Patent Description:
The present invention relates to a transporter according to the preamble of claim <NUM>, such as it is, e.g., known from <CIT>. <CIT> relates to a device for joining ends of material strips of rubber or plastic materials with rubber properties. Tires are commonly manufactured from multiple layers and components that are placed sequentially onto a cylindrical drum. In some known techniques, a layer of air impermeable rubber is laid onto a forming surface of a drum, and one or more carcass plies are placed thereon. The terms "carcass ply," "carcass," "reinforcement ply" or "body ply" may each refer to a ply that extends between and from the bead portions on opposing sides of the tire, through the opposing sidewall portions, and across the crown portion of the tire. The body ply may include ferrous reinforcements.

A pair of circular beads is placed on opposing drum sides and may include bead wires and bead fillers. After the plies are turned up and the beads moved towards each other to create a toroidal shape, a sidewall protective rubber and a tread portion are added.

It is well-known to adapt tire manufacturing techniques for the construction of self-supporting tire systems that include reinforced sidewalls (as used herein, "self-supporting tire system" and "self-supporting tire" may be used interchangeably). Such self-supporting tire systems, in supporting a vehicle upon loss of air pressure, permit continued vehicle operation up to a predetermined speed and distance (typically specified by the the manufacturer). Self-supporting tire systems help drivers maintain control in the absence or near-absence of air pressure and work reliably with a variety of synergistic technologies, including but not limited to tire pressure monitoring systems (TPMS).

There are challenges associated with the manufacture of self-supporting tires, including those having reinforcements in the sidewalls. A forming drum having a generally cylindrical shape and a flat profile along the axial direction may also include recesses for accepting features such as circular beads. When reinforcements are presented onto the forming drum before a carcass ply or reinforcing ply is laid thereonto, the reinforcements create a profile that is no longer flat along the axial direction of the drum. Presentation of a carcass ply onto this uneven profile can result in undesirable creases or wrinkles, notably when attempting to press the carcass ply towards the forming drum to make contact with an air impermeable layer disposed thereon. Consequently, these creases may incur deradialization, that is, an undesirable orientation and positioning of cords and/or other reinforcing elements present in the reinforcing ply. Additionally, variance may occur in the overlap of the joint of the ply ends. Solutions to such challenges are provided by co-owned and copending <CIT>. <CIT> discloses a further known prior art.

Complementary solutions for effective posing and assembling processes have been developed that accurately position each component of a self-supporting tire system relative to the reinforcements.

A transporter is provided for retrieving at least one reinforcing ply and conforming the at least one reinforcing ply to a forming surface of a rotatable forming drum having axial and circumferential directions. The forming surface is coextensive with a pair of opposed sides and has one or more tire components disposed thereon. An exemplary transporter includes a manifold including one or more supply ports each having a supply port inlet in communication with a vacuum supply source, and a supply port outlet for delivery of a vacuum to one or more suction cup assemblies supported by an assembly support bar. Each suction cup assembly includes a suction cup in generally coaxial alignment with a suction cup retainer. Each suction cup is reciprocatably and translationally positionable between a ply retrieval position, in <. > = Each suction cup assembly has a slide housing. which the at least one reinforcing ply is retrieved from a generally even surface, and a ply pose position, in which the at least one reinforcing ply assumes a profile shape of the forming surface of the drum before posing of the at least one reinforcing ply on the one or more tire components.

In some embodiments, the transporter includes at least one conduit having opposed extents that establish fluid communication between each supply port outlet and at least one corresponding delivery fitting so as to actuate at least one suction cup assembly upon delivery of the vacuum thereto. In Each suction cup assembly has a slide housing. some embodiments, each suction cup assembly includes a slide shaft reciprocatingly accommodated within the slide housing and coaxially disposed relative to an extension spring that governs vertical motion of the suction cup. The vertical motion may be limited by an adjustable stop tab that engages at least a portion of the slide housing. In some embodiments, a pair of stops may be included that provide adjustment limits for the stop tab. The adjustment limits may be optionally preset to accommodate actuation of one or more suction cup assemblies between the ply retrieval position and the ply pose position.

In some embodiments, the transporter may be in signal communication with at least one programmable controller in which one or more profile shapes are programmed such that the ply pose position is selectable from a plurality of profile shapes.

A method of assembling tire components for the manufacture of self-supporting tires is also provided. In an exemplary method, one or more air impermeable layers are laid onto a forming surface of a rotatable forming drum having axial and circumferential directions and with the forming surface being coextensive with a pair of opposed sides. At least a pair of sidewall support inserts is positioned onto the one or more air impermeable layers with at least one sidewall support insert placed at a predetermined relative distance from each opposed side. At least one transporter as presently disclosed is provided for retrieving at least one reinforcing ply and placing the at least one reinforcing ply over the at least one pair of sidewall support inserts on the drum.

