Patent ID: 12202701

DETAILED DESCRIPTION OF THE INVENTION

FIGS.1-4shows an apparatus1for correcting misalignment of the reinforced strips9, in particular breaker plies. The apparatus1comprises a cutting device2according to WO 2016/159759 A1 for cutting a continuous strip90into one or more cut-to-length strips91,92.FIGS.1and2show the apparatus1during steps of a method for manufacturing one or more first reinforced strips91.FIGS.3and4shows the same apparatus1during steps of a further method for manufacturing one or more second reinforced strips92. The reinforced strips91, are preferably reinforced with metal or ferromagnetic reinforcement elements93. The apparatus1further comprises a correcting device3according to the present invention for correcting misalignment of the reinforced strips91,92.

As shown inFIG.1, the cutting device2comprises a support member20, in this exemplary embodiment in the form of a cutting table, with a cutting surface21that forms a support plane P. The cutting device2further comprises a feeding member22, e.g. a feeding roller, for feeding a continuous strip90of elastomeric material, preferably a rubber material, into the apparatus1and/or onto the cutting surface21in a feeding direction F. Like in WO 2016/159759 A1, the support plane P of the cutting device2is placed at a steep, nearly vertical angle, preferably within at a support angle in the range of five to thirty degrees with respect to a first vertical plane V1. The support plane P intersects with a second vertical plane V2that is perpendicular to the first vertical plane V1at an intersecting line L. Said intersecting line L can form a reference line (also referenced by the letter L) for aligning the continuous strip90. The feeding direction F is parallel or substantially parallel to the said intersecting line L. The feeding member22is arranged for feeding the continuous strip90downwards in the feeding direction F over the steep support plane P. Preferably, the strip90is allowed to slide in said support plane P over the cutting surface21solely under the influence of gravity.

The cutting device2further comprises a cutter that is arranged for cutting the continuous strip90into the one or more first strips91as shown inFIGS.1and2or the one or more second strips92as shown inFIGS.3and4. The cutting device2comprises one or more guides24for guiding the cutter23along a cutting line K across the cutting surface21at a cutting angle H that is oblique with respect to the feeding direction F. Preferably, the cutting angle H is adjustable in a range between fifteen and sixty degrees with respect to the feeding direction F. In this exemplary embodiment, the cutting surface21is rotatable about a rotation axis R that extends normal to the cutting surface21. The one or more guides24are mounted to and rotatable together with the cutting surface21to adjust the cutting angle H. Preferably, the support member20has an at least partly circular circumference25, concentric to the rotation axis R and/or wherein the rotation axis R is located at the center of the at least partly circular circumference25.

As further shown inFIG.1, the cutting device2comprises one or more retaining magnets26arranged at or near the cutting line K, preferably on both sides of the cutting line K, for retaining the strip90during the cutting. The retaining magnets26can be permanent magnets which can be retracted into a position spaced apart from the strip90by a retraction mechanism (not shown) or electromagnets which are arranged to be switched on and off.

As shown inFIGS.1-5, the correction device3comprises an alignment surface31for receiving and/or supporting one of the one or more first strips91or the one or more second strips92. The alignment surface31extends in the same support plane P as and/or at the same steep support angle as the cutting surface21of the cutting device2. In this example, the strip91,92is fed onto the alignment surface31from the cutting surface21, preferably solely under the influence of gravity. The alignment surface31itself remains stationary.

As shown inFIGS.1-4, the correction device3is provided with an alignment member4for abutting the strip91,92in an abutment direction A parallel to the support plane P and transverse or perpendicular to the intersecting line L. As shown in more detail inFIG.5, the alignment member comprises an alignment body40with an abutment surface41that extends parallel to the intersection line L and that faces in an abutment direction A parallel to the support plane P and transverse or perpendicular to the intersecting line L towards the strip91,92.

