Patent ID: 12233616

BEST MODE FOR CARRYING OUT THE INVENTION

Reference will now be made in detail to embodiments of the present disclosure, one or more drawings of which are set forth herein. Each drawing is provided by way of explanation of the present disclosure and is not a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the teachings of the present disclosure without departing from the scope of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment.

Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present disclosure are disclosed in, or are obvious from, the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

The words “connected”, “attached”, “joined”, “mounted”, “fastened”, and the like should be interpreted to mean any manner of joining two objects including, but not limited to, the use of any fasteners such as screws, nuts and bolts, bolts, pin and clevis, and the like allowing for a stationary, translatable, or pivotable relationship; welding of any kind such as traditional MIG welding, TIG welding, friction welding, brazing, soldering, ultrasonic welding, torch welding, inductive welding, and the like; using any resin, glue, epoxy, and the like; being integrally formed as a single part together; any mechanical fit such as a friction fit, interference fit, slidable fit, rotatable fit, pivotable fit, and the like; any combination thereof; and the like.

Unless specifically stated otherwise, any part of the apparatus of the present disclosure may be made of any appropriate or suitable material including, but not limited to, metal, alloy, polymer, polymer mixture, wood, composite, or any combination thereof.

Referring toFIGS.1-2, a tire building drum100is shown. The tire building drum100includes a working surface102and a rotational axis104. The rotational axis104defines a longitudinal direction110. The working surface102of the tire building drum100is an outer circumferential surface configured to receive various tire building materials thereon.

As can best be seen inFIG.1, a first sheet of tire material116is received by the working surface102of the tire building drum100and a second sheet of tire material120is received on the first sheet of tire material116. The first sheet of tire material116may also be referred to herein as a carcass116or a tire carcass116. The second sheet of tire material120may also be referred to herein as a body ply120. The first sheet of tire material116may include at least an inner liner, sidewalls, and/or a wire reinforcement layer.

The first sheet of tire material116may be wrapped around the working surface102by rotating the tire building drum100about the rotational axis104. The second sheet of tire material120may proceed to be wrapped around the first sheet of tire material116also by rotating the tire building drum110about the rotation axis104. The second sheet of tire material120includes two ends122(e.g., a first end122A and a second end122B) which may be oriented parallel to the longitudinal direction110.

As can best be seen inFIG.2, the second sheet of tire material120is fully received on the working surface102of the tire building drum100. The second sheet of tire material120is wrapped on the tire building drum100and the two ends122of the second sheet of material120may be abutting and face each other. The second sheet of tire material120may be a tire body ply which contains reinforcement wires arranged parallel to the longitudinal direction.

The strength and integrity of the finished tire depends on the two ends122of the second sheet of tire material120abutting and not overlapping, and being securely bound together (e.g., stitched or spliced). Another factor that potentially affects the strength and integrity of the finished tire is a hump in the spliced second sheet of tire material120. A hump in the spliced second sheet of tire material120may be defined as a space between the first sheet of tire material116and a rearward side124(FIG.1) of the second sheet of tire material120. Any hump in the spliced second sheet of tire material120should be minimized. The larger the hump, the greater chance that the hump will negatively affect the strength, integrity, and quality of the finished tire.

As further illustrated inFIG.2, the tire building drum100and the first and second sheets of tire material116,120are shown in conjunction with an automatic spicing apparatus200. The automatic splicing apparatus200is configured to efficiently and securely splice (or “stitch”) the two ends122of the second sheet of tire material120together while positioned above the tire building drum100. The automatic splicing apparatus100includes a frame202configured to support the apparatus relative to the tire building drum100.

The automatic splicing apparatus200further includes a splicer foot assembly210and a splicer roller assembly250. The splicer foot assembly210is longitudinally translatable relative to the frame202in a forward direction204and a rearward direction206. The forward direction204may also be referred to herein as a forward longitudinal direction204. The forward and rearward directions204,206may be parallel to the longitudinal direction110. The splicer roller assembly250is longitudinally translatable relative to the frame202in the forward and rearward directions204,206independently of the splicer foot assembly210. Accordingly, the splicer roller and the splicer roller assembly250may be translated either in unison or independently of one another relative to the working surface102of the tire building drum100.

