A 4x1 ut steel cord production process

Abstract

This invention discloses a production process for 4x1UT steel cord. Four steel wires are fed from an I-beam reel, pass through a tension lever, go through a reversing wheel, and enter pre-deformer one. They then pass through a four-hole distributor at the corresponding position, and then through pre-deformer two and a DISC, where the wires are pre-deformed again. They then enter a pressing die, and sequentially pass through a reverse wheel, traction wheel one, straightener one, traction wheel two, a doubling device, traction wheel three, straightener two, traction wheel four, and finally take-up. The use of pre-deformer one + distributor + pre-deformer two + DISC + pressing die, V-shaped reverse wheel, and double straightener + doubling device stabilizes the 4x1UT cord structure and avoids cord defects such as misalignment, uneven twist, and looseness.

Description

Technical Field

[0001] This invention relates to steel cord production technology, specifically to a 4x1UT steel cord production process. Background Technology

[0002] 4x1UT is a new UT specification developed by our company in the field of steel cord, replacing the traditional 3*0.20+6*0.35HT and other specifications. Its ultra-high strength can effectively improve the strength of the tire carcass and belt layer and the safety performance of the tire, while also reducing the amount of steel cord and rubber material used in the tire (the diameter of 4*1UT is 0.84mm, and the diameter of 3*0.20+6*0.35HT is 1.13mm), thus reducing production costs.

[0003] There is no fixed process for the development and production of 4x1UT cables. The commonly used method is to use a 1+6HT preformed rope frame, such as... Figure 1 As shown, the steel wire is pre-deformed before twisting, twisted into a rope through a 3mm diameter rope-forming point (Widia), and then passed through a U-shaped reverse pulley, a false twister, and a straightener to meet the rope quality requirements.

[0004] Note: The purpose of pre-deformation is to pre-deform the steel wire so that it is easier to form a rope during the twisting process.

[0005] Because the single filament strength of 4x1UT is close to 3400 N / mm², and the lay length is 27 mm, the ultra-high strength of the steel wire and the special structure of the steel cord—with a gap in the center—caused a frequent occurrence during development and production where a single wire was intermittently squeezed into the center, resulting in misalignment. Figure 2 As shown, the large twist pitch, 0.38mm wire diameter, and ultra-high strength will cause uneven twist pitch during the double twisting process (approximately 25mm of untwisted twist). Figure 3 ), the problem of looseness.

[0006] During the production process using a 1+6 pre-deformed rope forming frame, rope forming defects may occur: misalignment and uneven lay. In this process, each steel wire, after pre-deformation, enters the rope forming point at a specific angle and is then twisted into a rope. Because the steel wire has undergone pre-deformation (the radial freedom of the steel wire is unrestricted), the distance from the pre-deformed wire exit end to the rope forming point is greater than 80mm. This causes the deformed steel wire to shift at the rope forming point (the deformation changes its position). (See the cross-section of the cord...) Figure 2 If one of the steel wires fluctuates or is subjected to external force, misalignment will occur, leading to inconsistent product quality during mass production. Because the rope-forming frame is fixed and parameters such as distance cannot be adjusted, it is difficult to correct defects. Summary of the Invention

[0007] This invention addresses the problems existing in the prior art by proposing a 4x1UT steel cord production process. It adopts a process of pre-deformer one + splitter disc + pre-deformer two + DISC + pressing die, V-shaped reverse wheel and double straightener + virtual twister, which stabilizes the rope structure of 4x1 UT and avoids rope defects such as misalignment, uneven twist and looseness.

[0008] The technical solution adopted in this invention is: a 4x1UT steel cord production process, in which four steel wires are fed from the I-beam reel, pass through the tension swing rod, enter the pre-deformer one through the reversing wheel, pass through the corresponding position of the four-hole wire divider, and then pass through the pre-deformer two and DISC, where the steel wires are pre-deformed again, enter the pressing die, and then pass through the reverse wheel, traction wheel one, straightener one, traction wheel two, false twister, traction wheel three, straightener two, traction wheel four, and take-up in sequence.

[0009] Based on the above scheme, as a preferred option, the reverse wheel adopts a V-groove reverse wheel.

[0010] Compared with the prior art, the present invention has the following beneficial effects:

[0011] The use of composite pre-deformation components, including pre-deformer one + splitter disc + pre-deformer two + DISC + pressure mold, V-shaped reverse wheel and double straightener + virtual twister process, stabilizes the rope structure of 4x1 UT and avoids rope defects such as misalignment, uneven twist and looseness. Compared with the original process 1+6 process, the improved process effectively improves the rope quality and process stability of 4x1 UT.

[0012] Using this solution ensures stable rope quality for the structure. The process spare parts used in this solution are all of existing specifications, so there is no need to purchase or customize them again, nor is it necessary to modify the machine itself. This facilitates the promotion of the solution or the conversion to produce other specifications, reduces the adjustment time for production technicians, has low modification costs, and ensures the stability of the production process and the quality of the finished product. Attached Figure Description

[0013] Figure 1 This is a flowchart of the 1+6HT (original process);

[0014] Figure 2 These are radial cross-sectional views of the original process cord (two screenshots);

[0015] Figure 3 This is a schematic diagram illustrating the uneven twist in the original process;

[0016] Figure 4 This is a schematic diagram of the pre-deformation component of the present invention;

[0017] Figure 5 This is a process flow diagram of the present invention;

[0018] Figure 6It is the torsion curve diagram of the original process;

[0019] Figure 7 This is the torsion curve diagram of the present invention;

[0020] Figure 8 It is a torsion comparison curve between the original process and the present invention (new process);

[0021] Figure 9 This is the radial cross-section (two sections) of the cord of the present invention. Detailed Implementation

[0022] The present invention will be further illustrated by the following examples, but the scope of the present invention is not limited thereto.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0024] like Figure 4-9 As shown, because the monofilament strength of 4x1UT is close to 3400N / mm² and the lay length is 27mm, this process requires pre-processing and deformation of the steel wire before twisting. Specifically, the four steel wires are fed from the I-beam reel, pass through the tension swing rod, go through the reversing wheel, enter pre-deformer one, pass through the corresponding position on the four-hole wire divider, and then pass through pre-deformer two and the DISC, where the steel wires are pre-deformed again, and their positions on the DISC are fixed to ensure the stability of the steel wires when forming the rope. A pressure die is used instead of a Widia at the rope-forming point, and the die spacing a can be adjusted. Figure 4 This also ensures the stability of the rope after it has been twisted.

