FORM 2
THE PATENTS ACT, 1970 (39 of 1970) & THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See section 10, rule 13)
1. Title of the invention: GREEN TIRE MANUFACTURING
2. Applicant(s)
NAME NATIONALITY ADDRESS
CEAT LIMITED Indian RPG HOUSE, 463, Dr. Annie Besant Road, Worli, Mumbai - Maharashtra 400030, India
3. Preamble to the description
COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in which it
is to be performed.

TECHNICAL FIELD
[0001] The present subject matter relates, in general, to a tire building process and, in particular, to applying a tire building component on a carcass building drum in the tire building process.
BACKGROUND
[0002] Green tires are made by different tire building components, such as one or more radial plies, inner liner, sidewalls, bead rings, fillers, etc., all combined to form a carcass. These tire building components are assembled and consolidated on a cylindrical carcass building drum, such that the one or more body plies have the body ply cords essentially parallel to the rotational axis of the carcass building drum as the carcass is assembled thereon, e.g. extending along with the cylindrical carcass. The carcass building drum may have one or more segments, which may be arranged to expand, in order to increase the diameter of the carcass building drum surface, to provide shoulders at both ends of the carcass building drum, and to collapse so as to reduce a diameter of the carcass building drum to enable the finished tire to be removed from the drum for subsequent vulcanizing operations thereafter.
BRIEF DESCRIPTION OF DRAWINGS
[0003] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.
[0004] Fig. 1 illustrates a perspective view of a tire building apparatus, in accordance with an example implementation of the present subject matter;

[0005] Fig. 2 illustrates a perspective view of a linear module of the tire
building apparatus, in accordance with an example implementation of the
present subject matter;
[0006] Fig. 3 illustrates a perspective view of a servo motor of the tire
building apparatus, in accordance with an example implementation of the
present subject matter;
[0007] Fig. 4 illustrates a perspective view of a controller of the tire building
apparatus, in accordance with an example implementation of the present
subject matter;
[0008] Fig. 5 is a diagram illustrating an example of turn-up height variation
before and after the implementation of the present subject matter.
[0009] Fig. 6 is yet another diagram illustrating an example of turn-up height
variation before and after the implementation of the present subject matter.
DETAILED DESCRIPTION
[0010] The present subject matter relates to the accurate positioning of bead pusher rings along a carcass building drum to improve the quality of a tire. [0011] Tire carcass building components comprise an inner liner, sidewalls, fillers, first ply, second ply, bead rings, and tread all of which are used to make a green tire by assembling them on a surface of a cylindrically shaped, rotatable carcass building drum. The carcass building drum may be radially collapsed and expanded without damage or distortion to the tire building components formed on the carcass building drum which permits the widthwise adjustment of the carcass building drum without interrupting the smooth continuity of the tire building surface. The carcass building drum expands in order to increase the diameter of the drum surface, to provide shoulders at both ends of the carcass building drum, and collapses so as to reduce the carcass building drum diameter to enable the finished tire to be

removed from the carcass building drum for subsequent vulcanizing operations thereafter.
[0012] In the collapsed state of the carcass building drum, the tire beads are encased in bead areas of the carcass building drum, and then the carcass building drum is expanded and pusher rings are moved inwardly to apply the sidewall components and the outer end portions of the carcass components to the sidewalls.
[0013] Conventionally, pneumatic cylinders consuming compressed air are used for controlling the movement of bead pusher rings of the tire building machine. However, the use of pneumatic cylinders not only fails to provide precise positioning of the bead pusher rings along with the carcass building drum but may also lead to bearing failure and/or jerking movement of the bead pusher rings. Also, conventional pneumatic cylinders are heavy and high in volume which increases cost and complexity. Conventional pneumatic cylinders may also lead to an increased turn-up height variation thereby decreasing the cut-tire rating and uniformity yield of product, i.e. tire. [0014] The present subject matter provides an apparatus for manufacturing a green tire, wherein the apparatus comprises a cylindrical shaft, a carcass drum that is mounted on the cylindrical shaft in surrounding relation thereto, and have an outer circumferential surface, wherein the carcass drum comprises a first and second bead area. The apparatus further comprises two bead pusher rings that are disposed around the cylindrical shaft on opposite sides of the carcass drum, for supporting the bead, wherein the bead pusher rings are radially movable. The apparatus also comprises a positioning device configured with each of the bead pusher rings to radially move the bead pusher ring towards the center of the carcass drum, wherein a green tire carcass is transferred onto the outer circumferential surface of the carcass drum by placing a first and second bead onto the first and the second bead