The independent movement of the splicer foot assembly210and the splicer roller assembly250allow for greater versatility of the automatic splicing apparatus200. The splicer foot assembly210and the splicer roller assembly250may function in unison according to an automatic operational mode to automatically splice the two ends122of the second sheet of tire material120together without the assistance of an operator. Alternatively, the splicer roller assembly250may be manually manipulated by an operator, without the splicer foot assembly210, in accordance with an optional manual operational mode to manually splice the two ends122of the second sheet of tire material120together. Typically, the automatic splicing apparatus200operates exclusively in the automatic operational mode, however, an operator may switch the automatic splicing apparatus into the manual operational mode, for example, when fixing a bad splice. Accordingly, the automatic splicing apparatus200may reduce the number of scrapped or reworked tires, thus increasing efficiency and profits.

Referring toFIGS.3-6, the splicer foot assembly210and the splicer roller assembly250of the automatic splicing apparatus200are shown in greater detail. The splicer roller assembly250may be positioned rearwardly relative to the splicer foot assembly210. The splicer foot assembly210includes a splicer foot212and a plurality of upper preparation rollers220. The splicer foot212may also be referred to herein as a splicer foot frame212. The plurality of upper preparation rollers220may also be referred to herein as upper preparation rollers220. As can best be seen inFIGS.3,7,8,11-14, the splicer foot212includes a plurality of forward lower preparation rollers214and a plurality of rearward lower splicer rollers216.

The upper preparation rollers220are configured to operate in coordination with the plurality of forward lower preparation rollers214to pull the two ends122of the second sheet of tire material120towards each other over the splicer foot212as the splicer foot assembly210advances in the forward direction204relative to the second sheet of tire material120. The act of pulling the two ends122of the second sheet of tire material120together using upper preparation rollers220and the plurality of forward lower preparation rollers214may increase the strength of the splice because the two ends122are pressed tightly together immediately prior to being spliced. The upper preparation rolls220in coordination with the forward lower preparation rollers214also provide holding and stretching of the two ends122of the second sheet of tire material120together to allow the splicer roller assembly250to complete the splice.

To further aid in the pulling together of the two ends122of the second sheet of tire material120together, the plurality of forward lower preparation rollers214may include external ridges (e.g., helical ridges or sequential separate ridges) to help grip and manipulate a position of the two ends122of the second sheet of tire material120. The external ridges may be a continuous helical ridge configured in such a manner that as the second sheet of tire material120causes the plurality of forward lower preparation rollers214to spin, the external ridges cause the two ends122of the second sheet of tire material120to be pulled together. Alternatively, the external ridges may be separate sequential ridges. The plurality of rearward lower splicer rollers216may include similar external ridges.

As can best be seen inFIG.9-10, the upper preparation rollers220may include two cylindrical rollers arranged in a V-shaped pattern. The upper preparation rollers220may include ends224configured in meshed engagement with each other so that the two cylindrical rollers rotate together, one driving the other. Alternatively, the upper preparation rollers220may be driven separately and synchronized together using timing belts. The V-shaped pattern forces the two ends122of the second sheet of tire material120together when received between the upper preparation rollers220and the plurality of forward lower preparation rollers214during a forward movement of the splicer foot assembly210.

The upper preparation rollers220may be powered rollers and the plurality of forward lower preparation rollers214may be non-powered rollers. As can best be seen inFIGS.3,4, and7, the upper preparation rollers220may be powered by a preparation roller motor226. As illustrated, the preparation roller motor226may be an electrically powered motor such as for example a servo motor. In other embodiments (not shown), the preparation roller motor226may be a pneumatic powered motor or the like.

The splicer foot assembly210may further include a preparation roller actuator228configured to translate the upper preparation rollers220up and down relative to the splicer foot212(e.g., towards and away from the plurality of forward lower preparation rollers214). The preparation roller actuator228may be a pneumatic cylinder or the like. The preparation roller actuator228enables the upper preparation rollers220and the plurality of forward lower preparation rollers214to manipulate (e.g., pull together) the two ends122of the second sheet of tire material120when received therebetween. The preparation roller actuator228may apply a specific and consistent amount of pressure to the two ends122of the second sheet of tire material120such that the upper preparation rollers220and the plurality of forward lower preparation rollers214effectively pull the two ends of the second sheet of tire material together over the splicer foot212. The specific and consistent amount of pressure applied to the two ends122of the second sheet of tire material120over the course of a given splice may at least partially contribute to generally more consistent splices.

