Apparatus and method of manufacture for a green tyre

Abstract: A green tyre manufacturing apparatus comprising an unwinding means (8,9) for umwinding tyre fabric in sheet form from a reel (10,11), characterised by a transfer means (6,7) for transferring the unwound tyre component longitudinally thereof, said transfer means (6,7) comprising a first conveyor (18) disposed upstream of the transferring means and a second conveyor (19) disposed downstream of the same, the first and the second conveyors (18,19) being independently driven; a cutter means (26) disposed on the first conveyor, for cutting a tyre component (12,13) at a predetermined angle slanted against the transferring direction; a separating means (21) disposed between the first and second conveyors (18,19), for separating a portion of the tyre component (12) cut by the cutter means (26) to have a predetermined length and lying downstream, from subsequent portions of the tyre fabric lying upstream; and a guide pan means (14) for guiding downstream the cut portion (12) of the tyre providing widthwise positioning with the same, the apparatus providing means to supply the tyre component cut to a predetermined length for winding the same on to a building drum for a green tyre.

Description: This invention relates to an apparatus and method of manufacture for a green tyre and in particular for supplying a tyre component, for example, a reinforced fabric material usually of steel cord, such as is used for a tyre carcass or a steel breaker which is fed as a predetermined cut length to a green tyre building drum. This operation involves cutting, separating the cut component from the following continuous portions and guiding the cut component with positioning thereof. Generally, green tyres are manufacture by several steps. A first step is to build or assembly a cylindrical tyre carcass by fitting a pair of beads one over either end of the cylindrical carcass, folding back the two ends of the cylinder around the beads and attaching two sidewalls for form a green carcass. Secondly a belt reinforcement is formed and then fitted around the green carcass which is shaped up into a toroid and bonding the belt to the green carcass. Finally tread is fitted. In the belt forming process tyre components or tyre materials (for example, tow plies of steel breaker, a reinforcing band and a rubber tread strip are supplied in turn in a direction perpendicular to the axis of a belt building drum to a belt assembly stage, the components being in order of winding and fitting to the drum to form an annual belt/tread assembly. Each breaker as mentioned comprises sheets of fabric in the shape of a long belt or sheet in which many parallel steel cords are incorporated. The cords are at an acute angle to the longitudinal direction, and are embedded in rubber. A conventionally known process for supplying this breaker to a belt building drum comprises unwinding the breaker from a reel into a transfer apparatus with guides and control to avoid a snaky feed, placing the breaker into a place for measurement of its length and cutting it, and after cutting off the required length, sending the cut breaker on to a guide pan for positioning and then supplying the cut breaker to the belt building drum in a direction perpendicular to the drum axis, and fitting it on to the drum. (For example, Japanese Examined Patent Publication SHO. 53-24483). An apparatus in which this process is put into execution is disclosed in the same Japanese Examined Patent Publication Sho. 53-24483. The apparatus comprises unwinding means for unwinding the breaker from a reel; a guide mechanism for correcting snaky feed and means for determining the breaker fabric position; a conveyor for transferring the breaker; a cutter provided at an intermediate position on the conveyor to cut the fabric to the predetermined length; means for positioning the cut breaker lengths; guide pan conveyors for the breaker lengths set up to have upper, middle, and lower levels (guide pan) for supplying in a direction perpendicular to a drum axis the cut breakers to a belt building drum and for attaching them to the assembly on a belt building drum. The three stage guide pan conveyor for supplying the breakers to the drum has each level independently driven and includes frames for supporting the guide pans so they may be moved towards and away from the drum by pivoting in a vertical direction. The breaker fabric has steel cords embedded at an acute angle to the longitudinal direction and the breaker is then cut parallel to the steel cords. To separate the cut breaker length from the length of subsequent breaker material, the conveyor on which the cut breaker lies is operated so that its downstream sector is driven and its upstream sector on which the top portion of the subsequent long length breaker is not driven. In this position, the breaker is already cut at the acute angle and thereby a rear triangular portion (this triangular portion is produced by the slant cut) of the cut breaker lies on the non-driven upstream sector. As a result, when the downstream conveyor sector is driven to convey the cut breaker, the conveyor sector on which the rear triangular portion lies is not put into drive, movement of the breaker by the downstream sector causes slipping and resultant sideways displacement and in many instances irregular elongation of the rear triangular