[0025] exist Figure 4 In the middle, 1. wire feeding; 2. pre-deformer one; 3. wire divider; 4. pre-deformer two; 5. DISC; 6. pressing mold.

[0026] The pre-deformer first deforms the steel wire in the radial direction. Then, after passing through the splitter plate + pre-deformer second + DISC, the steel wire is pre-deformed again. Pre-deformer second deforms the steel wire axially and restricts the radial freedom of the deformed steel wire on the DISC. By adjusting the die spacing, the stability of the steel wire entry position at the rope forming point is ensured (the die spacing 'a' can be adjusted according to the rope forming quality). After the cord is twisted into a rope, the cord passes through the reverse wheel and then through the traction wheel one into the straightener one. After passing through the traction wheel two through the virtual twister, and then through the traction wheel three, it passes through the straightener two, the traction wheel four, and the take-up. The reverse wheel adopts a V-shaped reverse wheel, so that the cord after rope forming maintains its original regular state within the small arc of the V-groove, restricting the movement of the steel wire during rope forming (the U-groove is prone to single wire deviation during twisting). This avoids the risk of steel wire misalignment during the twisting process and ensures the stability of the cord twisted into a rope. The cord first passes through a traction wheel and then enters a straightener, which is used before the twister to tighten the cord before it enters the twister. It then enters a second straightener, where the double straighteners increase the twister's speed, resolving the issue of loose cord. This process design ensures the quality of the 4x1UT cord and meets the requirements for large-scale production.

[0027] Example illustration: After actual on-site measurement, the improved process is superior to the original process.

[0028] 1. Example 4 x 0.38UT

[0029] The new process produces cords with very stable quality and stable torsion during production, resulting in a smooth torsion curve (0.33*1.20 for flat springs).

[0030] The large torsional fluctuations are actually caused by the instability of the cord strands.

[0031] The torsion test data of the original process are shown in Table 1 and Figure 6 Analysis: The cord forming is unstable and periodic, with a torsional fluctuation period of approximately 30 meters, and the fluctuation range within 5 minutes is close to 0±3 (standard range). The equipment's torsion control—ATC automatically detects the analog position and adjusts the virtual twister (acceleration / deceleration) according to the detected analog value, bringing the torsion towards the target value. Analysis of torsion control reveals large torsion fluctuations: a large torsion value m causes the ATC position to deviate—the corresponding change in the virtual twister speed is instructed—the cord torsion value decreases by m—bringing it closer to the ATC target value—a large torsion value m causes the ATC position to deviate again… (cyclic adjustment).

[0032] The new process achieves a 5-minute torsion test value fluctuation range of ±0.25, and the stability of its rope structure (Table 1) ensures torsion stability, with the overall torsion controlled smoothly within the normal range. Finished product data are shown in Table 2.

[0033] Table 1 Comparison of the original process and the new process of this invention

[0034]

[0035] Table 2 shows the finished product inspection data.

[0036]

[0037] It should be noted that the embodiments described above are only for explaining the present invention and do not constitute any limitation on the present invention. The present invention has been described with reference to typical embodiments, but it should be understood that the words used therein are descriptive and explanatory terms, not limiting terms. Modifications can be made to the present invention within the scope of the claims, and revisions can be made to the present invention without departing from the scope and spirit of the present invention. Although the present invention described herein relates to specific methods, materials, and embodiments, it does not mean that the present invention is limited to the specific examples disclosed herein; on the contrary, the present invention can be extended to all other methods and applications with the same function.

Claims

1. A manufacturing process for 4×1UT steel cord, characterized in that: The four monofilaments of the 4×1UT have a monofilament strength of 3400 N / mm. 2 Four high-strength steel wires with a lay length of 27mm are fed from the I-beam reel, pass through the tension swing arm, and enter the first pre-deformer via the reversing wheel. The first pre-deformer applies bending deformation to each wire radially. After radial deformation, the four wires pass through the four holes of the four-hole wire separator, achieving positioning and separation. Each wire then passes through the second pre-deformer, which deforms each wire axially. After axial deformation, the four wires then pass through the DISC limiting plate. The C-limiting disc restricts the radial freedom of the deformed steel wire and fixes its position, preventing radial displacement before rope formation. Subsequently, the four steel wires enter the pressing die together and are gathered and twisted into a rope at the pressing die. The distance 'a' between the pressing die and the DISC limiting disc is adjustable. Adjusting the distance 'a' ensures the stability of the steel wire entry position at the rope formation point. The pressing die replaces the Widia gathering die. After being twisted into a rope, the cord passes through the reverse wheel, traction wheel one, straightener one, traction wheel two, virtual twister, traction wheel three, straightener two, and traction wheel four in sequence before being wound up.

2. The 4x1UT steel cord manufacturing process as described in claim 1, characterized in that, The reverse wheel uses a V-groove design.

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