Tire Ply Synchronization Unit for Automated Cutting
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Solution Overview
Problem
The existing methods for manufacturing pneumatic tires are inefficient due to the manual and time-consuming process of cutting and laying reinforcing plies, which requires precise cutting and can lead to operator fatigue and ergonomic issues, especially when the ply angle is low, resulting in longer cutting lines and non-ergonomic postures.
Innovation Solution
A tire manufacturing device that includes a feed system for a continuous strip, a cutting tool capable of moving transversely to cut the strip, and a synchronization unit that automatically synchronizes the cutting movement with the winding movement, allowing for precise and efficient detachment of the reinforcing ply from the continuous strip without interrupting the winding process, thus reducing cycle time and operator workload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cutting is used to section the continuous strip, then the operator can perform the cutting operation, but the operator must remain present at the workstation throughout the entire installation cycle and adopt non-ergonomic postures for long cutting paths
Solution Approach 1:
The patent replaces the manual mechanical cutting operation with an automated cutting tool that moves along the continuous strip. The cutting tool is driven by a drive mechanism that synchronizes with the drum rotation, eliminating the need for manual operation and allowing the operator to be freed from the workstation during the cutting process.
Solution Approach 2:
The system performs the cutting operation automatically as part of the continuous winding process. The cutting tool is activated and moved along the strip without requiring operator intervention, and the synchronization mechanism automatically coordinates the cutting timing with the drum rotation, making the system self-sufficient during the cutting phase.
2Manufacturing precision
If the cutting line follows the interstitial space between reinforcing wires, then precise cutting is achieved without cutting wires, but the cutting path becomes significantly longer when the ply angle is small
Solution Approach 1:
The patent employs dynamic synchronization between the cutting tool movement and the drum rotation. The cutting tool's position and speed are continuously adjusted based on the actual drum rotation speed and ply angle, allowing the cutting path to adapt to different geometric conditions while maintaining precision along the interstitial spaces between wires.
Solution Approach 2:
The synchronization mechanism uses feedback from the drum rotation to control the cutting tool movement. Sensors detect the drum's rotational position and speed, and this information is fed back to control the cutting tool's positioning and speed, ensuring the cutting line accurately follows the interstitial spaces regardless of the ply angle.
3Productivity
If the cutting operation is performed while the drum rotates continuously, then cycle time is reduced and automation is achieved, but the cutting tool must be precisely synchronized with the winding motion
Solution Approach 1:
The patent merges the cutting operation with the drum rotation process into a single synchronized sequence. The cutting tool's drive mechanism is coupled with the drum's rotation mechanism, combining two operations (cutting and winding) that would traditionally be separate into one integrated process, thereby reducing cycle time while managing complexity through unified control.
Solution Approach 2:
The cutting operation is performed periodically during the drum rotation, with the cutting tool activated at specific phases of the rotation cycle. This periodic action allows the cutting to be synchronized with the winding motion, performing cuts at optimal moments during rotation without requiring continuous complex control throughout the entire cycle.
Data Source
Figure 1A~3B
Figure 4A~6
AI summary
The present invention relates to a tyre building device (1) which comprises a synchronizing unit (30) designed to automatically synchronize a cutting movement (M10) for cutting a continuous strip with a winding movement (M20) for winding the said continuous strip (3) onto a drum (20), so as to drive the cutting tool (10) in movement across the entire width (W3) of the continuous strip (3) so as to detach a reinforcing ply (4) from the continuous strip (3) while the forward front (4F) of the said reinforcing ply (4), formed by the forward front of the continuous strip (3), is engaged on the drum (20) and the continuous strip (3) is being driven with the said reinforcing ply (4) at a non-zero speed in the direction of winding (S20) so as to accompany the on-going winding movement (M20).