portion. Further, in such a conventional conveyor the guide pan apparatus is complex in structure and needs a large area to include a standby position and is high in cost to maintain. Such conveyors use guide rollers to accurately place the breakers in alignment with the centre of the drum and such alignment devices are not very effective. Still further, the drum for attachment of the breakers has conventionally not been provided with a means for positioning the breaker with accuracy, which has caused difficulty in supplying and attaching the breakers accurately onto the drum, and all these problems require complex structures and frequent adjustment in the building operation. It is an object of the present invention to address the above problems and to provide a green tyre manufacturing apparatus which includes a device for separating a tyre component cut to a predetermined length from a subsequent tyre component portion without causing elongation or deformation and further without positional offset, and a guide pan apparatus with a simple structure and effective positioning to align the cut breakers accurately and to accurately guide them to the building drum. According to one aspect of the present invention a green tyre manufacturing apparatus comprising an unwinding means for unwinding tyre fabric in sheet form from a reel, a transfer means for transferring the unwound tyre component longitudinally thereof, a cutter means disposed for cutting a tyre component at a predetermined angle slanted against the transferring direction and a guide pan means for guiding downstream the cut portion of the tyre providing widthwise positioning with the same, the apparatus providing means to supply the tyre component cut to a predetermined length for winding the same on to a building drum for a green tyre, characterised by the transfer means comprising a first conveyor disposed upstream of the transferring means and a second conveyor disposed downstream of the same, the first and the second conveyors being independently driven, a separating means disposed between the first and second conveyors, for separating a portion of the tyre component cut by the cutter means to have a predetermined length and lying downstream, from subsequent portions of the tyre fabric lying upstream, wherein the separating means comprises an upstream conveyor sector and a downstream conveyor sector, the conveyor in the upstream sector and the conveyor in the downstream sector being separated by an interjacent line slanted to the transfer direction, said interjacent line being substantially parallel to the cutting line by the cutter device, and wherein the conveyors of the upstream and downstream sector of the separating means include many rollers having various lengths and being rotatably mounted and disposed widthwise on two opposite sides with respect to the slanted line, and wherein each roller of the upstream conveyor sector and each roller of the downstream conveyor sector have a common core shaft, and each pair of rollers of the upstream and downstream sectors comprises sleeves mounted over the common core shaft, the roller sleeves of the upstream conveyor sector are secured to the common core shafts and the roller sleeves of the downstream conveyor sector are loosely mounted over the common core shafts, the common core shafts are drive-connected to the first conveyor of the transfer means, the roller sleeves of the upstream conveyor sector and the roller sleeves of the downstream conveyor sector have varying lengths on the common core shafts, so that the difference in lengths between the upstream roller sleeves and the downstream roller sleeves changes gradually along the transferring direction. The conveyor sectors may be multi-roller conveyors and may be freely rotatable or driven. Another aspect of the invention provides a manufacturing apparatus characterised in that of the upstream and downstream conveyor sections of the separating means the rollers of one sector are driven for rotation and rollers of the other sector are of free rotation. By causing the guide pan to at least vertically shift and/or pivot, a plurality of the components can be supplied using only one guide pan, and therefore, connection/disconnection of the guide pan apparatus to the vertically pluralised transfer apparatus and a move to the standby position thereof are permitted so that the apparatus is fully effective but is simple in structure, requires less space than hitherto and is easy to adjust. It is more compact and cheaper to maintain. This invention thus allows separation of a cut tyre component from a following tyre component material without making slip, thus preventing deformation and positional offset of the cut component and allowing transfer with the cut dimension accurately kept and without deformation or positional offset. As a result final tyre quality is improved. Further, the provision of a widthwise alignment by the guide pan apparatus permits more correct positioning onto the building drum. Further, the method of this invention allows retention of accuracy in cutting a tyre component and also improves the supply and attachment to the building drum with accuracy, and this gives an improvement in the tyre quality. Embodiments will now be described in conjunction with the attached diagrammatic drawings in which: Figure 1 shows a whole side view of an apparatus according to this