In some embodiments of the presently disclosed method, one or more posing cycles is performed for shaping and depositing the at least one reinforcing ply on the drum. A posing cycle may include providing a tension device having a plurality of tension values for selective application of a laying tension of the at least one reinforcing ply.

Other aspects of the presently disclosed invention will become readily apparent from the following detailed description.

The nature and various advantages of the presently disclosed invention will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:.

Reference now will be made in detail to embodiments of the presently disclosed invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation and not by limitation. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment can be used with one or more other embodiments to yield at least one further embodiment.

Now referring to the figures, wherein like numbers represent like elements, a user can initiate an exemplary method for forming a self-supporting tire as provided herein (although it is understood that the presently disclosed processes are suitable for production with any amenable self-supporting tire system). As used herein, a "user" may be a single user or one or more groups of users and may refer to any electronic apparatus configured for receiving control input and configured to send commands and/or data either interactively or automatically to other devices (including but not limited to user devices, client devices, network-connected devices and devices). As used herein, the term "process" or "method" may include one or more steps performed at least by one electronic or computer-based apparatus. Any sequence of steps is exemplary and is not intended to limit methods described herein to any particular sequence, nor is it intended to preclude adding steps, omitting steps, repeating steps or performing steps simultaneously.

Further referring to <FIG>, an air impermeable layer <NUM> (also known as an "inner liner") is placed on a forming drum <NUM> and generally centered between opposed sides 102a and 102b thereof (as used herein, "drum," "assembly drum" and "tambour" may be used interchangeably to refer to a circumferentially rotating element having a surface for receipt of one or more tire components during tire manufacture). Drum <NUM> has a cylindrically-shaped forming surface 102c coextensive with opposed sides 102a, 102b that is substantially flat along an axial direction A and curved along a circumferential direction C (see <FIG>). Drum <NUM> is rotatable so as to allow forming surface 102c to receive various components thereon during tire construction. Drum <NUM> may include various internal features for positioning components placed onto forming surface 102c. While only one layer <NUM> is illustrated, it is understood that one or more air impermeable layers may be used.

At least a pair of sidewall support inserts <NUM> may be disposed upon layer <NUM>. Each sidewall support insert <NUM> is placed at a predetermined relative distance from respective side 102a, 102b (i.e., such the opposing inserts are generally equally spaced about a center line C/L). Sidewall support inserts <NUM> may assume any shape and size amenable to practice of the present disclosure and are not limited to the exemplary shape and size shown herein. Also, while only a pair of sidewall support inserts <NUM> is shown, it is understood that more than one pair may be employed (e.g., to increase the sidewall strength of the assembled self-supporting tire).

A carcass ply <NUM> is disposed relative to layer <NUM> and inserts <NUM> as shown, which carcass ply may include respective reinforcing plies <NUM>, <NUM>. As used herein, "ply," "reinforcement ply" and "reinforcing ply" (in both singular and plural forms) may be used interchangeably to refer to one or more reinforcement plies. A cutting implement (not shown) as known in the art directs cutting of plies <NUM>, <NUM> to form respective leading and trailing edges that meet along a joint <NUM> (see <FIG>). Each reinforcement ply <NUM>, <NUM> includes a plurality of cords and/or other reinforcing features that inure stiffness while allowing the plies to remain substantially non-expandable in an axial direction. Accordingly, in an exemplary embodiment of the presently disclosed invention, plies <NUM>, <NUM> are placed onto, and between, sidewall support inserts <NUM> so that they are suspended over forming surface 102c. This creates a temporary cavity <NUM> extending circumferentially about drum <NUM> between air impermeable layer <NUM> and reinforcing ply <NUM>.

As particularly seen in <FIG>, one or more reinforcing plies may include a plurality of perforations <NUM> along a circumferential direction C. Each perforation <NUM> may be centrally positioned, for example, on reinforcing ply <NUM>. In some embodiments, perforations <NUM> may be located in a crown region of the tire.

While two plies are shown herein, it is understood that a single reinforcing ply or more than two reinforcing plies may also be employed without departing from the scope of the present disclosure. Additionally, where multiple reinforcing plies are used, such plies do not require simultaneous application over drum <NUM>. It is further understood that other components may be added between the application of adjacent reinforcing plies (such as reinforcement plies <NUM>, <NUM>). For example, additional sidewall reinforcement inserts may be disposed axially outward of sidewall support inserts <NUM> and reinforcing ply <NUM> subsequently positioned thereover.

