Ultrasonic Cleaning Device for Tire Mould Microvalves
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Solution Overview
Problem
Existing devices for cleaning elastomer particles from microvalves in tire baking molds lack targeted detection of interior zones, leading to inefficiencies and potential damage to microvalves, as they cannot accurately determine the cleaning limit.
Innovation Solution
A device equipped with a camera for microvalve detection, connected to a computer with a data management algorithm, and an accelerometer or microphone to detect frequency changes, allowing for precise and non-intrusive cleaning by monitoring vibrations to determine the end of the cleaning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic cleaning devices are used to remove elastomer particles from microvalves, then cleaning effectiveness is improved, but the risk of damaging microvalves increases due to inability to detect cleaning limit
Solution Approach 1:
The patent implements a feedback mechanism using an accelerometer to continuously monitor vibration frequency during ultrasonic cleaning. When the cleaning is complete (detached particles cause a frequency shift), the system automatically stops the ultrasonic vibration. This prevents over-cleaning and potential damage to the microvalve structure while ensuring complete particle removal.
Solution Approach 2:
The patent uses controlled mechanical vibration at ultrasonic frequencies (20-100 kHz) to detach elastomer particles from microvalves. The vibration amplitude and frequency are precisely controlled, and the system monitors the natural frequency of the microvalve to detect when particles are successfully removed, allowing for safe and effective cleaning.
2Device complexity
If traditional cleaning methods are used without targeted detection, then device complexity is reduced, but cleaning efficiency and precision deteriorate
Solution Approach 1:
The system performs self-detection and self-control through the accelerometer mounted on the ultrasonic pen. The accelerometer automatically detects the frequency changes caused by particle detachment and triggers the stop command without external intervention. This self-service capability maintains simplicity while achieving precise, targeted cleaning of individual microvalves.
Solution Approach 2:
The ultrasonic pen integrates multiple functions into a single device: it generates ultrasonic vibrations for cleaning, houses an accelerometer for detection, and includes a control unit for automated operation. This multi-functional design eliminates the need for separate detection and cleaning devices, reducing overall system complexity while improving cleaning precision.
3Extent of automation
If manual cleaning procedures are used, then automation level is reduced, but the ability to detect frequency changes and determine cleaning endpoint is lost
Solution Approach 1:
The patent replaces manual visual inspection and manual operation with automated electronic detection using an accelerometer and control unit. The accelerometer electronically measures vibration frequency changes, and the control unit automatically processes this data to determine when cleaning is complete, eliminating the need for manual judgment and improving measurement precision.
Solution Approach 2:
The accelerometer serves as an intermediary between the ultrasonic cleaning process and the control system. It converts the physical vibration signals into electrical signals that can be processed by the control unit, enabling automated detection of the cleaning endpoint without requiring direct human intervention or complex sensing systems.
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
Enables targeted and efficient cleaning of microvalves within tire baking molds by detecting the end of the cleaning process, preventing damage and reducing cycle time, while maintaining simplicity and automatability.
Implementation Method 1
a portable vibrating cleaning device generating ultrasound
Implementation Method 2
an accelerometer for detecting the frequency change indicating the end of the microvalve cleaning
Data Source
Figure 1~2
AI summary
The invention relates to a device for removing elastomer particles adhering to microvalves (3) arranged on the inner surface of a vehicle tyre curing mould (2) comprising at least one means for detecting (5) microvalves (3), and at least one pen (7) emitting ultrasound. Said device is characterised in that it comprises at least one means (9) for detecting the change in frequency indicating the end of the cleaning of the microvalve (3), the detection means (9) being an accelerometer.