invention; Figure 2 shows a plan view of Figure 1; Figure 3 shows a plan view of a material for manufacturing tyres having steel cords incorporated; Figure 4 shows an enlarged plan view of a device for separating the material on an upper process line; Figure 5 shows a sectional views along the line A-A in Figure 4; Figure 6 shows a plan view of a device for separating the material on a lower process line, especially to show the roller arrangement; Figure 7 shows an enlarged sectional view along the line B-B in Figure 4; Figure 8 shows an enlarged view along the line C-C in Figure 4; Figure 9 shows an enlarged plan view of the guide pan; Figure 10 shows a side view with a partial break of the guide pan; Figure 11 shows a sectional view along the line D-D in Figure 9; Figure 12 shows an enlarged sectional view along the line E-E in Figure 10. Figure 13 shows an enlarged side view with a partial break of the structure to support the guide pan; Figure 14 shows a plan view of the structure shown by Figure 13; Figure 15 shows a right side view of the structure shown by Figure 13; Figure 16 shows an enlarged view along the line F-F in Figure 15; Figure 17 shows a view as viewed along the arrow line G in Figure 15. In Figures 1 and 2 reference numeral 1 indicates a main frame structure of the apparatus. In use this frame structure 1 is set up, at the rear of a drum for building a tyre belt, with the aid of front and rear legs 4,5 so that its longitudinal axis is at right angles to the drum axis 3. (Here, right is to the front and downstream, and left is to the rear and upstream). The main frame 1 supports two apparatus 6,7 for transferring breakers on upper and lower levels or lines. In the area to the rear and downward of the main frame 1, two units 8,9 comprising two removable carriages 8a and 9a are positioned in series for unwinding or supplying breaker material. On the carriages 8a,9a the breaker material 12,13 is mounted or wound on reels 10,11 with a separating liner L so that the breakers 12, 13 can be unwound from the reels 10 and 11. At the front end of the main frame structure 1, a guide pan apparatus 14 is arranged to be vertically pivotable with the aid of a mounting frame 15, a vertically mobile frame 16, and a front/rear mobile frame 17. The upper and lower breaker transfer apparatus 6,7 are each of much the same structure, wherein a first conveyor 18, a second conveyor 19, and a transhipping belt conveyor 20 are included in the longitudinal direction of transfer in the above-mentioned order. Between the first conveyor 18 and the second conveyor 19 a separating apparatus 21 is positioned comprising a roller conveyor for separating or removing breakers cut to a predetermined length 12a,13a. (The breakers having a determined cut length 12a,13a indicate the breakers that lie downstream of the cutter device 26 and hence are already cut). The first and second conveyors 18,19 are belt conveyors, wherein although not shown in the drawings, permanent magnets are embedded in a belt supporting panel at a predetermined distance so that they attract through the belt the steel cords 22 included in the breakers 12,13 (see Figure 3) so that the breakers 12,13 can be transferred without making a snaky or meandering path. The transhipping belt conveyor 20 is set, in front of or downstream of the second conveyor 19, positioned such that the working conveying surface is located in a plane inclined tangentially and normally to the belt building drum 2 and, to the front end of or downstream of the conveyor 20. The rear end of the guide pan apparatus 14 is able to come close to or move away from the drum, and in a belt supporting panel permanent magnets are embedded at a predetermined distance to prevent the cut breaker from making meandering run. At the rear end or starting end of the first conveyor 18 set is a means 25 for determining the position of the breaker comprising omni-rollers 23 and side guide rollers 24, which are intended so that the breakers 12,13 can be guided with accuracy to take suitable positions on the first conveyor 18. On the upper and lower first conveyors 18 are mounted cutting devices 26 for cutting the breakers into the predetermined lengths. The cutter device 26 is provided with a running track or lane (panel anvil) adjustable to give any desired cutting angle. Also the cutter devices 26 on the upper and lower levels are disposed with respect to each other so that looked at in plan view they have an opposite slanting or bias cutting angle or to be across from each other (see Figure 2). These cutter devices are intended to cut the breakers along a slanted cut line 33. The cutter devices 26 themselves are conventional and hence the description thereof is abbreviated, and in this description, the already cut breakers lying downstream of the devices are noted the breakers having a determined length 12a,13a. The two unwinding apparatus 8,9 are much the same and include on the carriages 8a,9a a winding roll 27 for the liner L and a drive motor 28 therefor. Roll supporting panels 29 are mounted on the carriages 8a,9a and are provided with plural guide rollers 30, and the carriages 8a,9a are movable sidewards of the main frame structure 1. The separating apparatus 21, as shown in Figures 4 to 8, comprises an upstream conveying sector 32 and a downstream conveying sector 31. All the rollers are arranged laterally side by side, but most rollers