As can best be seen inFIGS.3,6, and8, the splicer foot assembly210may include a plurality of magnetic rollers230located forward of the splicer foot212. The plurality of magnetic rollers230are configured to lift the two ends122of the second sheet of tire material120proximate to the plurality of magnetic rollers230as the splicer foot212advances in the forward direction204under the second sheet of tire material120. The plurality of magnetic rollers230reduce any potential friction which may be caused by the splicer foot212attempting to lift the two ends122of the second sheet of tire material120manually as it advances in the forward direction. For example, by lifting the two ends122of the second sheet of tire material proximate to the splicer foot212, the magnetic rollers230reduce the friction and any potential jam which could be caused by the splicer foot212attempting to wedge under the two ends122of the second sheet of tire material120that lay on at least one of the first sheet of tire material116or the working surface102of the tire building drum100.

As can best be seen inFIGS.3,6,7, and8, the automatic splicing apparatus200may include a splicer foot actuator234coupled between the frame202and the splicer foot assembly210. The splicer foot actuator234may be a linear motion (LM) guide and a pneumatic cylinder or the like for controlling movement of the splicer foot assembly210. The splicer foot actuator234may be configured to translate the splicer foot assembly210up and down relative to the frame202. Accordingly, the splicer foot actuator234translates the splicer foot assembly210towards and away from the tire building drum100. The splicer foot actuator234may precisely position the splicer foot assembly210at the correct height above the first sheet of tire material116.

As can best be seen inFIGS.3and5, the splicer roller assembly250of the automatic splicing apparatus200includes a pair of truncated conical upper splicer rollers252. The pair of truncated conical upper splicer rollers252may also be referred to herein as the upper splicer rollers252. As can best be seen inFIG.5, the pair of truncated conical upper splicer rollers252include roller teeth254meshed with each other. The pair of truncated conical upper splicer rollers252may rotate together, one driving the other. The upper splicer rollers252are configured to operate in coordination with the plurality of rearward lower splicer rollers216to splice together the two ends122of the second sheet of tire material120using the roller teeth254as the splicer roller assembly250and the splicer foot assembly210advance together in the forward direction204.

The upper splicer rollers252may be powered rollers and the plurality of rearward lower splicer rollers216may be non-powered rollers. As can best been seen inFIGS.3-6, the upper splicer rollers252may be powered by a splicer roller motor256. As illustrated, the splicer roller motor256may be an electrically powered motor such as for example a servo motor. In other embodiments (not shown), the splicer roller motor256may be a pneumatic powered motor or the like.

The splicer roller assembly250may further include a splicer roller actuator258configured to translate the upper splicer rollers252up and down relative to the splicer foot212(e.g., towards and away from the plurality of rearward lower splicer rollers216). The splicer roller actuator258may be a LM guide and a pneumatic cylinder or the like for controlling movement of the splicer roller assembly250. The splicer roller actuator258enables the upper splicer rollers252and the plurality of rearward lower splicer rollers216to manipulate (e.g., splice together) the two ends122of the second sheet of tire material120when positioned therebetween. The splicer roller actuator258may apply a specific and consistent amount of pressure to the two ends122of the second sheet of tire material120during a given splice. The specific and consistent amount of pressure may result in more consistent and higher strength splices.

As can best be seen inFIG.3, the splicer roller assembly250may include a press roller260located rearward of the upper splicer rollers252. The splicer roller assembly250may further include a press roller actuator262configured to translate the press roller260downward (e.g., toward the tire building drum100and the first and second sheets of tire material116,120) to engage the spliced ends of the second sheet of tire material120. The press roller actuator262may be a pneumatic cylinder or the like. The press roller260may help reduce or remove any potential hump in the spliced ends of the second sheet of tire material120, while also providing additional strength by sticking the two spliced ends122of the second sheet of tire material120to the first sheet of tire material116.