Posing of carcass ply <NUM> is effected so as to avoid modifications to the drum that are dimension specific, thereby accommodating production processes that use multiple drums. Posing may include use of a transporter that is used on automatic equipment to pick up a carcass ply (for example, at or near a leading edge thereof as further described hereinbelow). A transporter is a device that is used on automatic equipment to retrieve a tire component, bring it to the forming drum and place it on a forming surface thereof (e.g., placing the transported tire component directly on the forming drum surface or upon one or more other components already disposed thereon). Examples of such transporter assemblies are disclosed by co-owned and copending <CIT>.

As shown by <FIG>, an exemplary transporter <NUM> is provided that is amenable for use with the presently described invention. Transporter <NUM> includes a manifold <NUM> to which a bar support <NUM> is affixed for retention of an assembly bar <NUM> thereby. Bar support <NUM> is shown as a generally U-shaped member having legs 204a with free extents 204b secured to manifold <NUM> such that retention pin <NUM> is centrally disposed therebetween. It is understood that bar support <NUM> may assume any other suitable geometry and any other equivalent securement configuration may be employed. Retention pin <NUM>, while shown as an adjustable threaded fastener that enables modifiable positioning of transporter <NUM> relative to any automatic equipment to which it is attached, may include any suitable fastening means amenable with successful practice of the presently disclosed invention.

Referring further to <FIG>, manifold <NUM> includes one or more vacuum supply ports <NUM>. Each supply port has an inlet 210a in communication with a vacuum supply source (not shown) as is known in the art for delivery of a vacuum to one or more corresponding vacuum supply fittings <NUM>. Each vacuum supply fitting has an outlet 212a in fluid communication with one or more suction cup assemblies <NUM>. Fluid communication may be established via a conduit such as duct <NUM> shown in <FIG> (although it is understood that other equivalent conduits may be utilized without deviating from the scope of the present disclosure).

Each duct <NUM> has opposed extents 216a, 216b that establish fluid communication between each supply port outlet 212a and at least one corresponding delivery fitting <NUM>. Each delivery fitting <NUM> includes a delivery inlet 218a that accommodates unimpeded delivery of a vacuum to a lumen 214b. It is understood that ducts <NUM> may establish a one-to-one correspondence between each vacuum supply fitting <NUM> and a corresponding delivery fitting <NUM>. Alternatively, one or more ducts <NUM> may be bifurcated, trifurcated or otherwise segregated such that one duct serves multiple ports and/or fittings. It is understood that the depicted numbers of vacuum supply fittings <NUM> and delivery fittings <NUM> are merely exemplary and that such numbers are modifiable without departing from the scope of the present disclosure.

A vacuum may be supplied via each delivery fitting <NUM> so as to actuate at least one retention device in communication therewith and actuatably supported by assembly bar <NUM>. As shown in further detail in <FIG>, such retention device may include an exemplary suction cup assembly <NUM> that, in operation, exhibits reciprocatable and translational movement relative to assembly bar <NUM>. Assembly bar <NUM>, which is fixed, may support a plurality of suction cup assemblies <NUM> thereby, although the number of suction cup assemblies is not limited to those presently shown. Suction cup assemblies <NUM> may be aligned and arranged consecutively so as to substantially cover an entire width of a carcass ply retrieved thereby (e.g., such as exemplary carcass ply <NUM> described herein with respect to <FIG>). It is contemplated that one or more suction cup assemblies <NUM> may be added to or removed from assembly bar <NUM> to adjust for variations in carcass ply dimensions.

In each suction cup assembly <NUM>, a suction cup <NUM> is in generally coaxial alignment with a suction cup retainer <NUM> and a slide shaft <NUM> reciprocatingly accommodated within a slide housing <NUM>. Slide shaft <NUM> is coaxially disposed relative to a cup extension spring <NUM> that governs vertical motion of suction cup <NUM>. Such vertical motion is limited by an adjustable stop tab <NUM> engaging slide housing <NUM> (and particularly detent 226a thereof). Stop tab <NUM> is adjustable relative to slide housing <NUM> so as to accommodate a plurality of dimensions thereby. In some embodiments, a pair of stops 232a, 232b may serve as adjustment limits for stop tab <NUM>, which adjustment limits may be preset to the shape of a selected forming drum surface and thereby accommodate actuation of at least one suction cup assembly between the ply retrieval position and the ply pose position.

