Automated Splicing Roller for Continuous Tire Winding
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Solution Overview
Problem
Existing tire manufacturing methods require frequent manual intervention to switch between spool bandages, leading to machine downtimes and inefficient splicing of material strip ends, which affects production continuity and quality.
Innovation Solution
A method involving continuous winding, automated spool bandage splicing using a splicing unit with a splicing roller and adjustable components to ensure constant contact pressure and precise alignment of material strip ends, allowing for seamless transition between spool bandages without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual splicing of material strip ends is used, then the splicing process can be completed, but machine downtime increases and production efficiency decreases
Solution Approach 1:
The splicing system performs splicing operations automatically without manual intervention. The splicing device moves along the material strip, automatically positioning, aligning, and joining strip ends, allowing the system to service itself during the winding process.
Solution Approach 2:
The splicing operation is integrated into the continuous winding process. The splicing device operates during the winding operation, maintaining continuous production flow without stopping the machine, thus eliminating idle time and keeping the useful action continuous.
2Strength
If automated splicing with constant contact pressure is used, then splice connection strength improves, but device complexity increases
Solution Approach 1:
The splicing device is divided into functional modules: a splicing head with contact pressure application mechanism, a positioning system, and a movement mechanism. Each module performs a specific function, making the overall complex system manageable and maintainable while achieving high splice strength.
Solution Approach 2:
The system performs preliminary alignment and positioning of material strip ends before applying contact pressure for splicing. The strip ends are pre-positioned in correct alignment, and the splicing device is prepared in advance, ensuring strong connections without requiring overly complex real-time adjustment mechanisms.
3Manufacturing precision
If precise alignment of material strip ends is implemented, then splicing quality improves, but the complexity of positioning systems increases
Solution Approach 1:
Complex mechanical positioning systems are replaced with simpler guidance mechanisms. The splicing device follows a predetermined path along the material strip, using geometric constraints and guide rails to achieve precise alignment without requiring complex sensors or active control systems.
Solution Approach 2:
The positioning system maintains constant geometric relationships between components throughout the splicing process. By designing the mechanism so that all critical points remain in optimal positions relative to each other during movement, precise alignment is achieved through geometric invariance rather than complex active positioning.
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
Significantly reduces machine downtimes and enhances the strength and quality of the splice connection between material strip ends, enabling continuous tire production with minimal operator intervention and adaptability to different material requirements.
Implementation Method 1
The splicing roll is rolled over the overlapping material strip ends with constant contact pressure so that the two material strip ends are firmly spliced together
Data Source
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Figure 5
AI summary
The invention relates to a vehicle tire manufacturing process comprising the following steps: a) Continuous winding of a first winding band (16) to produce a tire blank, b) Stopping the winding process and fixing the first winding band (16) with a material guide (5), c) Cutting the first winding band (16) in the rear region of the material guide (5) with a cutting device (7), d) Arranging the rear material strip end (20) of the first winding band (16) in a groove (13) of the material guide (5), e) Positioning the material guide (5) with the rear material strip end (20) of the first winding band (16) below a splicing unit (17), wherein the front material strip end (21) of a second winding band (23) is already inserted in the splicing unit (17), f) Joining the front material strip end (21) of the second winding band (23) with the rear material strip end (20) of the first coil bandage (16),wherein the front and rear material strip ends (20, 21) lie on top of each other within a predetermined length range and a splicing roller (1) arranged on the splicing unit (17) joins the material strip ends (20, 21) together.