have two portions, an upstream portions 32a and a downstream portion 31a, to provide a slant cut line 33. Specifically, there are provided many rollers having various long to short lengths which are arranged on two laterally opposite sides of the slant line 33 which is angled to the direction of transferring the breakers. All rollers are arranged parallel to the axis 3 of the belt building drum 2, and as shown in Figure 4, in the separating apparatus 21 on the upper level, the rollers 31a as seen close to the mark X to indicate the direction for transferring the breakers (see Figure 4, right end) or in the top left region, are freely rotatable and the rollers 32a as seen in the bottom right region are driven. Then, as shown in Figure 6, in the separating apparatus 21 on the lower level, the rollers 32a as seen in the top right region are driven, and the rollers 31a as seen in the lower left region are of free rotation. Specifically, each separating roller 31a, 32a has, as shown in Figure 7, a core shaft of a uniform diameter and two roller portions 31,32a are mounted over the common core shaft 34, wherein one roller 31a is made freely rotatable by bearings 35 and the other roller 32a is secured to the shaft 34 and thus can he driven. In addition, locating collars 36,37,38 are fitted over an interjacent portion of the shaft 34 and the two opposite ends thereof. Further, two ends of respective common shafts 34 are mounted, with the aid of bearings 39,40, to be freely rotatable in L-shaped support frames 41 which are secured to the main frame 1. At the ends of the separating rollers 31a, toothed pulleys 42 are mounted. As shown in Figure 8, above the toothed pulleys 42, a drive belt 43 is pressed by press rollers 44 which are mounted on the frame 41 to be freely rotatably so that drive is provided. the drive belt 43 is positioned over a toothed pulley 47 which is secured to an end of a shaft 46 for a belt roller 45 located at the front end of the first conveyor 18 and also over a freely rotatable toothed pulley 48 at the front so that the timing belt 43 will start/stop at the same time as the first conveyor 18. At the outer end of the toothed pulley 47 of the belt roller shaft 46, a toothed pulley 49 is mounted, over which a drive belt 50 for driving the first conveyor 18 is placed. As shown in Figure 1, numeral 51 indicates a tension roller, 52 indicates a member connecting the support frames, 53 indicates a free roller, 54 indicates a belt roller placed at the rear end of the second conveyor 19, and above the belt roller 54 is set a photo-sensor 55 (photoelectric cell) which provides one component of a means for determining the cutting position of the breakers. The means for determining the cutting position consists of the photo-sensor 55 as mentioned and a rotary encoder (not shown) provided on the drive sector of the first conveyor 18. Therein, when a triangular front edge of the breaker 12,13 is detected by the photo-sensor 55, measurement of the transfer distance by the rotary encoder starts, and when the transfer reaches a length which is obtained by subtracting a distance between the centre 26a of the breaker cutter 26 and the photo-sensor 55 from the required length to encircle the belt building drum 2, the first conveyor 18, second conveyor 19, and separating rollers 32a are stopped. As an alternative, the separating rollers 31a,32a may be all made freely rotatable. The guide pan apparatus 14, as shown in Figures 9 to 12, is provided with a roller conveyor 60 which comprises two opposite frames 56, rollers shafts 58 borne by bearings 57 between the two parallel frames, and omni rollers 59 secured to each shaft 58. Further means is provided for controlling the width of a passing breaker piece. This means comprises guide members 62,63 which are disposed longitudinally within the two frames 56,56 and spaced apart to define two opposite walls. Therefor the guides 82,83 are secured to the guide rods 61. This is, the means for causing the guides 62,63 to come closer together and apart comprises a plurality of guide rods 61, the ends of which are secured to the frame 56,56. Also the guides 62,63 are positioned above the omni rollers 59. At the front end of or downstream of the guide members 62,63 are provided sub-guide members 64,65 which are further movable in relation to the guides 62,63. On the two opposite frames 56, specifically at a place somewhat backward from a central portion, a pivotal shaft 66 is secured, and the frames 56 are set vertically pivotable by a pivot shaft 66 which is mounted at the lower end of the front/rear mobile frame 17. The two opposite frames 56 are connected by interconnecting members 67,68,69. At the left outer end of each roller shaft 58, a toothed pulley 70 is secured. Under the interconnecting member 69 set is a servo motor 71 with an output shaft conveying a toothed pulley 73, and a drive belt 74 is placed over the toothed pulley 73, and other toothed pulleys 70 secured to each shaft 58, by which arrangement all the omni rollers 59 are driven in unison. Therein, on the left frame 56, press rollers 75 to press the drive belt are set to be of free rotation with a space adequate to do so. Finally toothed pulleys 76,77 are provided for tensioning the drive belt 74. In the span at the front end of the two opposite frame 56 are a freely rotatable omni roller 78 and a conveyor roller 79. The guide members 