The splicer roller assembly250may further include a splice sensor264. The splice sensor264may be connected to the splicer roller assembly250and may be positioned rearward of the splicer roller assembly250such that there is line of sight from the splice sensor264to the spliced ends of the second sheet of tire material120. The splice sensor264may be configured to monitor the consistency of the splice and to detect if a gap between the two ends122of the second sheet of tire material120is properly closed so as to identify any bad splices (e.g., open splices or otherwise). Bad splices may result in a tire being scrapped due to an open splice detected during later stages of the tire building process using an x-ray or the like. The automatic splicing apparatus200includes the versatility of the manual operational mode, discussed above, which allows the operator to manually re-zip the open splice using only the splicer roller assembly250, independent from the splicer foot assembly210.

In other embodiments, the splice sensor264or an additional sensor (not shown) may be positioned such that the sensor has line of sight to the two ends122of the second sheet of tire material120just prior to being spliced (e.g., the portion spanning between the preparation rollers214,220and the splicer rollers216,252). The sensor may be configured to sense whether the two ends122of the second sheet of tire material120are properly positioned as they move into the splicer roller assembly250. For example, the sensor may be configured to detect whether a gap between the two ends122of the sheet of material120is within an acceptable range (e.g., not greater than 5 mm). The sensor may enable more consistent splicing by detecting jam-ups and other issues with the second sheet of tire material120. The sensor may further enable the automatic splicing apparatus200to compensate or alert an operator if said issues are present.

As discussed above, the splicer foot assembly210and the splicer roller assembly250are both independently longitudinally translatable relative to the frame202. As can best be seen inFIG.4, the automatic splicing apparatus200may further include a first longitudinal drive270and a second longitudinal drive272. The first longitudinal drive270is configured to longitudinally translate the splicer foot assembly210relative to the frame202in the forward and rearward directions204,206. The second longitudinal drive272is configured to longitudinally translate the splicer roller assembly250relative to the frame202in the forward and rearward directions204,206. Each of the first and second longitudinal drives270,272may include ball screws, drive belts, pulleys, servo motors, LM guides, rack and pinions and the like necessary to enable independent longitudinal translation of the splicer foot assembly210and the splicer roller assembly250relative to the frame202.

Referring toFIGS.11-15C, the splicer foot212of the splicer foot assembly210is shown in greater detail. As can best be seen inFIGS.12and14, the splicer foot212may include at least one opening302defined therein. The at least one opening302includes first and second opposing sides304,306.

The at least one opening302may include a first opening310having first and second opposing sides304A,306A. The first opening310may also be referred to herein as a first frame opening310or forward opening310. The first opening310may be configured to receive the plurality of forward lower preparation rollers214.

The plurality of forward lower preparation rollers214are arranged as a plurality of V-shaped pairs of forward lower preparation rollers320. The plurality of pairs of forward lower preparation rollers320may be non-powered rollers. As can best be seen inFIGS.12and15A-15C, each of the V-shaped pairs of forward lower preparation rollers320include a continuous unitary V-shaped axle322having a first arm324and a second arm326. As illustrated, the first arm324may be attached to the first side304A of the first opening310and the second arm326may be attached to the second side306A of the first opening310. The V-shaped pair of forward lower preparation rollers320may be mounted on the first and second arms324,326, respectively, of the continuous unitary V-shaped axle322.

The at least one opening302may further include a second opening312having first and second opposing sides304B,306B. The second opening312may also be referred to herein as a second frame opening312or rearward opening312. The second opening may be configured to receive the plurality of rearward lower splicer rollers216. The plurality of rearward lower splicer rollers216are arranged as a plurality of V-shaped pairs of rearward lower splicer rollers330. The plurality of V-shaped pairs of rearward lower splicer rollers330may be non-powered rollers. As can best be seen inFIGS.12and15A-15C, each of the V-shaped pairs of rearward lower splicer rollers330include a continuous unitary V-shaped axle332having a first arm334and a second arm336. As illustrated, the first arm334may be attached to the first side304B of the second opening312and the second arm336may be attached to the second side306B of the second opening312. The V-shaped pair of forward preparation rollers330may be mounted on the first and second arms334,336, respectively.

