carcass or inner section (13′) coupled with a belt package or outer section (13″), comprising a first tyre processing assembly (12) for manufacturing the carcass or inner section (13′), a second tyre processing assembly (14) for finishing said carcass (13′), a third tyre processing assembly (16) for manufacturing a belt package or outer section (13″) and for coupling said carcass or inner section with said belt package or outer section (13′, 13″) to form a tyre (13), and an unloading station (60) for unloading said tyre (13), said tyre processing assemblies comprising interface means for transferring the product being manufactured from one tyre processing assembly to another one and for moving said product being processed internally to said individual tyre processing assemblies in a fully automatic manner.