Referring to <FIG>, transporter <NUM> changes its profile shape by effecting actuation of each suction cup <NUM> between a carcass ply retrieval position (also referred to herein as "retrieval position"), wherein carcass ply <NUM> is retrieved from a generally flat surface <NUM> (see <FIG>), and a carcass ply pose position (also referred to herein as "pose position"), wherein carcass ply <NUM> is posed upon an uneven surface <NUM> having a profile (see <FIG> for an exemplary profiled surface having profiles 305a thereat). A vacuum applied though each delivery fitting <NUM> effects retrieval of the carcass play in a predictable and reliable manner. It is understood that while the vacuum effectively retrieves carcass ply <NUM>, other means may complement the vacuum, including but not limited to one or more magnets or equivalent retrieval means, as is known in the art.

From the retrieval position, when carcass ply <NUM> is retrieved from flat surface <NUM>, each cup extension spring <NUM> is compressed when an automatic mechanism in operating communication with transporter <NUM> effects downward movement of the transporter toward carcass ply <NUM> in the direction of arrows <NUM> (see <FIG>) (such automatic mechanisms that effect up/down translation are well known in the art and do not form any part of the presently disclosed invention). Consequently, one or more suction cup assemblies <NUM> are horizontally directed along bearing rail <NUM> in the directions of arrows <NUM>. Compression of spring <NUM> consequently effects movement of adjustable stop screw <NUM> toward stop 232b. Upon lifting of carcass ply <NUM> from flat surface <NUM>, the carcass ply is held in the profile of uneven surface <NUM> to which it will be applied (see <FIG>).

As the contour of carcass ply <NUM> changes from a straight profile to an undulating one, compensation for this change becomes necessary as the carcass ply is shaped. Failure to consider such compensation would undesirably prevent full extension of cup extension springs <NUM>. Slide housing <NUM> is therefore fastened by at least one lateral return cord <NUM> to a horizontal slide bearing <NUM>. Slide bearing <NUM> is actuatably disposed proximate a bearing rail <NUM> affixed to assembly bar <NUM>. One or more additional fasteners may optionally secure slide housing <NUM> to slide bearing <NUM> as is known in the art.

Lateral return cord <NUM> has a predetermined length coextensive with opposed free extents 232a. Each lateral cord free extent 232a may have a retention means provided thereat for retention by at least one retaining fastener <NUM>. As shown in the figures, such retention means may include an eyelet hook <NUM> or equivalent structure that is readily secured by a return spring <NUM> having opposed spring hooks 240a, 240b for selective removable securement of the spring with retaining fastener <NUM>. The retention of lateral return cord <NUM> by return spring <NUM> in such a configuration ensures sufficient tension in the lateral return cord, thereby preserving suction cup assemblies <NUM> in, and returning them to, the retrieval position while facilitating change to an accurate pose position.

Upon application of carcass ply <NUM> to uneven surface <NUM>, one or more suction cup assemblies <NUM> are horizontally directed along bearing rail <NUM>. Such horizontal movement is accommodated by lateral return cord <NUM> and the consequent extension of each return spring <NUM> to reach the ply pose position (e.g., as shown by example in <FIG>). Upon release of carcass ply <NUM> upon uneven surface <NUM>, return springs <NUM> urge suction cup assemblies <NUM> to the ply retrieval position (e.g., as shown by example in <FIG>) in preparation for a subsequent posing cycle.

Each suction cup assembly <NUM> is independently actuatable relative to any other suction cup assembly and relative to assembly bar <NUM>. Thus, each suction cup assembly <NUM> has an adjustable height and an adjustable spacing relative to any other suction cup assembly so as to adapt an uneven profile such as that shown in <FIG>. Each suction cup assembly <NUM> is positionable prior to retrieving a carcass ply such that, upon such retrieval, the carcass ply automatically assumes the uneven profile of the forming surface to which it will be applied. One or more profile contours may be preprogrammed (for example, as by one or more programmable logic controllers, or PLCs) such that a single production session can accommodate identical contours multiple times and/or varying contours in succession.

Transporter <NUM> is generally fabricated from commercially available hardware and simple machined parts. It is therefore a readily available lightweight complement to existing automatic machines. For example, each of manifold <NUM>, bar support <NUM>, assembly bar <NUM> and retention pin <NUM> may be fabricated from materials including but not limited to aluminum, stainless steel, metal, composite and any comparable and/or equivalent material. Suction cup assemblies <NUM> are easily assembled from commercially available parts and/or parts that are readily machined with minimal temporal and fiscal investment (e.g., such as by rapid prototyping).