The continuous unitary V-shaped axles322,332are designed to minimize the requisite height of the splicer foot212necessary to rigidly support and maintain the V-shaped axles322,332in a fixed position as attached to the sides of the openings. The unitary shape of the V-shaped axles322,332is designed for increased strength and to minimize the height of the splicer foot212. The strength provided by the unitary shape of the V-shaped axles322,332enables the plurality of forward lower preparation rollers214and the plurality of rearward lower splicer rollers216to be able to support and interact with the upper preparation rollers220and the upper splicer rollers252, respectively, without breaking or flexing.

As can best be seen inFIGS.12and14, the splicer foot212may include a toe340, a heel342, a center frame portion344, a first side rail346, and a second side rail348. The first and second side rails346,348may also be referred to herein as a pair of side rails. Each of the toe340, the heel342, and the center frame portion344extend between the first and second side rails346,348. The toe340may define a forward end350of the splicer foot212. The forward direction204may be defined from the heel342toward the toe340. Each continuous unitary V-shaped axle322,332may be pointed in the forward direction204.

The first opening310may be defined between the toe340, the center frame portion344, and the first and second side rails346,348. The second opening312may be defined between the heel342, the center frame portion344, and the first and second side rails346,348.

The toe340may further include an upwardly extending flange341configured to connect the splicer foot212to the remainder of the splicer foot assembly210. As the splicer foot assembly210advances in the forward direction204, the two ends122of the second sheet of tire material120are configured to split around the upwardly extending flange341before being engaged by the plurality of lower preparation rollers214and the upper preparation rollers220.

As can best be seen inFIGS.11and14, the first and second side rails346,348have opposed pairs of non-circular recesses352defined therein. Each of the continuous unitary V-shaped axles322may include non-circular ends328configured to be closely received in one of the opposed pairs of non-circular recesses352of the first and second side rails346,348that are aligned with the first opening310. Each of the continuous unitary V-shaped axles332may also include non-circular ends338configured to be closely received in one of the opposed pairs of non-circular recesses352of the first and second side rails346,348that are aligned with the second opening312. The opposed pairs of non-circular recesses352fixedly hold the continuous unitary V-shaped axles322,332between the first and second side rails346,348. The opposed pairs of non-circular recesses352maintain the continuous unitary V-shaped axles322,332pointing in the forward direction204.

As can best be seen inFIGS.11-14, the splicer foot212may include a plurality of lower rollers370designed to reduce any potential friction between a bottom surface of the splicer foot212and at least one of the first sheet of tire material116or the working surface102of the tire building drum100when the splicer foot212advances in the forward or rearward directions214,206along the working surface102of the tire building drum100. The plurality of lower rollers370may include a special coating to further reduce friction. The plurality of lower rollers370may also be referred to herein as a plurality of anti-friction rollers370.

The splicer foot212has a thickness354of no greater than ⅜ of an inch. The plurality of forward lower preparation rollers214and the plurality of rearward lower splicer rollers216each have a diameter356of no greater than ⅜ of an inch. The plurality of lower rollers370each have a diameter of approximately 5 mm. The diameter356is minimized based on the design of the continuous unitary V-shaped axles322,332. The minimal diameter356enables the thickness354of the splicer foot212to be minimized. An overall thickness of the splicer foot212including the plurality of forward lower preparation rollers214, the plurality of rearward lower splicer rollers216, and the lower rollers370is approximately 0.5 inches. The minimal overall thickness of the splicer foot212including the rollers help reduce and/or eliminate any potential hump caused by the splicer foot212being positioned between the second sheet of tire material120and at least one of the first sheet of tire material116or the tire building drum100when splicing the two ends122of the second sheet of tire material120together.

Referring now toFIG.16, a control system for the automatic splicing apparatus200is schematically illustrated. A controller380is operably associated with all of the preparation roller motor226, the preparation roller actuator228, the splicer foot actuator234, the splicer roller motor256, the splicer roller actuator258, the press roller actuator262, the splice sensor264, the first longitudinal drive270, the second longitudinal driver272, and various other components of the automatic splicing apparatus200.

The controller380includes a processor382, a computer readable memory medium384, a database386, and an input/output module or control panel388having a display390.

