Tyre Production Transfer Devices and Vulcanization Layout
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Solution Overview
Problem
Existing tyre production processes are hindered by the need for large manoeuvring spaces and are prone to productivity issues due to anomalies or malfunctions in vulcanization, mounting/dismounting, and temperature stabilizing units, leading to overvulcanization and waste.
Innovation Solution
A process that distributes the workload of transfer devices between the building line and vulcanization line, using separate transfer devices for different operations to absorb anomalies and reduce plant size, including a pre-heating step for vulcanization moulds and multiple vulcanization units to maintain productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single transfer device is used for both building line and vulcanization line, then device complexity is reduced, but productivity decreases due to anomalies causing overvulcanization and waste
Solution Approach 1:
The transfer device is segmented into two independent devices: a first transfer device for transferring toroidal supports from the building line to the holding unit, and a second transfer device for transferring toroidal supports from the holding unit to the vulcanization line. This segmentation allows independent operation of each transfer function, preventing anomalies in one line from affecting the other, thereby maintaining productivity while managing device complexity through functional separation.
Solution Approach 2:
A holding unit is introduced as an intermediary between the building line and vulcanization line. This holding unit acts as a buffer that decouples the two production lines, allowing the first and second transfer devices to operate independently. The holding unit absorbs anomalies and prevents them from propagating between lines, ensuring continuous productivity while managing overall system complexity.
2Manufacturing precision
If vulcanization and temperature stabilizing units are integrated in sequence, then manufacturing precision is improved, but plant size increases due to large manoeuvring spaces required
Solution Approach 1:
The thermal processing function is segmented into separate units: a vulcanization unit for curing the tyre and a temperature stabilizing unit for cooling. These units are positioned to receive toroidal supports from different transfer devices, allowing parallel operation and reducing the linear sequence length. This segmentation maintains precise temperature control while reducing the plant footprint by eliminating long sequential manoeuvring paths.
Solution Approach 2:
The layout transitions from a linear sequential arrangement to a more distributed spatial configuration where the vulcanization and temperature stabilizing units are positioned to be accessed by separate transfer devices. This dimensional reorganization allows parallel processing paths, reducing the overall plant footprint while maintaining the necessary temperature control precision for tyre production.
3Productivity
If multiple transfer devices are used to distribute workload, then productivity is maintained during anomalies, but device complexity and plant size increase
Solution Approach 1:
The transfer system is segmented into two specialized devices with distinct functions: the first transfer device handles building line to holding unit transfers, while the second transfer device handles holding unit to vulcanization line transfers. This segmentation allows each device to be optimized for its specific function and operate independently, maintaining productivity during anomalies while keeping individual device complexity manageable.
Solution Approach 2:
The holding unit serves as an intermediary buffer that enables the two transfer devices to operate independently. By decoupling the building line and vulcanization line through this intermediate storage point, the system maintains productivity during anomalies in either line while managing overall device complexity through functional separation and independent operation.
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 allows for a more flexible tyre production process that minimizes waste and reduces plant size while maintaining productivity by effectively managing transfer devices and incorporating additional vulcanization units and pre-heating, thus preventing overvulcanization.
Implementation Method 1
a pre-heating step for vulcanization moulds
Implementation Method 2
moulding and vulcanizing the green tyre in the vulcanization line of the production plant
Data Source
AI summary
A plant and a process for producing tires wherein the process includes the steps of: a) building a green tire on a toroidal support in a building line of a tire production plant; b) transferring the green tire and the relevant toroidal support from the building line of the production plant to a first holding unit; c) transferring the green tire and the relevant toroidal support from the first holding unit to a vulcanization line of the production plant; d) molding and vulcanization the green tire in the vulcanization line of the production plant; e) separating the molded and vulcanized tire from the relevant toroidal support; f) transferring the toroidal support, separated from the relevant tire, from the vulcanization line to the first holding unit; and g) transferring the toroidal support, separated from the relevant tire, from the first holding unit to the building line of the production plant, wherein steps b) and g) are carried out through a first transfer device and steps c) and f) are carried out through a second transfer device different from the first transfer device.