Tyre Crown Structure Building Process with Parallel Drum Operations
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Solution Overview
Problem
The manufacturing process for ultra-high performance tires, particularly for sports car races, faces challenges in productivity due to the lengthy times required for turning-up belt layers and spiralling tread bands, which also necessitates complex and bulky equipment, making it difficult to achieve both high-quality standards and efficient production.
Innovation Solution
A process and plant design that allows for simultaneous execution of turning-up belt layers and spiralling tread band operations, utilizing an auxiliary drum for forming belt structures and a service drum for tread band formation, with robotized arms for efficient transfer and positioning, enabling the division of crown structure processing without compromising productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If turning-up belt layers and spiralling tread bands are performed sequentially using complex equipment, then manufacturing precision is improved, but productivity deteriorates due to lengthy processing times
Solution Approach 1:
The patent divides the crown structure building process into two independent parallel operations: (1) turning-up operations on an auxiliary drum for belt layers, and (2) spiralling operations on a service drum for tread bands. This segmentation allows both operations to occur simultaneously without interfering with each other, thereby maintaining precision while doubling productivity.
Solution Approach 2:
The patent introduces a temporal dimension by executing turning-up and spiralling operations simultaneously in parallel rather than sequentially. The auxiliary drum and service drum operate in different spatial zones but are coordinated in time, transforming the process from a single-dimensional sequential operation to a multi-dimensional parallel operation.
2Productivity
If turning-up and spiralling operations are performed simultaneously on separate drums, then productivity is improved, but device complexity increases
Solution Approach 1:
The auxiliary drum and service drum are designed as multi-functional components that can independently perform their respective operations (turning-up and spiralling) while being part of a unified crown structure building system. This universality allows the system to handle multiple operations without requiring entirely separate dedicated equipment for each function.
Solution Approach 2:
The patent introduces a control system as an intermediary that coordinates the simultaneous operation of the auxiliary drum and service drum. This intermediary manages the synchronization and coordination between the two drums, reducing the overall system complexity by providing centralized control rather than requiring complex point-to-point integration between all components.
3Manufacturing precision
If complex bulky equipment is used for turning-up and spiralling operations, then manufacturing precision is improved, but ease of manufacture deteriorates due to integration difficulties
Solution Approach 1:
The patent segments the complex equipment into two independent modular units: an auxiliary drum system for turning-up operations and a service drum system for spiralling operations. Each module can be manufactured, tested, and maintained independently, significantly improving ease of manufacture while maintaining the precision benefits of specialized equipment.
Solution Approach 2:
The system incorporates dynamic positioning and coordination mechanisms that allow the auxiliary drum and service drum to operate independently yet cooperatively. This dynamic design enables flexible integration into existing production lines and simplifies manufacturing by allowing each drum to be optimized for its specific function rather than requiring a monolithic complex structure.
Data Source
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AI summary
During tyre building, a crown structure (7) is built through the actions of: forming at least one belt layer (8a, 8b) on an auxiliary drum (22) for manufacturing a belt structure (8) at least partly; turning up axially opposite side flaps (10) of said at least one belt layer (8a, 8b) formed on the auxiliary drum (22); transferring the belt structure (8) from the auxiliary drum (22) to at least one service drum (31); forming a tread band (9) by winding of at least one continuous elongated element of elastomeric material into coils disposed mutually adjacent around the belt structure (8) carried by the service drum (31).