Wire Assembly Unit with Independent Twisting and Preforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing assemblies of wire elements, such as those used in tire reinforcements, face limitations in achieving high structural elongation while maintaining productivity, as they require heavy and bulky preforming and twisting equipment, which restricts speed and efficiency.
Innovation Solution
An installation that allows for independent dimensioning of twisting and preforming means, enabling high-capacity wire element assembly without the need for a rotating nacelle, allowing for individual twisting and balancing of wire elements to achieve significant structural elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heavy preforming and twisting equipment is used to achieve high structural elongation, then structural elongation is improved, but productivity deteriorates due to restricted speed
Solution Approach 1:
The patent divides the wire element processing into separate twisting and preforming stages, with twisting performed first on stationary equipment, then preforming performed downstream on moving wire elements. This segmentation allows each process to be optimized independently, resolving the contradiction between achieving high structural elongation through preforming and maintaining high productivity through unrestricted assembly speed.
2Ease of manufacture
If a rotating nacelle is used to position preforming and twisting devices, then wire element assembly is achieved, but device complexity increases and speed is restricted due to inertia
Solution Approach 1:
The patent extracts the twisting operation from the rotating nacelle and performs it on stationary equipment upstream. This removes the heavy rotating components and complex synchronization mechanisms, allowing the assembly point to operate at high speeds without inertia limitations while still achieving proper wire element assembly.
Solution Approach 2:
Instead of performing preforming before assembly as in conventional methods, the patent inverts the sequence by performing twisting first on stationary equipment, then preforming downstream after the assembly point. This reversal eliminates the need for heavy rotating equipment and allows high-speed production.
3Manufacturing precision
If preforming is performed before assembly, then structural elongation is improved, but the curvature of wire elements is affected and aeration is reduced
Solution Approach 1:
The patent performs the twisting action preliminarily on stationary equipment before the wire elements undergo preforming downstream. This preliminary twisting creates the necessary structural characteristics without interfering with the subsequent preforming process, allowing both high structural elongation and proper wire element curvature to be achieved.
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
The solution enables the production of wire element assemblies with structural elongation greater than 3.0%, enhancing the performance of tire reinforcements while improving installation productivity and reducing the need for frequent shutdowns.
Implementation Method 1
the individual twisting means for each wire element are arranged upstream of the individual preforming means, the curvature of the wire elements obtained during and after the preforming step using the individual preforming means is not affected. Indeed, because the individual preforming step takes place downstream of the individual twisting step, the twisting cannot eliminate the helix created subsequently by the preforming.
Implementation Method 2
the individual preforming means, the curvature of the wire elements obtained during and after the preforming step using the individual preforming means is not affected
Data Source
Figure 1
Figure 2~7
Figure 4
AI summary
The invention relates to a unit for producing an assembly (A) of filiform elements (14) wound together in a spiral, comprising: means (16) for twisting at least first and second filiform elements (14), arranged such as to twist the first and second filiform elements (14) separately from one another; means (18) for preforming at least the first and second twisted filiform elements (14) in a spiral, arranged downstream of the twisting means such as to preform the first and second twisted filiform elements (14) separately from one another; and means (20) for assembling at least the first and second preformed and twisted filiform elements (14), arranged downstream of the preforming means such as to form the assembly (A) of filiform elements (14).