Tyre Finishing Station Dual Auxiliary Drum Synchronization
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Solution Overview
Problem
Conventional tyre manufacturing processes face a productivity mismatch between the building station for carcass structures and the finishing station for belt and tread band assembly, leading to extended cycle times and reduced overall efficiency.
Innovation Solution
The method involves using two auxiliary drums in the finishing station to simultaneously perform cyclic production steps and drum positioning, allowing for concurrent assembly of the carcass structure and tread band by winding coils of continuous elastomeric material at different working positions, thereby synchronizing the productivity of both stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-station tyre manufacturing processes are used, then the process structure is simple, but the productivity is reduced due to productivity mismatch between building station and finishing station
Solution Approach 1:
The finishing station is divided into multiple working positions (first working position for belt structure assembly, second working position for tread band assembly, picking position for sleeve transfer) that operate simultaneously on different auxiliary drums. This segmentation allows parallel processing of different tyre components, resolving the productivity mismatch between building and finishing stations while maintaining manageable complexity through functional decomposition.
Solution Approach 2:
The invention transitions from a sequential single-position process to a multi-position spatial arrangement where multiple auxiliary drums are positioned at different locations (first working position, second working position, picking position) around the building station. This spatial dimensionality change enables simultaneous operations across different locations, dramatically improving overall productivity without excessive complexity increase.
2Loss of time
If conventional sequential manufacturing steps are used, then the process control is simple, but the cycle time is extended due to productivity mismatch
Solution Approach 1:
The multi-position finishing station enables continuous useful action by having multiple auxiliary drums operating simultaneously at different working positions. While one drum is being assembled, another is being transferred, and a third is ready for the next cycle. This eliminates idle waiting time and extends productive action continuously throughout the cycle, reducing overall cycle time despite the added complexity of the drum positioning system.
Solution Approach 2:
The invention implements preliminary action by pre-positioning multiple auxiliary drums at different working positions before the actual assembly begins. The first auxiliary drum is prepared for belt structure assembly, the second for tread band assembly, and the picking position is ready for sleeve transfer. This preliminary arrangement of resources eliminates setup time during the cycle and reduces overall cycle time through advance preparation.
3Productivity
If simultaneous assembly operations are performed at multiple working positions, then the productivity is enhanced, but the coordination complexity increases
Solution Approach 1:
The invention merges the functions of multiple auxiliary drums and working positions into a coordinated system that operates in unison. The first auxiliary drum for belt assembly, second auxiliary drum for tread band assembly, and picking position for sleeve transfer are merged into a single integrated finishing station that produces completed tyre sleeves simultaneously. This merging of previously separate operations into one coordinated system enhances assembly productivity while managing complexity through functional integration.
Data Source
AI summary
A method and a plant for manufacturing tires for vehicle wheels wherein the method includes the steps of: a) building in a building station a substantially cylindrical carcass structure; b) manufacturing in a finishing station a substantially cylindrical sleeve including a tread band applied at a radially outer position with respect to a belt structure including at least one belt layer. Step b) includes the steps of assembling a first belt structure at a first working position on a first auxiliary drum of the finishing station; applying a tread band at a second working position at a radially outer position with respect to a second belt structure previously assembled on a second auxiliary drum of the finishing station, positioning the first auxiliary drum supporting the first belt structure at the second working position; and positioning the second auxiliary drum supporting the substantially cylindrical sleeve thus obtained at a picking position of the finishing station.