Rubber Sheet Protrusion Measurement via Cord Position Detection

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Solution Overview

Problem

Existing methods for measuring protrusion lengths in rubber sheets with embedded cords are inaccurate due to variations in cord positions, leading to deviations in protrusion rubber formation and potential cutting errors in the rubber sheet body.

Innovation Solution

A sheet forming apparatus equipped with calender rolls, cutter units, and sensor units that measure and adjust the protrusion lengths by imaging the cross-sectional profile of the rubber sheet, allowing for precise detection of cord positions and computation of protrusion lengths, ensuring accurate cutting of protrusion rubbers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the width of the rubber sheet is measured to estimate the width of protrusion rubber, then the measurement process is simple, but the measurement precision deteriorates due to variations in cord positions

Engineering Contradiction:

Improvemeasurement process simplicityVSAvoidprotrusion rubber width measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical width measurement method with an optical detection system. Sensors detect the positions of embedded cords through optical means, and a control unit calculates the protrusion rubber width based on these detected cord positions. This substitution eliminates the inaccuracies of mechanical width measurement while maintaining operational simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces cord position detection as an intermediary measurement approach. Instead of directly measuring the rubber sheet width, the system detects the positions of embedded cords (which remain relatively stable) and uses these intermediate measurements to calculate the protrusion rubber dimensions, thereby achieving higher precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the rubber sheet width is measured without considering cord position variations, then the measurement process is fast, but the manufacturing precision deteriorates leading to cutting errors

Engineering Contradiction:

Improvemeasurement speedVSAvoidprotrusion rubber cutting accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary detection of cord positions using sensors before the cutting process. The control unit calculates the required cutter positions based on these pre-detected cord locations, allowing the cutting operation to proceed efficiently without requiring slow, complex measurements during the cutting process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from cord position detection to adjust the cutting operations. The control unit receives sensor data about cord positions and uses this feedback information to accurately position cutters, ensuring high manufacturing precision while maintaining productivity through automated feedback control.

Inventive Principle:

Principle #23Feedback

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 apparatus ensures accurate detection and measurement of protrusion lengths, maintaining consistent protrusion rubber dimensions, improving productivity and quality by preventing deviations and ensuring accurate cutting of protrusion rubbers.

Implementation Method 1

a sensor unit (30a, 30b) as imaging means for imaging a cross-sectional profile of the rubber sheet (1)

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentEP2990168B1Excess piece protrusion amount measurement method and excess piece protrusion amount measurement device

Publication Date: 2017.08.30 BRIDGESTONE CORP

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AI summary

To provide a method and apparatus capable of measuring a protrusion length of a protrusion portion on each side of a sheet after cutting even when there is variation in positions of cords embedded in the sheet, the apparatus is provided with imaging means that images a cross-sectional profile in a width direction of the sheet including the protrusion portions, and is arranged to generate waveform data from the imaging of the cross-sectional profile, detect maximum height positions of crests and minimum height positions of troughs of the waveform data, set, based on the waveform data, a maximum height position of a crest closest to a width end of the sheet as a maximum height position of an end crest, set a position corresponding to an edge of the protrusion portion of the sheet, which is located on more width end side than the maximum height position of the end crest, as a minimum height position of a terminal trough, detect a distance in the width direction of the sheet between the maximum height position of the end crest and the minimum height position of the terminal trough, and measure the protrusion length of the protrusion portion based on the detected distance.