Referring to <FIG>, another exemplary transporter <NUM> is provided in which a polymer support structure <NUM> accommodates a plurality of retention devices. Transporter <NUM> may include a manifold <NUM> to which polymer support structure <NUM> is affixed for retention of a plurality of suction cups <NUM>. Polymer support structure is desirably fabricated from a flexible polymer (e.g., one or more types of rubber, polyurethane, etc.), although it is understood that equivalent materials are contemplated that are amenable for use with the present disclosure. Suction cups <NUM> may be aligned and arranged consecutively so as to substantially cover an entire width of a carcass ply retrieved thereby.

Manifold <NUM> may include at least one retention pin <NUM> for securement of transporter <NUM> to automatic equipment as is known in the art. Manifold <NUM> may also include a plurality of vacuum supply ports <NUM>. Each vacuum supply port includes an outlet in fluid communication with one or more suction cups <NUM> and an inlet in communication with a vacuum supply source (not shown) as is known in the art. Each port outlet enables delivery of a vacuum to one or more corresponding suction cups <NUM> for effective retrieval of one or more carcass plies thereby. The vacuum is delivered by one or more ducts (not shown) in a manner similar to that described hereinabove with respect to transporter <NUM>. It is understood that the number of supply ports <NUM> depicted herein is merely exemplary and that such number is modifiable without departing from the scope of the present disclosure.

In use, transporter <NUM> changes a suction cup profile shape by effecting actuation of at least one suction cup <NUM> between a carcass ply retrieval position, wherein carcass ply <NUM> is retrieved from a generally flat surface (such as flat surface <NUM> shown in <FIG>) and a carcass ply pose position, wherein carcass ply <NUM> is posed upon an uneven surface <NUM>' having a profile (see <FIG>). A vacuum applied though each supply port <NUM> effects retrieval of the carcass play in a predictable and reliable manner. It is understood that while the vacuum effectively retrieves carcass ply <NUM>, other means may complement the vacuum, including but not limited to one or more magnets or equivalent retrieval means, as is known in the art.

From the retrieval position, when the carcass ply (not shown) is retrieved from a flat surface, transporter <NUM> continuously moves in a downward vertical direction toward uneven surface <NUM>' of the forming drum. Because polymer support structure <NUM> remains flexible throughout the process, when pressed upon the forming drum, the retrieved carcass ply conforms to the profile of uneven surface <NUM>'. The flexibility of polymer support structure <NUM> additionally facilitates vertical and horizontal actuation of suction cups <NUM> to ensure accurate profile conformance as well as immediate returns to the retrieval position to commence subsequent retrieval-posing cycles.

In some embodiments, transporter <NUM> takes on a predefined profile (e.g., an exemplary profile as shown in <FIG>) at the onset of a posing cycle. Transporter <NUM> may be fabricated (e.g. molded) such that the predefined profile is not malleable and therefore suction cups <NUM> remain in pre-set positions for the duration of use of transporter <NUM>. In such embodiments, one or more transporters <NUM> may be provided, for example, in a kit having multiple transporter profiles for use with multiple forming drum surfaces. Alternatively, one or more forces may be applied at least at or near a center of a length of transporter <NUM> to effect the predefined profile shape.

Transporters <NUM> and <NUM> are modifiable to apply carcass ply <NUM> over reinforcement layers up to a thickness as determined by the production process for the self-supporting tire. For example, in some embodiments, transporter <NUM> applies carcass ply <NUM> over reinforcement layers having a thickness up to and including <NUM>. Such thickness is provided as merely one example of the modifiability of the presently disclosed invention, and a person of ordinary skill would understand that successful practice of the presently disclosed invention is not limited to such reinforcement layer thicknesses.

Referring to <FIG>, an exemplary posing cycle is disclosed that incorporates the strategic application of tension to a carcass ply. Such tension is selected for proper positioning of the ply relative to the drum forming surface. As used herein, a "posing cycle" includes one or more methods that are executed for shaping and depositing a tire ply on a drum. It is understood that exemplary methods as disclosed herein, and any variation thereof, are equally effective for both simple structures (e.g., those having an interior liner, two profiled sidewall reinforcement elements and a carcass reinforcement ply) and more complex structures (e.g., those having a plurality of carcass reinforcement plies and two or more profiled sidewall reinforcement elements).

Referring to <FIG>, a ply positioning and posing system <NUM> is shown having a belt or roller feeder <NUM> for carrying at least one carcass ply <NUM> from an initial location (e.g., a storage depot) toward an assembly drum <NUM> which may have a configuration commensurate with that of forming drum <NUM> shown and described herein with respect to <FIG> (although a person of ordinary skill understands that any equivalent assembly drum configuration may be employed that is amenable to successful practice of the presently disclosed invention). Drum <NUM> includes a drum forming surface 506a upon which have been deposited an internal butyl layer and profiled elements of a predetermined thickness.