The terms “controller,” “control circuit” and “control circuitry” as used herein may refer to, be embodied by or otherwise included within a machine, such as a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed and programmed to perform or cause the performance of the functions described herein. A general purpose processor can be a microprocessor, but in the alternative, the processor can be a controller, microcontroller, or state machine, combinations of the same, or the like. A processor can also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.

The term “computer-readable memory medium” as used herein may refer to any non-transitory medium384alone or as one of a plurality of non-transitory memory media384within which is embodied in a computer program product392that includes processor-executable software, instructions or program modules which upon execution may provide data or otherwise cause a computer system to implement subject matter or otherwise operate in a specific manner as further defined herein. It may further be understood that more than one type of memory media may be used in combination to conduct processor-executable software, instructions or program modules from a first memory medium upon which the software, instructions or program modules initially reside to a processor for execution.

“Memory media” as generally used herein may further include without limitation transmission media and/or storage media. “Storage media” may refer in an equivalent manner to volatile and non-volatile, removable and non-removable media, including at least dynamic memory, application specific integrated circuits (ASIC), chip memory devices, optical or magnetic disk memory devices, flash memory devices, or any other medium which may be used to stored data in a processor-accessible manner, and may unless otherwise stated either reside on a single computing platform or be distributed across a plurality of such platforms. “Transmission media” may include any tangible media effective to permit processor-executable software, instructions or program modules residing on the media to be read and executed by a processor, including without limitation wire, cable, fiber-optic and wireless media such as is known in the art.

The term “processor” as used herein may refer to at least general-purpose or specific-purpose processing devices and/or logic as may be understood by one of skill in the art, including but not limited to single- or multithreading processors, central processors, parent processors, graphical processors, media processors, and the like.

The controller380receives input data from various sensors such as the splice sensor264. The controller380may receive various other inputs from internal and external sources regarding other operating parameters of the tire building drum100and the associated second sheet of tire material120.

Based upon various operational parameters which may be defined by the computer programming product392the controller380generates various control signals which may be communicated to the tire building drum100, the preparation roller motor226, the preparation roller actuator228, the splicer foot actuator234, the splicer roller motor256, the splicer roller actuator258, the press roller actuator262, the first longitudinal drive270, and the second longitudinal driver272as schematically illustrated via the dashed communication lines393a-iinFIG.16. Any of the communication lines393-a-imay be hardwired or may be wireless. The controller380may also be communicatively linked to various other peripheral systems associated with the tire building drum100and any other related equipment.

The controller380may be configured to control positions of the various actuators228,234,258,262via the respective control signals transmitted by the controller380. The controller380may further be configured to control a pressure being applied by the various actuators228,234,258,262.

The controller380may be configured to coordinate the first and second longitudinal drives270,272for coordinating longitudinal translation of the splicer foot assembly210and the splicer roller assembly250. Coordination of the longitudinal translation associated with the splicer foot assembly210and the splicer roller assembly250is necessary in order for the two ends122of the second sheet of tire material120to be engaged between the upper splicer rollers252and the plurality of rearward lower splicer rollers216as the automatic splicing apparatus200advances in the forward direction204along the tire building drum100.

The controller380may be configured to coordinate the operation of the upper preparation rollers220and the upper splicer rollers252. Initially upon engagement by the upper preparation rollers220with leading edges of the two ends122of the second sheet of tire material120the upper preparation rollers220are powered. The upper preparation rollers220are powered initially to aid in advancing the second sheet of tire material120between the upper preparation rollers220and the plurality of forward lower preparation rollers214toward the upper splicer rollers252. After the leading edges of the two ends122of the second sheet of tire material120are received between the upper splicer rollers252and the plurality of rearward splicer rollers216the controller may cause power to be disconnected from the upper preparation rollers220. The power to the upper preparation rollers220may be terminated using a clutch or the like to allow free rotational movement of the upper preparation rollers220when power is disconnected thereto.

The controller380may be configured to analyze the two ends122of the second sheet of tire material120after being spliced together by the pair of truncated conical upper splicer roller252and the plurality of rearward lower splicer rollers216based upon inputs from the splice sensor264. The controller380may automatically analyze the splice and determine whether it is good (e.g., there is no gap between the spliced ends of the second sheet of tire material) or bad (e.g., there is a gap between the spliced ends of the second sheet of tire material). In certain embodiments, the controller may also display the spliced ends of the second sheet of tire material120to the operator via the display390. Should the controller380or the operator detect a bad splice, then the automatic operation of the automatic splicer assembly210may be contemporaneously terminated and the splice may be completed in accordance with the previously outlined manual protocol. Alternatively, the controller may cause the automatic splicing apparatus to complete the entire splice before prompting the operator via the display390to manually repair the portion of the splice tagged as “bad.”

