One-Stop Portable Fixture For Tire Dimension

Measurement Instruments
Gilbert Lim1, Douglas Tong1, and Jonathan Lim2 Commented [MFA1]
1
Taylor's University, School of Engineering
2Continental Tire Technology Centre Malaysia Sdn. Bhd.

Abstract. The research details design concepts of a fixture that will be

used to take measurements of conventional passenger car tires. Engineering
design techniques were studied and implemented in this research. Several
design concepts were drawn using 3D CAD software Solidworks and the
aspects of designs will be evaluated based on feasibility, manufacturability,
cost and ergonomics. Commented [MFA2]
important info on the p
1 Introduction

1.1 Background

Tires are an important component of all land vehicles used in this modern day and age.
Stability of the vehicle, fuel economy, comfort of the passengers and braking distance safety
are some of the features of a well-designed tire. More than a billion tires are produced
annually by several tire manufacturing companies such as Michelin, Bridgestone, Goodyear,
Pirelli and Continental Tires.

A fixture as defined in the manufacturing industry, is a support device used for securely
holding and positioning/orienting a workpiece relative to the tools, which in this case is a car
tire and the tools being the measuring instruments. The use of fixtures improves economy of
production because it allows smoother and faster operations with conformity. [1] The fixture
in this project, is a car tire lift with some modifications. The tire which is installed onto its'
respective sized rim, will be mounted to the fixture on the centre hub of the wheel. There are
two fixtures which have been made, one being an electrical lift and the other being a hydraulic Commented [MFA3]
lift. An image of these 2 fixtures with a tyre mounted are shown in figure 1. paragraph
Fig. 1: 3D Part Assembly of the hydraulic fixture (left) and the electric fixture (right)

1.2 Tire Manufacturing Process

The first step in the tire manufacturing process is the mixing of raw materials to form rubber
compounds. Large quantities of natural and synthetic rubber, carbon black, zinc oxide, sulfur,
and other chemicals and oils are all delivered to factory site and are stored until needed.
Automated computer control systems contain various recipes and can measure out specific
weight portions of rubber and chemicals for mixing. These mixtures will undergo milling
with heating to soften the batch and undergo mixing again with additional chemicals before
being cooled and rolled into rubber slabs for the following processes. There are 3 separate
processes to prepare the components of the tire using this rubber compound.

The extrusion process applies heat to the rubber compound, mixed with additional
chemicals and extruded into sheets and before being precisely weighed, cut and cooled. The
tire components made form the extrusion process are the sidewall and the tire treads. The
calendering process is where the rubber compound is rolled into thin sheets. Fabric
calendering coats and adheres the fabric cords between layers of rubber sheets and rolled to
form multiple layers. The process is similar with steel calendering, using steel cords instead.
The body plies, inner liner and belt package are produced from this process. The bead
building process is where a coil of steel bead wire is uncoiled, coated with rubber and coiled
up again.

The subsequent process is the creation of the basic tire shape using a tire building
machine. The manufactured parts from all the previous processes are delivered to a skilled
assembler at the tire building machine. The centre of the machine is a collapsible rotating
drum which holds the tire's parts. The tire assembler begins building a tire by wrapping the
rubber-covered fabric plies around the machine drum. The ends of these plies are joined with
glue, after which, the loops of beads are added and locked into place with additional tire body
plies laid over the beads. The assembler then uses special power tools to shape the edges of
the tire plies. Finally, the extruded rubber layers of the sidewalls and tread are glued into
place, and the assembled tire, called a 'green tire', is removed from the tire-building machine.

The 'green tire' is then sent to the curing press, where tires attain their final shape and
tread pattern. The curing machine is a large metal mold, inside which is an expandable
balloon like component called a 'bladder'. The molds are engraved with the tread pattern and
sidewall markings. The green tire is fitted onto the 'bladder' and the mold closes. The bladder
fills with a recirculating heat transfer medium such as steam or inert gas, and expands to
shape the tire, forcing the blank tread rubber against the interior of the mold, which is also
heated up in the process. Tires are cured at above 100 degrees Celsius within 10 – 30 minutes,
depending on their size. The heating from the curing process strengthens the rubber
compound by forming the cross link, the chemical bond that links one polymer chain to
another similar to rubber vulcanization without the use of sulfur. At the end of curing the
press swings open, the tires are popped from their molds and onto a long conveyor that carries
them for inspection and testing.[2]