Carcass ply <NUM> is shown in the form of a length of ply having an upstream leading edge 504a proximate drum <NUM> and a downstream trailing edge 504b. Carcass ply <NUM> has a predetermined width delineated by a pair of opposed lateral edges 504c positioned relative to drum <NUM> in a manner commensurate with that of lateral edges 102a, 102b shown in <FIG>. A tension device, such as adjustable brake device <NUM>, allows selective application of a laying tension so as to promote application of ply <NUM> onto drum forming surface 506a. Adjustable brake device may be a commercially available tension device having selective tension controls. Tension applied to the ply removes excess ply at respective leading and trailing edges 504a, 504b, thereby obviating any undesirable creases prior to posing of subsequent products. Removal of excess material also attenuates any distance between leading edge 504a and drum forming surface 506a, thereby ensuring clearance of a bead wire and accurate posing thereof.

System <NUM> may include a roller subsystem <NUM> having one or more of a conforming roller <NUM>, an application roller <NUM> and a center roller <NUM>, one or more of which is supported by at least one frame as is known in the art. Each roller may be selected from any commercially available industrial roller. Each roller is displaceable in the vertical direction (e.g., see arrow <NUM> in <FIG>) in order to come into and out of contact with forming surface 506a as required during the posing cycle, for example, by means of a piston-cylinder unit or like means. Center roller <NUM> is similarly displaceable relative to application roller <NUM> at a plane P therebetween. A plane P' corresponds generally with a plane of contact of ply <NUM> with drum forming surface 506a. A width of at least one of rollers <NUM>, <NUM> and <NUM> may correspond generally to that of ply <NUM>.

Conforming roller <NUM> is employed as carcass ply <NUM> is posed over sidewall reinforcing rubber (e.g., inserts <NUM> or 305a as shown and described herein) to further conform the ply to drum forming surface 506a. Conforming roller <NUM> may therefore be a deformable roller of multidisc type as shown in <FIG>, formed of a set of discs 512a that are juxtaposed relative to one another and mobile relative to one another in the radial direction. A pneumatic system (and/or one or more equivalents thereof) may be employed to force each disc 512a to move in the radial direction (e.g., in the direction of arrow X as shown in <FIG>) until the disc comes into contact with the selected laying profile. In the alternative, a soft roller may be employed, and/or any equivalent thereof (e.g., a foam roller or one or more compressible bladders the elasticity of which is suitable for conformance to the laying profile).

Due to an uneven profile provided along drum forming surface 506a, rolling is optionally segmented in an axial direction on carcass ply <NUM> such that the ply is subject to pressure in the center thereof and also along sidewall reinforcing rubber. In some embodiments, application roller <NUM> and center roller <NUM> may incorporate a minimum segmentation of three sections for anchoring ply <NUM> along the extent of its width. In an exemplary embodiment shown in <FIG>, application roller <NUM> includes two rollers in communication with one another and vertically reciprocatable (e.g., in the direction of arrow Y) relative to an independently reciprocatable (e.g., in the direction of arrow Z) center roller <NUM>. Ply <NUM> is pulled forward thereby without distortion at or near leading edge 504a. A center section of the segmentation of three may be selectively removed as ply <NUM> is posed until termination of the posing cycle, upon which the center section may be reapplied to anchor trailing edge 504b.

Referring to <FIG>, during a posing cycle, feeder <NUM> delivers carcass ply <NUM> upstream toward stationary drum forming surface 506a and particularly toward a contact plane P'. Upon initiation of a posing cycle, roller subsystem <NUM> is in a ready position elevated above drum <NUM>. Tension is selectively applied to ply <NUM> by setting adjustable brake device <NUM> to a value commensurate with a height of sidewall reinforcing rubber (e.g., a height of inserts 305a as described and shown with respect to <FIG>).

Upon initiation of a posing cycle, at least one transporter <NUM> starts a laying operation by gripping leading edge leading edge 504a. Transporter <NUM> may be selected from transporter <NUM> and transporter <NUM> as described and shown herein, although it is understood that another amenable transporter may be amenable to practice of the presently disclosed methods. Gripping is effected by one or more gripping assemblies, including one or more suction cups <NUM>, each of which may be controllably displaceable in both lateral and longitudinal directions. One or more suction cups <NUM> may remain stationary while the remaining suction cups are displaced laterally and/or longitudinally. The distance between successive suction cups <NUM> may be adjusted such that the suction cups effect sufficient retention and tension along a width of ply <NUM> during the posing cycle.

