Tyre Building Junction Zone Inspection Using Visible-Light AI Imaging
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Solution Overview
Problem
Existing methods for checking the quality of junction zones in tyre manufacturing are unreliable, time-consuming, and pose safety risks due to complex optical instrumentation, hindering efficient in-line production.
Innovation Solution
A process and apparatus utilizing image acquisition in the visible spectrum and AI-driven analysis to identify and classify junction zones, ensuring precise and safe detection without delays, using harmless wavelengths and simplified instrumentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex optical instrumentation is used for quality checking, then measurement precision is improved, but device complexity and safety risks increase
Solution Approach 1:
The patent replaces complex optical instrumentation with a camera-based image acquisition system. Instead of using sophisticated optical devices to directly measure junction zone characteristics, the system captures images and processes them through image analysis algorithms, substituting mechanical/optical measurement systems with a vision-based system that is simpler and safer.
Solution Approach 2:
The patent creates a digital copy (image) of the junction zone and performs all measurements and analyses on this copy rather than directly on the physical object. This allows multiple measurements to be taken from the same image without requiring complex optical instrumentation, thereby reducing device complexity while maintaining measurement precision.
2Device complexity
If manual quality checking is performed, then device complexity is reduced, but productivity and reliability deteriorate
Solution Approach 1:
The system performs automated quality checking without requiring manual intervention. The camera captures images, the processing unit analyzes them, and quality decisions are made automatically. This self-service capability eliminates the need for manual checking while maintaining simple device complexity, thereby improving productivity.
Solution Approach 2:
The patent replaces manual quality checking operations with an automated image-based system. Instead of operators visually inspecting junction zones, a camera and image processing system perform the inspection automatically, substituting human labor with a simple automated system that improves productivity without increasing complexity.
3Ease of operation
If traditional quality checking methods are used, then ease of operation is maintained, but reliability and measurement precision worsen
Solution Approach 1:
The system creates a permanent digital record (image) of the junction zone that can be analyzed multiple times with different parameters. This copying approach allows simple operation (capturing an image) while achieving high reliability through repeated, consistent measurements from the same image data, eliminating variability associated with manual methods.
Solution Approach 2:
The system provides automated feedback by analyzing the captured image and determining quality status. The processing unit compares measured parameters against quality criteria and provides clear pass/fail decisions, making the operation simple while ensuring reliable and consistent quality assessment without human subjectivity.
Data Source
AI summary
A process for building tyres for wheels of vehicles, with the following building operations: winding a cut-to-size semifinished element around a forming drum, thereby forming a corresponding component of a tyre, wherein the semi-finished element has opposite ends juxtaposed with each other to form a junction zone; repeating the winding operation until completion of the building operations on the forming drum. During the building operations, a checking operation is performed on the tyre, including: acquiring a two-dimensional image of the tyre; identifying, in the image, at least one junction zone in a radially external position of the tyre; providing reference images, each representing a junction zone type; comparing the at least one identified junction zone with each reference image; selecting a junction zone type; classifying the at least one identified junction zone on the basis of the junction zone type; and generating a stop or a consent signal.