Abstract:
An apparatus for joining a carcass ply, which butt-joins a wind start end and a wind finish end of a carcass ply wound around a cylindrical drum, is disclosed. The apparatus comprises: a joining section for joining the ends of the carcass ply; and aligning sections for aligning the ends of the carcass ply during joining by the joining section, the joining section and the aligning sections being disposed below the cylindrical drum supported in a horizontal state.

Description:
TECHNICAL FIELD 
     This invention relates to an apparatus for joining a carcass ply which is used as a material for constituting a tire in a tire manufacturing process. 
     BACKGROUND ART 
     With this type of apparatus, a carcass ply is formed as a band-shaped member by winding a sheet-shaped material, cut to a size of one tire, around a cylindrical drum, and butt-joining ends thereof (a wind start end and a wind finish end). To ensure the strength of a joint formed by butt joining, it is necessary to dispose cone-shaped joining rollers (toe-in roller devices) on both surfaces of the carcass ply and generate a pressing force strongly from both sides of the line of joining (or the joining line or joint line). 
     To attain the above-mentioned purpose, Patent Document 1, for example, discloses a structure in which drum segments (pieces) forming a cylindrical portion for supporting the ends of a carcass ply to be joined (hereinafter referred to as the joining ends or joint ends) are sequentially retreated in accordance with the movement of the joining apparatus, whereby joining can be performed accurately. 
     Patent Document 2 discloses a joining apparatus in which the joint ends of a carcass ply are held between a pressing member and a support roller having a spiral ridge to draw the ends to each other, and a restraint member for restraining overlapping or the like of the ends is disposed in the center, whereby joining can be performed accurately. 
     Further, Patent Document 3 discloses a joining apparatus in which the lower side of a carcass ply is supported by a receiving piece of a nearly T-shaped receiving body, while a dowel body (joining means) disposed on the upper side of the carcass ply is moved, with the supporting piece of the receiving body running in a small clearance of the carcass ply in a preceding manner, whereby joining can be performed accurately. 
     SUMMARY OF INVENTION 
     Technical Problem 
     With the structure disclosed in Patent Document 1, however, the joint ends are simply borne on the drum segments (pieces). In this case, when the drum segments (pieces) are retreated radially inwardly, the joint ends may sag, or there may be a gap between the joint end surfaces. The provision, inside the drum, of the structure in which the drum segments (pieces) are retreated radially inwardly may also pose the problem that the structure is complicated, its production is difficult, and its accuracy is difficult to maintain. 
     In the apparatus disclosed in Patent Document 2, the carcass ply is moved, with its free end surfaces being held by the support roller. If the holding force of the support roller is strong, the carcass ply moves too much, resulting in an overlap of the joint ends. If the holding force of the support roller is weak, the force to draw the joint ends together does not occur. This involves the problem that the holding force is very difficult to adjust, leading to the lack of versatility. 
     The apparatus disclosed in Patent Document 3 poses the following problem: The dowel body (joining means) is disposed only on the upper side of the carcass ply, and the force to draw the joint ends to each other acts only on one surface of the carcass ply. Thus, it has been difficult to bring the joint ends accurately close to each other, and so doing has been unreliable. 
     The present invention has been accomplished in the light of the above-mentioned problems. It is an object of this invention to provide a reliable apparatus for joining a carcass ply, in which a joining section is disposed together with aligning sections below a drum, whereby the drum can be simplified and accurate joining can be performed. 
     Solution to Problem 
     An aspect of the present invention for attaining the above object is an apparatus for joining a carcass ply, which butt-joins a wind start end and a wind finish end of a carcass ply wound around a cylindrical drum, comprising: 
     a joining section for joining the ends of the carcass ply; and 
     aligning sections for aligning the ends of the carcass ply during joining by the joining section, 
     the joining section and the aligning sections being disposed below the cylindrical drum supported in a horizontal state. 
     A pair of the joining sections may be installed at a right position and a left position so as to be slidable in an axial direction of the drum, each of the joining sections comprising an upper cone-shaped joining roller and a lower cone-shaped joining roller as a pair, upper and lower vertical drive sections for driving the joining rollers in a vertical direction, and a connecting member for connecting the vertical drive sections. 
     Each of the aligning sections may comprise a multiplicity of aligning rollers, and a multiplicity of roller drive sections for supporting the aligning rollers rotatably and driving the aligning rollers from a central side of the carcass ply toward a joining end of the carcass ply while pressing the carcass ply against the cylindrical drum by the aligning rollers, the aligning rollers and the roller drive sections being installed on both sides of a joining line of the carcass ply and along the joining line. 
