Rubber material breakage monitoring method for tread production

Abstract

The invention provides a rubber material breakage monitoring method for tread production, which is characterized in that a pair of gratings for detecting rubber materials is mounted at an inlet of a conveyor belt at a feeding port of a molding rubber host, a proximity switch is mounted on a free roller at the tail end of the conveyor belt and used for detecting the rotation condition of a roller, and then a motor real-time current comparison program is written in a host program. In the production process of the extruder, when an optical grating at an inlet of a conveying belt does not detect a sizing material or a proximity switch at the tail end of the conveying belt does not detect rotation of a free roller, a host operation table computer can give a feeding conveying belt material breakage alarm prompt, meanwhile, an audible and visual alarm is given on an operation table, and workers are reminded of the feeding operation state in real time. According to the tread produced by the method, the annual remelting rate caused by rubber material breakage is as low as 0.12%.

Description

Technical Field

[0001] The invention relates to the technical field of tire production and manufacturing, and in particular to a method for monitoring rubber material breakage in tire tread production. Background Art

[0002] The tread is the main working part of the tire. It is in direct contact with the road surface, protecting the carcass cord layer and the buffer layer from puncture and direct impact, improving the adhesion between the tire and the road surface, and transmitting traction, steering force and braking force through the tread pattern. Because the tread is located on the outermost side of the tire, it is the place where the tire is subjected to the most complex and severe stress. High quality and performance requirements are required for it, and it needs to achieve low rolling friction, high anti-skid, and wear resistance. It is closely related to the fuel consumption, safety and life of the car.

[0003] In the process of rubber product processing, the extrusion forming method is widely used because it has the advantages of simple operation, high production efficiency and good product quality. The die head is connected to the extruder, which supplies refined rubber materials to each part of the tread, and then extrudes it through the die. The extrusion process and each procedure on the manufacturing assembly line have an important impact on the product quality. They must be strictly managed to ensure that the weight and cross-sectional profile dimensions of various semi-finished products meet the process requirements, and the tolerances of grams, length, width and thickness are within the process requirements. If the manufactured parts do not meet the design requirements, the geometric shape and mass distribution of the rubber tire will be uneven, and the uneven tread will cause vibration of the entire vehicle, which will have an adverse effect on the service ability of the vehicle when running at high speed.

[0004] However, in the tread production process, it is often difficult to control the key parameters that affect the tread quality. For a long time, the tread upper machine has frequently been interrupted, and employees cannot find it in time, resulting in unqualified product dimensions and increased rubber recycle.

[0005] In order to solve the above problems, the research team installed a detection alarm device on the upper computer conveyor belt to prompt employees of the feeding operation status in real time. Summary of the invention

[0006] The purpose of the present invention is to provide a method for monitoring rubber material shortage in tread production, so as to solve the problem that the tread upper machine frequently breaks the material and the employees cannot find it in time, resulting in unqualified product size and increased rubber return.

[0007] The technical solution of the present invention is as follows:

[0008] The object of the present invention is to provide a method for monitoring rubber material shortage in tire tread production, comprising the following steps:

[0009] S1 installs the detection device;

[0010] S2 writes the judgment program;

[0011] S3 alarms according to the detection signal and judgment procedure.

[0012] Furthermore, the step S1 of installing a detection device is specifically to install a detection device on a conveyor belt of the host computer, including a grating and a proximity switch.

[0013] Furthermore, the grating includes a pair of light projectors and a light receiver, which are installed at the entrance of the feeding conveyor belt of the glue host machine to detect the rubber. When feeding, the rubber passes through the middle of the grating. When there is rubber between the light projector and the light receiver, the black output line at the light receiver end has no voltage output. When there is no rubber between the light projector and the light receiver, the black output line at the light receiver end outputs a DC24V voltage, and the signal is collected by the remote I / O module.

[0014] Furthermore, the proximity switch is installed on the free roller at the end of the conveyor belt to detect the rotation of the roller. When the free roller rotates normally, the sensor will continuously and intermittently input 24V to the PLC.

