Swivel Block Winding System for Solid Tire Base Layer Automation
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Solution Overview
Problem
The existing production methods for solid tires are not efficient enough, particularly in automating the manufacturing of the bottom layer, which limits the precision and speed of the process.
Innovation Solution
A device with a swivel block and two winding drums, a winding system for the rubber under-core and top layers, and a laying unit for the core layer, allowing for automatic production of the bottom layer on separate winding drums, with the ability to pivot and move the wire feeder for optimal winding patterns and reinforcement distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly methods are used to join rubber under-core layer and core assemblies, then flexibility in handling is maintained, but production efficiency is low and automation is limited
Solution Approach 1:
The device is segmented into modular functional units: a winding system for applying rubber under-core and top layers, a laying unit for applying core layers, and a swivel block with multiple winding drums. Each unit operates independently but coordinates through the swivel block, enabling automated production while maintaining manageable system complexity
Solution Approach 2:
The swivel block with multiple winding drums serves multiple functions: it can be positioned to assign different drums to different operational positions, allowing the same physical structure to handle both rubber layer winding and core layer application, thereby increasing automation capability without proportionally increasing overall device complexity
2Productivity
If single winding drum configuration is used, then device simplicity is maintained, but production speed and efficiency are limited
Solution Approach 1:
The single winding drum is segmented into multiple winding drums (at least two) arranged on a swivel block. This allows parallel processing where multiple layers can be wound and positioned simultaneously, increasing production speed while the modular swivel block design keeps the added complexity manageable
Solution Approach 2:
The swivel block can be pivoted to dynamically reassign winding drums between operational positions. This dynamic reconfiguration enables the system to optimize production speed by having multiple drums ready to serve different positions sequentially or in parallel, without requiring a permanently complex multi-position structure
3Manufacturing precision
If fixed wire feeder position is used, then positioning simplicity is maintained, but winding pattern flexibility and core layer quality are limited
Solution Approach 1:
The wire feeder is designed with dynamic positioning capability, allowing movement in axial and radial directions relative to the winding drum. This enables the wire feeder to adapt its position for different winding patterns and core layer configurations, improving core layer quality through precise control while the guided motion paths keep the positioning system relatively simple
4Productivity
If sequential production of rubber layers and core layers is used, then process simplicity is maintained, but manufacturing time and production efficiency are increased
Solution Approach 1:
The winding system for rubber layers and the laying unit for core layers are merged into a single integrated device through the swivel block mechanism. Both units can operate simultaneously on different winding drums, eliminating sequential production delays while the shared swivel block infrastructure keeps the integrated system manageable in complexity
Solution Approach 2:
The system enables continuous production by having multiple winding drums ready in advance. While one drum is being processed, another can be prepared with rubber under-core and top layers already applied, allowing the laying unit to immediately apply core layers without waiting for sequential completion, thereby maintaining continuous useful action and improving manufacturing efficiency
Data Source
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AI summary
The invention relates to an apparatus and a method for producing a base layer of solid tyre blanks, consisting of a radially inner rubber subcore layer (4), a central core layer (5) and a radially outer covering layer (6). The apparatus has a pivot block (7) with two winding drums (8, 9), a winding system (10) for feeding and depositing the rubber subcore layer (4) and the covering layer (6) on the winding drum (8, 9), a laying unit (11) with a wire support (12) for feeding and depositing the core layer (4) on the winding drum (8, 9), wherein the pivot block (7) with the two winding drums (8, 9) is arranged between the winding system (10) and the laying device (11) in such a way that, in a first position, the first winding drum (8) is assigned to the winding system (10) and the second winding drum (9) is assigned to the laying unit (11), and wherein the pivot block (7) can be pivoted about an axis (13) in such a way that, in a second position, the first winding drum (8) is assigned to the wire support (12) and the second winding drum (9) is assigned to the winding system (10).