     A scooping plate for scooping joining ends of the carcass ply may be disposed in the lower vertical drive section of each joining section forwardly in an advancing direction of the lower joining roller. 
     Wedge-shaped slant portions may be formed in parts of the connecting member which joining end surfaces of the carcass ply contact, whereby a function of a partition plate for preventing an overlap of the joining end surfaces is imparted. 
     Advantageous Effects of Invention 
     According to the apparatus for joining a carcass ply concerned with the present invention, the joining sections are disposed, together with the aligning sections, below the drum. Thus, the property of the ends of the carcass ply deforming downward (outwardly of the drum) is effectively restrained from below (from outside the drum), so that accurate joining can be performed without requiring delicate adjustments. Moreover, a device for joining need not be disposed within the drum. Thus, the drum can be simplified, and restrictions on the spaces of the joining sections and the aligning sections are relaxed. Also, the rigidity of the joining apparatus is increased to enhance the reliability of the apparatus. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a front view of an apparatus for joining a carcass ply, showing Embodiment 1 of the present invention. 
         FIG. 2  is a side view of the apparatus for joining a carcass ply. 
         FIG. 3  is a front view of a joining section. 
         FIG. 4  is a side view of the joining section. 
         FIG. 5  is a detailed side view of aligning sections. 
         FIG. 6  is a motion explanation drawing of a cylindrical drum. 
         FIG. 7  is another motion explanation drawing of the cylindrical drum. 
         FIG. 8  is a detail view of  FIG. 7 . 
         FIG. 9  is a motion explanation drawing of the joining sections. 
         FIG. 10  is a motion explanation drawing of aligning rollers. 
         FIG. 11  is a detail view of  FIG. 10 . 
         FIG. 12  is a motion explanation drawing of the aligning sections. 
         FIG. 13  is a motion explanation drawing of joining rollers and the aligning rollers. 
         FIG. 14  is a detail view of  FIG. 13 . 
         FIG. 15  is a motion explanation drawing of the aligning sections. 
         FIGS. 16(   a ) to  16  ( d ) are motion explanation drawings of the joining sections. 
         FIG. 17  is a front view of the joining section, showing Embodiment 2 of the present invention. 
         FIG. 18  is a side view of the joining section. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     An apparatus for joining a carcass ply according to the present invention will now be described in detail by embodiments using the appended drawings. 
     Embodiment 1 
       FIG. 1  is a front view of an apparatus for joining a carcass ply, showing Embodiment 1 of the present invention.  FIG. 2  is a side view of the apparatus for joining a carcass ply.  FIG. 3  is a front view of a joining section.  FIG. 4  is a side view of the joining section.  FIG. 5  is a detailed side view of aligning sections.  FIG. 6  is a motion explanation drawing of a cylindrical drum.  FIG. 7  is another motion explanation drawing of the cylindrical drum.  FIG. 8  is a detail view of  FIG. 7 .  FIG. 9  is a motion explanation drawing of the joining sections.  FIG. 10  is a motion explanation drawing of aligning rollers.  FIG. 11  is a detail view of  FIG. 10 .  FIG. 12  is a motion explanation drawing of the aligning sections.  FIG. 13  is a motion explanation drawing of joining rollers and the aligning rollers.  FIG. 14  is a detail view of  FIG. 13 .  FIG. 15  is a motion explanation drawing of the aligning sections.  FIGS. 16(   a ) to  16 ( d ) are motion explanation drawings of the joining sections. 
     As shown in  FIGS. 1 and 2 , a cylindrical drum  10  wound with a carcass ply W corresponding to one tire (to be described later) is supported on a horizontal rotating shaft  12  of a drum support section  11  so as to be rotatable by a rotational drive section  13  and expansible and contractible by an expansion/contraction mechanism  14 . 
     A pair of (right and left) joining sections  15 A and  15 B, which run in the axial direction of the drum along an opening portion (gap) G of the cylindrical drum  10  and join ends (a wind start end and a wind finish end) of the carcass ply W facing and entering the opening portion G, and a pair of (front and rear) aligning sections  16 A and  16 B for approaching and aligning the ends of the carcass ply W during joining by the joining sections  15 A and  15 B, are arranged below the cylindrical drum  10 . The opening portion G is designed to be naturally formed when the diameter of the cylindrical drum  10  (respective segments thereof) is increased. 