It is understood that transporter <NUM> may simultaneously grip the entire width of ply leading edge 504a for the duration of transfer of ply <NUM>. Suction cups <NUM> may be distributed along one or more predetermined gripping sectors of ply <NUM>, wherein each gripping sector may by independently gripped by a selected number of gripping assemblies. Transporter <NUM> may deposit in succession a central portion of ply <NUM> and then the axial edges thereof (for example, by release of suction cups <NUM> in a predetermined order of succession).

Still referring to <FIG>, transporter <NUM> lifts leading edge 504a along a width thereof (see arrow <NUM>) and transfers the ply toward contact plane P' (see arrow <NUM>). Transporter <NUM> transports ply <NUM> across a cutting surface <NUM> having a cutting corridor 520a that accommodates one or more cutting members (not shown) as further described herein. Upon alignment of leading edge 504a with contact P', transporter <NUM> approaches drum forming surface 506a and deposits ply <NUM> generally at the level of contact plane P' proximate application roller <NUM>. In this manner, the reinforcement cords of ply <NUM> are aligned in the axial direction. Roller subsystem <NUM> remains in the ready position, and drum <NUM> remains stationary.

Referring further to <FIG>, all rollers in roller subsystem <NUM> descend toward drum <NUM> (see arrows <NUM>) such that application roller <NUM> secures leading edge 504a thereby. After deposit and release of leading edge 504a, center roller <NUM> ascends as does transporter <NUM> (see arrows <NUM>). Transporter <NUM> returns upstream past cutting surface <NUM> and toward adjustable brake device <NUM> (see arrow <NUM>), upon which return drum <NUM> initiates circumferential movement (see arrow <NUM>). The speed of rotation of drum <NUM> desirably remains constant such that the speed of feeder <NUM> may be regulated accordingly.

The rotation of drum <NUM> advances ply <NUM> to a cut position relative to cutting surface <NUM>, whereupon rotation of drum <NUM> ceases. A cutting tool (not shown) is located upstream of drum <NUM> so as to cut carcass ply <NUM> and thereby obtain a desired ply length. The cutting tool may include a cutting assembly as known in the art, for example, as by a floating blade. In some embodiments, two knives are provided in alignment with the same reinforcement cord and drawn across the width of ply <NUM> to effect cutting thereof. Movement of the knives is guided along cutting corridor 520a such that the knives translate along a width of ply <NUM>. Translation may be effected by one or more translation means as is known in the art (e.g., one or more of a linear actuator, a servo motor, a pneumatic or hydraulic cylinder and any equivalent and combination thereof). During a pose cycle, cutting is effected after the upstream return of transporter <NUM> and passage thereof over cutting surface <NUM>, whereupon the ply is sufficiently secured to ensure a precise cut thereof.

After cutting of ply <NUM>, center roller <NUM> descends to effect contact with application roller <NUM> at plane P (see <FIG>, arrow <NUM>). Drum <NUM> circumferentially advances to a joint press position such that joining of two ply extents does not cause, at the joint, a material portion that is thicker than the ply material thickness (e.g., due to overlap). In this manner, an edge-to-edge joining of the two ply edges is precisely effected. At the end of the pose cycle, roller subsystem <NUM> returns to the ready position (e.g., as shown and described with reference to <FIG>) and transporter <NUM> is downstream of drum <NUM> proximate ply <NUM> in preparation for the initiation of the subsequent pose cycle.

One or more controllers or control systems (collectively "controllers") may determine the instructions to drive the various components of system <NUM> (e.g., according to the posing cycle, tension values, measured values and correction algorithms). Such controllers may also synchronize a longitudinal advance of the ply as determined by circumferential movement of the drum so as to strategically apply tension during the cycle. These controllers may communicate with one or more sensors (e.g., to detect leading edge 504a) and one or more timers as is known in the art.

It is understood that the present disclosure contemplates one or more systems for manufacturing a plurality of self-supporting tire configurations. Each such system may include a series of posts, one or more of which is selected to execute one or more steps of the presently disclosed methods. Two or more posts may perform identical steps in accordance with current production requirements to support modularity of production capacity.

One or more networked devices may be implemented with the presently disclosed systems, e.g., in a cluster or other distributed computing system. The network may be a LAN, a WAN, a SAN, a wireless network, a cellular network, radio links, optical links and/or the Internet, although the network is not limited to these network selections. Accompanying interactive software applications may be downloaded on a desktop or uploaded from a remote site onto a mobile device. Instructions for use of the software applications may also be included along with resources for accessing any remote platforms that provide one or more users with an interface for collaboration with others. It is contemplated that a mobile device may be employed that has the software applications pre-loaded for ready use.

