Patent Description:
Often, a single manufacturing facility may produce several types of beads with varying sizes and shapes. Existing equipment may not be able to form more than one type of bead, and therefore multiple machines, each associated with a specific type of bead, can be required in each of these facilities. Other equipment may be adjustable to accommodate different types of beads, but the adjustment process may be burdensome and require substantial modifications to the machinery (thereby requiring downtime). For example, the former, which is generally associated with a particular bead type, must be removed and replaced. The former is generally a heavy piece of equipment and may require a substantial amount of time to remove and replace, thereby increasing costs and production times when adjusting machinery to accommodate a different bead.

Examples for bead forming devices are disclosed in <CIT>, <CIT> and <CIT> B. A system for applying a bead filler to a bead core is disclosed in patent application <CIT>.

Thus, an improved bead forming system with a former having improved efficiency and ease of use may be desirable. Therefore, the present invention relates to a bead forming system for forming a tire bead according to independent claim <NUM>.

The embodiments of the present disclosure may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, with emphasis instead being placed upon illustrating the principles of the present disclosure. Moreover, in the figures, like referenced numerals designate similar or identical features.

The present embodiments are described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood from the following detailed description. However, the embodiments of the invention are not limited to the embodiments illustrated in the drawings. It should be understood that in certain instances, details have been omitted which are not necessary for an understanding of the present invention, such as conventional fabrication and assembly.

Notably, in addition to the features described below (and variations thereof), the systems herein may incorporate readily-available equipment and technology for the formation of annular bead ring, such as components from commercially-available products like the SWS-<NUM> Single Wire Bead Winding System and/or the TDS-<NUM> Bead Winder System, each of which are manufactured by Bartell Machinery Systems, L. of Rome, New York. Incorporation of certain existing components may provide backwards compatibility with respect to certain mechanical parts, thereby reducing up-front cost to certain customers.

Referring now to the figures, <FIG> shows a perspective view of a bead forming system <NUM> for forming at least one tire bead. <FIG> shows a top view of the bead forming system <NUM>. <FIG> shows a front view of the same. The bead forming system <NUM> depicted in <FIG>, and variations thereof, may have the ability for producing tire beads of multiple sizes. Further, as discussed in detail below, the bead forming system <NUM> may be advantageously capable of rotating a first bead former <NUM> between an operational position and a loading or setup position. When the first bead former <NUM> is in the first position <NUM> (e.g., for bead manufacturing), the second bead former <NUM> may be in the second position <NUM>, whereby the second bead former <NUM> may be manipulated to later manufacture a bead of a particular size. At an appropriate time, the first bead former <NUM> and the second bead former <NUM> may switch places, thereby allowing a bead of a different characteristic (e.g., a different diameter) to be formed by the associated bead winding equipment.

Such a feature is advantageous for providing a quick and efficient way for configuring the bead forming system <NUM> to form a bead of a different characteristic (e.g., a different size) while reducing machine downtime relative to other systems. For example, while other systems must shut down for substantial periods of time when changing bead sizes (e.g., for hours in some circumstances), the present embodiments provide a way for such setup to occur without any, or very little, machine downtime. For example, the only required machine downtime may occur when the first bead former <NUM> and the second bead former <NUM> are switching positions (which may occur in less than <NUM> seconds in certain exemplary embodiments). Systems with this capability may also occupy relatively little space relative to their manufacturing capacity (e.g., as less downtime increases the output of each system).

As shown in <FIG>, a housing <NUM> may form a substantial portion of the bead forming system <NUM>. The housing may be formed of sheet metal, for example. In the depicted configuration, the first bead former <NUM> is located in a first position <NUM> on the first side <NUM> of the housing <NUM> and the second bead former is located in a second position <NUM> on the second side of the housing <NUM>. The first position <NUM> may be a position where a corresponding bead former engages bead winding equipment <NUM>. That is, when the first bead former <NUM> (and/or the second bead former <NUM>) is located in the first position <NUM>, it is located with an appropriate proximity relative to the bead winding equipment <NUM> such that a bead can be formed on the first bead former <NUM>. The second position <NUM> may lack bead winding equipment. Instead, the second position <NUM> may include setup equipment (as discussed below) and/or appropriate floor space for manual setup such that a bead former in this position can be adjusted for future manufacturing of a bead with particular characteristics. Notably, the first bead former <NUM> and the second bead former <NUM> may be separately operable (e.g., operation/rotation of one does not affect the other) such that bead formation on the first bead former <NUM> does not affect a setup procedure on the second bead former <NUM>, and vice versa.

A base <NUM> may be secured to the first bead former <NUM> and/or the second bead former <NUM>. During a bead-winding operation in the depicted orientation, for example, the base <NUM> may remain substantially still (i.e., locked in place) while at least one tire bead is formed on a bead-receiving surface <NUM> of the first bead former <NUM>. The first bead former <NUM> may rotate relative to the base <NUM> during this bead formation. Simultaneously, the second bead former <NUM> may be substantially still (or at least unaffected by the rotation of the first bead former <NUM>) such that a setup process can occur.