     The joining sections  15 A,  15 B, as shown in FIGS.  3  and  4 , each include a pair of (upper and lower) cone-shaped joining rollers (toe-in roller devices)  17   a  and  17   b , vertical drive sections  18   a  and  18   b  for driving the joining rollers  17   a  and  17   b  in a vertical direction by cylinders or the like, and a thin plate-shaped connecting member  19  for connecting the vertical drive sections  18   a  and  18   b . The joining sections  15 A and  15 B can each be allowed to run (slide) by a joining section travel drive motor  24  (see  FIG. 2 ) via a pair of (front and rear) linear guides  20   a  and  20   b  extending in the axial direction of the drum on a suitable counter. 
     The lower vertical drive section  18   b  has a scooping plate  21  disposed forwardly of the lower joining roller  17   b  in the advancing direction of the joining roller  17   b  (see an arrow in  FIG. 3 ), the scooping plate  21  being adapted to scoop joint ends of the carcass ply W. In front and rear edge parts of the connecting member  19 , wedge-shaped slant portions  19   a  and  19   b  are formed in their parts which joining or joint end surfaces of the carcass ply W contact, whereby the function of a partition plate for preventing an overlap of the joint end surfaces is imparted. In  FIG. 3 , an auxiliary roller  22  is adapted to hold the joint ends of the carcass ply W between the auxiliary roller  22  and the scooping plate  21 . 
     In the upper and lower paired cone-shaped joining rollers (toe-in roller devices)  17   a  and  17   b , one of the constituent rollers of the lower joining roller  17   b  is rotationally driven by a cone-shaped roller drive motor  23 , whereby the other constituent roller is also rotated in the opposite direction via a bevel gear mechanism. As a result, the function of a so-called shifting roller is achieved. On the other hand, the upper joining roller  17   a  holds the joint ends of the carcass ply W between it and the lower joining roller  17   b . In this state, the joining sections  15 A,  15 B run, whereby both rollers are rotated in a following manner. Thus, the function of a so-called shifting roller is achieved. 
     The aligning sections  16 A and  16 B, as shown in  FIG. 5 , are arranged on both sides of the travel line of the right and left paired joining sections  15 A and  15 B, and are of the same configuration, except for a part thereof to be described later. That is, the aligning sections  16 A and  16 B have support stands  28  installed horizontally on a pair of (right and left) counters  25  so as to be ascendable and descendable by the action of a pair of (right and left) parallel links  26  and a pair of (right and left) hoisting cylinders  27 . The support stand  28  is a long object having a length slightly exceeding the entire length of the cylindrical drum  10  (see  FIG. 1 ). 
     A slider  30  is placed on the support stand  28  so as to be movable (slidable) in a fore-and-aft direction (a direction orthogonal to the travel line of the joining sections  15 A and  15 B) via a linear guide  29 . A two-stage cylinder  31  for slider driving is interposed between the slider  30  and the support stand  28 . These members (linear guide  29 , slider  30 , two-stage cylinder  31 , etc.) constitute a roller drive section, and a multiplicity of these roller drive sections are installed on each support stand  28  in its right-and-left direction (a direction along the travel line of the joining sections  15 A and  15 B) (see  FIG. 1 ). 
     Proximal ends of a pair of (right and left) arms  33 , which support the constituent rollers of aligning rollers  32  near the leading ends thereof so as to be rotatable in forward and rearward directions, are pinned onto the sliders  30 . A spring  34  for always urging the leading end side of the arm  33  upward is interposed between an intermediate site of the arm  33  and the slider  30 . 
     The aligning roller  32  is composed of four rollers, i.e., two rollers arranged forward and rearward, and two rollers arranged on both sides of these rollers overlappingly in the fore-and-aft direction, as shown in  FIG. 9 . That is, as many of the aligning rollers  32  as possible are arranged in the fore-and-aft direction (the direction from the central side of the carcass ply toward the joint ends thereof) so that the end side of the carcass ply W located on the respective rollers can be linearly supported and regulated. 
     As will be seen from the layout of the aligning rollers  32  shown in  FIG. 9 , the roller drive sections of the aligning section  16 A and the roller drive sections of the aligning section  16 B are arranged in a staggered configuration (zigzag arrangement) in the right-and-left direction (the direction along the travel line of the joining sections  15 A,  15 B). At the extension limit position of the two-stage cylinder  31 , namely, the most forward position of the aligning roller  32 , the foremost rollers of the aligning rollers  32  of both the aligning section  16 A and the aligning section  16 B can be located on the line of joining of the carcass ply W (see  FIG. 10 ). 
     In  FIG. 5 , magnets  35   a ,  35   b  embedded along the opening portion G of the cylindrical drum  10  can temporarily hold the end sides of the carcass ply W. 
