Tire Production Handling Devices Simultaneous Movement Control
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Solution Overview
Problem
The existing tire production methods experience significant delays due to dead times and safety intervals caused by data transmission and processing times, leading to increased cycle times and reduced efficiency in tire manufacturing processes.
Innovation Solution
Implementing a control method where handling devices are driven simultaneously during part of their movement sequence, with a master axis coordinating sub-processes and local controllers to minimize communication times and avoid dead times, allowing for continuous and coordinated movements without waiting periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sequential process steps with safety intervals are used, then reliability and safety are improved, but productivity deteriorates due to increased cycle times
Solution Approach 1:
The patent implements continuous movement of the green tire through overlapping process steps, eliminating idle waiting periods between sequential operations. Multiple handling devices operate simultaneously to maintain continuous motion, thereby improving productivity while maintaining safety through coordinated control
Solution Approach 2:
The control system pre-coordinates multiple handling devices and process steps in advance, preparing subsequent actions while previous operations are still in progress. This allows safety intervals to be minimized while maintaining reliable operation through pre-planned coordinated movements
2Productivity
If data transmission and processing times are reduced, then productivity is improved, but measurement precision may deteriorate
Solution Approach 1:
The control system is divided into hierarchical levels with distributed intelligence. Local controllers handle real-time actuator control with minimal communication overhead, while higher-level controllers manage coordination. This segmentation allows fast local responses without sacrificing overall system precision
Solution Approach 2:
The system implements real-time feedback loops at multiple levels, with actuators reporting status and position information continuously. This enables precise control decisions to be made with minimal delay, maintaining measurement precision while reducing overall communication cycle times
3Productivity
If handling devices are moved simultaneously, then productivity is improved by reducing dead times, but device complexity increases
Solution Approach 1:
Multiple handling devices are merged into a coordinated system under unified control, where devices that would normally operate sequentially now work simultaneously. The control system integrates positioning and movement coordination to manage the increased complexity while achieving faster overall processing
Data Source
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AI summary
The method involves subdividing a production process into two temporal consecutive process steps. A green tire loaded during individual steps and/or tool used in one of the steps and/or material is moved during the production. The movement of the green tire and/or tool and/or material associated to one of the steps and partially overlapped with the movement of the green tire and/or tool and/or material associated to other process step is executed. Subprocesses are temporally coordinated by a control axis (4) i.e. virtual axis (9). Servomotors are controlled by the control axis. An independent claim is also included for a device for controlling production of a tire.