Tyre Vulcanisation Feedback Control for Cross-linking Consistency
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Solution Overview
Problem
The vulcanization process for tires is challenging due to unpredictable and hard-to-control factors that affect the optimal cross-linking degree, leading to varying vulcanization times and potential production defects, even under seemingly identical conditions.
Innovation Solution
Implementing a process that monitors actual vulcanization times and adjusts the heating fluid temperature based on recorded warning signals to maintain the process within tolerance limits, ensuring consistent cross-linking and improving productivity by reducing deviations from nominal times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the vulcanisation process is monitored and controlled to maintain consistent cross-linking degrees, then tire quality and manufacturing precision are improved, but the device complexity and process control difficulty increase
Solution Approach 1:
The patent implements a feedback control system that monitors actual vulcanisation times and compares them against nominal values. When deviations exceed predetermined thresholds, the system automatically adjusts heating fluid temperature to bring actual times back within tolerance limits, ensuring consistent cross-linking degrees while managing process complexity through automated closed-loop control
Solution Approach 2:
The patent changes the temperature parameter of the heating fluid dynamically based on monitored vulcanisation time deviations. By adjusting temperature upward when actual times are shorter than nominal and downward when actual times are longer, the system maintains optimal cross-linking conditions and achieves manufacturing precision without requiring overly complex control mechanisms
2Manufacturing precision
If the heating fluid temperature is adjusted frequently to correct vulcanisation time deviations, then manufacturing precision is improved, but energy consumption and process instability increase
Solution Approach 1:
The feedback control system adjusts heating fluid temperature only when actual vulcanisation times deviate from nominal values by predetermined thresholds. This conditional adjustment prevents unnecessary energy consumption while maintaining manufacturing precision, as the system responds only to significant deviations rather than continuous minor fluctuations
Solution Approach 2:
The system uses predetermined tolerance thresholds and nominal time values established in advance to determine when temperature adjustments are necessary. By pre-defining acceptable ranges and correction criteria, the system avoids excessive energy consumption from frequent minor adjustments while still ensuring consistent vulcanisation quality
3Device complexity
If external factors such as ambient temperature and humidity are not controlled, then device complexity is reduced, but manufacturing precision and product quality deteriorate
Solution Approach 1:
The patent implements a self-service control approach where the vulcanisation system automatically compensates for external environmental factors through its own monitoring and adjustment capabilities. The system monitors actual vulcanisation times and adjusts heating parameters independently, eliminating the need for separate environmental control systems while maintaining manufacturing precision
Solution Approach 2:
The system changes heating fluid temperature parameters in response to observed vulcanisation time deviations caused by external factors. By dynamically adjusting temperature based on actual process performance rather than attempting to control environmental conditions, the system maintains manufacturing precision without adding complex environmental control infrastructure
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 ensures higher quality tires by maintaining consistent cross-linking degrees, reducing the risk of defects, and enhancing productivity by adjusting the operating temperature to align actual vulcanization times with nominal values.
Implementation Method 1
Another part of the heat is supplied from outside the tyre through the mould, suitably heated by circulation channels of steam or other heating fluid, arranged in the vulcanisation apparatus
Implementation Method 2
the green tyre is introduced into a suitably-heated vulcanisation mould... a moulding and vulcanisation treatment is performed. Such treatment is essentially aimed to determine the structural stabilisation of the tyre via cross-linking of the aforesaid elastomeric compositions
Data Source
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AI summary
Heat is supplied to a tyre (2) closed in a vulcanisation mould (3) in order to determine the vulcanisation thereof. During the heat supplying, the cross-linking degree reached in at least one detection zone (14a, 15a, 18a, 19a) located within the tyre (2) is monitored, in order to interrupt the heat supplying when the cross-linking degree reaches a predetermined reference value. An actual vulcanisation time, running between the beginning and the interruption of the heat supplying, is compared with a preset nominal vulcanisation time. When the difference between the actual vulcanisation time and the nominal vulcanisation time exceeds at least one predetermined attention threshold, a warning signal is recorded. Upon repeating a predetermined number of recorded warning signals, the operating temperature of the heating fluid is modified, in order to modify the actual vulcanisation time in the subsequent vulcanisation cycles.