Once a bead winding on the first bead former <NUM> is complete (and/or setup of the second bead former <NUM> is complete), the base <NUM> may rotate or otherwise move such that the first bead former <NUM> and the second bead former <NUM> switch places. Once switched, the second bead former <NUM> may be located in the first position <NUM> on the first side of the housing <NUM> (for bead formation using the second bead former <NUM>) and the first bead former <NUM> may be located in the second position <NUM> on the second side of the housing <NUM> (e.g., where it may be reconfigured for forming a different bead type, if desired).

A setup area <NUM> may be located on the second side <NUM> of the housing <NUM>. In some embodiments (such as the embodiment of <FIG>), the setup area <NUM> may simply include floor space that is sufficient for retooling a bead former, which may be occupied by tools, bead former components, workstations, and/or other equipment for use by a worker with expertise in bead former setup. Additionally or alternatively, at least one robotic or other automatic retooling mechanism may be included. In the depicted example of <FIG>, a robotic arm <NUM> is included. The robotic arm <NUM> may be configured for changing the second bead former <NUM> between a first bead setting and a second bead setting, where these bead settings are associated with different bead characteristics. For example, the robotic arm may change the size of the second bead former <NUM> (in the depicted orientation) such that, when appropriate, the second bead former <NUM> can be moved into the first position <NUM> (discussed above, see <FIG>) ready for the immediate initiation of manufacturing a bead with desired characteristics (which may be different from a bead previously manufactured on the second bead former <NUM>). To illustrate, the robotic arm <NUM> is moving a chuck portion <NUM> into place in <FIG> (which may be replacing a prior chuck portion).

<FIG> shows a portion of the bead forming system <NUM> where the housing <NUM> (see <FIG>) is absent. A base housing is also absent from view in <FIG> such that base components <NUM> of the base are shown. The base <NUM> may include actuators for operating the first bead former <NUM> and the second bead former <NUM> (and it is noted that the second bead former <NUM> is shown with a smaller setup in this image). For example, a first actuator <NUM> may be included for rotating the first bead former <NUM> about a bead former axis <NUM>. A second actuator <NUM> may be included for controlling the radial position of at least one bead-receiving surface <NUM> (with the grooves <NUM>) of the first bead former <NUM> (e.g., such that the bead-receiving surface <NUM> may move into and out of engagement with a bead). Similar or identical actuators may be associated with the second bead former <NUM>. Optionally, the actuators associated with the first bead former <NUM> and the actuators associated with the second bead former <NUM> may be wholly separately operable such that operation of one bead former does not affect the other (as discussed above).

The base <NUM> may also be rotatable (e.g., through attachment to a rotatable base plate <NUM> as discussed in more detail below). For example, the base <NUM> may be rotatable about a base axis <NUM> (shown in <FIG>). Such rotation may be utilized for moving the first bead former <NUM> and/or the second bead former <NUM> between operational and setup positions, as discussed above. As shown in <FIG>, the base axis <NUM> may be perpendicular to the bead former axis <NUM>. Notably, the base axis <NUM> may be angled relative to the true vertical (where "true horizontal" is defined as a plane parallel to flat ground and determined by the gravity of Earth, and where "true vertical" is defined as a direction perpendicular to "true horizontal"). For example, the base axis <NUM> may be angled at least <NUM> degrees, such as at least <NUM> degrees, such as at least <NUM> degrees (or more) relative to true vertical. Such an angle ensure that contact is not made between the bead formers and winding equipment during bead former movement. That is, referring to <FIG> (which shows space <NUM> that may be occupied during the rotation of a former), the pathway of the first bead former <NUM> does not interfere with any bead winding equipment <NUM> or other components. Such a feature is advantageous relative to certain other embodiments since the bead winding equipment <NUM> can remain fixed in place during movement of the bead formers rather than being moved out of the way, which may further enhance the efficiency of the bead forming system <NUM> by further reducing downtime.

<FIG> shows an exploded view of the housing <NUM> of the bead forming system <NUM> along with the base plate <NUM>. The base plate <NUM>, which may be rotatable relative to the depicted housing components, may include a top surface <NUM> that fixes to the base <NUM> (discussed above). The top surface <NUM> may be substantially planar, and it may remain in a plane as it rotates. Thus, axis of rotation of the base plate <NUM> (which may define the base axis, discussed above) may be perpendicular to the top surface of the base plate <NUM>. Such an arrangement may be advantageous for providing a predictable and stable rotation of the base plate <NUM> (and therefore the base <NUM> and associated bead formers, discussed above).

While not shown in the figures, the base plate <NUM> and/or another component coupled to the base <NUM> (<FIG>) may be driven via an actuator, such as a pneumatic or hydraulic actuator, and electric motor, etc. When an actuator is included, it may be fixed to the housing, for example. Alternatively, it is contemplated that the base plate <NUM> may be rotatable manually by a human operator. In such embodiments, the base plate <NUM> preferably includes a locking device such that it can be fixed from rotation relative to the housing at least when a bead is being formed.

