Tire Ply Front Alignment Correction Using Sensor-Based Measurement
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Solution Overview
Problem
The existing methods for assembling reinforcing plies in tire manufacturing face challenges in accurately aligning and correcting the geometry of the plies due to their tendency to deform under stress, particularly in ensuring the front and rear edges butt perfectly within tolerance limits during the assembly process.
Innovation Solution
A method involving central and lateral measurement lines to determine length corrections, allowing for precise adjustment of the throwing mat and receiving surface rotation to ensure the plies align within defined tolerance zones, using sensors to detect and correct deviations, and calculating a correction value to achieve optimal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the front of the ply is adjusted using conventional alignment devices, then the alignment of the ply front is improved, but the complexity of the assembly device increases and the alignment precision deteriorates due to the inability to correct curved fronts
Solution Approach 1:
The invention changes the measurement parameters by using multiple measurement lines (central and lateral) instead of a single line, and uses sensors to detect positional parameters of the ply front. This allows for comprehensive detection of front geometry deviations without requiring complex mechanical adjustment devices
Solution Approach 2:
The invention replaces complex mechanical alignment devices with a sensor-based detection system and computational correction approach. Sensors detect the ply front position, and a microprocessor calculates correction values, substituting mechanical complexity with electronic sensing and computational processing
2Manufacturing precision
If multiple measurement lines are used to detect ply front geometry, then the alignment precision is improved, but the measurement and detection difficulty increases
Solution Approach 1:
The invention segments the measurement task by dividing the ply front detection into multiple independent measurement lines (central and lateral). Each line has its own sensors that independently measure positional deviations, simplifying the detection process while comprehensively capturing the entire front geometry
Solution Approach 2:
The measurement system is designed to be universal by using the same sensor type and measurement principle across all measurement lines. This multi-functional approach allows the system to handle different ply front geometries and deformation patterns using a unified measurement methodology
3Manufacturing precision
If the throwing mat longitudinal displacement is adjusted to correct length variations, then the alignment precision is improved, but the device complexity and control system complexity increase
Solution Approach 1:
The invention implements a feedback control system where sensors continuously detect the ply front position on the throwing mat, the microprocessor calculates the deviation from the target position, and the throwing mat displacement is adjusted accordingly. This closed-loop feedback enables precise alignment while using a relatively simple control architecture
Solution Approach 2:
The invention introduces a microprocessor as an intermediary between the sensor detection system and the throwing mat drive system. The microprocessor processes measurement data, calculates correction values, and generates control signals, simplifying the overall control system while achieving precise alignment
4Device complexity
If conventional single-point measurement is used, then the device complexity is reduced, but the alignment precision deteriorates due to inability to account for geometric variations across the ply front
Solution Approach 1:
The invention applies local quality measurement by placing sensors at specific locations (central and lateral measurement lines) to detect local deviations in the ply front geometry. This localized measurement approach captures the varying deformation characteristics across different parts of the ply front, enabling precise correction
Data Source
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AI summary
The invention relates to a method for laying a reinforcing layer (1) on a receiving surface having an overall cylindrical shape, said layer including a leading edge (F) and a trailing edge (R) which, after complete rotation of the receiving surface, are intended to be arranged end-to-end between a maximum tolerance (Ts) and a minimum tolerance (Ti) measured relative to a reference front, during which: a layer of a given theoretical length is produced, the length separating the leading edge from the trailing edge is determined along a central measurement line (Lm), and along at least two lateral measurement lines (La, Lb) arranged transversely on either side of the central measurement line, said layer is deposited on a launching conveyor, the length correction (COR) to be made is determined at the central measurement line so that the two points (Af, Mm) of a front (F) of the layer, which correspond to the measured lengths the values of which are most distant from one another (Lmax, Lmin, La, Lm), are placed equidistant from the middle reference line situated at a distance (Tc) from the reference front, the value of which corresponds to the mean value of the maximum tolerance and the minimum tolerance, the leading edge of the layer is conveyed onto the receiving surface (6), and the remainder of the layer is deposited by adjusting the ratio of the longitudinal movement of the launching conveyor to the circumferential movement of the receiving surface, whereby the length laid down at the central line is equal to the length measured at said central measurement line (Lm) corrected by said length correction (COR).