The final stage of the tire manufacturing is testing and inspections. Each tire is thoroughly
inspected visually for flaws such as bubbles or voids in the rubber of the tread, sidewall, and
interior of the tire. The tire is also placed on a test wheel where it is inflated and spun. Sensors
in the test wheel measures the balance of the tire and determines if the tire runs in a straight
line. Tires are rarely rejected because of the competent design and assembly process of a
modern tire. Once the tire has been inspected and run on the test wheel, it is moved to a
warehouse for distribution. Some of the tires are sampled from the production line and X-
rayed to detect hidden weaknesses or internal failures.

1.4 Tire measurements and significance of research

There are several categorised dimensions of the car tire and wheel rim which is shown in
figure 2. The dimensions that define the size of a car tire and the rim that will fit it will be
printed on the sidewall of the tire as a code. An example of this code is: 205/55 R16 V where
205 is the tire’s width measured in millimetres, 55 is the percentage ratio of the sidewall
height to tire’s width, and 16 is the wheel diameter measured in inches. The letters R and V
represent the tire’s construction and speed index.

The three measurements of the tire that the fixture will help measure are the tire’s width,
circumference and tread depth. The circumference of the tire is used to determine the tire’s
overall diameter. These three measurements are taken to determine first and foremost,
whether the tire meets the specified tolerances based on a Manual of Standards. [3]
Fig. 2: Dimensions of a tire (left) and dimensions of a wheel rim (right)

The portable fixture for tire dimension measurement instruments will be used in the final
stage of the tire manufacturing industry, during testing and inspection. The measurement data
is important for tire manufacturers to ensure the tire meets specifications and dimension
standards, assess the quality of their assembly processes and machines, and identify trends in
data with new changes to the processes or machinery equipment. With such a large volume
of tire production, it would benefit the tire industry if the measurement processes can be made
more efficient.

1.4 Objectives

The main objective is to design a mechanism that will be built onto the fixture that will help
an operator take the tire’s three measurements of circumference, tire overall width and tread
depth, easily and quickly. The design should be structurally sound and able to be used
repetitively without failing. Additionally, the design must be adaptable for a range of car tire
sizes, limited only to passenger car tires.

2 Literature Review

2.1 Alternative Tire Measuring Methods and Devices

Initial research was conducted to determine the measuring tools and methods currently
available for tire measurements. Contactless measurement methods were found to be one of
the more popular and recent advancement. A science journal published in 2015 details the
use of electronic sensors to measure the circumference of the tires during the industrial
manufacturing stage. The paper discusses measurement methods that include the use of Commented [MFA4]
capacititive sensors, ultrasonic sensors, inductive sensors and optoelectric sensors.[4]
Another contactless measurement device was developed by Sigmavision which patented a
laser measurement device for measuring the tire tread depth, and is now being used in Hunter
Engineering Company’s ‘QuickTread®’ and Nokian® Tire’s ‘SnapSkan®’ products.[5] The
technology developed is able to be used as a handheld device or even driven over a steel
housing with the device within. The system measures an estimated 2 inch segment of the car
tire, which will generate a ‘point cloud’, a 3D image of the segment with the groove depth
accurately calculated. The major advantage is it’s ability to detect irregular tire wear.

2.2 Measuring Instruments

The measuring instruments that are used to measure the tire are researched thoroughly to
understand their working principles and capabilities, associated terminologies, variety in
design and shape and size. Commented [MFA5]
elaborate more classific
2.2.1 Vernier Calipers purpose of measureme
in tire manufacturing p

The Vernier calipers is a precise instrument that can be used to measure both internal and
external distances accurately with the use of the Vernier scale. It is also able to measure depth
using the depth measuring blade which extends from the bottom of the sliding jaw. The use
of the Vernier scale allows the precision of down to 0.01 millimetres (10 micrometres) or
1/1000. The calipers common flaw is the 'zero-point error' in which the calipers do not read
0.000cm when it's jaws are fully closed.

