Radial tire molding modular production line and production process thereof

Abstract

The invention discloses a modular production line for radial tire forming. The modular production line comprises a forming drum device, a tire body forming system and a tire tread forming system, the forming drum device comprises a forming drum base, a forming drum machine box, a belt drum machine box and a combined forming device, the forming drum machine box and the belt drum machine box are arranged on the front side and the rear side of the forming drum base respectively, and the tire body forming system synthesizes a tire body semi-finished product on a forming drum. According to the tread forming system, after the belt drum is combined into a tread semi-finished product, the forming drum case and the belt drum case convey a carcass semi-finished product and the tread semi-finished product to the combined forming device for rolling forming. According to the method, the minimum units of all parts of the tire are standardized according to the mathematical differential principle, then the standardized minimum units are superposed according to the shapes of all the parts and the algorithm according to the mathematical integration principle, finally the tire blank is produced, the production efficiency can be improved, the production cost can be reduced, and the method has wide application prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of tire production, and in particular to a radial tire molding modular production line and a production process thereof. Background Art

[0002] The traditional tire manufacturing process is complex and involves multiple key steps, including rubber mixing, extrusion, calendering, semi-finished product production, molding, and vulcanization. Each step plays a crucial role in the final tire quality and requires multiple key steps to be coordinated and coordinated. Traditional tire production requires the storage and circulation of semi-finished products, which can pose a risk of deterioration during storage.

[0003] The utility model patent with authorization announcement number CN201913813U discloses an intensive ultra-large-scale high-performance radial tire production system for passenger cars, including a three-story building. The first floor is equipped with a semi-finished product extrusion and calendering area, a cutting area, a molding area, a vulcanization area, a finished product inspection area, and a storage and transportation delivery area. The second floor includes a rubber compound storage area, a semi-finished product production area, a tire blank spraying area, a tire blank storage area, and a finished tire storage area. The semi-finished product production area is equipped with multiple apex glue laminating machines and multiple wire ring extrusion and winding production lines. The third floor includes a tire edging area, a tire inflation area, and a tire repair area. The semi-finished product extrusion and calendering area includes at least one sidewall three-composite extrusion production line, multiple tread composite extrusion production lines, and a tire edging area. lines, multiple cold feed extruders, multiple inner liner calendering production lines, multiple hot mills, at least one fiber cord calendering production line, multiple pad finishing machines 17, 18, multiple longitudinal cutting machines and multiple nylon belt layer slitting machines; the cutting area includes at least one high-platform fiber cord cutting machine and multiple steel cord cutting machines; the forming area includes multiple radial tire first-stage forming machines and radial tire second-stage forming machines arranged in an array, the radial tire first-stage forming machines and the radial tire second-stage forming machines are matched, the radial tire first-stage forming machines and the radial tire second-stage forming machines are arranged in 2 to 6 rows, each row has 6 to 20 sets, and a tire blank conveying device is provided between every two rows of radial tire first-stage forming machines and radial tire second-stage forming machines, A hoist is provided at the end of the green tire conveying device, which is connected to the green tire storage area on the second floor; the right side of the green tire storage area is the green tire spraying area, which is equipped with multiple green tire spraying machines, and the left side of the green tire storage area is the finished tire storage area, which is equipped with a finished tire conveying system, and multiple tire polishing machines and local repair vulcanizing agents are provided on the side; the vulcanization area includes multiple tire dual-mode shaping vulcanizing machines arranged in an array and multiple tire vehicles for transporting green tires, a monorail electric hoist is provided at the front end of the tire dual-mode shaping vulcanizing machine, and the monorail electric hoist is connected to the hoist, the tire dual-mode shaping vulcanizing machine is arranged in 6 to 12 rows, with 10 to 24 machines in each row, and a finished tire vulcanizing machine is provided between every two rows. The finished product inspection area includes a tire trimming machine, an appearance inspection machine, multiple tire uniformity testing machines and tire dynamic balance testing machines. The tire trimming machine and the appearance inspection machine are arranged as a set. The tire trimming machine is arranged next to the inclined belt conveyor, and the appearance inspection machine is arranged adjacent to the tire trimming machine. Multiple tire uniformity testing machines and tire dynamic balance testing machines are arranged in the middle of the finished product inspection area; the storage and transportation delivery area is provided with an unloading platform; the total area of ​​the production system is ≥250,000 m2, the total height is ≥23.5 m, the length is ≥450 m, the width is ≥190 m, the temperature of the molding area is controlled at 23°C ± 5°C, and the humidity is controlled at ≤70%.

