Rubber presents a challenge for optical-based measurement sensors. By nature, the black surface is difficult to capture reliable data from and accurately measure. This challenge is often intensified by the complex shapes into which rubber derivatives are extruded or molded.

As a solution to this challenge, 3D laser sensor manufacturers have optimised the design of their sensors to successfully implement scanning and quality control functions for both in-process and final product inspection applications in rubber and tyre manufacturing.

3D laser scanning

Rubber material comes in two forms on the production line, either as fresh and uncured from an extruder or a calender, or as a finished product (e.g., vulcanised tyres). Non-contact 3D laser scanning offers the most practical solution for inspection of both of these rubber material types.

Here’s why:

1. The soft, gummy nature of the rubber makes contact-type measurement ineffective. This measurement approach is also too slow to keep up with the high-speeds of continuous web material production.

2. 2D sensors require complex lighting to see black-on-black contrast. In some applications the lighting is placed underneath the material (e.g., when measuring the width of a strip), and hot sticking rubber can contaminate the lights. In addition, 2D can’t produce measurements related to object geometry (i.e., 3D shape), which means they are unable to measure critical features such as object flatness, surface angles, or part volumes, and are limited to contrast-based inspection. This makes 2D sensors a poor solution for scanning complex shape-based features on dark surfaces, or for operation in low lighting conditions.

          3. In comparison, 3D laser sensors are contrast invariants and generate high-resolution scans regardless of the material or lighting conditions. They also capture the complete 3D geometry of the scan target, including critical depth measurements on surface features such as grooves in a tyre tread. 3D laser sensors are also able to achieve the high speeds required for continuous web material scanning.

Laser profile sensors provide an ideal solution to both in-process and final rubber and tyre measurement and quality control applications. Built-in measurement tools for strip positions, including multiple groove location and depth measurement monitoring with automated alignment enable engineers to configure setup parameters––without requiring any measurement software development.

In addition, the ability to store multiple geometry configurations in the sensor makes changes between different recipes quick and simple, which is critical in minimising downtime for operations that make model changes multiple times per shift.

Application examples

1. In-Process Inspection

Extrusion Profiling with High-Resolution Gocator® 2440 Laser Profiler

Extruding rubber in a specific shape makes up the tread portion of a tyre. Measurement of the extrusion profile is carried out in-process, correcting the extrusion parameters in real-time to maintain the required shape. Key measurement parameters include thickness, width, and profile. Another required sensor capability is monitoring the position of surface features, such as ridges, center lines, and edges.

Profiling these tread extrusions is done by using 3D laser sensors to scan across the extrusion, generating a profile to which built-in measurement tools and pass/fail decision-making logic can be applied.

In this example, two Gocator 2440 laser line profilers are used to measure the rubber web’s extrusion groove pattern, geometry, and location with an X resolution down to 13 microns. Gocator 2440 sensors are able to inspect multiple grooves in a single setup, and groove measurements are unaffected by changes in surface angle relative to the sensor.

Most importantly, Gocator 2440 sensors generate critical 3D height data for robust shape measurement. 2D solutions are limited to contrast-based inspection.

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3. Final tyre inspection

Tyre Sidewall Inspection with High-Speed Gocator 2530 Laser Profiler

Traditional methods for measuring tyre sidewalls for defects such as bulges and dents suffer from too many false rejects (i.e., classifying a good tyre as defective). Due to measurement system limitations, many manufacturers have no choice but to “oversensitise” their sidewall bulge and dent measurement systems, resulting in costly manual inspection requirements for all rejected tyres.

In fact, some measurement systems cannot even distinguish between bulges or dents. However, with state-of-the art laser measurement precision and advanced built-in software analysis, false positive rates can be substantially reduced and, in many cases, eliminated altogether.

Using a Gocator 2530 laser profiler the engineer is able to generate full surface point cloud geometry data in order to detect small defects (down to 28 microns X resolution) anywhere on the sidewall surface. The sensor also delivers complete scan, measurement, and control at 4 kHz, allowing engineers to meet stringent cycle time requirements––with no need for industrial PCs or external controllers.

In this configuration, two profile sensors are typically used, one for each sidewall (top and bottom buddy system). A third sensor is often used to monitor radial runout of the tread.

Leveraging 3D Laser Scanning and Inspection

Laser-based laser triangulation sensors meet the high speed and high resolution requirements for accurate rubber and tyre measurement. These sensors are used in a variety of in-process and final inspection applications, including extrusion profiling and tyre sidewall inspection.

Adding 3D laser sensors for automated quality control is vital to reducing scrap and rework, and improving final product quality by maintaining consistency throughout the tyre manufacturing process.

Courtesy of LMI Technologies www.lmi3d.com

Al Salem Transportation & Tourism Co. (Al Salem) is reaping the benefits of Goodyear’s CheckPoint tyre monitoring technology system, which was implemented in its Dammam depot. This is a first for passenger transport companies in Saudi Arabia and builds upon the existing partnership between Al Salem Transportation & Tourism Co. (Al Salem), Goodyear and its official Saudi distributor, Al Rashed Tires.

Goodyear CheckPoint is a connected, yard-based drive-over tyre inspection system that provides fleet managers with useful information by reading vehicle data and tyre condition. Tyre pressure and tread depth examinations are time-consuming tasks that may be completed in seconds by Goodyear CheckPoint's automated system.

