Segmented Forming Drum Sectors for Tire Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing tires require a specific forming drum for each tire size, leading to the need for a large warehouse to manage different drum sizes and shapes, which is inefficient and limits production flexibility.
Innovation Solution
A system where a single central body can be coupled with a series of circumferential sectors, allowing for quick and efficient replacement of sectors to accommodate different tire sizes, using reversible quick-fit devices such as snap-fit mechanisms to simplify and speed up the process of changing between tire sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a specific forming drum is used for each tire size, then the manufacturing precision for different tire sizes is ensured, but the device complexity and warehouse space requirements increase significantly
Solution Approach 1:
The forming drum is divided into a central body and separate circumferential sectors. The central body remains stationary while multiple circumferential sectors can be attached or removed to change the drum's effective diameter. This segmentation allows a single central body to serve multiple tire sizes by simply changing which sectors are attached, eliminating the need for separate forming drums for each size and reducing warehouse space requirements.
Solution Approach 2:
The central body is designed with a universal interface that can accommodate different combinations of circumferential sectors. By using the same central body with different sector configurations, the system achieves multi-functionality across multiple tire sizes. The reversible quick-fit devices enable rapid switching between different sector combinations, allowing one central body to perform the function of multiple specialized forming drums.
2Adaptability or versatility
If multiple forming drums of different sizes are maintained, then production flexibility for various tire sizes is achieved, but the loss of time for warehouse management and drum replacement increases
Solution Approach 1:
The system transitions from static, fixed forming drums to a dynamic configuration system. The circumferential sectors can be quickly attached or detached from the central body using reversible quick-fit devices, allowing the forming drum to dynamically adapt to different tire sizes. This dynamic capability enables production flexibility while minimizing the time required to switch between different drum configurations, as sectors can be rapidly exchanged without requiring complete drum replacement.
3Ease of operation
If reversible quick-fit devices are used for attaching circumferential sectors, then the ease of operation for changing tire sizes is improved, but the device complexity increases
Solution Approach 1:
The reversible quick-fit devices are designed to enable operators to quickly attach and detach circumferential sectors with minimal intervention. The mechanisms self-align and self-lock when sectors are positioned correctly, reducing the need for complex alignment procedures or multiple adjustment steps. This self-service capability improves ease of operation by allowing rapid sector exchange, while the modular design keeps the overall system complexity manageable.
Data Source
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AI summary
A method of building a sequence of tyres (2) different from each other, comprises generating a first deposition surface (22) by a first series of consecutive circumferential sectors (21). The first deposition surface is selected as a function of the type of a first tyre to be built. Each circumferential sector (21) of the first series is removably coupled to a central body (20) of a forming drum (16). The method further comprises manufacturing at least one component (3; 8; 8a, 8b) of said at least one first tyre by deposition of said at least one component at a radially external position to said first deposition surface (22) of the forming drum (16), removing said at least one component from the forming drum (16) and replacing each circumferential sector (21) of the first series with a circumferential sector of a second series for generating a second deposition surface selected as a function of the type of a second tyre to be built which is different from said first tyre. The replacement comprises uncoupling each circumferential sector (21) of the first series from the central body and removably coupling each circumferential sector of the second series to the same central body (20).