In certain embodiments, the controller380may be configured to analyze the two ends122of the second sheet of tire material120after being pulled together by the upper preparation rollers220and the plurality of lower preparation rollers214based upon inputs from the splice sensor264or another sensor (not shown). Once the two ends122of the second sheet of tire material120have been positioned on the splicer foot212and have been pulled together by the upper and lower preparation rollers220,214there should be little to no gap (e.g., roughly less than 5 mm) between the two ends122of the second sheet of tire material120. If the sensor senses too large of a gap between the two ends122of the second sheet of tire material120, then the controller380may either continue or terminate the automatic operation of the automatic splicing apparatus200depending upon a size of the gap. The controller380may alert an operator of the termination of the automatic operation via at least the display390. Upon appropriate inputs by the operator, the controller380may remove the splicer foot assembly210and the remainder of the splice will have to be completed manually by the operator.

In other embodiments, the controller380may be configured to provide proper alignment between the automatic splicing apparatus200and the two ends122of the second sheet of tire material120disposed on the tire building drum100. In order to provide proper alignment, a positional sensor (not shown) may continually sense or pre-scan a position of the two ends122of the second sheet of tire material120and the controller380may transmit a control signal via the communication line393ato the tire building drum100in order to change a position of the tire building drum100about its rotational axis104.

In certain embodiments (not shown), the plurality of forward lower preparation rollers214may include only a single continuous unitary V-shaped axle and a pair of non-powered lower rollers positioned thereupon. Likewise, in certain embodiments (not shown), the plurality of rearward lower splicer rollers216may include only a single continuous unitary V-shaped axle and a pair of non-powered lower rollers positioned thereupon

In other embodiments (not shown), the pluralities of forward lower preparation rollers214and the rearward lower splicer rollers216may comprise a single plurality of lower rollers spanning continuously from the toe340to the heel342.

A method of automatically splicing together the two ends122of the second sheet of tire material120is also provided herein. The method comprises a step of providing the splicer foot assembly210. The splicer foot assembly includes the splicer foot212and the plurality of upper preparation rollers220. The splicer foot212includes the plurality of forward lower preparation roller214and the plurality of rearward lower splicer rollers216.

The method further comprises a step of providing the splicer roller assembly250which includes the plurality of upper splicer rollers252.

The method further includes a step of wrapping the second sheet of tire material120on the tire building drum100so that the two ends122of the second sheet of tire material120face each other. The second sheet of tire material120may or may not be wrapped onto the first sheet of tire material116.

The method further includes a step of inserting the splicer foot212under the two ends122of the second sheet of tire material120at a rearward side124of the second sheet of tire material120. The rearward side124of the second sheet of tire material120faces the working surface102of the tire building drum100and may rest upon the first sheet of tire material116when present. Accordingly, the splicer foot212is positioned between the second sheet of tire material120and at least one of the first sheet of tire material116or the tire building drum100.

The method further includes a step of gripping the two ends122of the second sheet of tire material120between the upper preparation rollers220and the forward lower preparation rollers214.

The method further includes a step of advancing the splicer foot assembly210in the forward direction204relative to the tire building drum100while simultaneously power rotating the upper preparation rollers220and thereby pulling the two ends122of the second sheet of tire material120toward each other over the splicer foot212as the splicer foot assembly210advances in the forward direction204. The V-shaped pattern of the upper preparation rollers200and the plurality of forward lower preparation rollers214are optimally configured to pull the two ends122of the second sheet of tire material120flush together and hold them in place for the upper splicer rollers252.

The method further comprises a step of gripping the two ends122of the second sheet of tire material120between the upper splicer rollers252and the plurality of rearward lower splicer roller216.

The method further includes a step of splicing the two ends122of the second sheet of tire material120as the splicer roller assembly250and the splicer foot assembly210advance together in the forward direction204.