area, respectively, of the carcass drum. Further, a bead setting force is applied, simultaneously, by the positioning device inwardly towards one another with moving of the bead pusher ring, and then, the green tire carcass is inflated, by passing pressurized fluid or air in the carcass drum, into engagement with a belt and tread package while the at least one of the bead area is free to slide axially inward.
[0015] Thus, the present invention provides techniques to control the movement of the bead pusher ring on the cylindrical shaft, wherein the positioning device is used for accurate positioning of the bead pusher ring on the cylindrical shaft with respect to the carcass drum to improve the quality (uniformity yield) of the tire. The positioning device improves the bead setting process and reduces the turn-up height variation thereby increasing the cut-tire rating and uniformity yield of the product, i.e. tire.
[0016] By using the positioning device of the present invention, the jerking movement of the bead pusher rings may be eliminated resulting in the elimination of LM (Linear Module) bearing failure and looseness of LM bearing mounting bolts, thus improving the green tire manufacturing machine reliability. Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings, and the appended claims.
[0017] The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and, should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein

reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.
[0018] Fig. 1 shows an apparatus 100 for manufacturing a green tire, according to an example implementation of the present subject matter. The apparatus 100 for manufacturing the green tire comprises a cylindrical shaft 102 and a carcass drum 104 mounted on the cylindrical shaft 102 in surrounding relation thereto. The carcass drum 104 has a first bead area 108-1 and a second bead area 108-2 on the periphery of the outer circumferential surface 106.
[0019] In an example embodiment of the present subject matter, the cylindrical shaft 102 may be connected to an (unillustrated) rotational driving apparatus and is capable of providing a rotational movement to the carcass drum 104 about the longitudinal axis of the cylindrical shaft 102. In another example, the carcass drum 104 may include an intermediate drum (unillustrated) having a porous sleeve comprised of an intermediate portion and two oppositely disposed end portions connected to respective opposite sides of the carcass drum 104.
[0020] The apparatus 100 for manufacturing the green tire further comprises two bead pusher rings 110-1, 110-2 that are disposed on the cylindrical shaft 102 on opposite sides of the carcass drum 104. The two bead pusher rings 110-1, 110-2 are for supporting a bead each and are radially and axially movable relative to the carcass drum 104.
[0021] The movement of each bead pusher ring 110-1, 110-2 is obtained by a positioning device 112, wherein the positioning device 112 allows each bead pusher ring 110-1, 110-2 to radially move towards the center of the carcass drum 104. The positioning device 112 is also responsible for