A server may be further configured to facilitate communication between at least one system as presently disclosed and one or more of the networked devices. A database may be built and accessed that includes stored data (e.g., tire types and sizes, availability of carcass plies, sequence of product assembly, etc.) and calculated data forecasts that can be generated for intended manufacturing integrity.

The presently disclosed inventions obviates modifications to a forming drum that may be necessary to accommodate precision pose of the carcass ply during production of self-supporting tire systems. The relatively thick product that is added to a tire sidewall is typically posed on a forming drum just after posing of a tire inner liner (for example, a butyl inner liner). The carcass ply, being posed directly thereafter, is desirably posed on a smooth surface that is attained by modifying a forming drum by creating grooves therearound. The grooves accommodate the thick reinforcement product to ensure a smooth surface. Such modifications are dimension specific and therefor incur temporal and fiscal costs, particularly in those processes that employ multiple drums. The presently disclosed inventions avoid such costs by initiating pose of the carcass ply over the inner liner and thick reinforcement material on a standard drum. In this manner, a variety of self-supporting tire systems are readily produced by existing forming drum systems without compromising the performance benefits thereof and without significant capital expenditures.

Selected combinations of aspects of the disclosed technology correspond to a plurality of different embodiments of the present invention. It should be noted that each of the exemplary embodiments presented and discussed herein should not insinuate limitations of the present subject matter. Features or steps illustrated or described as part of one embodiment may be used in combination with aspects of another embodiment to yield yet further embodiments. Additionally, certain features may be interchanged with similar devices or features not expressly mentioned that perform the same or similar function.

" Also, the dimensions and values disclosed herein are not limited to a specified unit of measurement. For example, dimensions expressed in English units are understood to include equivalent dimensions in metric and other units (e.g., a dimension disclosed as "<NUM> inch" is intended to mean an equivalent dimension of "<NUM>").

As used herein, the term "method" or "process" refers to one or more steps that may be performed in other ordering than shown without departing from the scope of the presently disclosed invention. As used herein, the term "method" or "process" may include one or more steps performed at least by one electronic or computer-based apparatus. Any sequence of steps is exemplary and is not intended to limit methods described herein to any particular sequence, nor is it intended to preclude adding steps, omitting steps, repeating steps, or performing steps simultaneously. As used herein, the term "method" or "process" may include one or more steps performed at least by one electronic or computer-based apparatus having a processor for executing instructions that carry out the steps.

The terms "a," "an," and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The terms "at least one" and "one or more" are used interchangeably. Ranges that are described as being "between a and b" are inclusive of the values for "a" and "b.

Claim 1:
A transporter (<NUM>) for retrieving at least one reinforcing ply (<NUM>) and conforming the at least one reinforcing ply (<NUM>) to a forming surface (102c) of a rotatable forming drum (<NUM>) having axial (A) and circumferential (C) directions and with the forming surface (102c) being coextensive with a pair of opposed sides (102a, 102b) and having one or more tire components (<NUM>) disposed thereon, the transporter (<NUM>) comprising:
a manifold (<NUM>) including one or more supply ports (<NUM>) each having a supply port inlet (210a) in communication with a vacuum supply source and a supply port outlet (212a) for delivery of a vacuum to one or more suction cup assemblies (<NUM>) supported by an assembly support bar (<NUM>), with each suction cup assembly (<NUM>) including a suction cup (<NUM>) in generally coaxial alignment with a suction cup retainer (<NUM>) and each suction cup (<NUM>) being reciprocatably and translationally positionable between a ply retrieval position, in which the at least one reinforcing ply (<NUM>) is retrieved from a generally even surface, and a ply pose position, in which the at least one reinforcing ply (<NUM>) assumes a profile shape of the forming surface (102c) of the drum (<NUM>) before posing of the at least one reinforcing ply (<NUM>) on the one or more tire components (<NUM>),
wherein each suction cup assembly (<NUM>) includes a slide shaft (<NUM>) reciprocatingly accommodated within a slide housing (<NUM>) and coaxially disposed relative to an extension spring (<NUM>) that governs vertical motion of the suction cup (<NUM>), and wherein the slide housing (<NUM>) is fastened to a slide bearing (<NUM>) by at least one lateral return cord (<NUM>) and the slide bearing (<NUM>) is actuatably disposed proximate a bearing rail (<NUM>) affixed to the assembly support bar (<NUM>), characterized in that the retention of the at least one lateral return cord (<NUM>) by a return spring (<NUM>) ensures sufficient tension in the at least one lateral return cord (<NUM>), thereby preserving suction cup assemblies (<NUM>) in, and returning them to, the ply retrieval position while facilitating change to an accurate ply pose position.