62,63 are each supported by the guide rods 61 with the aid of a linear bearing 80, and these guides 62,63 are connected to the two opposite frame 56 at two points within the frame lateral span, wherein the guide 62,63 are fitted with nuts 83 which are engaged on two screw shafts 82 which are laterally supported to be freely rotatable in bearings 81. The screw shaft 82 includes two parts coupled by a coupling 82c, wherein the left half is referenced 82a, and the right half is 82b, by rotative actions of 82a and 82b, the distance between the two opposite guides 62,63 can be changed. The guide members 62,63 are provided with vertical rectangular through holes 84, and each hole 84 is provided with a pin 85 having an axis on a line square with a line which connects the centres of the roller shafts 58. A breaker guide roller 87 is mounted around the pin 85 to be freely rotatable in a bearing 86, wherein a plurality of the guide rollers 87 are set so as to project somewhat from the two opposite faces (see Figure 12). At an outer end of the right half screw shaft 82b, a toothed pulley 88 is secured, and there is another toothed pulley 91 which is secured to an output shaft 90 of the servo motor 89, and a drive belt 92 is placed over the toothed pulleys 88,91 so that two screws halves 82a,82b are rotated in synchronism to increase or decrease the distance between the two guides 62,63 whilst keeping the parallel relationship between the two members. A tension pulley 83 is also provided. The sub-guide members 64,65 are adapted to move laterally in parallel relative to the guides 62,63. Specifically, these members 64,65 are secured to brackets 94,95 which are also secured to the front upper face of the guide 62,63, thereby the members 64,65 are allowed the same movement as the members 62,63. Further with the aid of guide shoes 86,87 and guide bars 88,89, the guides 84,85 are adapted to make further movements by the action of air cylinders 100,101. That is, only when the triangular front end of the cut breaker 12a,13a has passed may the guides 84,85 come away so that no resistance will be given to the passing breakers to avoid their snaky move. The means for determining the positions of the breakers of the guide pan apparatus 14 comprises omni rollers 59, guide panels 62,63 and sub-guide panels 64, 65. The mounting frame 15 comprises two opposite side plates 102,102, front end plate 103, an interconnecting member 104 which connects two rear ends of the side plates 102, rear end plate 105 secured to the rear ends of the two side plates 102, and a reinforcing member 105, wherein the rear end plate 105 is secured to the front end of the main frame structure 1. On the two ends of the front face of the front plate 103 set are guide rails 107, and on the upper face of the frame is mounted a servo motor 108, on a mounting plate 10a, for driving the vertically mobile frame with its output shaft 110 held upwardly and at a central upper portion of the front end plate 103, a screw shaft 111 for vertical drive is set vertical rotatably in a bearing 112. At the top ends of the screw shaft 111 and of the output shaft 110, toothed pulleys 113,114 are mounted, and a drive belt 115 is placed over these two pulleys 113,114. Further at the rear of the two opposite reinforcing members, specifically backward positions therein, bolts 116 for suspending the belt conveyor 20 are set to be vertically adjustable by nuts 117. At the low end of the guide rail 107 set is a stopper 118, and at the right side end of the front end plate 103, a proximity switch 119 for detecting a stop point for the vertical movement is set to be positionally adjustable (the same arrangement as in Figure 17). The vertically mobile frame 16 is generally a box having a bottom, and on the rear face of a rear end plate 120 of the vertically mobile frame 16, guide shoes 121 for engaging the guide rails 107 as mentioned above are provided at right, left and upper, lower positions. On the front face of the rear end plate 120, specifically at a central position thereon, a ball nut 122 is mounted, to which nut 122 the screw shaft 111 as mentioned above is engaged to be freely rotatable. At a backward portion of the right side plate 123 set is a kicker 124 for the proximity switch 119 (see Figure 17). Further, on the front end plate 125 of the vertically mobile frame 16, a servo motor 126 for driving the front/rear mobile frame 17 to have an output shaft 127 forwarding front, a toothed pulley 128 is mounted on the output shaft 127, and on the bottom plate 129 of the frame 16, specifically on the back side thereof, a pair of parallel guide rails 130 are mounted in a front/rear direction. At a centrally front position of the same back side of the bottom plate 129 set is a bearing 131, by which bearing 131 a screw shaft 132 for driving the front/rear movement is rotatably mounted. At the front end of the screw shaft 132 set is a toothed pulley 133, and a drive belt 134 is placed over the toothed pulleys 133 and 128 as mentioned above. On the right side plate of the frame 16, specifically at the lower end thereof, as shown in Figure 17, a proximity switch 135 for detecting the limits of front/rear movement is set on a base plate 136. The front/rear mobile frame 17 is designed to have the same width or lateral length between the two opposite plates 137,138 as that of the vertically mobile frame 16. On the top plate 