In certain embodiments, the method may further include, after the step of gripping the two ends122of the second sheet of tire material120between the upper splicer rollers252and the plurality of rearward lower splicer roller216, a step of terminating the power rotation of the upper preparation rollers220while the power rotation of the upper splicer rollers is continued.

In certain embodiments, the method may further include, during the step of gripping the two ends122of the second sheet of tire material120between the upper preparation rollers220and the forward lower preparation rollers214, a step of moving the upper preparation rollers220toward the tire building drum100relative to the splicer foot212.

In certain embodiments, the method may further include, during the step of gripping the two ends122of the second sheet of tire material120between the upper splicer rollers252and the plurality of rearward lower splicer roller216, a step of moving the upper splicer rollers252toward the tire building drum100relative to the splicer foot212.

In certain embodiments, the method may further include, prior to the step of inserting the splicer foot212under the two ends122of the second sheet of tire material120, a step of lifting the two ends122of the second sheet of tire material120with the plurality of magnetic rollers230. The plurality of magnetic rollers230may be located forward of the plurality of upper preparation rollers220.

Referring toFIGS.17A-19B, various steps of the method are illustrated and discussed in greater detail.FIG.17Aillustrates a front cross-sectional elevation view of the automatic splicing apparatus200just prior to inserting the splicer foot212under the ends122of the second sheet of tire material120above the first sheet of tire material116.FIG.17Billustrates a plan view of the automatic splicing apparatus200and the second sheet of tire material120ofFIG.17A.FIG.18Aillustrates a front cross-sectional elevation view of the automatic splicing apparatus200gripping the ends122of the second sheet of tire material120between the upper preparation rollers220and the forward lower preparation rollers214.FIG.18Billustrates a plan view of the automatic splicing apparatus200and the second sheet of tire material120ofFIG.18A.FIG.19Aillustrates a front cross-sectional elevation view of the automatic splicing apparatus200gripping the two ends122of the second sheet of tire material120between the upper splicer rollers252and the rearward lower splicer rollers216.FIG.19Billustrates a plan view of the automatic splicing apparatus200and the second sheet of tire material120ofFIG.19A.

Referring toFIGS.17A and17B, the automatic splicing apparatus200is shown advancing in the forward direction204along at least one of the first sheet of tier material or the working surface102of the tire building drum100toward the second sheet of tire material120. The plurality of magnetic rollers230are shown lifting up the leading edges of the two ends122of the second sheet of tire material120. The splicer foot212may thus easily be inserted between the first sheet of tire material116and the reward side124of the second sheet of tire material120as the splicer foot212advances in the forward direction204.

Referring toFIGS.18A and18B, the two ends122of the second sheet of tire material120are gripped between the upper preparation rollers220and the forward lower preparation rollers214. The splicer foot212advances in the forward direction204at least partially by power rotating the upper preparation rollers220. As the splicer foot212advances in the forward direction204the upper preparation rollers220and the forward lower preparation rollers214pull the two ends122of the second sheet of tire material120toward each other over the splicer foot212. The plurality of magnetic rollers230continue to assist in picking up the two ends122of the second sheet of tire material120as the splicer foot212advances in the forward direction204. As can be seen inFIG.18B, after the two ends122of the second sheet of tire material120have advanced through upper preparation rollers220and the forward lower preparation rollers214, the two ends122are positioned closely together and are held in said position ready to be spliced together by the upper splicer rollers252and the rearward lower splicer rollers216.

Referring toFIGS.19A and19B, the two ends122of the second sheet of tire material120are gripped between the upper splicer rollers252and the rearward lower splicer rollers216. The two ends122of the second sheet of tire material120are spliced together (e.g., the portion of the second sheet of tire material120positioned rearward of the splicer roller assembly250) as the splicer roller assembly250and the splicer foot assembly210advance together in the forward direction204.

To facilitate the understanding of the embodiments described herein, a number of terms have been defined above. The terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but rather include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as set forth in the claims. The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may.

Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

The previous detailed description has been provided for the purposes of illustration and description. Thus, although there have been described particular embodiments of a new and useful apparatus and method for automatic tire ply splicing, it is not intended that such references be construed as limitations upon the scope of this disclosure except as set forth in the following claims.