[0015] Furthermore, the grating and the proximity switch are connected to the I / O module via a signal line, and the I / O module is connected to the extruder host computer via a network cable.

[0016] Furthermore, the step S2 is to write a judgment program, specifically, to write a motor real-time current comparison program in the host program. During the normal production process of the extruder host, when the motor current is lower than the average current of the previous minute for 2 consecutive seconds, the program determines that the extruder is out of material.

[0017] Furthermore, the specific procedure for judging the grating signal at the entrance of the feeding conveyor belt of the rubber host is that when the grating at the entrance of the conveyor belt does not detect the rubber, a 24V signal is output, indicating that the material is broken here.

[0018] Furthermore, the free roller proximity switch signal judgment procedure is specifically as follows: if there is no 24V signal or the 24V signal is always input to the PLC, it means that the free roller is not rotating, and it is concluded that the material is broken here.

[0019] Furthermore, after the program determines that the material is broken, it sends a feeding conveyor belt alarm reminder to the host operating table computer, and the operating table sends out an audible and visual alarm. When the current is restored, the alarm stops automatically.

[0020] Furthermore, the step S3 alarms according to the detection signal and the judgment program. Specifically, the signal output by the detection device is judged by the judgment program, and the sound and light alarm of the operating table has two response states:

[0021] When the sound and light alarm lights are off, there is no alarm, which means the feeding is normal;

[0022] When the sound and light alarm lights flash, it means that the material is broken and employees are required to check the rubber condition at both ends of the feeding conveyor belt.

[0023] The beneficial effects of the present invention are:

[0024] 1. By adding a detection alarm device to the upper computer conveyor belt, employees can be promptly informed of the feeding operation status to ensure that the product size is qualified and reduce the return to the furnace due to material breakage.

[0025] 2. The method of reducing the tread recycling rate is practical. After implementation on the production line, the annual tread recycling rate caused by rubber material shortage was reduced from 0.31% to 0.12%, saving 21,977.04 yuan per year. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a schematic diagram of the steps of reducing the tread recycling rate in Example 1;

[0027] Figure 2 is a grating principle diagram of Example 1;

[0028] Figure 3 This is a schematic diagram of the proximity switch of Embodiment 1, 1 is connected to the positive power line, 3 is connected to the negative power line, and 4 is the output line;

[0029] Figure 4 This is a schematic diagram of the connection between the grating and the proximity switch in Example 1;

[0030] Figure 5 This is a schematic diagram of the material shortage alarm program of Example 1;

[0031] Figure 6 It is a line chart of the melt-down rate caused by material supply interruption in 2022 and 2023. DETAILED DESCRIPTION

[0032] Example 1

[0033] Figure 1 Schematic diagram of the steps for reducing the tread recycling rate in this embodiment. As can be seen from the figure, the following steps are included:

[0034] S1 Install the detection device: Install the detection device on the upper computer conveyor belt, including the grating and proximity switch.

[0035] Figure 2This is the principle diagram of the grating of this embodiment. The grating model used in this embodiment is Panasonic Electric Electromechanical NA2-N12-PN. It includes a pair of projectors and receivers, which are installed at the entrance of the feeding conveyor belt of the glue host to detect the glue; when feeding, the glue passes through the middle of the grating. When there is glue between the projector and the receiver, the black output line at the receiver end has no voltage output. When there is no glue between the projector and the receiver, the black output line at the receiver end outputs DC24V voltage, and the signal is collected by the remote IO module.

[0036] Figure 3 This is the schematic diagram of the proximity switch of this embodiment. The proximity switch model used in this embodiment is Balluff Automation BESM12MI-POC40B-BP03. The free roller installed at the end of the conveyor belt is used to detect the rotation of the roller. When the free roller rotates normally, the sensor will continuously input 24V to the PLC at intervals.

[0037] Figure 4 Schematic diagram of the connection between the grating and the proximity switch of this embodiment. The grating and the proximity switch are connected to the I / O module through a signal line, and the I / O module is connected to the extruder host computer through a network cable.