[0004] Although this plan adopts an ultra-large-area production system that is conducive to the flexible layout and technological transformation of process equipment, and semi-finished products no longer need to be transported outdoors, which shortens the transportation distance and time of semi-finished products and avoids the pollution of semi-finished products caused by sunlight, ultraviolet rays, dust, etc. during open-air transportation, the investment required for this plan is large and the burden on enterprises is heavy. In addition, traditional processes also require a large number of non-standard auxiliary equipment to assist in production, resulting in increased production investment for enterprises. Summary of the Invention

[0005] In order to solve the problems raised by the above background technology, this solution provides a modular production line for radial tire molding and its production process, which can adapt to the full range of needs of diversified, flexible processes, complex processes, and unpopular tire model production, improve production efficiency, and reduce production costs.

[0006] The technical solution adopted by the present invention to solve its technical problems is as follows: a radial tire molding modular production line, including a molding drum device, a carcass molding system and a tread molding system; the molding drum device includes a molding drum base, a molding drum chassis, a belt drum chassis and a combined molding device, the combined molding device is installed in the middle of the molding drum base, and the front side part of the molding drum base is divided into a carcass molding station part, the front side part of the molding drum base is divided into a tread molding station part, the carcass molding system and the tread molding system are respectively arranged in the carcass molding station part and the tread molding station part. The forming drum chassis and the belt drum chassis are respectively arranged on the front and rear sides of the forming drum base; the forming drum base is provided with an X-direction slide rail; the forming drum chassis and the belt drum chassis can be slidably installed on the X-direction slide rail; the forming drum chassis and the belt drum chassis are respectively provided with a forming drum and a belt drum; the carcass forming system synthesizes the carcass semi-finished product on the forming drum; after the tread forming system synthesizes the tread semi-finished product on the belt drum, the forming drum chassis and the belt drum chassis can respectively transport the carcass semi-finished product and the tread semi-finished product to the combined forming device for rolling forming.

[0007] Furthermore, the tire body forming system includes an inner liner extrusion and winding device, a spur rubber extrusion device, a cord fabric fixed-length cutting and splicing device, a left sidewall extrusion and winding device, and a right sidewall extrusion and winding device.

[0008] Furthermore, the tread forming system includes a tread extrusion and winding device, a wing rubber extrusion and winding module and a belt extrusion and rubber coating device.

[0009] Furthermore, the combined molding device includes a combined pressure roller, a molding pressure roller and a preformer, the combined pressure roller is installed in the middle of the molding drum base, the molding pressure roller is arranged directly above the combined pressure roller, and the preformer is arranged on the rear side of the combined pressure roller.

[0010] Furthermore, the combined molding device also includes a transfer ring, which is installed on the rear side of the preformer and is used to transfer the carcass assembly during the molding process to smoothly transfer the carcass from the bonding drum to the molding drum to ensure accurate positioning of the carcass and the tire bead.

[0011] Furthermore, the forming drum device also includes a light scale, which is arranged at the tread forming station and is used for the production of radial tires. Through vertical and longitudinal adjustment, the fit between the tread and the rim is ensured to avoid local wear or performance degradation of the tire due to positioning deviation.

[0012] Furthermore, the forming drum device also includes a tire unloading roller, and the tire unloading roller is connected to the transfer ring.

[0013] Furthermore, the belt extrusion and rubber coating device includes a spindle rack, an extruder, a cooling device, a material storage and cutting device, a belt layer deflecting device and a belt feeding rack. The steel wire completes the initial radial arrangement and sorting of the steel wire on the spindle rack to form a steel belt, which enters the extruder. In the extruder, the rubber compound is covered around the steel wire and extruded to form a rubber-coated tire belt layer of a flat steel belt with steel wire as a radial skeleton material and rubber compound as a connecting material. The tire belt layer extruded from the extruder passes through a cooling device to reduce the high temperature generated during extrusion, and then enters the material storage and cutting device, and is wound and composited on the belt drum through the belt layer deflecting device and the belt feeding rack.

[0014] Furthermore, the tread forming system also includes a cap fiber cord pay-out arrangement and rubber extrusion coating device.

