Wire Element Assembly Preforming for Structural Elongation
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Solution Overview
Problem
Current methods for manufacturing wire element assemblies in tires, such as those for heavy goods vehicles, are limited by low productivity and achievable structural elongation, as they require preforming and assembly processes that restrict speed and dimensionality of equipment, resulting in maximum structural elongation of only 2.0%.
Innovation Solution
A method involving individual twisting of wire elements before preforming, allowing for higher structural elongation without the need for a rotating nacelle, enabling the use of heavier and more capable equipment, and independent dimensioning of preforming and twisting means, which results in assemblies with significant aeration and structural elongation up to 5.0%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire elements are individually preformed and assembled by laminating to obtain high structural elongation, then structural elongation increases to 2.0%, but productivity decreases due to low rotational speeds required for heavy feeding and preforming devices
Solution Approach 1:
The wire elements are individually preformed before assembly, creating preliminary helical shapes that enable higher structural elongation (up to 5.0%) when assembled. This preliminary action allows the wire elements to be prepared in advance with optimal geometry, resolving the contradiction by achieving high elongation through pre-forming rather than through slow assembly processes
Solution Approach 2:
The process segments the manufacturing into independent stages: individual wire feeding, individual preforming, and assembly. Each wire element is preformed separately before being assembled with others, allowing heavy preforming devices to operate independently without requiring synchronized rotation, thereby enabling higher productivity while maintaining high structural elongation
2Ease of manufacture
If feeding and preforming devices are made heavier to handle wire elements, then manufacturing capability improves, but the nacelle must be sized larger to withstand inertia, which limits rotational speed and reduces productivity
Solution Approach 1:
The feeding and preforming devices are segmented into independent units, each handling individual wire elements. This segmentation allows each device to be optimized for its specific function without requiring the entire assembly to rotate at low speeds, enabling heavier more capable devices to be used while maintaining high productivity through independent operation
Solution Approach 2:
Wire elements are preformed individually before assembly, allowing heavy preforming devices to operate in advance rather than during rotation. This preliminary action transfers the mass and complexity requirements to stationary preforming stations, freeing the rotating assembly mechanism from inertia constraints and enabling higher rotational speeds
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 enables the production of wire element assemblies with higher structural elongation while maintaining high productivity, allowing for the use of more robust equipment and achieving structural elongation greater than 3.0%, enhancing the performance of tire reinforcements.
Implementation Method 1
an assembly of wire elements wound together in a helix
Implementation Method 2
each wire element undergoes individual torsion about its own axis. During this individual torsion, each wire element is plastically deformed, and a residual torsional torque is generated within each wire element
Data Source
Figure 1
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AI summary
The invention relates to a method for producing an assembly (A) of filiform elements (14) wound together in a spiral, comprising: a step of twisting at least first and second filiform elements (14), the first and second filiform elements (14) being twisted separately from one another; a step of preforming at least the first and second twisted filiform elements (14) in a spiral, the first and second twisted filiform elements (14) being preformed separately from one another; and a step of assembling at least the first and second twisted and preformed filiform elements (14) in order to form the assembly (A) of filiform elements (14).