     Next, the motions of the present apparatus for joining a carcass ply will be described using the appended drawings. 
     As shown in  FIG. 6 , the cylindrical drum  10  having the segments increased in diameter by the expansion/contraction mechanism  14  to form the surface of the cylinder is wound with the carcass ply W cut to a size corresponding to one tire. The wind ends of the carcass ply W are positioned at the center of the opening portion G of the cylindrical drum  10 . (Winding may start in a lower part of the cylindrical drum  10 , but here, starts in an upper part of the cylindrical drum  10 .) Each end of the carcass ply W sags inwardly of the drum from the opening portion G of the cylindrical drum  10  under its own weight. 
     Then, as shown in  FIGS. 7 and 8 , the cylindrical drum  10  is rotated by the rotational drive section  13  to locate the opening portion G of the cylindrical drum  10  at a lower site. At this time, each end of the carcass ply W sags outwardly of the drum from the opening portion G of the cylindrical drum  10  under its own weight, with the result that the joint ends of the carcass ply W become open. The amount of the sag is not constant, but varies, depending on the characteristics of the carcass ply W, or the status of handling of the leading end or the rear end of the carcass ply W when wound. 
     Then, as shown in  FIGS. 8 and 9 , the right and left paired joining sections  15 A and  15 B are caused to run (slide) to nearly the center of the joining line of the carcass ply W by the respective joining section travel drive motors  24 . This position is not necessarily required to be the center, but preferably should not be an end region. On this occasion, the carcass ply W wound on the cylindrical drum  10  does not wrinkle or move, because the wedge-shaped slant portions  19   a  and  19   b  (see  FIG. 3 ) are formed in the portion of the connecting member  19  which the joint end surfaces of the carcass ply W contact. 
     Then, as shown in  FIGS. 10 to 12 , the support stands  28  of the front and rear paired aligning sections  16 A and  16 B are raised by the hoisting cylinders  27  to press the aligning rollers  32  against the cylindrical drum  10  (the lower surface of the carcass ply W) (see the state of the aligning section  16 B in  FIG. 5 ). Then, with this state being maintained, the aligning rollers  32  are moved from the outside of the opening portion G of the cylindrical drum  10  toward the center of the opening portion G by the two-stage cylinders  31 . That is, the two-stage cylinders  31  are moved from the contraction limit position to the extension limit position. 
     The constituent rollers of each aligning roller  32  are arranged such that when the foremost roller has moved to the center of the opening portion G of the cylindrical drum  10 , the rearmost roller contacts the opening end of the cylindrical drum  10 . In this state, the constituent rollers in the rows are nearly horizontal (see  FIG. 11 ). At this time, the ends of the carcass ply W (i.e., the wind start end and the wind finish end) are brought close to and aligned with each other, and are nearly in contact. However, gaps along the thickness of the connecting member are formed at the sites of the connecting members  19  of the joining sections  15 A and  15 B and places ahead of and behind them (see  FIG. 12 ). 
     Then, as shown in  FIGS. 13 and 14 , the lower joining roller  17   b  of the left joining section  15 B, for example, is raised by the vertical drive section  18   b  to bring the cone part of the joining roller  17   b  into contact with the lower surface of the ends of the carcass ply W. Simultaneously, the scooping plate  21  is also raised to make contact with the lower surface of the ends of the carcass ply W, whereby the ends of the carcass ply W (i.e., the wind start end and the wind finish end) separated by the connecting member  19  (the slant portions  19   a ,  19   b ) are aligned in a lifted form. Then, the upper joining roller  17   a  of the left joining section  15 B is lowered by the vertical drive section  18   a  to bring the cone part of the joining roller  17   a  into contact with the upper surface of the ends of the carcass ply W. 
     Then, as shown in  FIG. 15 , the left joining section  15 B is advanced (see the arrow in the drawing) along the linear guides  20   a ,  20   b  by the joining section travel drive motor  24 . On this occasion, the aligning rollers  32  located ahead of the left joining section  15 B are sequentially retracted by the two-stage cylinders  31 . At this position of retraction (an intermediate position between the extension limit position and the contraction limit position of the two-stage cylinder  31 ), the carcass ply W is sandwiched between the foremost roller and the opening edge portion of the cylindrical drum  10  to hold the carcass ply W (see  FIGS. 13 and 14 ). 
