Profile-Based Tyre Tread Cutting to Reduce Scorching and Cracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tire manufacturing methods often result in defects due to using a constant cutting speed, leading to issues like scorching in thick areas and cracking in thin areas of the tire tread, affecting the quality and homogeneity of the cut.
Innovation Solution
Implementing a multi-speed cutting process with varying cutting speeds tailored to the tire profile, using a heating device to adjust the cutting element's temperature and speed based on the tread's thickness variations, ensuring a smooth and homogeneous cut.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a constant cutting speed is used throughout the tread, then the cutting process is simple and fast, but defects occur in thick areas (scorching) and thin areas (cracking)
Solution Approach 1:
The cutting device transitions from constant speed to variable speed operation, dynamically adjusting the cutting speed based on the local thickness of the tread. The control unit modifies the cutting speed profile in real-time as the cutting element moves across different regions of the tread, enabling both high productivity and defect-free cutting quality.
Solution Approach 2:
The cutting speed parameter is changed according to the tread thickness. The system implements a speed profile where the cutting speed varies as a function of position across the tread width, with lower speeds in thick areas and higher speeds in thin areas, thereby preventing scorching and cracking while maintaining efficient cutting.
2Manufacturing precision
If a lower cutting speed is used to prevent scorching in thick areas, then cutting quality improves in thick regions, but productivity decreases overall
Solution Approach 1:
The cutting process applies different quality standards locally: lower cutting speeds are applied specifically in thick areas where scorching risk exists, while higher speeds are used in thin areas where cracking is not a concern. This localized approach ensures high cutting quality in critical regions without compromising overall productivity.
Solution Approach 2:
The cutting speed is dynamically adjusted based on the local tread thickness encountered during cutting. The control system continuously modifies the speed parameter to match the local requirements, maintaining optimal cutting quality across all regions while maximizing overall cutting efficiency.
3Productivity
If a higher cutting speed is used to maintain productivity, then cutting efficiency improves, but defects occur in thin areas (cracking)
Solution Approach 1:
The system applies different cutting speed regimes to different local regions: high speeds are used in thin areas where cracking risk is low, while lower speeds are applied in thick areas. This spatially differentiated approach maintains high productivity overall while preventing defects in vulnerable regions.
Solution Approach 2:
The cutting speed parameter is continuously adjusted based on the local tread thickness profile. The control unit implements a speed profile that increases speed in thin areas to maintain productivity while decreasing speed in thick areas to prevent scorching, thereby achieving both high efficiency and defect-free cutting.
4Manufacturing precision
If the cutting device operates at variable speeds, then cutting quality improves across all tread regions, but process complexity increases
Solution Approach 1:
The system uses feedback from the tread thickness profile to automatically adjust the cutting speed. The control unit receives information about the tread geometry and dynamically modifies the cutting speed parameter in response, achieving high cutting quality across all regions through automated closed-loop control rather than manual intervention.
Solution Approach 2:
The cutting device is equipped with automated speed control that self-adjusts based on the tread profile being cut. The system monitors its own operating conditions and automatically modifies the cutting speed parameter to maintain optimal cutting quality, reducing the need for operator intervention and simplifying the overall process despite the variable speed requirement.
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 method reduces defects such as unwanted holes and improves tire roundness by adapting cutting speeds and temperatures to the tread's profile, enhancing cutting quality and reducing operator corrections.
Implementation Method 1
using a heating device to adjust the cutting element's temperature and speed based on the tread's thickness variations
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for manufacturing a tire for a motor vehicle comprises providing a tread (L) that establishes a material web along a longitudinal axis (A) for forming the tire, and providing data that includes information about a profile cross-section (P) of the tread (L). The method further comprises determining a profile (V1) for a cutting speed (v) of a cutting device (SV) as a function of the provided data, wherein the profile includes at least a first cutting speed and a second cutting speed that differs from the first cutting speed. The method further comprises activating the cutting device (SV) and setting the first cutting speed of the cutting device (SV) as a function of the determined profile (V1), and cutting the tread (L) using the cutting device (SV).The procedure further includes adjusting the second cutting speed of the cutting device (SV) depending on the determined course (V1) and cutting the running strip (L) using the cutting device (SV).