Multi-Row Sensor Device for Tire Reinforcement Break Detection
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Solution Overview
Problem
Existing tire inspection methods face challenges in detecting damage to reinforcement elements within tires, particularly due to the presence of ferrous metal in the bead area and non-linear geometry, which interferes with magnetic flux detection, and are prone to false signals from vibrations during inspection.
Innovation Solution
A sensor device with multiple rows of sensors positioned along the inner surface of the tire, using Hall Effect sensors and a magnetic field to detect breaks in reinforcement elements, while compensating for vibration-induced signals by analyzing signal timing and magnitude from adjacent sensor rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single row of sensors is used for tire inspection, then the device complexity is reduced, but the ability to distinguish true breaks from vibration-induced false signals deteriorates
Solution Approach 1:
The sensor array is divided into multiple rows positioned at different locations within the tire. Each row independently monitors reinforcement elements, and by comparing signals across multiple rows, the system can distinguish true breaks from vibration-induced false signals, thereby improving reliability without excessive complexity increase
Solution Approach 2:
The system uses feedback from multiple sensor rows to validate detected anomalies. When a break is detected in one row, the system cross-references signals from other rows to confirm whether the anomaly is a true break or a false signal caused by vibration or sensor movement, improving signal accuracy through comparative analysis
2Measurement precision
If sensors are placed close to the tire surface for improved detection sensitivity, then measurement precision improves, but sensor saturation from ferrous metal in the bead area worsens
Solution Approach 1:
The sensor system employs different measurement strategies for different tire regions. In the bead area where ferrous metal causes saturation, the system uses multiple rows to compare signals and identify true breaks despite saturation conditions, while in other regions it optimizes for maximum sensitivity, allowing precise detection across varying local conditions
Solution Approach 2:
The system adjusts measurement parameters based on location. In areas with high ferrous metal content like the bead portion, it uses comparative analysis across multiple sensor rows to compensate for saturation effects, while maintaining close proximity to the surface for optimal detection sensitivity where conditions permit
3Manufacturing precision
If the tire profile and size are standardized, then sensor placement consistency improves, but the adaptability to different commercial tire specifications deteriorates
Solution Approach 1:
The sensor device is designed as a universal inspection system that can accommodate different tire profiles, sizes, and types. The multiple-row sensor arrangement allows the system to adapt to various tire geometries while maintaining consistent measurement quality across different commercial tire specifications
Solution Approach 2:
The sensor positioning system is designed to be dynamic and adaptable rather than fixed. It can adjust to different tire profiles and sizes, allowing consistent sensor placement across various tire types while maintaining the ability to detect breaks accurately in each specific configuration
4Productivity
If inspection speed is increased for higher productivity, then the number of tires inspected per unit time improves, but the accuracy of break detection deteriorates due to increased vibrations
Solution Approach 1:
The inspection system divides the monitoring task across multiple sensor rows, allowing continuous high-speed inspection while using comparative analysis to filter out vibration-induced false signals. This segmentation enables maintained productivity with improved accuracy despite increased vibrations from faster inspection speeds
Solution Approach 2:
The system uses real-time feedback from multiple sensor rows to distinguish true breaks from vibration artifacts during high-speed inspection. By continuously comparing signals across rows, the system maintains accurate break detection even when inspection speed increases cause elevated vibration levels
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
Enables accurate detection of breaks in tire reinforcement elements across various tire sizes and profiles, reducing false positives and negatives, and allowing for efficient inspection of tires with minimal sensor saturation.
Implementation Method 1
If the reinforcement elements in the body plies for commercial tires such as e.g., heavy truck tires are frequently constructed from a ferrous material, one or more sensors can be used to detect discontinuities in the reinforcement elements
Implementation Method 2
the bead provides a substantial amount of ferrous metal that impedes the level of saturation of the reinforcement elements with magnetic flux that is desired for break detection
Data Source
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Figure 2
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AI summary
A method of using a sensor device for tire inspection is provided. Signals are received from multiples rows of sensors separated by a predetermined distance. The sensors are positioned next to the inner surface of the tire for inspection. Signals from the different rows of sensors are used to identify e.g., breaks in the reinforcements of the tire and also used to identify undesirable signals generated from vibration or jarring of the sensor device.