Tyre Building Plant Automatic Visual Control System
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Solution Overview
Problem
Current tyre production processes result in high discard rates due to assumptions about initial components and machinery operating within pre-established tolerances, leading to increased production costs and prolonged inspection times, which could be improved by implementing a more accurate inspection method.
Innovation Solution
A method and plant for building tyres that involves predisposing initial components, manufacturing semi-finished products, building, and curing tyres while detecting and controlling specific parameters associated with quality indices, allowing for immediate feedback and differentiation between acceptable and discard levels, thereby optimizing quality and reducing discards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to check tyre quality, then inspection can be performed, but inspection time is prolonged and discard rates remain high
Solution Approach 1:
The patent replaces manual visual inspection with an automatic visual control system using cameras and image processing technology. The system captures images of the tyre, processes them through a control unit, and automatically determines quality parameters, eliminating the need for manual inspection while improving both speed and consistency.
Solution Approach 2:
The system creates visual copies (images) of the tyre and its components, processing these digital representations instead of physically examining the actual tyre. This allows for rapid, repeated inspection without contact or time loss, as the same images can be analyzed multiple times and from different perspectives.
2Productivity
If pre-established tolerances are assumed for initial components and machinery, then production can proceed, but discard rates increase due to actual variations
Solution Approach 1:
The system implements continuous feedback by automatically measuring actual parameters of initial components and machinery during production. The control unit compares these measurements with tolerance specifications and provides real-time feedback, allowing for immediate adjustments before defects occur, thus maintaining both productivity and quality consistency.
Solution Approach 2:
The system performs preliminary inspection and measurement of initial components before they are fully integrated into the tyre manufacturing process. By detecting potential deviations early in the production sequence, the system can take corrective action beforehand, preventing the creation of defective tyres and reducing discard rates.
3Reliability
If high discard rates occur at the end of production, then quality control is performed, but production costs increase
Solution Approach 1:
The system performs quality control measurements at multiple early stages of production rather than only at the final inspection stage. By detecting and addressing quality issues in initial components and during the manufacturing process, the system prevents the production of defective tyres, eliminating the waste of materials and energy associated with high discard rates at the end of production.
Data Source
AI summary
A plant (2) for building tyres comprises a system for managing initial components (3); a system for managing the manufacturing of semi-finished products (4) starting from one or more initial components; a system for managing the building of a green tyre (5) starting from one or more semi-finished products; a system for managing the curing of said green tyre (6). The logical set of a control unit (8) for the plant (2) and/or of one or more from among control units (8a-8e) for the management systems (3-6) and/or of a automatic visual control system (7) is programmed for controlling at least two parameters, assigning to each of these a quality index (I), discarding a tyre being processed when a quality index (I) corresponding to said discard level (5) is assigned to at least one of said parameters and feedbacking the control result of at least one parameter in order to verify the quality index (I) of the parameters.