Tire Fitting Machine Torque Control via Motor Current Monitoring
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Solution Overview
Problem
Existing tire fitting and removal machines lack automation, require operator expertise, and are inefficient for large or specialized tires, often risking damage to tires and rims due to inadequate torque control and monitoring.
Innovation Solution
A tire fitting machine equipped with a three-phase electric motor, a detection device for current consumption, and a monitoring system that adjusts frequency, amplitude, and voltage of the motor current to maintain optimal torque-speed conditions, automatically detecting and responding to tire type and operational conditions to prevent damage and optimize the fitting/removal process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated control systems with multiple sensors and processing units are added to existing tire fitting machines, then the extent of automation and productivity improve, but the device complexity and manufacturing cost increase
Solution Approach 1:
The motor's own current consumption serves as the sensing signal for torque detection. The system uses the motor's inherent electrical characteristics (current draw) to automatically determine when torque thresholds are reached, eliminating the need for separate mechanical torque sensors or complex feedback mechanisms. The motor essentially senses and reports its own operational state through its electrical consumption patterns.
Solution Approach 2:
The patent replaces mechanical torque sensing and limiting mechanisms with an electrical control system that monitors motor current consumption. Instead of using mechanical force sensors, linkages, or torque limiters, the system uses electrical measurement of current draw to detect torque conditions and automatically adjusts motor operation accordingly, substituting mechanical sensing with electrical measurement and control.
2Object-affected harmful factors
If torque limiting mechanisms are added to protect tires during fitting, then tire damage prevention improves, but the device complexity and operational time increase
Solution Approach 1:
The system continuously monitors the motor's current consumption in real-time during tire fitting operations. When the current draw exceeds a predetermined threshold that corresponds to excessive torque application, the control system automatically interrupts or adjusts motor operation to prevent tire damage. This closed-loop feedback mechanism provides continuous protection without requiring manual intervention or complex mechanical limiting devices.
Solution Approach 2:
The motor's current consumption serves as the intrinsic sensing mechanism for detecting excessive torque. The system leverages the motor's own electrical characteristics to automatically detect and respond to dangerous operating conditions, eliminating the need for separate torque sensing devices or complex mechanical protection mechanisms that would add time and complexity.
3Productivity
If manual operation with operator judgment is used for tire fitting, then adaptability to different tire types is maintained, but productivity and consistency improve with automation
Solution Approach 1:
The system uses variations in motor current consumption parameters to detect and adapt to different tire types during operation. By monitoring changes in electrical characteristics (current draw patterns, torque requirements) rather than requiring pre-programmed tire specifications, the system automatically adjusts its operation to suit different tire types, maintaining versatility while achieving automated consistency and high productivity.
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
The system enables automated, efficient, and safe tire fitting and removal for various tire types, including large and specialized ones, extending equipment lifespan, reducing operator effort, and improving productivity while preventing damage to tires and rims.
Implementation Method 1
un known electric motor, preferably of the three-phase type
Data Source
AI summary
A method is presented for fitting a tyre onto a rim or removing a tyre from a rim in a tyre fitting machine using an appropriate tool. A wheel, a tyre/rim assembly, or the rim alone is caused to rotate about an axis of rotation, and at least one operating parameter of the tyre fitting machine is continuously monitored during the rotation to determine every actual value. Change in or gradient of such actual value is automatically monitored over time and each actual value found and/or the change in the value over time is compared with corresponding predetermined threshold values. The predetermined threshold values define a range of present values and/or change in values delimiting an accepted operating range for the tyre fitting machine, and the machine is controlled to maintain each measured present value and/or change therein over time within the range of corresponding predetermined threshold values.