[0038] S2 writes a judgment program, specifically, writes a motor real-time current comparison program in the host program. During the normal production process of the extruder host, when the motor current is lower than the average current of the previous minute for 2 consecutive seconds, the program determines that the extruder is out of material. Figure 6 Schematic diagram of the material shortage alarm program in this embodiment.

[0039] The specific procedure for judging the grating signal at the entrance of the feeding conveyor belt of the rubber host is that when the grating at the entrance of the conveyor belt does not detect the rubber, a 24V signal is output, indicating that the material is broken here.

[0040] The specific procedure for judging the signal of the free roller proximity switch is that if there is no 24V signal or the 24V signal is always input to the PLC, it means that the free roller is not rotating, and it is concluded that the material is broken here.

[0041] When the program determines that the material is broken, it sends a feeding conveyor belt alarm reminder to the host operating table computer. At the same time, the operating table emits an audible and visual alarm. When the current is restored, the alarm stops automatically.

[0042] S3 alarms according to the detection signal and the judgment program. Specifically, the signal output by the detection device is judged by the judgment program, and the sound and light alarm on the operating table has two response states:

[0043] When the sound and light alarm lights are off, there is no alarm, which means the feeding is normal;

[0044] When the sound and light alarm lights flash, it means that the material is broken and employees are required to check the rubber condition at both ends of the feeding conveyor belt.

[0045] The actual effect of the judgment program of this embodiment is that when the grating at the entrance of the conveyor belt does not detect the rubber, or the proximity switch at the end of the conveyor belt does not detect the rotation of the free roller within 30 seconds, an alarm reminder of the feeding conveyor belt breakage will be given on the host operating table computer, and there will be an audible and visual alarm on the operating table at the same time.

[0046] By the above method, when production starts, the detection device of the present invention is started, and through the compiled judgment program, when the grating at the entrance of the conveyor belt does not detect the rubber material, or the proximity switch at the end of the conveyor belt does not detect the rotation of the free roller within 30 seconds, there will be a feeding conveyor belt break alarm reminder on the host operating table computer, and there will be an audible and visual alarm on the operating table at the same time, which will remind employees of the feeding operation status in real time, respond to the breakage situation, and reduce the return of the rubber mold caused by the breakage.

[0047] In order to verify the effectiveness of the present invention, the invention team conducted a series of verification experiments, which are excerpted as follows.

[0048] Table 1 shows the recycling rate due to feed interruption in production without adopting the present invention from January to December 2022. The annual recycling rate caused by feed interruption is 0.31%.

[0049] Table 1 Feed interruption and remelting rate from January to December 2022

[0050] date Glue quantity / kg Remelting weight / kg Recycling rate % January 2022 2886696 7664.9 0.27％ February 2022 2762767 10464.7 0.38％ March 2022 4214588 9620.3 0.23％ April 2022 2706003 8083.8 0.30％ May 2022 3188674 10909.9 0.34％ June 2022 3668810 9157.9 0.25％ July 2022 3850565 10544.0 0.27％ August 2022 3208832 10139.1 0.32％ September 2022 2804907 9628.6 0.34％ October 2022 3317462 9651.3 0.29％ November 2022 3196053 12870.2 0.40％ December 2022 2750921 9282.1 0.34％ total 38556277 118016.9 0.31％

[0051] The recycling rate is calculated by the following formula:

[0052]

[0053] Table 2 shows the recycling rate due to feed interruption from January to December 2023 after production using the method of the present invention. The annual recycling rate due to feed interruption is 0.12%.

[0054] Table 2 Feed interruption and remelting rate from January to November 2023

[0055] date Glue quantity kg Remelting weight kg Recycling rate % January 2023 2282771 4101.4 0.18％ February 2023 3429816 5844.8 0.17％ March 2023 4334253 3691.7 0.09％ April 2023 4256639 4866.1 0.11％ May 2023 3852384 4779.9 0.12％ June 2023 3642581 4324.4 0.12％ July 2023 4021462 4572.0 0.11％ August 2023 4218122 5573.8 0.13％ September 2023 4008279 4717.2 0.12％ October 2023 5779244 3944.3 0.07％ November 2023 4497614 4838.7 0.11％ December 2023 4122557 4947.1 0.12％ total 44323165 51254.3 0.12％

[0056] Figure 6 It is a line chart of the recycling rate caused by material supply interruption in 2022 and 2023. By comparison, it can be seen that after the implementation of the production line, the annual recycling rate of the tread caused by rubber feed interruption dropped from 0.31% to 0.12%.

