Ultrasonic Tyre Rubber Cutting With Thickness-Adaptive Control
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Solution Overview
Problem
Existing tire manufacturing methods face challenges in achieving consistent and efficient cutting of rubber components with varying thicknesses, leading to defects and increased manual intervention for parameter adjustment, which affects cutting quality and efficiency.
Innovation Solution
An ultrasonic cutting method using a sensor unit with a distance sensor to detect the local thickness of the rubber component, coupled with a control unit to adjust the cutting blade's amplitude and feed rate automatically, ensuring precise cutting based on the detected thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual determination and adjustment of cutting parameters is used for different tire sizes, then cutting quality can be adapted to specific tire requirements, but the process becomes time-consuming and requires frequent manual intervention
Solution Approach 1:
The patent replaces manual mechanical measurement and parameter adjustment with an automated optical measurement system (laser scanner) and computer-controlled parameter adjustment. The laser scanner automatically measures the rubber component's geometry, and the control unit automatically calculates and adjusts cutting parameters, eliminating the need for manual determination of cutting areas and parameters for different tire sizes.
Solution Approach 2:
The system enables self-service automation where the measurement and control systems automatically adapt to different tire sizes without manual intervention. The laser scanner autonomously measures the rubber component, the control unit autonomously calculates optimal cutting parameters, and the ultrasonic cutting device autonomously executes the cutting process, making the system self-adjusting for different tire specifications.
2Ease of manufacture
If conventional cutting methods are used without automated thickness detection, then the cutting process is simpler, but cutting quality varies when material thickness deviates from specified parameters
Solution Approach 1:
The patent implements a feedback mechanism where the laser scanner continuously measures the actual geometry and thickness of the rubber component during production. This measurement data is fed back to the control unit, which automatically adjusts the ultrasonic cutting parameters in real-time to maintain optimal cutting quality regardless of material thickness variations.
Solution Approach 2:
The system transitions from static, pre-programmed cutting parameters to dynamic, real-time parameter adjustment. The cutting parameters are continuously adapted based on actual measured thickness values, allowing the system to respond dynamically to material variations and maintain consistent cutting quality throughout the production process.
3Productivity
If ultrasonic cutting is used with fixed parameters, then the cutting process is faster and more automated, but blade wear increases and cutting quality decreases for varying material thicknesses
Solution Approach 1:
The patent dynamically changes cutting parameters (amplitude, frequency, feed rate) based on real-time thickness measurements. The control unit adjusts these parameters according to the actual material conditions detected by the laser scanner, optimizing the ultrasonic cutting process for each specific section of the rubber component to maintain high cutting quality while preserving productivity.
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 reduces defects and manual intervention, enabling high-quality, efficient, and consistent cutting of rubber components, improving tire production by minimizing unwanted holes and ensuring a smooth, homogeneous interface for reliable vulcanization.
Implementation Method 1
an ultrasonic cutting device... an ultrasonic cutting blade
Implementation Method 2
a sensor unit with a distance sensor... configured to use the distance sensor to detect a distance representative of a local thickness
Data Source
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AI summary
A method for manufacturing a tire for a motor vehicle comprises providing a rubber component (1) with a profile cross-section of varying thickness, and providing a system (2) for cutting the rubber component (1), wherein the system (2) comprises a control unit, a holder (3), an ultrasonic cutting blade (4), and a sensor unit with a distance sensor (5). The sensor unit is arranged upstream of the ultrasonic cutting blade (4) with respect to a processing direction of the rubber component (1) to be cut and is configured to detect a distance (A) by means of the distance sensor (5) that is representative of a local thickness of the rubber component (1) to be cut. The method further comprises detecting the distance (A) by means of the distance sensor (5), and controlling the ultrasonic cutting blade (4) to cut the rubber component (1) by means of the control unit depending on the detected distance (A).