retracting the bead pusher ring 110-1, 110-2 to its original position. Further, the amount of axial and radial movement of the bead pusher ring 110-1, 110-2 may be adjusted by the positioning device 112.
[0022] While certain details of the tire building apparatus 100, which are important for fully and particularly describing the present invention, have been shown and discussed, it will be apparent to those skilled in this art that the tire building apparatus 100 may also include various other components as well, such as right and left-hand shoulder section of the carcass drum (104), bead-lock mechanism for bead pusher ring 110-1, 110-2, a flange of the cylindrical shaft 102, etc., which have not been elaborated.
[0023] In an example embodiment, to make the green tire, a green tire carcass is transferred onto the outer circumferential surface 106 of the carcass drum 104 by placing a first and second bead onto the first bead area 108-1 and the second bead area 108-2, respectively, of the carcass drum 104. Further, a bead setting force is applied, simultaneously, by the positioning device 112 inwardly towards one another with moving of the bead pusher rings 110-1, 110-2. Then, the green tire carcass is inflated, by passing pressurized fluid or air in the carcass drum 104, into engagement with a belt and tread package while at least one of the bead area is free to slide axially inward.
[0024] In an example embodiment of the present subject matter, the positioning device 112 may consist of a linear module 114, a servo motor 116, and a controller. In operation, the bead pusher ring 110-1, 110-2 linearly slides under the drive of the servo motor 116 through the linear module 114, and a rotation of the servo motor 116 is controlled by the controller. [0025] In another example embodiment of the present subject matter, the apparatus 100 for manufacturing the green tire may be provided with a programmable logic control (PLC) (unillustrated) which is interfaced with the

controller of the positioning device 112 to control the actuation of the positioning device 112. The apparatus 100 for manufacturing the green tire may also comprise a human-machine interface (HMI) that may be coupled with the PLC. The HMI may enable a user to set position value settings for the PLC to control the actuation of the positioning device 112 with respect to a position of the bead pusher ring 110-1, 110-2 on the cylindrical shaft 102. In one example embodiment, the controller may be a PLC type Controller. The position value settings may be based on the type of tire being manufactured. [0026] In yet another example embodiment of the present subject matter, the PLC may be provided with a software component such as a PLC application which may have a configuration file to define the objects and logic of movement of the bead pusher rings 110-1, 110-2 with respect to the carcass drum 104, by assigning input/outputs (IO), and logic based on the system as define via a configuration tool. In an example implementation, the components of the PLC may include, IO controllers, power supply, input module, output module, processor (CPU), rack or mounting assembly, a programming unit (software), for example, for running the PLC without interrupting tire building operation. The IO controllers of the PLC may be jointly operative for managing the signals and logic required for linear sliding of the bead pusher rings 110-1, 110-2.
[0027] In an example, the positioning device 112 may be capable of controlling the sliding speed of both bead pusher rings 110-1, 110-2 individually and set the speed of the bead pusher rings 110-1, 110-2 in a manner that both the bead pusher rings 110-1, 110-2 may reach at a predefined position on the cylindrical shaft 102 at the same time.
[0028] Fig. 2 illustrates a detailed view of the linear module 114 of the positioning device 112, in accordance with an example implementation of the present subject matter. In an implementation, the linear module 114 may

operate according to the position values set in the HMI. The operator sets the position values in the HMI through an interface of the HMI. The HMI may further communicate the position value settings to the PLC, wherein the PLC may give a signal to the linear module 114 to perform the radial movement of the bead pusher ring 110-1, 110-2 due to which the bead pusher ring 110-1, 110-2, which is attached to linear module 114, slide over the cylindrical shaft 102.
[0029] In an example implementation, the HMI may comprise a display (unillustrated), a multidimensional input device (unillustrated), a computer communicating (unillustrated) with a network. The HMI, in response to an input provided to the multidimensional input device, may allow an operator viewing the display and operating the multidimensional input device to feed the position values in the HMI with the help of a multidimensional input device. The computer may further execute interface programs on the PLC in response to the position values set by the operator in the HMI. The PLC, through the linear module 114 of the positioning device 112 and in accordance with the position values fed through the HMI, may control the movement of the bead pusher ring 110-1, 110-2 so that the desired bead setting on the carcass drum 104 can be achieved.
[0030] In one of the example embodiment of the present subject matter, the display may be a cathode ray tube (CRT), LED, LCD, or any other type of display. Such display types are well known in art. The multidimensional input device may be a conventional keyboard and mouse, or a space ball, or other similar devices which all are well known in the art for providing multi-dimensional input for the operator.
[0031] Fig. 3 illustrates a detailed view of the servo motor 116 of the positioning device 112, in accordance with an example implementation of the