[0015] This solution also discloses a radial tire molding production process, based on the above-mentioned radial tire molding modular production line, performing the following steps:

[0016] The left sidewall extrusion and winding device and the right sidewall extrusion and winding device wind the sidewall rubber on the forming drum, and the inner liner extrusion and winding device, the bead rubber extrusion device, and the cord fabric fixed-length cutting and splicing device are combined with the inner liner carcass through cord splicing and fixed-length cutting, and are laminated and formed together with the sidewall rubber on the forming drum, and then pressed on the forming drum to form a semi-finished carcass after buckling and turning up.

[0017] The belt extrusion and coating device cuts the belt to a fixed length, enters the cap rubber cooling section, storage section, cutting section and secondary storage section, and then cooperates with the tread extrusion and winding device and the wing rubber extrusion and winding device to wind and composite the semi-finished tread on the belt drum;

[0018] Then, the forming drum case and the belt drum case are controlled to move on the X-axis slide rail, and the semi-finished carcass and the semi-finished tread are transported to the combined forming device for roll forming to form a tire blank. Finally, the tire unloading robot unloads the formed tire blank from the tire machine and sends it to a special tire blank transfer vehicle.

[0019] The beneficial effects of the present invention are as follows: the production line of this design is mainly used for the manufacture of radial tires. The modules of the whole machine are perfectly integrated and can operate independently. The specification switching is quick and convenient. The whole machine is controlled by information automation. The various components have visual digital display screens that display the remaining rubber in real time and remind the rubber preparation personnel to be ready in advance. The production line of this design integrates an extruder, a cord cutting machine, a crown strip, etc., and does not require cord calendering equipment or tread / cushion rubber extrusion equipment, so the equipment investment cost is low. Based on the principles of advanced mathematical calculus, the latest units are standardized, and a variety of specification products are finally unified into a minimum unit production. This not only greatly reduces the storage and circulation of semi-finished products during the production process, but also eliminates the quality risks that may be caused by the parking of semi-finished products, and saves the investment required for a large number of non-standard auxiliary equipment required in traditional processes. The production line designed in this paper has flexible process. The parameters of the online winding of the tread, sidewall and cap strip can be modified directly on the equipment according to the process requirements. The labor cost is low. There are no joints in the online winding of the tread, sidewall and cap strip. The uniformity and dynamic balance performance are better. The production links are reduced. It is suitable for small-batch and multi-variety customized production, equipment integration, and reduced material process control. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the overall structural arrangement of the horizontal plane of the present invention;

[0021] Figure 2 It is a schematic diagram of the vertical surface structure arrangement of the present invention;

[0022] Figure 3 It is a structural schematic diagram of the forming drum device of the present invention;

[0023] Figure 4 The present invention is a flowchart of the radial tire molding production process. DETAILED DESCRIPTION

[0024] The present invention will be further described below with reference to the examples. It is worth noting that these specific embodiments are only representative specific embodiments of the present invention, wherein the specific methods, devices, conditions, materials, etc. cited are not intended to limit the present invention or the corresponding specific embodiments. Figure 1 As a reference standard, the front and rear sides of the building drum base mentioned in this article refer to Figure 1 Middle up and down position.

[0025] Modular production line for radial tire building, such as Figure 1-Figure 3 As shown, it includes a forming drum device 1, a carcass forming system and a tread forming system; the forming drum device 1 includes a forming drum base 11, a forming drum case 12, a belt drum case 13 and a combined forming device, the combined forming device includes a combined pressure roller 14, a forming pressure roller 15, a preformer 16 and a transfer ring 17, the combined pressure roller 14 is installed in the middle of the forming drum base 11, the forming pressure roller 15 is arranged directly above the combined pressure roller 14, the preformer 16 is arranged on the rear side of the combined pressure roller 14, the transfer ring 17 is installed on the rear side of the preformer 16, the transfer ring 17 is used to transfer the carcass assembly during the forming process to smoothly transfer the carcass from the bonding drum to the forming drum, so as to ensure the precise positioning of the carcass and the tire bead. The combined molding device divides the front side part of the molding drum base 11 into a carcass molding station part, and the front side part of the molding drum base is divided into a tread molding station part. The carcass molding system and the tread molding system are respectively arranged in the carcass molding station part and the tread molding station part. The molding drum case 12 and the belt drum case 13 are respectively arranged on the front and rear sides of the molding drum base 11. The molding drum base 11 is provided with an X-direction slide rail, and the molding drum case 12 and the belt drum case 13 can be slidably installed on the X-direction slide rail. The molding drum case 12 and the belt drum case 13 are respectively provided with a molding drum 121 and a belt drum 131. The carcass molding system synthesizes the carcass semi-finished product on the molding drum 121. After the tread molding system synthesizes the tread semi-finished product on the belt drum 131, the molding drum case 12 and the belt drum case 13 can respectively transport the carcass semi-finished product and the tread semi-finished product to the combined molding device for rolling molding.