The system provides the ability to access data through user-friendly reports and allows Al Salem to address all their operational needs related to tyres. This decision is consistent with Al Salem's commitment to using cutting-edge technology to achieve the greatest levels of safety and efficiency, as well as the Saudi Vision 2030 aim of boosting the quality and connectedness of transportation networks.

Mustafa Alsalem, Business Development Manager, Al Salem Transportation & Tourism Co, said, "At Al Salem, our mission is to provide safe and comfortable journeys for everyone in the Kingdom. We pride ourselves on working only with industry leaders to deliver premium safety and service levels. Partnering with a leading global tyre manufacturer like Goodyear, renowned for their premium tyres and innovative digital fleet solutions, is a testament to our commitment to this mission."

Yasser Meyer, CEO, Al Rashed Tires, said, “We have a proud legacy of supporting the development of Saudi Arabia's automotive industry. Leveraging our in-depth market knowledge, we are able to localise global tyre technology, like Goodyear’s CheckPoint monitoring solutions, to empower our valued partners like Al Salem in their achievement of business goals.”

Saban Gungor, General Manager, Goodyear Middle East & Africa, said, "As a preferred fleet mobility partner, Goodyear is dedicated to delivering not only high-quality tyres but also value-added mobility solutions, like the CheckPoint tyre monitoring, to our fleet customers. We are thrilled to support Al Salem on their digitalisation journey with the adoption of this technology, setting a new benchmark for safety and operational efficiency in the Kingdom."

Vittoria, a global leader in cycling tyres and accessories, has announced opening new state-of-the-art research and development centres known as VittoriaLabs. These facilities, located in Italy and Thailand, are designed to push the boundaries of cycling technology and performance.

The VittoriaLabs will focus on developing innovative tyre and accessory solutions that enhance rider performance, safety, and sustainability. The centres will leverage advanced testing equipment and cutting-edge research methodologies to analyse and optimise product design.

“Vittoria Labs will be the engine driving our ambitions for market leadership in innovation in a future we are already shaping,” says Stijn Vriends, Chairman and CEO of Vittoria. “By combining state-of-the-art indoor and outdoor testing facilities, we can push the limits of what’s possible in cycling tyres and accessories while keeping sustainability at the core of our innovations,” adds Vanessa ten Hoff, Chief Innovation & Marketing Officer of Vittoria.

Vittoria’s investment in these facilities underscores the company’s commitment to innovation and its dedication to providing cyclists with the best possible products. By combining advanced technology with real-world testing, Vittoria aims to deliver products that meet the evolving needs of cyclists worldwide.

With the opening of the VittoriaLabs, Vittoria reinforces its position as a global leader in the cycling industry. The company’s focus on research and development, coupled with its passion for cycling, ensures that it will continue to drive innovation and set new standards in the years to come.

Webfleet, Bridgestone’s fleet management solution, has expanded its OEM.connect partner programme to include trailers. Schmitz Cargobull, a leading manufacturer of semi-trailers, is the first trailer manufacturer to join the programme.

This collaboration allows commercial fleet operators to seamlessly connect their Schmitz Cargobull trailers to the Webfleet platform through factory-fitted telematics. By eliminating the need for aftermarket hardware installations, fleet managers can save time and reduce costs.

“Trailers are the backbone of long-haul goods transportation, but managing a trailer fleet can be challenging,” says Taco van der Leij, Vice President, Webfleet Europe at Bridgestone Mobility Solutions.

“Making our proven Webfleet Trailer solution now easily accessible via OEM data, will help even more businesses with real-time data insights and actionable intelligence to maximise trailer performance. We are happy that we are collaborating with Schmitz Cargobull, offering our customers seamless integration with Europe’s leading semi-trailer manufacturer”.

Sören Danielsen, Manager, Strategy & Business Development at Schmitz Cargobull adds:  “With the TrailerConnect Data Management Center from Schmitz Cargobull, hauliers have full control over their data and can pass on selected data to third parties in an efficient way. By intelligently linking information on the vehicle, tour and order, more than just position and temperature data can be selected, processed and transmitted to third-party systems at the touch of a button in future. The TrailerConnect Data Management Center stands for connectivity and transparency. Everyone involved along the supply chain benefits from this.”

The integrated solution provides fleet operators with valuable insights into trailer performance, including location tracking, maintenance alerts and payload monitoring, said the tyre maker.

Bridgestone has joined hands with Astrobotic Technology to develop lunar rover tyres.

Bridgestone will leverage its 90 years of expertise in developing tyres for Astrobotic’s 24U CubeRover. These tyres will be designed to withstand the harsh lunar environment, including extreme temperatures and rugged terrain.

Bridgestone’s tyres will play a crucial role in enabling the rover to navigate the challenging lunar terrain.

The collaboration highlights the Japanese tyre maker’s commitment to expanding its reach into new and innovative areas of mobility. By partnering with Astrobotic, a leading space exploration company, Bridgestone aims to contribute to the advancement of lunar exploration and space technology.

The 24U CubeRover is a compact lunar rover designed to provide mobility, power and communication support for scientific instruments and payloads on the lunar surface.

As per Bridgestone, this partnership marks a significant milestone for the company as it expands its horizons beyond Earth and into the cosmos.