[0057] Based on the tread rubber consumption of 38556277kg from January to December 2022, the rubber recycling will be reduced by 38556277*0.19%=73256.9kg, calculated at an average processing cost of 0.30 yuan / kg:

[0058] Monthly saving in recycling costs = 73256.9*0.3 / 12 = 1831.42 yuan.

[0059] Annual cost savings = 1831.42*12 = 21977.04 yuan.

[0060] Although the present invention has been described in detail above by means of general description, specific implementation methods and experiments, it is obvious to those skilled in the art that some modifications or improvements can be made to the present invention. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of protection claimed by the present invention.

Claims

1. A method for monitoring rubber material shortage in tire tread production, characterized in that: The following steps are included: S1 installs the detection device; S2 writes the judgment program; S3 alarms according to the detection signal and judgment procedure.

2. The method for monitoring rubber material shortage in tire tread production according to claim 1, characterized in that: The step S1 of installing the detection device is specifically to install the detection device on the upper computer conveyor belt, including a grating and a proximity switch.

3. The method for monitoring rubber material shortage in tire tread production according to claim 2, characterized in that: The grating includes a pair of light projectors and a light receiver, which are installed at the entrance of the feeding conveyor belt of the rubber host to detect the rubber. When feeding, the rubber passes through the middle of the grating. When there is rubber between the light projector and the light receiver, the black output line at the light receiver end has no voltage output. When there is no rubber between the light projector and the light receiver, the black output line at the light receiver end outputs a DC24V voltage, and the signal is collected through a remote I / O module.

4. The method for monitoring rubber material shortage in tire tread production according to claim 2, characterized in that: The proximity switch is installed on the free roller at the end of the conveyor belt to detect the rotation of the roller. When the free roller rotates normally, the sensor will continuously and intermittently input 24V to the PLC.

5. The method for monitoring rubber material shortage in tire tread production according to claim 2, characterized in that: The grating and the proximity switch are connected to the I / O module via a signal line, and the I / O module is connected to the extruder host computer via a network cable.

6. The method for monitoring rubber material shortage in tire tread production according to claim 1, characterized in that: The step S2 is to write a judgment program, specifically, to write a motor real-time current comparison program in the host program. During the normal production process of the extruder host, when the motor current is lower than the average current of the previous minute for 2 consecutive seconds, the program determines that the extruder is out of material.

7. The method for monitoring rubber material shortage in tire tread production according to claim 6, characterized in that: The specific procedure for judging the grating signal at the entrance of the feeding conveyor belt of the rubber host is that when the grating at the entrance of the conveyor belt does not detect the rubber, a 24V signal is output, indicating that the material is broken here.

8. The method for monitoring rubber material shortage in tire tread production according to claim 6, characterized in that: The specific procedure for judging the signal of the free roller proximity switch is that if there is no 24V signal or the 24V signal is always input to the PLC, it means that the free roller is not rotating, and it is concluded that the material is broken here.

9. The method for monitoring rubber material shortage in tire tread production according to claim 6, characterized in that: When the program determines that the material is broken, it sends a feeding conveyor belt alarm reminder to the host operating table computer. At the same time, the operating table emits an audible and visual alarm. When the current is restored, the alarm stops automatically.

10. The method for monitoring rubber material shortage in tire tread production according to claim 1, characterized in that: The step S3 alarms according to the detection signal and the judgment program. Specifically, the signal output by the detection device is judged by the judgment program, and the sound and light alarm of the operating table has two response states: When the sound and light alarm lights are off, there is no alarm, which means the feeding is normal; When the sound and light alarm lights flash, it means that the material is broken and employees are required to check the rubber condition at both ends of the feeding conveyor belt.

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