As best seen inFIG.5, the correction device3further comprises one or more correction elements5for exerting a displacement force D onto said strip91,92in the correction direction C parallel to the support plane P and transverse to the intersecting line/reference line L. In this exemplary embodiment, the one or more correction elements5comprise one or more attraction elements for attracting the strip91,92in the correction direction C. More in particular, the one or more correction elements5comprise one or more magnets, preferably permanent magnets, to magnetically attract the ferromagnetic material in the strip91,92.

As clearly shown inFIG.5, the one or more correction elements5are located at the same side of the alignment surface31that is arranged for supporting the strip91,92, i.e. the upwardly facing side of the alignment surface31. As such, the one or more correction elements5are arranged for acting on the strip91,92primarily in the correction direction C parallel to said support plane P. More in particular, the one or more correction elements5are arranged for acting on the strip91,92solely in the correction direction C. This is also reflected by the arrows of the displacement force D, which inFIG.5are parallel to the correction direction C.

In this exemplary embodiment, the one or more correction elements5are provided in or on the alignment member4. In particular, the one or more correction elements5are provided at the abutment surface41and face in the abutment direction A.

As shown inFIGS.1-4, the alignment member4is movable in the abutment direction A parallel to the support plane P and transverse to the intersecting line L and in a correction direction C, opposite to the abutment direction A. By moving the alignment member4away from the reference line L, the strip90can be supplied onto the alignment surface31without the alignment member4obstructing said supply. The alignment member4can subsequently be moved back in the abutment direction A towards the reference line L to define a position in which it can abut the strip91,92after cutting.

Preferably, the alignment member4is further movable back and forth in the feeding direction F, parallel to, substantially parallel to and/or along the reference line L, for positioning the alignment member4along the reference line L as close as possible to the cutting line K. Preferably, the alignment member4is provided with a sharp tapering end42facing towards the cutting line K that allows the abutment surface41at said tapering end42to extends as close as possible towards the cutting line K. In such a way, the abutment surface41can abut a substantial part if not substantially the entire length of the strip91,92in the feeding direction F.

As shown inFIGS.6,7and8, the apparatus1comprises an alignment drive81for driving the movements of the alignment member4in the abutment direction A and the correction direction C. The alignment drive81is preferably formed by a linear drive, most preferably a spindle drive. However, it will be apparent to one skilled in the art that various alternative drives will be suitable for driving the movement of the alignment member4in the abutment direction A and the correction direction C.

As shown inFIG.9, the apparatus1further comprises a proximity drive82for driving the movement of the alignment member4back and forth in the feeding direction F. The proximity drive82can be formed by a linear drive, e.g. a spindle drive. However in the embodiment as shown inFIG.9, the proximity drive82comprises a transmission83for converting the movement of the support member20into a movement of the alignment member4back and forth in the feeding direction F and/or along the reference line L. In the embodiment as shown, the support member20has a fully circular circumference25and is rotatable about the rotation axis R for setting the cutting angle H. This rotation is converted by the transmission83into a linear or substantially linear back and forth movement of the alignment member4in the feeding direction F.

The transmission83comprises a first belt84that is placed around the circular circumference25of the support member20. The transmission83is further provided with a first pulley85, a second pulley86and a second belt87that is placed in a loop around the first pulley85and the second pulley86. The first belt84is connected to and/or placed around the first pulley85to drive the rotation of said first pulley85in a transmission ratio to the rotation of the support member20. The alignment member4is fixedly connected to a part of the second belt87so as to be movable together with said part of the second belt87.

The diameter of the first pulley85is chosen such that an appropriate transmission ratio between the rotation of the support member20and the first pulley85is obtained. The transmission ratio is preferably one that causes an appropriate displacement of the alignment member4with respect to and/or in relation to the rotation of the support member20. An appropriate displacement is aimed at positioning and/or maintaining the alignment member4along the reference line L in a position as close as possible to the cutting line K.

Preferably, the transmission83comprises a plurality of guide pulleys88for redirecting and/or guiding at least a part of the first belt84away from the circumference25of the support member20and in a loop around the first pulley85.

