Tyre Belt Assembly Transfer for Cylindrical-to-Toroidal Shaping
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Solution Overview
Problem
Existing tire production processes struggle to efficiently control deformations during molding and vulcanization, particularly in high-performance tires, making it difficult to achieve the desired reactivity and driving precision, especially when transitioning from cylindrical to toroidal shaping of belt assemblies.
Innovation Solution
A process and plant design that utilizes a cylindrical forming drum for building the crossed belt structure and transfers it to a toroidal forming drum for depositing the zero degrees belt layer, allowing for automatic joining of belt layers and flexible shaping between cylindrical and toroidal configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a cylindrical forming drum is used for building the crossed belt structure, then the automatic joining of belt layers is enabled, but the deformation control during molding and vulcanization is insufficient
Solution Approach 1:
The patent applies the dynamics principle by making the forming drum shape changeable between cylindrical and toroidal configurations. The forming drum can dynamically adjust its geometry to match different production stages: cylindrical shape during belt layer deposition for automatic joining, and toroidal shape during molding and vulcanization for precise deformation control. This dynamic transformation resolves the contradiction by allowing the same equipment to provide both automation and precision at different phases of the manufacturing process.
2Reliability
If a toroidal forming drum is used for shaping the belt assembly, then the tire reactivity and driving precision are improved, but the manufacturing complexity and space requirements increase
Solution Approach 1:
The patent applies the universality principle by designing a single forming drum that can perform multiple functions: it can be configured in cylindrical shape for belt layer deposition and in toroidal shape for final tire shaping. This multi-functional design eliminates the need for separate forming drums for different production stages, thereby reducing manufacturing complexity and space requirements while maintaining the reliability benefits of toroidal shaping when needed.
Solution Approach 2:
The forming drum's ability to dynamically transform between cylindrical and toroidal shapes allows the system to achieve high reliability through toroidal shaping only when necessary, rather than requiring a dedicated complex toroidal drum for all operations. This reduces overall device complexity while preserving the reliability advantages.
3Ease of manufacture
If traditional cylindrical shaping is used for the belt assembly, then the manufacturing process is simpler, but the tire reactivity and driving precision are reduced
Solution Approach 1:
The patent resolves this contradiction by implementing a dynamic forming drum that starts in cylindrical configuration for simple belt layer deposition, then transforms to toroidal configuration for the molding and vulcanization stages. This allows the process to maintain manufacturing simplicity during initial stages while achieving high tire reactivity through toroidal shaping during critical deformation control phases.
Solution Approach 2:
The forming drum is preliminarily configured in cylindrical shape to simplify the belt layer deposition process, then transformed to toroidal shape in preparation for the molding and vulcanization stages. This preliminary configuration strategy allows the system to ease of manufacture when needed while preparing for high reliability performance in subsequent stages.
Data Source
AI summary
A process and a plant for producing tyres for vehicle wheels are described. Building of a crown structure of the tyre includes building a crossed belt structure on a substantially cylindrical first forming drum, transferring the crossed belt structure from the first forming drum to an annular holding member, positioning a second forming drum in a radially inner position with respect to the annular holding member, transferring the crossed belt structure from the annular holding member to the second forming drum by radially expanding the second forming drum until it is brought into contact with the crossed belt structure so as to toroidally shape the crossed belt structure, and depositing at least one zero degrees belt layer on the second forming drum in a radially outer position with respect to the toroidally-shaped crossed belt structure.