Vulcanization Control Using One-Dimensional Thermal Conduction
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Solution Overview
Problem
Current methods for determining optimal vulcanization time in tire manufacturing are inefficient, requiring extensive man-hours and complex analysis models, leading to either insufficient vulcanization or over-vulcanization, and are not capable of instantaneous calculation.
Innovation Solution
A vulcanization control method and system that uses a one-dimensional thermal conduction model to calculate vulcanization time based on input data of affecting factors, reducing the need for complex models and allowing for instantaneous calculation of optimal vulcanization time while preventing insufficient vulcanization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a three-dimensional thermal conduction/vulcanization reaction rate analysis model is used to ascertain heat conduction state, then measurement precision is improved, but device complexity and calculation time increase significantly
Solution Approach 1:
The patent divides the tire into multiple measurement points along the radial direction and uses separate one-dimensional thermal conduction models for each point. This segmentation approach maintains measurement precision by capturing temperature variations at different depths while avoiding the computational complexity of a full three-dimensional model.
Solution Approach 2:
The patent extracts the essential thermal conduction characteristics from the complex three-dimensional model by using one-dimensional thermal conduction models that focus only on the radial temperature distribution. This extraction maintains the necessary measurement precision while dramatically reducing model complexity and calculation time.
2Manufacturing precision
If a three-dimensional analysis model is used with extensive FEM calculations, then manufacturing precision is improved, but productivity deteriorates due to long calculation times
Solution Approach 1:
The patent segments the vulcanization process into multiple measurement points and applies simplified one-dimensional thermal conduction models to each point. This segmentation maintains manufacturing precision by capturing the essential temperature evolution at critical locations while enabling rapid parallel calculations that significantly improve productivity.
Solution Approach 2:
The patent uses simplified one-dimensional thermal conduction models that are computationally inexpensive and can be rapidly executed. These simplified models serve as disposable calculation tools that provide sufficient precision for vulcanization time determination without the heavy computational burden of three-dimensional FEM calculations.
3Measurement precision
If a large scale database and extensive experiments are conducted to ascertain impact degrees, then measurement precision is improved, but loss of time and man-hours increases
Solution Approach 1:
The patent enables the system to self-determine impact degrees by using the measured temperature distribution data directly in the one-dimensional thermal conduction models. This self-service approach eliminates the need for extensive external experiments and large-scale database creation, significantly reducing time loss while maintaining measurement precision through direct measurement-based calculations.
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 significantly reduces the time and man-hours required for analysis, allows for accurate and instantaneous calculation of optimal vulcanization time, and logically shortens the vulcanization time while ensuring complete vulcanization, avoiding both insufficient and over-vulcanization.
Implementation Method 1
calculating, by the computation device that uses the input data, a change in temperature distribution of a tire cross section over time with a one-dimensional thermal conduction model
Data Source
AI summary
A vulcanization control method and a vulcanization control system are provided that are capable of preventing insufficient vulcanization while shortening a vulcanization time and obtaining an optimal vulcanization time instantly, even when a simple analysis model is used. Data (Xi) of predetermined types of vulcanization-affecting factors (X) are input into a computation device (2) by an input device (6) before vulcanizing a green tire (G). Using the input data (Xi), a change in temperature distribution of a tire cross section over time is calculated with a one-dimensional thermal conduction model for a tire cross-section that passes through a vulcanization rate-limiting section. On the basis of the calculation results, a vulcanization time Tc is instantly calculated. Upon calculating the vulcanization time Tc, a safety time Ts set on the basis of each vulcanization-effecting factor (X) is shortened on the basis of the input data (Xi) of the individual vulcanization-affecting factors (X).