Overlap Measurement Using Molding Mark Imaging
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Solution Overview
Problem
Existing methods for measuring the overlap of sheet-shaped members in tire manufacturing are inaccurate, leading to defective tires due to difficulties in determining the proper overlap state, especially when the winding completion end rises or rolls back relative to the start end, resulting in insufficient or excessive overlap.
Innovation Solution
An overlap measuring apparatus and method that utilize image capturing means to detect molding marks on the sheet-shaped members and calculate the distance between these marks to accurately measure the overlap, ensuring correct overlapping and precise measurement of the overlap amount by capturing images from above and processing them to determine the edge and ridge positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser sensors and encoders are used to measure overlap by detecting winding start and completion ends, then the length of the sheet-shaped member can be measured, but the amount of overlap cannot be accurately measured and proper overlapping state cannot be determined
Solution Approach 1:
The patent transitions from one-dimensional linear measurement (laser sensor detecting position along the winding direction) to two-dimensional area imaging (camera capturing the entire overlap region from above). This dimensional change enables simultaneous detection of both the amount of overlap and the overlapping state (whether ends are properly aligned or misaligned), resolving the contradiction by providing comprehensive measurement information in a different spatial dimension.
2Manufacturing precision
If the winding completion end rises or rolls back relative to the winding start end, then the measured length may be sufficient, but proper overlapping is not executed resulting in defective tires
Solution Approach 1:
The patent replaces mechanical contact-based detection methods with optical imaging technology. By using a camera to capture images of the overlap region and analyzing the positions of molding marks in the captured image, the system can detect not only the quantity of overlap but also the quality state (whether the ends are properly positioned relative to each other), thereby ensuring manufacturing precision and tire reliability without mechanical interference.
3Area of stationary object
If multiple laser sensors are arranged to cover the whole width of the molding drum, then the measurement coverage is improved, but the system complexity and difficulty in determining proper overlap state increases
Solution Approach 1:
The patent merges multiple measurement functions into a single imaging device. Instead of using multiple laser sensors arranged across the width of the molding drum, a single area camera captures the entire overlap region in one image, providing full-width coverage while simplifying the device structure and making it easier to determine the overlapping state.
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 solution enables accurate measurement of the overlap amount, unaffected by surface unevenness, warpage, or thickness variations, ensuring proper tire construction and reducing defective tire production.
Implementation Method 1
a light-receiving means for receiving the reflected light
Data Source
AI summary
An apparatus and method accurately measures an amount of overlap in joining together the end portions of a sheet-shaped member constituting a tire. The overlap amount of the sheet-shaped member front and rear ends is measured when the sheet-shaped member having been molded into a predetermined length with molding marks extending on the surface in width direction is wound around the periphery of a molding drum from the front end. In doing so, a detector detects a first molding mark formed on the sheet-shaped member on the rear end side and a second molding mark formed on the sheet-shaped member on the front end side by capturing images of an entire area including the overlap from above by an image capturing device. A calculator calculates the amount of overlap by measuring the distance between the first and second molding marks on the sheet-shaped member from the frames of captured images.