139 of the front/rear mobile frame 17, specifically at the four corners thereof, guide shoes 140 are set to engage the guide rails 130. At a central and front portion of the back side of the same top plate 139 the ball nut 141 is set to be engaged to the screw shaft 132 rotatably. At a central and lower portion of the two side panels 137,138, two ends of the pivotal shaft 66 for the guide pan apparatus 14 are borne rotatably in a bearing 142, and the left end of the pivotal shaft 66 is connected to an output shaft of a worm type speed reducer 143. The speed reducer 143 is set on a vertical portion 144a of an L-shaped mounting plate 144 which is fastened on the outside face of the left side plate 137. The reducer 143 is connected, through a coupling 147, to an output shaft 146 of a servo motor 145 for driving the pivotal shaft which is set on a horizontal portion 144b of the mounting plate 144. On the right side plate 138 of the front/rear mobile frame 17, specifically at the top end thereof, a kicker 148 for the proximity switch is set, (see Figure 17) and at a lower area, as shown in Figure 16, three proximity switches; upper, lower, and standby positions 149.150,151 are set to take positions on the same one circle centring on the pivotal shaft 66. Kickers 152 for the proximity switches 149 to 151 are set on an end of the pivotal shaft 66. Next, description will proceed to the operation of the apparatus as explained wherein the breakers 12,13 are supplied thereto and are then passed to the belt building drum 2. First, in the main frame 1, the side guide rollers 24 of the means for positioning the breakers 25 are positionally adjusted to suit the width of the breaker material to be handled. The guide pan apparatus 14 is prepared by diving the vertically mobile frame 16, the front/rear mobile frame 17, and the pivotable shaft 66, so that its rear end connects to the front end of the upper transhipping conveyor 20, and that, as shown in Figure 1, the front end of the guide pan 14 comes close to end above the belt building drum. It is assumed here that the positioning means of the guide pan apparatus 14 has already operated the guides 62,63 so as to take suitable lateral positions by action of the servo motor 89 and the screw shaft 82, and also has operated the sub-guides 84,85 to take positions in parallel on the same surface continuing to the guides 62,63. Then, the first breaker 12 to be sent to the upper line and second breaker 13 to be sent to the lower lines are unwound together with the liner L from the reels 10 and 11 respectively. The liner L is wound up onto the roll 27 for re-use. The breakers 12,13 proceed by the rotation of the rolls 27 by drive of the motor 28. Unwinding of the breakers 12,13 is automatic in synchronism with the roll 27. The first conveyors 18 of the upper and lower transferring apparatus 6,7 are put into drive, and the front end of the breakers 12,13 are led to predetermined positions in the cutter devices 26 for cutting the predetermined length, wherein guide actions of the side guide rollers 24 of the positioning means 25, and the omni rollers 23 rotatable front/rear and right/left are involved. then, the upper and lower first conveyors 18 are stopped and the square front end portion of the breaker is cut slantly by the cutter device 26 to form a triangular front edge. Thus, the upper and lower lines both have finished the job of shaping the breaker web. The first and second conveyors 18,19 of the upper transfer line 6 are put into drive to resume the transfer of the breaker 12, and when the triangular front edge of the breaker 12 comes, after passing the separating device 21, to the photoelectric sensor 55 of the means for positioning the determined length, the measurement of the length of the breaker is started by the rotary encoder. when the distance from the centre 26a of the cutter device 26 to the front edge of the breaker 12 comes to be the same as the predetermined length of belt building around the drum 2, the conveyors 18,19 of the upper line 6 are stopped and the cutter device 26 cuts the laid breaker web 12 to the predetermined length, so that one breaker length is cut off. Therein, the breaker 12 is transferred, on the first and second conveyors 18,19, held by magnetic attraction by the permanent magnets (not shown) embedded in the belt support panels. Thereby, the transfer has no trouble of snaky movement and the breaker is disposed at the predetermined position, and therefore, accurate cutting is performed. After the cutting, the first and second conveyors 18,19 of the upper line 6 are put into drive and the measurement of a length by the rotary encoder resumes, and when the cut line 33 of the breaker 12 comes to the central point of the separating apparatus 21, the first conveyor 18 and the separating rollers 32a which are drive-connected to the first conveyor 18 re stopped and only the second conveyor 19 is driven. By this action, the cut breaker 12a is separated at the cut edge from subsequent breaker material and is transferred further and is then put into a standby status on the second conveyor 19. In the meantime, the separating rollers 31a, that is, the downstream conveyor 31 of the separating apparatus 21, are in free rotation, and thereby the triangular rear portion of the cut breaker 12a transfers without needing to slide, over the rollers 31a avoiding distortion and any dimensional