Tire Ply Edge Joining via Image-Based Position Correction
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Solution Overview
Problem
The challenge in manufacturing tire ply materials lies in accurately connecting edges of cut pieces, which are prone to random curling deformation due to untwisting of tire cords and residual stress, making precise positional matching difficult and requiring manual correction.
Innovation Solution
An apparatus comprising an image capture device, a position presuming device, and a holding and positioning device that captures images of the cut pieces' edges, processes the data to determine exact vertex positions, and moves the cut pieces to ensure accurate alignment and connection, even correcting for curling deformations, using robotic arms with attracting, lifting, and clamping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual correction of deformation is performed before joint operation, then positional matching accuracy is improved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent replaces the manual mechanical correction system with an automated image processing and robotic positioning system. The image capture device captures deformation information, the position presuming device calculates correction amounts through image processing, and the holding and positioning device executes automated positioning, eliminating manual intervention entirely while maintaining high precision.
Solution Approach 2:
The system enables self-service by allowing the apparatus to automatically detect, measure, and correct its own positioning errors without external manual intervention. The image capture device detects edge deformations, the position presuming device calculates the necessary corrections, and the holding and positioning device executes the correction automatically.
2Productivity
If automated positioning system is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The automated positioning system is segmented into three independent functional modules: the image capture device for detection, the position presuming device for calculation, and the holding and positioning device for execution. Each module performs a specific function, making the overall complex system manageable through functional decomposition and independent optimization.
Solution Approach 2:
The position presuming device serves as an intermediary that bridges the image capture device and the holding and positioning device. It processes image data to calculate edge positions and generates positioning commands, acting as an intelligent mediator that translates detection information into actionable positioning instructions.
3Stability of the object's composition
If zipper joint method is used, then uniformity of tire ply material is improved, but manufacturing precision requirements increase due to narrow bonded area
Solution Approach 1:
The system implements feedback by using the image capture device to continuously monitor the actual positions of cut piece edges during the joining process. The position presuming device compares detected positions with target positions and generates real-time correction commands for the holding and positioning device, ensuring accurate alignment despite the narrow bonded area requirements of zipper joints.
Solution Approach 2:
The system performs preliminary action by capturing images and calculating edge positions before the actual joining operation. The holding and positioning device pre-adjusts the positions of cut pieces based on predicted edge locations, ensuring that when the zipper joint bonding occurs, the edges are already precisely aligned within the narrow bonded area.
Data Source
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AI summary
An apparatus (1) for manufacturing a lengthy tire ply material (10) as numbers of cut pieces (13) connected in series in a conveyed direction by successively joining the rear edge of a cut piece conveyed ahead and the front edge of a next cut piece. The apparatus comprises: an image capture device (2) capturing images of the cut pieces and outputting image data; a position presuming device (3) processing the image data and presuming the exact positions of the rear and front edges even if the edges are deformed by curling and outputting the positional data; and a holding and positioning device (4) holding and moving the next cut piece to a joint position according to the positional data, therefore, the edges are connected with accuracy and a nondefective uniform tire ply material (10) can be manufactured with a high percent yield.