Tyre Building Plant with Bypass Workstations for Parallel Production
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Solution Overview
Problem
Existing tyre building lines have limited technological and operational flexibility, as they can only produce tyres of different sizes but not different models, and are prone to production interruptions due to workstation failures or unavailability of resources, requiring downtime for conversion or repair.
Innovation Solution
A process and plant design that uses different elementary semi-finished products at each workstation to build carcass structures simultaneously, with a by-pass device allowing tyres to bypass certain workstations independently, enabling parallel production of multiple tyre models and maintaining production even if one workstation fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single workstation is used to build carcass structures sequentially, then device complexity is reduced, but productivity decreases and operational flexibility is limited
Solution Approach 1:
The patent divides the tyre building process into multiple independent workstations (first workstation, second workstation, third workstation), each capable of building complete carcass structures independently. This segmentation allows parallel production of different tyre models, increasing overall productivity while maintaining manageable complexity at each individual workstation.
Solution Approach 2:
Each workstation is designed as a universal unit capable of building different types of carcass structures (radial, diagonal, mixed ply patterns) using different elementary semi-finished products. This multi-functionality enables the production line to manufacture various tyre models without reconfiguring the entire system, enhancing both productivity and operational flexibility.
2Adaptability or versatility
If workstations are configured for specific tyre models, then manufacturing precision is improved, but adaptability decreases and conversion time increases
Solution Approach 1:
The patent implements local quality by providing each workstation with specific feeding units configured for particular elementary semi-finished products (radial plies, diagonal plies, belt strips). Each workstation maintains optimized local configurations for building specific carcass patterns while the overall system remains adaptable through the ability to select which workstations process which tyre models based on production requirements.
3Reliability
If a linear production sequence is used, then device complexity is minimized, but reliability decreases due to production interruptions from workstation failures
Solution Approach 1:
The production line is segmented into independent workstations that can operate autonomously. If one workstation fails or requires maintenance, the others continue producing carcass structures, ensuring production continuity. This segmentation isolates failures to specific stations rather than halting the entire production line.
Solution Approach 2:
The patent introduces dynamic routing through by-pass devices that allow forming supports to skip certain workstations based on real-time conditions. This dynamic adaptability enables the system to maintain production flow even when workstations are unavailable, enhancing reliability without requiring a rigid linear sequence.
4Productivity
If parallel production of multiple tyre models is implemented, then productivity increases, but device complexity and coordination requirements increase
Solution Approach 1:
The patent segments the production system into independent workstations, each with its own feeding units and forming support handling. This segmentation allows parallel production of multiple tyre models without requiring complex inter-workstation coordination, as each station operates autonomously while contributing to the overall production output.
Data Source
AI summary
A plant for building different models of green tyres for vehicle wheels, including a plurality of workstations using elementary semi-finished products is described. A first carcass structure of a first model of tyre is built on a first forming support, in a first workstation, the first carcass structure including at least one first carcass ply obtained from a first elementary semi-finished product, and at least one first pair of annular reinforcing inserts. The first forming support is delivered to a bypass device to go beyond at least one second workstation without transiting through it.