[0026] Furthermore, the carcass forming system includes an inner liner extrusion and winding device 21, a spur rubber extrusion device 22, a cord length cutting and splicing device 23, a left sidewall extrusion and winding device 24 and a right sidewall extrusion and winding device 25. The left sidewall extrusion and winding device 24 and the right sidewall extrusion and winding device 25 are respectively arranged on the left and right sides of the front side of the forming drum base 11 to perform extrusion and winding work on the forming drum 121. The inner liner extrusion and winding device 21, the sub-end protection glue extrusion device 22 and the cord fixed length cutting and splicing device 23 are arranged in the empty space on the left side of the front side of the forming drum base 11. The inner liner extrusion and winding device 21, the sub-end protection glue extrusion device 22 and the cord fixed length cutting and splicing device 23 are connected to the forming drum device 1 through a pad feeding device 26. The pad feeding device 26 includes a carcass feeding rack and a material transfer roller installed on the carcass feeding rack to realize the transportation of the materials output by the inner liner extrusion and winding device 21, the sub-end protection glue extrusion device 22 and the cord fixed length cutting and splicing device 23 to the forming drum 121 to synthesize the carcass semi-finished product. The tread forming system includes a cap fiber cord pay-out arrangement and extrusion coating device 30, a tread extrusion winding device 31, a wing rubber extrusion winding module 32 and a belt extrusion coating device. The tread extrusion winding device 31 and the wing rubber extrusion winding module 32 are arranged on the right side of the rear side of the forming drum base 11, and the belt extrusion coating device is arranged on the left side of the rear side of the forming drum base 11. The cap fiber cord pay-out arrangement and extrusion coating device 30 is set at the position of the cord fixed length cutting and splicing device 23. The belt extrusion and rubber coating device includes a spindle rack 33, an extruder 34, a cooling device 35, a material storage and cutting device 36, a belt layer unwinding device, and a belt feeding rack 37. The steel wire is initially radially arranged and arranged on the spindle rack 33 to form a steel belt, which then enters the extruder 34. In the extruder 34, the rubber compound is coated around the steel wire to form a rubber-coated tire belt layer composed of a flat steel belt with the steel wire as the radial skeleton material and the rubber compound as the connecting material. After being extruded from the extruder 34, the tire belt passes through the cooling device 35 to reduce the high temperature generated during extrusion, then enters the material storage and cutting device 36, and is wound and composited on the belt drum through the belt layer unwinding device and the belt feeding rack 37. In this embodiment, the belt feeding rack 37 includes a 1# belt feeding rack and a 2# belt feeding rack, each of which is provided with a 1# belt layer unwinding device and a 2# belt layer unwinding device at one end, respectively.

[0027] Furthermore, the forming drum device also includes a light scale 18, which is set at the tread forming station and is used for the production of radial tires. Through vertical and longitudinal adjustment, the fit between the tread and the rim is ensured to avoid local wear or performance degradation of the tire due to positioning deviation.

[0028] Furthermore, the forming drum device also includes a tire unloading roller 19, and the tire unloading roller 19 is connected to the transfer ring 17.

[0029] Furthermore, the building drum device 1 further comprises a plurality of sensor modules, which are arranged at different positions of the building drum base 11 and correspond to different carcass building system equipment and tread building system equipment respectively.

[0030] The modular radial tire production line in this embodiment adopts a modular design, comprising at least one set of modular production equipment. Each set consists of multiple modules that can be quickly disassembled and combined, allowing for flexible adjustments based on market demand. The equipment modules include a power module, an actuator module, a sensor module, and a control system module. The control system utilizes a distributed control architecture, enabling intelligent control of the equipment modules. The entire system utilizes a technical route principle (the application of advanced mathematical calculus theory) and production processes.