As shown inFIGS.6-8, the correction device3further comprises one or more fixation elements6for fixating the strip91,92with respect to the alignment surface31after the strip91,92has been displaced by the one or more correction elements5. The one or more fixation elements6preferably comprise one or more electromagnets at or below the alignment surface31, wherein the one or more fixation electromagnets31are switchable between an active state for magnetically fixating the strip91,92with respect to the alignment surface31and an inactive state for releasing the strip91,92from the alignment surface31. Alternatively, the one or more fixation elements may comprise permanent magnets (not shown) which can be withdrawn away from the alignment surface31to release the strip91,92from the alignment surface31.

FIG.10shows an optional embodiment in which the apparatus1further comprises a gripper7that is positionable in a pick-up position for picking up the strip91,92from the alignment surface31. Said gripper7comprises a plurality of gripper magnets71,72for magnetically retaining the strip91,92to the surface of the gripper7. When used in combination with the previously discussed fixation magnets31, the fixation magnets31can be switched off or withdrawn as soon as the gripper magnets71,72have retained the strip91,92to the surface of the gripper7. However, while the fixation magnets31can be switched off or withdrawn, the one or more correction magnets5in the alignment member4are still in close proximity to the gripper7. Hence, their magnetic fields could interfere with the magnetic pick-up by the gripper7.

Therefore, in this particular embodiment, the one or more correction elements5comprises a plurality of correction magnets51,52that form a first magnetic field array and the gripper magnets71,72form a second magnetic field array. The first magnetic field array is at least partially offset with respect to the second magnetic field array. In particular, the plurality of correction magnets51,52comprises a first group of correction magnets51that face towards the gripper7in the pick-up position with a north magnetic polarity N and a second group of correction magnets52that face towards the gripper in the pick-up position with a south magnetic polarity S, wherein the correction magnets51of the first group alternate with the correction magnets52of the second group within the first magnetic field array. Although each correction magnet51,52individually is still able to attract the strip91,92, the alternation provides for an at least partially repelling magnet field array with respect to the field array of the gripper magnets71,72to reduce the influence of the correction magnets51,52on the gripper magnets71,72.

Preferably, the pitch, i.e. the heart-to-heart distance, between the correction magnets51,52of the first magnetic field array is different from the pitch of between the gripper magnets71,72of the second magnetic field array, e.g. the pitch between the correction magnets51,52may be at least twice as small as the pitch between the gripper magnets71,72. Hence, reduced pitch causes two of the correction magnets51,52to be located opposite to only one of the gripper magnets71,72, thereby considerably reducing their effect on the single gripper magnet71,72.

A method for correcting misalignment of the strips91,92will be described hereafter in detail with reference toFIGS.1-10.

FIG.1shows the situation in which the support member20has been rotated about the rotation axis R such that the cutting line K extends at a chosen cutting angle H. A strip90has been supplied by the supply member22in the feeding direction F onto the cutting surface21of the support member20. The cutter23has been moved in a cutting direction E along the cutting line K to cut off a leading end of the strip90at the cutting angle H. During the cutting, the strip90is retained by the retaining magnets26. After the cutting, the retaining magnets26are retracted into the cutting surface21and/or deactivated to release the strip90. The cutter23is returned to the position as shown inFIG.1for a subsequent cutting step. The cutting has created a new, triangular leading end94. Typically, the leading end94is slightly deformed by the cutting step, as the leading end94has a relatively small contact surface with the cutting surface21and can be displaced relatively easily by the cutter23with respect to the rest of the strip90. The deformation inFIG.1is exaggerated to clearly illustrate the problem underlying the present invention. The alignment member4has been moved in the correction direction C into a first position spaced apart from the reference line L to allow the strip90to be fed onto the alignment surface31in the feeding direction F without the alignment member4hindering said feeding.

FIG.2shows the situation in which the strip90with the newly created leading end94is driven or has been allowed to move further over cutting surface21in the feeding direction F so that at least the leading end94of the strip90is positioned on and/or supported by the alignment surface31. Subsequently, the cutter23has been moved again in the cutting direction E along the cutting line K to cut off the aforementioned first strip91from the strip9at the cutting angle H. The cutting has created a triangular trailing end95similar to the leading end94. The leading end94is still slightly deformed by the cutting step ofFIG.1. Now, the alignment member4can be moved in the abutment direction A back towards the reference line L.

