Tire Bead Inspection via Laser Triangulation
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Solution Overview
Problem
Current methods for inspecting bead formation in tire production are inadequate for detecting defects such as axial miscentering, asymmetry, and structural issues in the beads, which can lead to performance and safety problems, as these defects are difficult to detect and often occur unpredictably due to adherence issues and technological limitations.
Innovation Solution
A method involving the acquisition and processing of digital images of the radially external surface of the carcass sleeve after bead turning-up to determine the circumferential trend of axial edge positions, allowing for the detection of defects like geometrical asymmetry, wrong axial length, and foldings, using a system with linear laser triangulation for accurate 3D imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for bead formation, then the inspection process is simple, but defect detection capability is insufficient and unreliable
Solution Approach 1:
The patent transitions from traditional 2D inspection methods to 3D imaging using laser triangulation technology. This dimensional change enables the system to capture axial, radial, and circumferential positions of bead edges simultaneously, allowing detection of complex defects like axial miscentering, asymmetry, and foldings that were previously undetectable with conventional methods.
Solution Approach 2:
The patent replaces mechanical measurement systems with an optical field-based inspection system. By using laser beams to illuminate the bead edges and capturing reflected light patterns with cameras, the system achieves non-contact measurement of three-dimensional bead geometry, eliminating the need for complex mechanical gauges or contact sensors.
2Reliability
If bead formation is performed without real-time inspection, then production speed is maintained, but defective tires are produced and quality control is compromised
Solution Approach 1:
The patent implements inspection during the bead formation process itself, before the tire completes all manufacturing steps. By capturing images of the bead edges at the critical moment when they are being formed and turned up, the system enables early detection of defects while the tire is still on the forming drum, allowing for immediate process adjustment or rejection of defective units.
Solution Approach 2:
The system processes captured images to determine circumferential trends of axial edge positions and provides real-time feedback on bead formation quality. This feedback mechanism enables the inspection system to detect deviations from specifications and trigger alerts or automatic adjustments during the formation process, ensuring only quality-compliant tires proceed to subsequent manufacturing stages.
3Ease of manufacture
If adhesive treatments are applied to forming drum surfaces, then bead formation is facilitated, but adherence issues cause unpredictable defects
Solution Approach 1:
The patent introduces an optical intermediary system that non-contactingly measures the bead edge positions and circumferential trends. Instead of relying solely on adhesive treatments to ensure bead formation, the optical system acts as an intermediary that objectively measures whether the beads are formed correctly, providing a reliable indicator of formation quality independent of adhesive performance.
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
Enables fast and automatic detection of bead defects in real-time, optimizing production processes by identifying issues immediately after bead formation, reducing the likelihood of defective tires and allowing for proactive process adjustments.
Implementation Method 1
using a system with linear laser triangulation for accurate 3D imaging
Implementation Method 2
acquire at least an image representative of at least a circumferential portion of radially external surface of the carcass sleeve
Data Source
AI summary
A station for checking the formation of beads of tyres, including: a forming drum for arranging a carcass sleeve with formed beads with the carcass sleeve in rotation, an image acquisition system for acquiring at least an image of a circumferential portion of external surface including the respective edges of the end flaps turned up; a processing unit for processing the image in order to determine a circumferential trend of the axial distance of each edge from an axial reference plane and for detecting possible defects of the beads as a function of such trend.