Systems and methods for maintaining automated quality control during tire manufacture using specialized RFID tags
Disclosed herein are automated systems and methods utilizing a plurality of specialized RFID tags incorporated within various tire manufacturing components (e.g., mold segments, mold container, bladder plates, tire presses, and extrusion dies) that are able to readily track tire manufacture and identify defect source(s) while concurrently being configured to the harsh processes and temperatures of tire manufacture.
1. A method for tracking tire manufacture and quality control with an RFID equipped tire mold system comprising:
(a) providing an RFID equipped tire mold having a plurality of mold segments
and/or
mold shoes and mold bladder components;
(b) placing the green unvulcanized tire into the RFID equipped tire mold;
(c) forming a vulcanized tire;
(d) removing the vulcanized tire from the tire mold
and determining whether any defects are present in the vulcanized tire,
wherein:
if no defects are present in the vulcanized tire, the vulcanized tire enters a supply chain and all data related to manufacture of the vulcanized tire with no defects is electronically stored within a database for review at a later date if necessary, but
if defects are present in the vulcanized tire after step (c), further correlating a defect position on the vulcanized tire with the corresponding position in the RFID equipped tire mold based on unique RFID identifiers provided by the RFID equipped tire mold and further determining whether repair is necessary to portions of the RFID equipped tire mold and/or whether vulcanization parameters should be modified to prevent and/or reduce occurrence of defects in the vulcanized tire(s).
2. The method of claim 1 , wherein:
the RFID equipped tire mold comprises a plurality of passive RFID equipped mold tags affixed to or within a recess on outer surfaces of the plurality of mold segments in a tire mold that define predetermined sectors within the tire mold corresponding to outer surface(s) of the vulcanized tire that, during step (d), are correlated manually and/or electronically with any defects present in the vulcanized tire.
3. The method of claim 2 , wherein an RFID equipped mold tag is affixed to an outer surface of a tire mold and/or a tire mold cover, the RFID equipped mold tag having a different construction and RFID read range than the passive RFID equipped mold tags affixed to or within the recess on the outersurfaces of the plurality of mold segments and the RFID equipped mold tag configured to communicate unique identifiers associated with the tire mold to which it is attached as well as having unique identifiers associated with the passive RFID equipped mold.
4. The method of claim 3 , further comprising, before step (a), locating the RFID equipped tire mold with unique RFID identifiers provided by the RFID equipped mold tag affixed to the outer surface of the tire mold and/or tire mold cover.
5. The method of claim 4 , wherein after locating the tire mold but before providing the green unvulcanized tire therein, confirming via unique RFID identifiers associated with the plurality of passive RFID equipped mold tags, as well as the RFID equipped mold tag affixed to the outer surface of the tire mold, that each mold segment associated with the RFID equipped tire mold having the RFID equipped mold tag is affixed to the outer surface is present.
6. The method of claim 5 , wherein, if a mold segment is not present, the method further comprises locating the missing mold segment via unique passive RFID identifiers associated therewith and pairing the missing mold segment with the tire mold having the RFID equipped mold tag is affixed to the outer surface.
7. The method of claim 6 , wherein, before step (c) and if an extraneous mold segment having a passive RFID equipped mold tag affixed thereto is present in the tire mold, the method further comprises identifying the extraneous mold segment by a unique RFID identifier associated therewith and pairing the extraneous mold segment with a proper tire mold, the proper tire mold having an RFID equipped mold tag is affixed to an outer surface of the proper tire mold having unique RFID identifiers associated with the proper tire mold to which it is attached as well as having unique identifiers associated with the passive RFID equipped tag affixed to the extraneous mold segment.