Tyre Extrusion Conveyor Speed Control
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Solution Overview
Problem
Existing tire production processes are inefficient, unreliable, and bulky, with complex apparatuses that require frequent servicing and are inflexible, often resulting in material adhesion issues and stress on the continuous elongated element during deformation.
Innovation Solution
A process and apparatus that eliminate calendering by directly feeding the continuous elongated element onto a moving conveyor, where it is deformed in two stages to achieve the desired cross-section, using an extruder with a linear delivery speed and a conveyor with a linear advancing speed, and a forming support rotating at a peripheral speed different from the delivery speed to simplify the apparatus and reduce bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a calender is used to deform the continuous elongated element, then the element can be shaped to the desired cross-section, but the apparatus becomes bulky, complex, and requires frequent servicing
Solution Approach 1:
The patent removes the calender from the apparatus entirely, extracting the problematic component that caused bulkiness and complexity. Instead of using a calender to deform the continuous elongated element, the invention feeds the element directly onto a rotating forming support where deformation occurs through the interaction with the support's surface and rotation, achieving the desired cross-section without the bulky calendering mechanism
Solution Approach 2:
The patent replaces the mechanical calendering system with a rotational forming system. The continuous elongated element is deformed by being fed onto a rotating forming support, where the rotation and surface interaction accomplish the shaping function that previously required a complex calender mechanism, thereby simplifying the overall apparatus structure
2Productivity
If the continuous elongated element is deformed quickly, then production speed increases, but stress and tension on the material increase causing adhesion issues
Solution Approach 1:
The patent employs dynamic control of the forming support's rotation speed, allowing the system to adapt to the material's deformation requirements. The forming support rotates at a speed that balances production efficiency with material integrity, preventing excessive stress and tension that would cause adhesion issues while maintaining high productivity
Solution Approach 2:
The patent changes the operational parameters of the forming process by controlling the rotation speed of the forming support and the feeding rate of the continuous elongated element. These parameter adjustments ensure that deformation occurs at optimal rates that maintain material adhesion while achieving high production speeds
3Adaptability or versatility
If the apparatus is made more flexible to handle different sections, then adaptability improves, but device complexity increases
Solution Approach 1:
The forming support is designed as a universal component that can accommodate different cross-section requirements through simple parameter adjustments rather than physical modifications. The same forming support structure handles various sections by varying rotation speed and feeding rate, providing adaptability without increasing device complexity
Solution Approach 2:
The patent achieves adaptability for different cross-sections by changing operational parameters (rotation speed, feeding rate) rather than modifying the apparatus structure. This allows the same simplified apparatus to produce various sections, maintaining flexibility while avoiding the complexity that would arise from multiple specialized components
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 approach simplifies the apparatus structure, reduces bulkiness and manufacturing costs, increases production speed and flexibility, and improves tire quality by reducing stress and tension on the material, allowing for precise sectioning without the need for frequent calender changes.
Implementation Method 1
delivering a continuous elongated element of elastomeric material produced by an extruder
Implementation Method 2
wherein the peripheral speed is different from the linear delivery speed, so as to deform the continuous elongated element
Implementation Method 3
applying the continuous elongated element into coils wound up on the forming support... wherein the peripheral speed is different from the linear delivery speed, so as to deform the continuous elongated element
Data Source
AI summary
A continuous elongated element of elastomeric material is produced through an extruder at a linear delivery speed and directly fed onto a moving surface of a conveyor without interposition of other devices. The continuous elongated element is advanced on the moving surface along a predetermined direction and at a linear advancing speed different from the linear delivery speed until a proximal end of the conveyor. Subsequently, the continuous elongated element is applied onto a forming support which rotates relative to the proximal end of the conveyor at a peripheral speed different from the linear delivery speed, so as to deform the continuous elongated element and apply it in the form of wound coils onto the forming support in order to form a component of elastomeric material of a tyre.