Tire Building Method with Rotating Bladder and Segmented Bead Setting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The traditional tire building process is inefficient due to the wear of turn-up bladders and bead setting components, premature wear of main shafts, and inaccuracies in transferring carcass assemblies between drums, leading to increased production costs and reduced quality.
Innovation Solution
A tire building method that involves manufacturing carcass assemblies on separate drums, using transfer devices to move them efficiently, and employing a bladder that rotates with the drum to reduce wear, along with a bead setting mechanism that ensures firm bonding and a robust main shaft design to improve durability and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional non-rotating bladder is used for turn-up process, then the bladder structure is simple, but the carcass material is worn by friction with the bladder and the turn-up bladder suffers serious wear
Solution Approach 1:
The bladder is designed to rotate together with the building drum during the turn-up process, transforming from a static component to a dynamic one. This rotation reduces relative friction between the bladder and carcass material, significantly decreasing wear on both the bladder and the tire components while extending bladder service life.
2Reliability
If a simple bead setting structure is used, then the device complexity is low, but the apex bead ring is not firmly bonded and bead setting members are severely worn
Solution Approach 1:
The bead setting mechanism is divided into multiple functional components including a bead setting member with pressing portion, positioning portions, and coordinated movement with the building drum. This segmented design allows each component to perform its specific function effectively, ensuring firm bonding of the apex bead ring while distributing wear across multiple parts.
Solution Approach 2:
The bead setting member is designed to move and rotate in coordination with the building drum, transforming from a static simple structure to a dynamic coordinated system. This dynamic movement ensures proper positioning and firm bonding of the bead ring while reducing concentrated wear on single components.
3Reliability
If traditional main shaft materials and manufacturing processes are used, then the manufacturing cost is low, but the main shafts are prone to premature wear and damage
Solution Approach 1:
The main shaft is manufactured using specialized materials and processes including alloy selection, heat treatment, and surface hardening techniques. These composite material approaches enhance the durability and wear resistance of the main shaft, allowing it to withstand the demanding rotational and loading conditions of the tire building process.
4Productivity
If carcass assemblies are transported sequentially between multiple drums, then each building step can be performed, but the production efficiency is reduced due to sequential processing and transfer time
Solution Approach 1:
Multiple carcass assemblies are manufactured simultaneously on separate parallel drums rather than sequentially on a single drum. This merging of production operations allows parallel processing of multiple tires, significantly reducing total production time and increasing overall productivity while maintaining quality control for each individual tire.
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
This method reduces the wear of bladders and bead setting components, improves the bonding of apex bead rings, extends the life of main shafts, enhances production efficiency, and reduces production costs by optimizing the layout and precision of the tire building process.
Implementation Method 1
meanwhile inflating a building bladder on the building drum to support the first carcass assembly
Implementation Method 2
respectively driving a first chuck seat and a second chuck seat to move oppositely by a first nut and a second nut
Data Source
AI summary
A tire building method comprises the following steps: step 1, manufacturing a first carcass assembly on a carcass drum, and transferring the first carcass assembly to a building drum through a first carcass transfer device; step 2, manufacturing a second carcass assembly on a belt drum, and transferring the second carcass assembly to the building drum through a second carcass transfer device; step 3, respectively driving a first chuck seat and a second chuck seat to move oppositely by a first nut and a second nut; step 4, sleeving the second carcass assembly on the supported first carcass assembly, and fitting the two carcass assemblies together and rolling the same to form a third carcass assembly; step 5, winding a tread to the outer surface of the third carcass assembly to form a fourth carcass assembly; and step 6, dismounting the fourth carcass assembly from the building drum.