     Then, as shown in  FIGS. 16(   a ) to  16 ( d ), the right joining section  15 A is retracted by the joining section travel drive motor  24  until the joining rollers  17   a ,  17   b  of the right joining section  15 A are located at the position where joining by the left joining section  15 B is started (see  FIG. 16(   a )→ FIG. 16(   b )). Then, the right joining section  15 A is allowed to act in the same manner as is the left joining section  15 B, as explained with reference to  FIGS. 13 to 15 , whereby the axially opposite sides of the ends of the carcass play W (see the arrow in  FIG. 15)  are joined together (see  FIG. 16(   c )→ FIG. 16(   d )). 
     Then, the right and left paired joining sections  15 A and  15 B are moved to the outside of the joining line of the carcass ply W to complete joining. Finally, the front and rear paired aligning sections  16 A and  16 B are lowered by the hoisting cylinders  27  to bring the joining action to a halt. 
     According to the present embodiment described above, the right and left paired joining sections  15 A and  15 B are disposed, together with the front and rear paired aligning sections  16 A and  16 B, below the cylindrical drum  10 . Thus, the property of the ends of the carcass ply W deforming downward (outwardly of the drum) is effectively restrained from below (from outside the cylindrical drum  10 ), so that accurate joining can be performed without requiring delicate adjustments. 
     Nor is it necessary to dispose a device for joining within the cylindrical drum  10 . Thus, the cylindrical drum  10  can be simplified, and restrictions on the spaces of the joining sections  15 A,  15 B and the aligning sections  16 A,  16 B are relaxed. Also, the rigidity of the joining apparatus is increased to enhance the reliability of the apparatus. 
     Moreover, the installation of the right and left paired joining sections  15 A and  15 B enables the ends of the wide carcass ply W to be joined smoothly and promptly. 
     Furthermore, many of the aligning rollers  32  of the front and rear paired aligning sections  16 A and  16 B are installed on both sides of the joining line of the carcass ply W and along the joining line. Thus, the aligning rollers  32  in cooperation with the scooping plates  21  of the right and left paired joining sections  15 A and  15 B enable the ends of the carcass ply W to be approached to and aligned with each other with high accuracy. 
     Embodiment 2 
       FIG. 17  is a front view of the joining section, showing Embodiment 2 of the present invention.  FIG. 18  is a side view of the joining section. 
     This is an embodiment in which a partition plate  40  having the same function as that of the slant portions  19   a ,  19   b  of the connecting member  19  in Embodiment 1 is formed integrally with the scooping plate  21  of the lower vertical drive section  18   b . The other features are the same as those in Embodiment 1, and thus duplicate explanations for them are omitted. 
     In the present embodiment, the same actions and effects as in Embodiment 1 are obtained. 
     It goes without saying that the present invention is not limited to the above embodiments, and various changes and modifications may be made without departing from the gist of the present invention. For example, the right and left paired joining sections may be limited to one of them, the linear guides of the joining section and the aligning section may be replaced by other moving mechanisms, or the number of the constituent rollers of the aligning roller may be increased or decreased. Furthermore, the opening portion in the axial direction of the drum, where the joining section runs, may be closed in a continuous cylindrical surface when the carcass ply is wound, but may be provided in an open form only during the joining action. 
     INDUSTRIAL APPLICABILITY 
     The apparatus for joining a carcass ply according to the present invention is preferably used in equipment for producing a large tire in a construction vehicle or the like. 
     REFERENCE SIGNS LIST 
     
         
         
           
               10  Cylindrical drum 
               11  Drum support section 
               12  Rotating shaft 
               13  Rotational drive section 
               14  Expansion/contraction mechanism 
               15 A,  15 B Joining section 
               16 A,  16 B Aligning section 
               17   a ,  17   b  Joining roller (toe-in roller device) 
               18   a ,  18   b  Vertical drive section 
               19  Connecting member 
               19   a ,  19   b  Slant portion 
               20   a ,  20   b  Linear guide 
               21  Scooping plate 
               22  Auxiliary roller 
               23  Cone-shaped roller drive motor 
               24  Joining section travel drive motor 
               25  Counter 
               26  Parallel link 
               27  Hoisting cylinder 
               28  Support stand 
               29  Linear guide 
               30  Slider 
               31  Two-stage cylinder 
               32  Aligning roller 
               33  Arm 
               34  Spring 
               35   a ,  35   b  Magnet 
             W Carcass ply 
             G Opening portion 
           
         
       
    
     CITATION LIST 
     Patent Literature 
     
         
         Patent Document 1: JP-A-2003-19761 
         Patent Document 2: Japanese Patent No. 3420727 
         Patent Document 3: Japanese Patent No. 3045459