<FIG> also illustrates that the housing <NUM> may have various openings, where appropriate. For example, a first housing opening <NUM> may be located on the first side <NUM> of the housing <NUM> and a second housing opening <NUM> may be located on the second side of the housing <NUM>. Thus, the first housing opening may accommodate a bead former when the bead former is in the first position <NUM> of <FIG>, and the second housing opening <NUM> may accommodate a bead former when it is in the respective second position <NUM>. While only two openings are included, additional openings are also contemplated (e.g., where three or more bead formers are attached to a base, and/or where there are multiple setup stations, for example).

<FIG> shows an alternative embodiment of a bead forming system <NUM>. In <FIG>, two manufacturing stages are included. For example, a set of bead winding equipment <NUM> may be located on the first side of a housing <NUM> and a set of apex application equipment <NUM> (which appears similar to the equipment <NUM>, though it may be substantially different in practice) may be located on a first side <NUM> of the housing <NUM>. A base (similar or identical to the base <NUM> discussed above) may be included for switching positions of a first bead former <NUM> and a second bead former <NUM> in a manner consistent with the embodiments above (and variations thereof). Advantageously, multiple steps of the tire forming process may be accomplished without manual intervention. While only two stages are depicted in this example, it is contemplated that three or more formers may be coupled to the base <NUM> and thus three or more manufacturing stages (and/or setup stages) may be included. When two formers are included, a common drive shaft may rotate these formers (but this feature is optional, and separate actuators may be desirable).

While various embodiments of the invention have been described, the invention is not to be restricted except in light of the attached claims and their equivalents. Moreover, the advantages described herein are not necessarily the only advantages of the invention and it is not necessarily expected that every embodiment of the invention will achieve all of the advantages described.

Without limitation, the subject matter of this disclosure may also relate to one or more of the following aspects (and combinations thereof):.

According to the invention, the bead forming system for forming a tire bead includes the following: a housing, a first bead former configured to facilitate the formation of the tire bead, and a base secured to the first bead former, where the first bead former includes a bead-receiving surface that is rotatable relative to the base. The base is adjustable such that the first bead former is movable from a first position to a second position. The first position is on a first side of the housing, and the second position is on a second side of the housing. A second bead former may be located in the second position when the first bead former is located in the first position, where the second bead former is located in the first position when the first bead former is located in the second position.

The bead former may engage one or more bead winding machinery components when the first bead former is in the first position. The first bead former is located in a setup area when the first bead former is located in the second position. The setup area may include at least one robotic component configured for changing the first bead former between a first bead setting and a second bead setting.

The bead-receiving surface may circumnavigate a bead former axis, where the first bead former is rotatable about the first bead former axis relative to the base. The base may be rotatable about a base axis, and the base axis may be perpendicular to the first bead former axis. The base axis may be angled relative to the true vertical.

The base may be fixed to a surface of a base plate, where the surface of the base plate is rotatable to move the first bead former between the first position and the second position. The surface of the base plate may remain in a plane when the base plate rotates, where the plane is angled relative to the true horizontal. The rotation of the base plate may be controlled via at least one actuator that is fixed to the housing.

The housing may include a first opening and a second opening, the first opening being on the first side of the housing and accommodating the bead when the first bead former is in the first position, and the second opening being on the second side of the housing and accommodating the bead when the first bead former is in the second position.

The base may include a first actuator for rotating the first bead former about a bead former axis, and where the base includes a second actuator for controlling a radial position of the bead-receiving surface of the bead.

In an aspect, a bead forming system for forming a tire bead may include the following: a bead former configured to facilitate the formation of the tire bead, and a base secured to the bead former, where the bead former includes a bead-receiving surface that is rotatable relative to the base about a first axis. The base may be rotatable about a second axis such that the bead former is movable from a first position to a second position.

The first axis may be perpendicular to the second axis.

The second axis may be angled relative to the true vertical.

The first position may be on a first side of a housing and corresponds with a first housing opening, and the second position may be on a second side of the housing and corresponds with a second housing opening.

The bead former may engage one or more bead winding machinery components when the bead former is in the first position.

Claim 1:
A bead forming system for forming a tire bead, the bead forming system comprising:
a housing (<NUM>) having a first side (<NUM>) and a second side (<NUM>); and
a base (<NUM>) coupled to a first former (<NUM>) and a second former (<NUM>),
wherein the first former is on the first side of the housing and comprises a first diameter,
wherein, when the first former (<NUM>) is on the first side of the housing, the second former (<NUM>) is on the second side of the housing, and
comprises a second diameter, which is different from the first diameter, and
wherein the base (<NUM>) is rotatable such that the first former is movable to the second side of the housing and the second former is movable to the first side of the housing;
a bead winding equipment (<NUM>),
wherein when the first former (<NUM>) or the second former (<NUM>) is located on the first side (<NUM>),
the first former or the second former is located with an appropriate proximity relative to the bead winding equipment (<NUM>) such
that a bead can be formed on the first former or the second former.