change including elongation or deformation. Thus the size at cutting is maintained. When the second conveyor 19 resume moving, the cut breaker 12a passes over this conveyor 19 and the transhipping conveyor 20, and when the front edge of the cut breaker 12a comes to ride on the rear end of the guide pan apparatus 14, the two opposite guides 62,63 are automatically moved to a suitable separation distance so that the two guides 62,63 contact with the two sides of the breaker 12a so as to centralise the breaker position with the centre of the belt building drum 2. In turn, the triangular front edge of the cut breaker 12a reaches the front end of the guide 63, when this is detected by the photosensor (not shown) the signal in response to the detection causes the air cylinder at the right side 101 to move the sub-guide at the right side 65 backward so that the cut breaker 12a does not contact it. thereby any deformation at the front portion of the cut breaker is avoided. When the front portion of the cut breaker 12a contacts the rotating belt building drum 2 and starts being wound therearound, the sub-guide 65 moves forward to contact the side portions of the breaker 12a for assisting an adequate positioning on the drum 2. Having finished the work of supplying and attaching the first component of the breaker 12a onto the rotating drum 2, the guides 62,63 of the guide pan apparatus 14 are retreated and put into a standby position to wait for the next cut breaker 13a. At the same time, the vertically mobile frame 16 comes down to a predetermined position by rotation of the screw shaft 111 caused by the servo motor 108. In the meantime, the front/rear mobile frame 17 moves backwards by rotation of the screw shaft 132 caused by the servo motor 126, and the pivotal shaft 66 of the guide pan apparatus 14 is put into a pivotal act by the servo motor 145 and stops at a position where the rear end of the guide pan apparatus 14 meets the front end of the transhipping conveyor 20. These operations take place simultaneously and, when the positional connection between the guide pan 14 and the conveyor 20 is finished, the conveyor roller 79 located at the front end of the guide pan apparatus 14 approaches the belt building drum 2 and the upper face of the roller conveyor 60 formed on the guide pan apparatus 14 is positioned on a tangential line to the drum 2. Thus, machinery preparation for the second breaker or breaker to go through the lower line of the transfer apparatus 7 is finished. Then, the second breaker 13 is moved from the place of the cutter device 26 on the lower line by drive of the first and second conveyors 18,19 of the transfer apparatus 7. Then, the breaker 13 is cut into a predetermined length and the cut breaker component 13 is separated by the separating means 21, and the separated breaker 13a is put into standby on the second conveyor 19, and then transferred to the guide pan apparatus 14 and positioning action is provided thereon. In turn the breaker 13a is supplied to the belt building drum 2 and is wound therearound. Therein, in the case of the breaker 13a, the triangular front edge comes to be the left side as shown in Figures 3 and 6, the sub-guide at left side 84 is put into action. When the second cut breaker 13a completes the process of its supply and attachment onto the drum 2, the servo motor 145 starts the pivotal shaft 66 to pivot in a direction as shown by Y in Figure 13 so that the front end of the guide pan apparatus 14 moves upward and comes away from the drum 2, and then stops at a predetermined position. On the other hand, the vertically mobile frame 16 raises and stops at the upper limit point, and the front/rear mobile frame 17 moves forwards and stops at the forward limit point, and the guide pan apparatus 14 is moved to the standby position as shown in two dot lines in Figure 1. If supply of the first breaker 12a is considered, first, the servo motor 145 is started and hence the pivotal shaft 66 is pivoted in a direction shown by Z in Figure 13 so that the front end of the guide pan apparatus 14 comes down to cause the conveyor roller 79 to be close on the belt building drum 2. Thus, the positional condition as shown in solid lines in Figure 1 is brought about and then the breakers 12a,13a will restart by the same operations as noted before. Control of all operations to be performed by each apparatus or device is by a program control system based on computers. As noted in the embodiment, the positioning means 25 uses the omni rollers 23 and thereby more accurate positional determinations can be made, and hence improvement is obtained in cutting the predetermined length. This invention is not limited to the above embodiment and obvious modification may be introduced. For instance, the fabric may be cut from steel cord chafer; the transfer apparatus may include three or four levels; the transhipping conveyor 20 may be replaced with the extended second conveyor 19, further sub-guides 64,65 may be adapted to be synchronised and to move simultaneously with the right and left sides. In an alternative embodiment, if it is assumed that the guide pan apparatus 14 is only provided with vertical and/or pivotal mobility, it is permitted to extend two brackets from the vertical mobile frame 16 and provide a shaft which extends through the two brackets, and thus, the guide pan apparatus 14 may be made movable about this shaft.