present subject matter. The servo motor 116 is used as a system for driving the linear module 114.
[0032] Fig. 4 illustrates a detailed view of a controller 118 of the positioning device 112, in accordance with an example implementation of the present subject matter. Controller 118 is similar to the controller described with regard to Figs. 1-3.
[0033] In an example, the positioning device 112 may consist of a servo driver (unillustrated) that receives an instruction signal from controller 118 via the PLC. The servo driver drives the servo motor 116 based on the instruction signal from the controller 118. Also, the servo driver may send anomaly information indicating an internal anomaly to the HMI via the PLC. The servo driver may receive alternating-current (AC) power from an AC power source. In this example embodiment, the servo driver is of a type that receives three-phase alternating current, but it may also be of a type that receives single-phase alternating current. Also, controller 118 may be able to stop the rotation of the servo motor 116, in case of an emergency stop, in a shorter stop time with a reduced stopping distance.
[0034] In an example operation, the bead pusher ring 110-1, 110-2 is moved through linear module 114 consisting of a ball screw and rotated by the servo motor 116 that gives accurate positioning of the bead pusher ring 110-1, 110-2. The use of the positioning device 112 may smooth the movement of the bead pusher ring 110-1, 110-2 on the cylindrical shaft 102, thereby eliminating the jerk while movement and both side bead setting on the carcass drum 104 may be achieved at the same time resulting in a proper bead set. The accuracy of the bead setting reflects in the tire quality and uniformity. The linear module 114 with the help of servo motor 116 may withstand turn-up force while turn-up. Replacing the conventionally used

pneumatic cylinders with servo-controlled cylinders eliminates the seal pass phenomenon and thus improves the reliability of apparatus 100.
[0035] Further, inbuilt servo motor 116 with linear module 114 makes design compact and high strength of ball screw makes design robust, which make apparatus 100 reliable.
[0036] Also, impact load on a bladder unit of the apparatus 100 while turn-up operation may also be eliminated by use of the positioning device 112. A reduction in impact load on the bladder unit helps to keep its position in the apparatus 100 undisturbed, thereby improving the apparatus 100 reliability. [0037] In another example operation, a permissible range of stroke of the positioning device 112 may lie in a range of about 30 mm to 800 mm. A permissible range of speed of the positioning device 112 may lie in a range of about 0.2 m/sec to 0.55 m/sec, and positional accuracy of the positioning device 112 maybe 0.1 mm.
[0038] The inventor(s) of the present invention in a laboratory test has noted that by using the positioning device 112 of the present invention there is a 20 percent improvement in a scrap for the same size of the tire. Also, 2N to 3N improvement in RFV (radial force variation) and H1 value was noted during the test. Further, it was noted that the cord length variation reduced from 3mm to 1.5mm and cut tire rating – ply turn-up standard deviation improved by 14 percent. These are just test results and are not meant to limiting the scope of the invention.
[0039] Thus, the beneficial technical effects of the positioning device 112 may comprise: compact design due to inbuilt servo motor 116 with linear module 114, robust design due to high strength of ball screw, gearbox with servo motor provides high position accuracy and jerk-free operation, long lifetime guarantee of lubrication for installed ball screw, easy calibration, easy synchronization of the bead pusher ring 110-1, 110-2 speed enabling both

