Tire Winding Tension Control via Compensation Loop
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Solution Overview
Problem
Existing methods for controlling the winding tension of circumferential reinforcements in tire manufacturing face challenges due to inertia and small instantaneous variations in the radius of windings, leading to significant variations in actual winding voltage.
Innovation Solution
A device comprising a motorized pulley connected to an electromechanical machine, a compensation loop with a movable pulley and spring, and sensors for monitoring tension and speed, which allows for precise control of winding tension by adjusting the length of the compensation loop and motor speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tension control methods (electromechanical machine with direct roller connection) are used, then tension can be controlled, but significant variations in actual winding voltage occur due to inertia and radius variations
Solution Approach 1:
The patent introduces a compensation loop as an intermediary element between the drive pulley and the winding drum. This loop acts as a buffer that decouples the direct connection, allowing the system to absorb tension variations caused by inertia and radius changes. The compensation loop includes a movable pulley and spring mechanism that physically mediates the tension transmission, smoothing out instantaneous variations before they reach the reinforcement being wound.
Solution Approach 2:
The compensation loop is designed to anticipate and cushion tension variations before they affect the winding process. The spring element in the compensation loop pre-absorbs tension fluctuations, providing a cushioning effect that prevents sharp variations in winding voltage. This beforehand cushioning approach proactively mitigates the harmful effects of inertia and radius variations.
2Productivity
If high winding speed is used to increase productivity, then manufacturing efficiency improves, but tension control precision deteriorates due to increased inertia effects
Solution Approach 1:
The compensation loop serves as a speed-independent intermediary that maintains tension stability regardless of winding speed. By placing the movable pulley and spring mechanism in the tension path, the system creates a buffer zone that filters out high-speed inertia effects. This allows high productivity to be achieved without sacrificing tension control precision, as the compensation loop actively mediates the inertial forces generated at higher speeds.
3Manufacturing precision
If variable tension requirements are implemented to meet different tire zone specifications, then product quality improves, but system complexity increases
Solution Approach 1:
The patent implements dynamic tension control by making the compensation loop movable rather than fixed. The movable pulley can adjust its position along the loop, and the spring mechanism can vary its compression, allowing the system to dynamically adapt tension levels. This dynamic capability enables variable tension requirements for different tire zones without requiring multiple separate control systems, thus improving product quality while managing complexity through a single adaptable mechanism.
Solution Approach 2:
The system changes the physical parameters of the compensation loop (position of movable pulley, spring compression level) to achieve different tension levels. By varying these parameters, the system can meet different tension requirements for various tire zones. This parameter-based control approach is simpler than implementing entirely different control systems for each zone, as it uses a single mechanism with adjustable parameters.
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
This solution reduces undesirable variations in winding voltage, enabling accurate and stable tension control during tire manufacturing, even at high speeds and variable tension requirements.
Implementation Method 1
a compensation loop (5) comprising a movable pulley (6) pushed by a spring (7)
Implementation Method 2
the device further comprises a strain gauge (11) delivering a signal representative of the effective tension of the yarn
Data Source
Figure 1
Figure 2
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AI summary
The invention concerns in particular a method for making a tyre comprising a circumferential reinforcement, said method including a step of winding a wire (2) around a form (1), the strain of the wire being monitored during the winding process, wherein the monitoring of the strain is exerted via the length of a compensation loop (5) subjected to the action of a spring (7).