Claims: A green tyre manufacturing apparatus comprising an unwinding means (8,9) for unwinding tyre fabric in sheet form from a reel (10,11), a transfer means (6,7) for transferring the unwound tyre component longitudinally thereof, a cutter means (26) disposed for cutting a tyre component (12,13) at a predetermined angle slanted against the transferring direction and a guide pan means (14) for guiding downstream the cut portion (12) of the tyre providing widthwise positioning with the same, the apparatus providing means to supply the tyre component cut to a predetermined length for winding the same on to a building drum for a green tyre, characterised by the transfer means (6,7) comprising a first conveyor (18) disposed upstream of the transferring means and a second conveyor (19) disposed downstream of the same, the first and the second conveyors (18,19) being independently driven, a separating means (21) disposed between the first and second conveyors (18,19), for separating a portion of the tyre component (12) cut by the cutter means (26) to have a predetermined length and lying downstream, from subsequent portions of the tyre fabric lying upstream, wherein the separating means (21) comprises an upstream conveyor sector (32) and a downstream conveyor sector (31), the conveyor (32) in the upstream sector and the conveyor (31) in the downstream sector being separated by an interjacent line slanted to the transfer direction, said interjacent line being substantially parallel to the cutting line by the cutter device (26), and wherein the conveyors of the upstream and downstream sector (32,31) of the separating means (21) include many rollers having various lengths and being rotatably mounted and disposed widthwise on two opposite sides with respect to the slanted line, and wherein each roller of the upstream conveyor sector (32) and each roller of the downstream conveyor sector (31) have a common core shaft (34), and each pair of hollers of the upstream and downstream sectors comprises sleeves (32a,31a) mounted over the common core shaft (34), the roller sleeves (32a,31a) of the upstream conveyor sector (32) are secured to the common core shafts (34) and the roller sleeves (31a) of the downstream conveyor sector (31) are loosely mounted over the common core shafts (34), the common core shafts (34) are drive-connected to the first conveyor (18) of the transfer means (6,7), the roller sleeves (32a) of the upstream conveyor sector (32) and the roller sleeves (31a) of the downstream conveyor sector (31) have varying lengths on the common core shafts, so that the difference in lengths between the upstream roller sleeves (32a) and the downstream roller sleeves (31a) changes gradually along the transferring direction. A green tyre manufacturing apparatus as claimed in claim 1, characterised in that of the upstream and downstream conveyor sections (32,31) of the separating means the rollers of one sector are driven for rotation and rollers of the other sector are of free rotation. A green tyre manufacturing apparatus as claimed in claim 1, characterised in that the rollers of the upstream and downstream conveyor sections (32,31) of the separating means (21) are freely rotatable. A green tyre manufacturing apparatus as claimed in claim 2, characterised in that the rollers of the upstream conveyor sector (32) of the separating means (21) are driven in synchronism with the first conveyor (18), and the rollers of the downstream conveyor sector (31) are freely rotatable. A green tyre manufacturing apparatus as claimed in any of claims 1 to 4, characterised in that the guide pan means (14) comprises a conveyor (60) for transferring a tyre components, said conveyor (60) being provided with guide members (62,63) which are disposed on two opposite sides of the conveyor, the two opposite guide members (62,63) being adapted to be movable together and apart to guide two sides of the tyre fabric component being transferred. A green tyre manufacturing apparatus as claimed in claim 5, characterised in that in the guide pan means (14) omni rollers are arranged to define a working conveying surface whereon the tyre component is transferred. A green tyre manufacturing apparatus as claimed in claim 5, characterised in that in front of the guide members (62,63) movable sub-guide members (64,65) are disposed, wherein the sub-guide members (64,65) are adapted to be movable laterally such that the sub-guide members (64,65) may retract relatively to each other on passing of an acute front portion of the tyre component to avoid contacting the sides thereof, and such that the sub-guide members (64,65) are positionally adjusted with respect to each other to guide the tyre component by contacting its sides subsequent to passing of the acute portion. A green tyre manufacturing apparatus as claimed in any of claims 1 to 7, characterised in that the unwinding means comprises a plurality of unwinding apparatus (8,9), the transfer means (6,7) are arranged vertically spaced to provide a plurality of processing levels the same as the number of the unwinding apparatus (8,9), the guide pan means (14) is adapted at least to be vertically mobile and/or vertically pivotable, the guide pan means (14) is provided with a rear end adapted to connect or disconnect to a front end of a second conveyor provided at each level of a vertically structured transfer means, and the guide pan means (14) is provided with a front end which can be disposed adjacent to the green tyre building drum (2). A method of manufacturing a green tyre, which comprises supplying a fabric reinforced tyre component in the form of a sheet unwound from a reel to a transfer means (6,7), cutting, on the transfer means (6,7) the tyre component at a point a predetermined length backward from a front edge thereof the cut slanting at an angle to the transferring direction, supplying the cut tyre component (12,13) to a guide pan means (14) having edge guide and positioning means, and then supplying the tyre component to a green tyre building drum for assembly thereto, characterised by separating the tyre component cut from following tyre component fabric by transferring the cut tyre component (12,13) and the following tyre component fabric to a separating means (21), stopping the transfer of the cut tyre component (12,13) and the following tyre component fabric when the slant cut line between them comes to the central point of the separating means (21) whereby the cut tyre component (12,13) and the following tyre component fabric are positioned respectively on downstream and upstream conveyor sectors (31,32) of the separating means (21) and the slant cut line is adjacent to and substantially aligned with an interjacent line slanted at an angle to the transfer direction separating the downstream and upstream conveyor sectors (31,32), restarting the transfer of the cut tyre component (12,13) on the downstream conveyor sector (31) so that the cut tyre component (12,13) moves relative to the following tyre component fabric and is separated from it.

Inventors: NAGAHATA TORU, NOJIRI YASUSHI, NAGAHATA, TORU, NOJIRI, YASUSHI
Applicants: SUMITOMO RUBBER IND, SUMITOMO RUBBER INDUSTRIES LIMITED
Application year: 1991
Main classification: B29D30
IPC codes: B29D30