In a shaping station (13), a toroidal forming drum (23) is positioned within a carcass sleeve (12) comprising at least one carcass ply (3) associated with a pair of beads (6) in radially inner position. The carcass sleeve (12) is toroidally shaped by radial expansion of the forming drum (23). The forming drum (23) carrying the shaped carcass sleeve (12) is removed from the shaping station (13). Tyre components (7, 8, 9) are applied externally on the shaped carcass sleeve (12), carried by the forming drum (23). At the end of the shaping and during the application of the tyre components (7, 8, 9), axially inner sides of said beads (6) are arranged axially against respective circumferential axially outer portions (S1) of an abutment surface (S) carried by the expanded forming drum (23), having shape corresponding to an inner shape of the shaped carcass sleeve (12).

In a shaping station (13), a toroidal forming drum (23) is positioned within a carcass sleeve (12) comprising at least one carcass ply (3) associated with a pair of beads (6) in radially inner position. The carcass sleeve (12) is toroidally shaped by radial expansion of the forming drum (23). The forming drum (23) carrying the shaped carcass sleeve (12) is removed from the shaping station (13). Tyre components (7, 8, 9) are applied externally on the shaped carcass sleeve (12), carried by the forming drum (23). At the end of the shaping and during the application of the tyre components (7, 8, 9), axially inner sides of said beads (6) are arranged axially against respective circumferential axially outer portions (S1) of an abutment surface (S) carried by the expanded forming drum (23), having shape corresponding to an inner shape of the shaped carcass sleeve (12).

A method of manufacturing a pneumatic tire including forming a green case by cylindrically winding a tire component member which includes at least one layer of a carcass ply. A green tire is shaped by expanding the green case into a toroidal shape with the supply of a fluid into the green case so that the green case adheres to a tread ring arranged radially outside the green case. The green tire is subjected to vulcanization molding within a mold die. During the shaping of the green tire, the fluid is supplied in accordance with a pressure profile which changes in a stepwise manner. The pressure profile is set such that a former stage expansion rate in a former stage is set to slower than a final stage expansion rate in a final stage.

A method of manufacturing a pneumatic tire including forming a green case by cylindrically winding a tire component member which includes at least one layer of a carcass ply. A green tire is shaped by expanding the green case into a toroidal shape with the supply of a fluid into the green case so that the green case adheres to a tread ring arranged radially outside the green case. The green tire is subjected to vulcanization molding within a mold die. During the shaping of the green tire, the fluid is supplied in accordance with a pressure profile which changes in a stepwise manner. The pressure profile is set such that a former stage expansion rate in a former stage is set to slower than a final stage expansion rate in a final stage.

In an assembly station, a carcass sleeve and an outer sleeve manufactured along respective building lines are mutually coupled. Integrated into the assembly station are engagement devices that can be alternatively-coupled to an auxiliary drum carrying an outer sleeve and to a building drum carrying a carcass sleeve. The building drum is engaged on the assembly station before removal of the auxiliary drum. A grip unit picks up the outer sleeve from the auxiliary drum associated with the engagement devices in order to position it around the carcass sleeve carried by the building drum.

A carcass sleeve including a carcass ply and a pair of annular anchoring structures is fitted around a toroidal forming drum arranged in a first radially contracted operational condition. The carcass sleeve is toroidally shaped against a radially inner surface of an annular contrast element. The forming drum is positioned inside the carcass sleeve and is concurrently expanded towards a second operational condition. Upon reaching the second operational condition, the toroidally shaped carcass sleeve is coupled to the forming drum. The forming drum, coupled to the carcass sleeve, is adapted to be transferred in proximity of an application device of additional components externally to the carcass sleeve.

A carcass sleeve including a carcass ply and a pair of annular anchoring structures is fitted around a toroidal forming drum arranged in a first radially contracted operational condition. The carcass sleeve is toroidally shaped against a radially inner surface of an annular contrast element. The forming drum is positioned inside the carcass sleeve and is concurrently expanded towards a second operational condition. Upon reaching the second operational condition, the toroidally shaped carcass sleeve is coupled to the forming drum. The forming drum, coupled to the carcass sleeve, is adapted to be transferred in proximity of an application device of additional components externally to the carcass sleeve.

In this method for turning up the plies of a green tire, longitudinal and radial movements, with reference to a main axis (8) of the green tyre (3), of ply-turning arms (20) are brought about independently of one another in order to apply a rubber element to at least one sidewall (5) of the green tire (3). The radial movement of the arms is controlled by means of a speed setpoint.

In this method for turning up the plies of a green tire, longitudinal and radial movements, with reference to a main axis (8) of the green tyre (3), of ply-turning arms (20) are brought about independently of one another in order to apply a rubber element to at least one sidewall (5) of the green tire (3). The radial movement of the arms is controlled by means of a speed setpoint.

A process for manufacturing a tire by the steps of producing and assembling the tire structural elements on a toroidal support to form a green tire, and the step of precuring at least an inner surface of the green tire by heating the toroidal support. The radially inner surface of the toroidal support is provided with a plurality of protruding elements to reduce the time required for the outer surface of the toroidal support to reach a temperature which is suitable for ensuring a uniform and homogeneous precuring of the inner surface of the green tire, preferably of the inner surface and the bead regions of the green tire.