The modern calipers developed and now commonly used is the Digital Calipers which is
similar in form and function to the Vernier calipers with the addition of an electronic body
attached to the jaw in the place of the Vernier scale. The electronic body is equipped with a
small converter and a digital display while the sliding body of the calipers is fitted with an
incremental capacitance transducer. The incremental capacitance transducer is fabricated
from a foil-like dielectric material that is adhered along the entire length of the caliper’s body.
[6] The advantages of this unit is the ability to save the measurement last taken, extremely
helpful when taking measurements of an object in a confined space that is impossible to read
the measurements of the Vernier scale. Newer models are equipped with bluetooth wireless
technology able to transmit the measurement data to an external device for easy records.
Other minor advantages include the ability to read measurements in bad lighting because of
the display, immediate conversion of units and a zero setting to be able to read relative
measurements. Commented [MFA6]
tools?what is your inno
2.2.1 Tread depth gage

The tread depth gage is used to measure the tire's tread depth. The tread depth gage is a small
handheld device which consists of the body, the protruding depth bar, which is a thin rod and
the scaled rod protruding from the other end of the body. The depth bar or ‘plunger’ and the
scaled rod are a single piece. The body of the depth gage will usually have a screw pin to
tighten and prevent the depth bar from moving. The tread depth gauge may also have a zero-
point error where the scaled rod does not read exactly zero when it’s base is compressed
against a flat surface. The digital tread depth gage is similar to the digital caliper, having
similar benefits when compared with a mechanical one. Commented [MFA7]
for the design??better
understanding
2.2.3 Measuring Tape

Measuring tape or tape measure is a common measuring tool able to measure great lengths
easily, measure around corners and curves, and able to roll up compactly. Measuring tapes
are designed for specific uses such as tailoring, carpentry or construction. Measuring tapes
may be made of cloth, plastic, fibre glass or as a steel or metal strip. The more common
retractable measuring tape that is made of steel used for carpentry and construction is not
suitable because of it’s rigid shape which is unable to curve around the tire. The measuring
tape that will be used is a thinner and more flexible steel strip which does not have the

3 Design Parts Commented [MFA8]

simulation part??
3.1 Support and Base

The support and base are the components which must be securely attached to the tire lift
fixture's base or on it’s standing body. The design of the support structure will complement
the design of the joint component. A simple support structure would be a hollow steel beam
or a rod.

3.2 Joint

The joint is the component that will connect the mechanical arm to the support structure. As
a result of the different sizes of car tires and different operator’s working height, the tire lift
will be used to raise the tire to various heights. The joint component must be able to raise or
lower the mechanical arm to the height of the tire easily. The joint component must also be
fool-proof in the event an operator raises the tyre and collides upwards into the mechanical
arm. Designs of hinges or elbows are incorporated into the joint for this reason. Examples
are shown in the figure 3 below.

Commented [MFA9]
one.

Fig. 3: Designs of joints with the safety feature

3.3 Mechanical Arm

The mechanical arm will be the component which will house all the measuring instruments
ready for use. The most direct and simplest method for this is to position the Vernier calipers
and measuring tape above the tire. It will position the Vernier calipers such that it is as close
to the tire tread as possible or even touching it, with both jaws of the calipers clamping onto
the tire sidewall. The measuring tape will be secured to the mechanical arm with the operator
able to draw out the tape at approximately the centre of the tire’s width. One of the designs
of a mechanical arm is shown in figure 4. Commented [MFA10
calculation,simulation a
.

Fig. 4: Sliding mechanical arm with the Vernier calipers and measuring tape attached Commented [MFA11
attach detailed design a
best desing?how do u e
this design can improve
joining design?bolt/rive
calculation??
References

[1] E. K. Henriksen, “Jig and Fixture Design Manual.” 1973.

[2] B. (Periyar U. Balachandran, “A study on financial performance of select tyre industry in

India,” Periyar University, 2016.

[3] “European Tyre and Rim Technical Organisation (ETRTO) Manual 2018.PDF.” .

[4] M. Navrátil and J. Zdražil, “Automatic contactless measurement of tyre circumference in

industrial conditions,” Procedia Eng., vol. 100, no. January, pp. 408–417, 2015.

[5] S. Corporation, “( 12 ) Patent Application Publication ( 10 ) Pub . No .: US 2006 / 0283920

A1,” 2006.

[6] M. I. Etingof, “Modern vernier caliper,” vol. 55, no. 8, pp. 29–30, 2012.

Commented [MFA12