Splitting Tire Wire Assemblies for High Structural Elongation
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Solution Overview
Problem
Existing methods for manufacturing tire wire assemblies, such as the 3.26 cable, achieve limited structural elongation due to the need for preforming, which reduces productivity and alters the wires, and do not allow for high structural elongation without preforming steps.
Innovation Solution
A method involving assembling M wire elements around a transient core to form a transient assembly, which is then split into M1 and M2 wire element assemblies, allowing for significant ventilation and curvature retention, thereby achieving high structural elongation without preforming steps.
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 by 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 in a helix around the core, providing the necessary structural elongation capability without requiring additional equipment or steps 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 into the assembly process itself, the harmful preforming tools and their associated friction are removed, maintaining both high structural elongation and productivity
2Manufacturing precision
If a preforming step is used to increase structural elongation, then structural elongation increases, but the wires are altered due to friction with preforming tools
Solution Approach 1:
The invention removes the preforming tools and their associated friction from the process. The curvature is formed by the assembly geometry itself rather than by mechanical preforming, eliminating the harmful friction that alters and damages the wire surfaces
Solution Approach 2:
The transient core acts as an intermediary element that enables the wire elements to acquire curvature during assembly. By winding around this temporary core, the wires naturally form the desired helical shape without contact with preforming tools, avoiding friction-induced wire alteration
3Ease of manufacture
If conventional twisting process is used, then manufacturing is simple, but structural elongation is limited (at most 0.5%)
Solution Approach 1:
The wire elements are nested around the transient core in a helical arrangement, with each wire following a curved path around the core. This nested configuration naturally provides the curvature needed for structural elongation while maintaining a simple assembly process that doesn't require complex preforming equipment
Solution Approach 2:
The invention introduces curvature into the wire elements by having them wind around the transient core in a helical pattern. This curvature is essential for achieving high structural elongation, and it is achieved through the simple geometric arrangement of the assembly process rather than complex twisting operations
Data Source
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AI summary
The invention relates to a method for producing at least first and second assemblies (26, 28) of M1 wire-type elements and M2 wire-type elements, at least one of the first and second assemblies (26, 28) comprising a plurality of the wire-type elements (14) wound together in the form of a helix. The method comprises a step of assembling M wire-type elements (14) together in a layer of the M wire-type elements (14) around a transitional core (16) in order to form a transitional assembly (22), and a step of 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.