Tyre Bead Core Positioning via Partial Air Chamber Inflation
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Solution Overview
Problem
Conventional tire manufacturing processes struggle to maintain the desired concentricity between the bead core and the forming support during the turning up of the carcass ply, as the bead core is subject to radial stresses that can cause it to move out of position, leading to inconsistent tire quality.
Innovation Solution
The process involves partial inflation of an air chamber while the bead core is retained by a positioning device, allowing the first part of the turning up to be completed with the bead core in contact, followed by complete inflation to ensure the bead core adheres to the carcass ply, preventing movement during the remaining turning up process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bead core is released early during the turning up process to allow carcass ply to turn up freely, then the turning up operation becomes simpler and faster, but the bead core moves out of position due to radial stresses, losing concentricity with the forming support
Solution Approach 1:
The air chamber is partially inflated before the bead core is released, creating preliminary adhesive forces between the bead core and carcass ply. This preliminary action ensures that when the bead core is released, the adhesive force is already sufficient to maintain concentricity during the turning up operation, allowing both early release for productivity and precision maintenance
Solution Approach 2:
The invention changes the parameter of air pressure in the air chamber from a binary state (inflated/not inflated) to a graduated state (partial inflation to complete inflation). By controlling the degree of inflation, the system can provide just enough adhesive force to maintain bead core position during turning up while allowing the bead core to be released early for efficient production
2Manufacturing precision
If the air chamber is fully inflated immediately to ensure bead core adhesion, then concentricity is maintained, but the turning up process takes longer and requires higher forces
Solution Approach 1:
The air chamber is partially inflated rather than fully inflated immediately. This partial action provides sufficient adhesive force to maintain bead core concentricity during the critical turning up phase, while avoiding the excessive forces and extended time that would result from complete inflation from the start
3Manufacturing precision
If the bead core is held in contact position throughout the entire turning up process, then concentricity is perfectly maintained, but the positioning device must withstand high radial stresses and the process becomes more complex
Solution Approach 1:
The invention replaces the mechanical positioning device with a pneumatic system (air chamber). Instead of relying on mechanical forces from a positioning device to hold the bead core, the system uses pneumatic pressure to create adhesive forces between the bead core and carcass ply, maintaining concentricity without requiring the positioning device to withstand high radial stresses throughout the entire turning up process
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 method ensures the bead core remains in the desired position, maintaining concentricity and improving tire quality by enhancing the anchoring between the bead core and the carcass ply, reducing the risk of movement and ensuring consistent tire performance.
Implementation Method 1
partial inflation of an air chamber while the bead core is retained by a positioning device, allowing the first part of the turning up to be completed with the bead core in contact
Implementation Method 2
complete inflation to ensure the bead core adheres to the carcass ply, preventing movement during the remaining turning up process
Data Source
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AI summary
A process for manufacturing a tyre for vehicle wheels comprises: laying at least one carcass ply (2) on a forming support (50) having a rotation axis (X-X); bringing an annular anchoring structure (10) in contact position with an end edge (2a) of the carcass ply (2); holding, through a positioning device (118), the annular anchoring structure (10) in contact position with said end edge (2a) while an air chamber (141) is partially inflated to carry out a first part of turning up said end edge (2a) around the annular anchoring structure (10); moving the positioning device (118) away from the annular anchoring structure (10); completing the inflation of the air chamber (141) to carry out the remaining part of turning up said end edge (2a) around the annular anchoring structure (10), so as to form a turned up end portion of the carcass ply (2) including the annular anchoring structure (10).