As shown inFIGS.3and4, the support member20can be rotated about the rotation axis R such that the cutting line K extends at a different cutting angle H with respect to the cutting angle H inFIGS.1and2. Consequently, the strip90can be cut into one or more second strips92for a different batch. During the rotation, the position of the alignment member4is adjusted, preferably automatically with the use of a suitable mechanism, e.g. the proximity drive82as shown inFIG.10, to be as close as possible to the cutting line K to provide an optimal alignment of the strip91,92during the subsequent steps of the method. The following steps of the method apply to any one strip91,92cut at the cutting angles H as shown inFIGS.1-4or any other cutting angles H within the adjustable range of the support member20.

FIG.6shows the alignment member4in the first position corresponding to the first position as shown inFIGS.1-4, spaced apart from the reference line L as the strip90is fed onto the alignment surface31. Once the strip91,92is approximately in position on the alignment surface31, e.g. within five millimeters from the reference line L, the alignment drive81is actuated to move the alignment member4from the first position, as shown inFIG.6, at a first distance from the reference line L towards a second position, as shown inFIG.7, at a second distance from the reference line L. The second distance is smaller than the first distance. In particular, the first distance is more than eight millimeters or more than ten millimeters and the second distance is in the range of five to eight millimeters. Preferably, the displacement force D exerted by the one or more correction elements5onto the strip91,92is insufficient to displace the strip91,92in the correction direction C when the alignment member4is between the first position and the second position. Hence, during the movement of the alignment member4from the first position to the second position, the magnitude of the displacement force D exerted onto the strip91,92does not exceed the friction between the strip91,92and the alignment surface31. However, said magnitude will increase as the alignment member4moves closer and as soon as the alignment member4arrives in the second position, as shown inFIG.7, or when the alignment member4is in any position between the second position, as shown inFIG.7, and a third position, as shown inFIG.8, at the reference line L, the displacement force D exerted by the one or more correction elements5onto the strip91,92will be sufficient to displace at least a part of the strip91,92in the correction direction C into abutment with the abutment surface41.

As shown inFIG.7, the strip91,92may be pulled into abutment against the abutment surface41while the alignment member4has not yet moved into the third position at the reference line L. Hence, the strip91,92may actually be pulled beyond the reference line L. Subsequently, as the alignment member4continues to move in the abutment direction A towards the third position as shown inFIG.8, the strip91,92retained thereto will also be displaced in the abutment direction A and will ultimately be forced into alignment along the reference line L.

As soon as the strip91,92has been aligned or corrected along the reference line L, the one or more fixation elements6underneath the alignment surface31may be switched to an active state to fix the aligned or corrected position of the strip91,92on the alignment surface31. The alignment member4may subsequently be retracted in the correction direction C into the first position as shown inFIG.6for a next cycle of the method.

Next, the aligned or corrected strip91,92may be picked-up by the gripper7as shown inFIG.10, e.g. in the manner as previously discussed, for transfer to a downstream assembly unit (not shown).

It is to be understood that the above description is included to illustrate the operation of the preferred embodiments and is not meant to limit the scope of the invention. From the above discussion, many variations will be apparent to one skilled in the art that would yet be encompassed by the scope of the present invention.

LIST OF REFERENCE NUMERALS

1apparatus2cutting device20support member21support surface22feeding member23cutter24guide25circular circumference26retaining magnets3correction device31alignment surface4alignment member40alignment body41abutment surface42tapering end5one or more correction elements51correction magnet52correction magnet6one or more fixation elements7gripper71gripper magnet72gripper magnet81alignment drive82proximity drive83transmission84first belt85first pulley86second pulley87second belt90continuous strip91first strip92second strip93reinforcement element94leading end95trailing endA abutment directionC correcting directionD displacement forceF feeding directionH cutting angleK cutting lineL intersecting line/reference lineP support planeV1first vertical planeV2second vertical plane