RFID Tool Tracking for Tire Mold Defect Traceability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for tracking and identifying tire manufacturing components, such as molds and presses, are unreliable due to environmental harshness, leading to inefficiencies and quality control issues, with 6-10% of tires failing quality checks and defects being difficult to trace back to specific tools.
Innovation Solution
The use of specialized RFID tags designed to withstand extreme conditions within tire manufacturing environments, applied to metal surfaces of mold segments, containers, and presses, allowing for automated identification and tracking of components, including unique identifiers for each tool and tire, enabling predictive maintenance and defect analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If engraved numbers are used to identify tire manufacturing components, then component identification is possible, but the engraved numbers wear over time becoming vague, dirty, damaged and difficult to read due to harsh environmental conditions
Solution Approach 1:
The patent replaces mechanical engraved identifiers with electronic RFID tags that can be read without physical contact. The RFID tags store component identification data and can be read by scanners throughout the manufacturing process, eliminating the wear and degradation issues associated with engraved numbers on metal surfaces.
2Loss of information
If manual paperwork systems are used to track tire manufacturing components, then component tracking is possible, but the system becomes unreliable as papers are lost, mixed up, fall off components, and cannot be read due to environmental conditions
Solution Approach 1:
The patent replaces manual paperwork systems with automated RFID tracking. RFID tags attached to components and presses enable automatic data capture and tracking without manual intervention. The system electronically stores and retrieves component information, eliminating paper loss, mixing, and readability issues in harsh environments.
Solution Approach 2:
The RFID system enables self-service tracking where components automatically carry their identification data and can be read by scanners at various points in the manufacturing process without requiring manual documentation or intervention.
3Reliability
If conventional identification methods are used, then defect identification is possible, but multiple presses must be shut down to investigate and identify which press, mold, or bladder is responsible for failures, leading to production inefficiencies
Solution Approach 1:
The patent implements automated RFID tracking that continuously monitors and records which press, mold, and bladder components are used for each tire production. When defects occur, the system automatically retrieves the component identification data, eliminating the need to shut down multiple presses for investigation and enabling immediate identification of the responsible component.
4Extent of automation
If RFID tags are used to identify tire manufacturing components, then automated identification and tracking is achieved, but the RFID tags must withstand extreme environmental conditions including temperature fluctuations from 0°C to 300°C, ultrasonic cleaning, laser cleaning, sandblasting, welding, and pH changes
Solution Approach 1:
The patent specifies that RFID tags must be constructed from materials and designs that can withstand extreme environmental conditions. This includes using corrosion-resistant, temperature-stable materials that can survive ultrasonic cleaning, laser cleaning, sandblasting, welding proximity, and pH changes while maintaining their identification functionality throughout the harsh tire manufacturing environment.
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 3A~3B
AI summary
Disclosed herein are automated systems and methods utilizing a plurality of specialized RFID tags incorporated within various tire manufacturing components (e.g., mold segments, mold container, bladder plates, tire presses, and extrusion dies) that are able to readily track tire manufacture and identify defect source(s) while concurrently being configured to the harsh processes and temperatures of tire manufacture.