Toroid Insertion Assembly for Safe Special Vehicle Wheel Handling

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Solution Overview

Problem

Existing machines for inserting and removing toroids from special vehicle wheels are complex, time-consuming, and pose safety risks to operators due to manual intervention and inaccurate operation, often causing tire and toroid damage.

Innovation Solution

A machine with gripping and retaining means and an insertion/removal assembly that includes deformation means, allowing precise and repeatable toroid insertion and removal without manual intervention, reducing stress on the tire and toroid, and enhancing safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual intervention is used for toroid insertion/removal, then operational flexibility is maintained, but safety risks increase and operation time increases

Engineering Contradiction:

Improveoperational flexibilityVSAvoidsafety

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The machine performs toroid insertion and removal operations autonomously through automated deformation means and gripping spindles, eliminating the need for manual intervention. The system self-regulates the deformation process and toroid extraction/insertion sequence, achieving both safety and operational efficiency simultaneously.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with an automated mechanical system comprising hydraulic actuators, deformation means, and controlled gripping spindles. This substitution eliminates human exposure to dangerous forces while maintaining precise control over the insertion/removal process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If crude and inaccurate methodology is used for toroid insertion/removal, then device complexity is reduced, but manufacturing precision deteriorates and damage risk increases

Engineering Contradiction:

Improvemethodology simplicityVSAvoidinsertion/removal precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The machine incorporates control systems that monitor and regulate the deformation process, gripping force, and toroid movement. This feedback mechanism ensures precise control over insertion and removal operations, preventing damage while maintaining manageable system complexity through automated regulation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The deformation means are activated in advance to pre-shape the toroid into an elongated-ellipsoidal conformation before insertion. This preliminary deformation action facilitates smooth insertion and removal while protecting the tire and toroid from damage during the operation.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If numerous manual interventions are required, then ease of manufacture is improved, but productivity decreases and operation time increases

Engineering Contradiction:

Improvemachine simplicityVSAvoidbusiness production output

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Multiple manual operations (deformation, gripping, insertion, removal) are merged into a single automated machine system. The integration of deformation means, gripping spindles, and control systems into one unified apparatus performs all operations sequentially without manual intervention, dramatically increasing productivity while maintaining reasonable manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The machine executes toroid insertion and removal operations continuously without interruption or manual reset. The automated system maintains continuous operation through coordinated action of deformation means and gripping spindles, eliminating downtime associated with manual interventions and maximizing production output.

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If high force is applied to pull toroid during removal, then removal efficiency is improved, but harmful factors increase due to ejection risk

Engineering Contradiction:

Improveremoval efficiencyVSAvoidsafety hazard from toroid ejection

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The gripping spindles and control system are designed to regulate the force applied during toroid extraction. By controlling the pulling force and speed, the system prevents sudden toroid ejection while maintaining efficient removal, thereby eliminating safety hazards associated with high-force manual operations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

Manual force application is replaced with a controlled mechanical system that regulates extraction force through hydraulic actuators and feedback control. This substitution maintains removal efficiency while eliminating the uncontrolled high forces that cause toroid ejection and safety hazards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The machine ensures safe, precise, and efficient toroid insertion and removal, reducing operation time and preventing tire and toroid damage, thereby increasing production output.

Implementation Method 1

deformation means of the toroid, e.g., of the type of hydraulic actuators, which are inserted by one or more operators inside the toroid itself for the purpose of giving the latter an elongated-ellipsoidal conformation that facilitates the insertion and removal thereof

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

one or more tire gripping spindles, configured to block the tire in place

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

the insertion/removal assembly grabs the latter and, tugging it vigorously, pulls it repeatedly to itself; in this way, the toroid progressively comes out of the tire and is, finally, extracted from the same

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 4

the insertion/removal assembly is operated to grasp the tire, dilate the central hole thereof and forcefully push the toroid within the latter, gradually introducing it into the tire

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentEP4389470B1Machine for the insertion/removal of toroids into/from wheels of special vehicles

Publication Date: 2025.07.09 GIULIANO GROUP

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AI summary

The machine (1) for the insertion/removal of toroids into/from wheels of special vehicles comprises: - at least one base frame (2) for resting on the ground; - gripping and retaining means (3) of a reinforced tire (P) associated with the base frame (2); - an insertion/removal assembly (6) of a toroid (T) into/from the reinforced tire (P); wherein the insertion/removal assembly (6) comprises deformation means (7) of the toroid (T) and close/away movement means (8) of the deformation means (7) for moving them close to/away from the gripping and retaining means (3) along a direction of close/away movement (D), wherein the deformation means (7) are extendable/compressible along a first vertical axis (A1) and a second horizontal axis (A2) between a configuration of vertical extension, an intermediate configuration and a configuration of horizontal extension and wherein the deformation means (7) are rotatable around the first axis (A1).