Tire Building Drum Diameter Adjustment for Consistent Overlap Splice
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Solution Overview
Problem
Existing methods for manufacturing vehicle tires, such as lap or butt splicing, often result in tire imbalance, non-uniformity, and sidewall constriction due to inconsistent overlap splices in the carcass ply, which affect tire quality.
Innovation Solution
A method involving a tire building drum with a sensor to measure and adjust the drum diameter for a precise overlap splice, ensuring a consistent material overlap of 2-6 mm, thereby maintaining the lap splice within a tolerance range and minimizing sidewall constriction by using an optical sensor to detect and adjust the material length of the carcass ply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If overlap splicing is used to join carcass ply material ends, then the tire can be manufactured continuously, but the overlap area causes sidewall constriction and tire imbalance
Solution Approach 1:
The invention changes the geometric parameters of the overlap splice by precisely controlling the material overlap length (2-6mm) and adjusting the drum diameter to compensate for material length variations. This parameter optimization reduces the harmful effects of the overlap area while maintaining continuous manufacturing capability
Solution Approach 2:
The invention performs preliminary measurement of the carcass ply material length using a sensor before splicing, and pre-adjusts the drum diameter accordingly. This preliminary action ensures that the overlap splice achieves the predetermined material overlap, preventing sidewall constriction before the splicing operation occurs
2Adaptability or versatility
If the material length of the casing ply varies, then production flexibility is maintained, but the overlap splice quality becomes inconsistent
Solution Approach 1:
The invention introduces a sensor that measures the actual material length of the carcass ply and feeds this information back to the control system. The control algorithm then determines the required drum diameter adjustment to achieve the target overlap splice quality, creating a closed-loop feedback system that maintains precision despite material length variations
Solution Approach 2:
The invention makes the drum diameter dynamic by allowing it to be adjusted based on the measured material length. This dynamic adaptation enables the system to maintain consistent overlap splice quality across different material lengths, transforming a static drum into a responsive component that adapts to production variations
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 ensures consistent quality of the overlap splice, reducing sidewall constriction and improving tire production by maintaining a predetermined material overlap, thus enhancing the overall quality and performance of vehicle tires.
Implementation Method 1
determining the material length of the casing ply with an optical sensor that detects the front and rear end sections and calculates the material length from this data
Implementation Method 2
the tire construction drum is expanded by 0.1 to 1%, preferably 0.2 to 0.6%, the expansion relating to the original drum diameter with the tire inner liner wound on it
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing a vehicle tire comprising the following steps: - placing and winding a tire inner liner (8) onto a tire manufacturing drum (1), wherein the material ends of the tire inner liner (8) are joined together with an overlap splice (12) on the tire manufacturing drum, - cutting and supplying a carcass ply (2) with a conveying means (6), - determining the material length (11) of the carcass ply (2) with a sensor (7), - comparing the actual value of the material length (11) of the carcass ply with a target value, - adjusting the drum diameter (14) to a length deviation of the measured carcass ply (2), wherein the drum diameter (14) is adjusted so that, after winding the carcass ply (2) onto the tire manufacturing drum (1), a defined overlap splice (12) with a predetermined material overlap is achieved, - placing and winding the carcass ply onto the tire manufacturing drum, - splicing the two together Material ends (4,5) of the carcass layer (2) on the tire building drum, joining both material ends together, - completing the vehicle tire.