Powered Roller Tension Control for Tire Building
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for building tires using continuous elongated elements made of elastomeric material with textile or metallic reinforcement cords result in structural deformations and residual tensions, leading to changes in tire form and reduced design diameter due to uneven tension and friction during the storage and delivery process.
Innovation Solution
A method and apparatus that control the delivery of the continuous elongated element by rotating the first rollers mounted on shafts, which reduces friction and inertia, allowing for consistent tension and minimizing deformations, using a zigzag path with powered shafts to manage speed and tension fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the continuous elongated element is stored and delivered using idle rollers in a zigzag path, then temporary storage and speed fluctuation management are achieved, but friction and inertia generate uneven tension causing structural deformations and residual tensions in the tire
Solution Approach 1:
The patent applies the dynamics principle by transforming the idle rollers into powered rollers that can actively control the tension of the continuous elongated element. The rollers are equipped with independently controllable drives that allow dynamic adjustment of tension forces during storage and delivery, enabling the system to maintain uniform tension and prevent deformations while providing temporary storage capability.
Solution Approach 2:
The patent implements parameter changes by modifying the operational parameters of the rollers from passive idle rotation to active powered rotation with controllable speed and torque. The control system adjusts the rotational parameters of each roller to maintain uniform tension distribution along the continuous elongated element, thereby preventing residual tensions and structural deformations in the final tire product.
2Productivity
If the delivery speed of the continuous elongated element is increased for faster tire building, then productivity improves, but tension fluctuations and deformations increase
Solution Approach 1:
The patent applies the feedback principle by implementing a control system that continuously monitors the tension and position of the continuous elongated element during delivery. The control unit receives feedback signals from sensors and automatically adjusts the speed and torque of the powered rollers to maintain uniform tension, enabling high-speed delivery without compromising tension uniformity or causing deformations.
Solution Approach 2:
The system uses dynamic speed control of the powered rollers to match the delivery requirements while maintaining tension uniformity. The rollers can independently adjust their rotational speed to accommodate variations in delivery rate, allowing the system to operate at high speeds for improved productivity while preventing tension fluctuations that would cause deformations.
3Manufacturing precision
If friction between rollers and shafts is reduced to minimize tension, then residual tensions decrease, but roller inertia and speed control become more challenging
Solution Approach 1:
The patent replaces the traditional mechanical friction-based tension control with an electronically controlled powered roller system. Instead of relying on friction between idle rollers and shafts, the system uses electric motors or drives on each roller to actively control tension through precise torque and speed regulation, thereby minimizing residual tensions while managing the complexity through electronic control systems.
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 minimizes the risk of tire form changes and maintains low residual tensions, enabling faster and more efficient tire building processes while maintaining the desired tire diameter and performance.
Implementation Method 1
rotating the first rollers mounted on shafts, which reduces friction and inertia
Implementation Method 2
rotating the first rollers mounted on shafts, which reduces friction and inertia
Implementation Method 3
forming at least one of the components of the green tyre comprises advancing a continuous elongated element towards the forming drum along a zigzag path defined by a plurality of rollers on which the continuous elongated element is partially wound
Data Source
Figure 1~7
Figure 2
Figure 3~5
AI summary
In an apparatus and in a process for building tyres, a method for controlling the delivery of a continuous elongated element comprises: arranging a continuous elongated element (11) along a zigzag path defined by a plurality of rollers (19, 31) on which the continuous elongated element is partially wound; advancing the continuous elongated element (11) in a feed direction (F) along the zigzag path; delivering the continuous elongated element in proximity of a work station (7) for building tyres. The longitudinal tension (ad) in the continuous elongated element (11) downstream of first rollers (19) of the plurality of rollers (19, 31) is maintained less than or equal to the longitudinal tension (σu) upstream of the same first rollers (19), by rotating the above-mentioned first rollers (19) in a sense in accordance with the feed direction (F) by means of a rotation imparted to respective first shafts (18) on which the first rollers (19) are mounted.