Splitting Facility for Helical Wire Assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing wire element assemblies, such as those used in tire reinforcements, face limitations in achieving high structural elongation without preforming steps, which can be unproductive and alter the wires due to friction, resulting in limited elongation capabilities.
Innovation Solution
An installation that assembles M1 and M2 wire elements into single helix assemblies around a transient core, allowing for the splitting of the core to create separate assemblies with ventilation, thereby achieving high structural elongation without preforming, and reusing the core through recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a preforming step is used to increase structural elongation, then structural elongation increases (up to 2.0%), but productivity decreases and wires are altered due to friction with preforming tools
Solution Approach 1:
The wire elements are given a preliminary curvature during the assembly process around the transient core, rather than through a separate preforming step. This preliminary shaping action occurs naturally as the wires are wound into the helical configuration, achieving the desired structural elongation without the need for additional preforming equipment that would reduce productivity.
Solution Approach 2:
The invention extracts and eliminates the separate preforming step from the manufacturing process. By integrating the curvature formation directly into the assembly process around the transient core, the patent removes the harmful friction contact with preforming tools while maintaining the beneficial structural elongation effect.
2Manufacturing precision
If a preforming step is used to increase structural elongation, then structural elongation increases (up to 2.0%), but the method becomes relatively unproductive compared to methods without preforming
Solution Approach 1:
The invention merges the preforming function with the assembly process. The curvature that would traditionally be imposed in a separate preforming step is now formed simultaneously with the helical winding around the transient core, combining two operations into one and simplifying the manufacturing process.
Solution Approach 2:
The transient core acts as an intermediary element that facilitates both the assembly and the curvature formation. By winding the wire elements around this temporary core, the system achieves both the helical configuration and the necessary wire curvature without requiring separate preforming tools or steps.
3Productivity
If conventional twisting process is used, then structural elongation is limited (at most 0.5%), but the process is simple and productive
Solution Approach 1:
The invention introduces curvature to the wire elements by winding them into a helical configuration around a transient core. This curvature of the individual wire elements, rather than simple twisting, enables structural elongation to exceed 2.0% while maintaining productivity, as the curved wires can better accommodate deformation during tire expansion.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a facility (10) that allows the production of at least first and second assemblies (26, 28) of M1 wire-type elements and M2 wire-type elements, comprising a plurality of the wire-type elements (14) wound together in the form of a helix. The facility (10) comprises: means for assembling M wire-type elements (14, 17) together in a layer of M wire-type elements (17) around a transitional core (16) in order to form a transitional assembly (22), and means (24) for splitting the transitional assembly (22) into at least the first and second assemblies (26, 28) of M1 wire-type elements and M2 wire-type elements.