side bead setting at the same time so that material shifting gets eliminated, improvement in the turn-up height variation/cord length variation thereby improving the radial force variation and uniformity/quality of the tire, no bead damage or un-even bead set hence tire scraping is eliminated, elimination of the compressed air cost, consistency in the accuracy of the bead pusher ring 110-1, 110-2 positioning and accurate bead setting provides consistence cut tire rating and hence improves the uniformity/quality of the product. [0040] Fig. 5 shows a trend for turn-up height variation of a tire of size 2175 BTTL before and after the installation of the positioning device 112. In that, the inventor(s) of the present invention have measured ply turn-up height at 12 locations in a single carcass. As shown in Fig. 5, before the installation of the positioning device 112, the turn-up height variation was up to 6 mm, and after the installation of the positioning device 112, turn-up height variation is a maximum of 2 mm.
[0041] Fig. 6 shows a trend for turn-up height variation of a tire of size 215/75R15CZRTLHT before and after the installation of the positioning device 112. In that, the inventor(s) of the present invention have measured ply turn-up height at 12 locations in a single carcass. As shown in Fig. 6, before the installation of the positioning device 112, the turn-up height variation was up to 5 mm, and after the installation of the positioning device 112, turn-up height variation is a maximum of 2 mm.
[0042] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. As such, the present disclosure should not be considered limited to the description of the preferred examples and implementations contained therein.

I/We Claim:
1. An apparatus (100) for manufacturing a green tire, the apparatus (100)
comprising:
a cylindrical shaft (102);
a carcass drum (104) mounted on the cylindrical shaft (102), the carcass drum (104) having an outer circumferential surface (106), a first bead area (108-1), and a second bead area (108-2) on the periphery of the outer circumferential surface (106);
two bead pusher rings (110-1, 110-2) disposed on the cylindrical shaft (102) on opposite sides of the carcass drum (104), for supporting a first bead and second bead, respectively, wherein the bead pusher rings (110-1, 110-2) are radially movable; and
a positioning device (112) for each bead pusher ring (110-1, 110-2) to radially move the bead pusher ring (110-1, 110-2) towards the carcass drum (104),
such that for a green tire carcass on the outer circumferential surface (106) of the carcass drum (104), the first and second bead is placed onto the first bead area (108-1) and the second bead area (108-2), respectively, of the carcass drum (104),
wherein a bead setting force is applied, simultaneously, by the positioning device (112) inwardly towards one another with moving of the bead pusher rings (110-1, 110-2), and
wherein the green tire carcass is inflated, by passing pressurized fluid in the carcass drum (104), into engagement with a belt and tread package while at least one of the first and second bead area (108-1, 108-2) is free to slide axially inward.

2. The apparatus (100) as claimed in claim 1, wherein the positioning device (112) comprises a linear module (114), a servo motor (116), and a controller (118), wherein the bead pusher ring (110-1, 110-2) slides linearly under the drive of the servo motor (116) through the linear module (114), and wherein a rotation of the servo motor (116) is controlled by the controller (118).
3. The apparatus (100) as claimed in claim 2, further comprises:
a programmable logic control (PLC) interfaced with the controller (118) of the positioning device (112) to control the actuation of the positioning device (112).
4. The apparatus (100) as claimed in any one of the preceding claims 3, further comprising a human-machine interface (HMI) coupled with the PLC, wherein the HMI is to enable providing of position value settings to the PLC to control the actuation of the positioning device (112) with respect to a position of the bead pusher ring (110-1, 110-2) on the cylindrical shaft (102).
5. The apparatus (100) as claimed in claim 1, wherein the positioning device (112) is configured to control the speed of both bead pusher rings (110-1, 110-2) individually and set the speed of the bead pusher rings (110-1, 110-2) such that both bead pusher rings (110-1, 110-2) reach at a predefined position on the cylindrical shaft (102) at the same time.
6. The apparatus (100) as claimed in claim 2, wherein
a permissible range of stroke of the positioning device (112) lies between 30 mm to 800 mm;

7. The apparatus (100) as claimed in claim 2, wherein
a permissible range of speed of the positioning device (112) lies between 0.2 m/sec to 0.55 m/sec.
8. The apparatus (100) as claimed in claim 2, wherein a positional accuracy of the positioning device (112) is 0.1 mm.
9. The apparatus (100) as claimed in claim 1, wherein the carcass drum (104) comprises an intermediate drum having a porous sleeve comprised of an intermediate portion and two oppositely disposed end portions connected to respective opposite sides of the carcass drum (104).