[0031] The modular radial tire production line of this embodiment is primarily used for radial tire manufacturing. The equipment modules are seamlessly integrated and independently operated, allowing for quick and convenient specification switching. The entire machine utilizes automated information control. Visual digital displays on various components indicate remaining rubber in real time, reminding personnel preparing the material in advance. The equipment's performance parameters are shown in Table 1, and its main functions are summarized in Table 2.

[0032] Table 1

[0033]

[0034]

[0035] Table 2

[0036]

[0037]

[0038] The radial tire molding modular production line of this embodiment completely abandons the extrusion, calendering, cord cutting and other processes in the large-scale batch manufacturing of traditional tires. It does not require fiber cord calendering equipment, nor does it require small extrusion equipment such as tread / cushion rubber. It not only greatly reduces the storage and circulation of semi-finished products during the production process, but also eliminates the quality risks that may be caused by the parking of semi-finished products. It also saves the cord calendering machine, three-composite extrusion production line, cap band slitting machine, etc. required in the traditional process, as well as the investment in workers and auxiliary tooling. The investment in using this set of equipment is only one-third of that in the traditional way.

[0039] This solution also discloses a radial tire molding production process, based on the above radial tire molding modular production line, such as Figure 4As shown, perform the following steps:

[0040] S1. The carcass forming system produces a carcass semi-finished product on the forming drum 121. Specifically, the left sidewall extrusion and winding device 24 and the right sidewall extrusion and winding device 25 are wound on the forming drum 121 with sidewall rubber. The inner liner extrusion and winding device, the sub-edge rubber extrusion device, the cord fixed-length cutting and splicing device are composited with the inner liner carcass through cord splicing and fixed-length cutting, and are bonded and formed together with the sidewall rubber on the forming drum 121. Thereafter, they are pressed into a carcass semi-finished product (carcass composite molding) on ​​the forming drum after being buckled and turned over. During the production process, the forming drum case 12 can automatically control its moving position according to the sequence of processes to cooperate with each device to complete the work.

[0041] S2. The tread forming system produces a semi-finished carcass on the belt drum 131. Specifically, the belt extrusion and coating device cuts the belt to a fixed length, enters the cap rubber cooling section, storage section, cutting section and secondary storage section, and then cooperates with the tread extrusion winding device and the wing rubber extrusion winding device on the belt drum to wind and compositely form the tread semi-finished product (tread composite molding). During the production process, the belt drum case 13 can automatically control its moving position according to the sequence of processes to cooperate with each device to complete the work; wherein, the cap belt fiber cord pay-out arrangement and the winding tension of the extrusion and coating device 30 are controlled at 10~40N±2N.

[0042] S3. Then control the forming drum chassis 12 and the belt drum chassis 13 to move on the X-axis slide rail, transport the semi-finished carcass and tread to the combined forming device for roll forming to form a tire blank, and finally the tire unloading robot unloads the formed tire blank from the tire machine and sends it to a special tire blank transfer vehicle.

[0043] Because steps S1 and S2 of this solution are performed at different workstations, they can be performed simultaneously without affecting each other, thereby improving production efficiency.

[0044] The above description is only a preferred embodiment of the present invention and should not be used to limit the scope of implementation of the present invention. In other words, any simple equivalent changes and modifications made according to the scope of the patent application and the content of the invention description are still within the scope of the patent of the present invention.

Claims

1. Modular production line for radial tire building, characterized by: The present invention comprises a forming drum device, a carcass forming system and a tread forming system; the forming drum device comprises a forming drum base, a forming drum casing, a belt drum casing and a combined forming device, the combined forming device is installed in the middle of the forming drum base, and the front side part of the forming drum base is divided into a carcass forming station part, the front side part of the forming drum base is divided into a tread forming station part, the carcass forming system and the tread forming system are respectively arranged in the carcass forming station part and the tread forming station part, the forming drum casing and the belt drum casing are respectively arranged in the carcass forming station part and the tread forming station part, They are respectively arranged on the front and rear sides of the forming drum base, and the forming drum base is provided with an X-axis slide rail. The forming drum chassis and the belt drum chassis can be slidably installed on the X-axis slide rail. The forming drum chassis and the belt drum chassis are respectively provided with a forming drum and a belt drum. The carcass forming system synthesizes the carcass semi-finished product on the forming drum, and the tread forming system synthesizes the tread semi-finished product on the belt drum. After the belt drum synthesizes the tread semi-finished product, the forming drum chassis and the belt drum chassis can respectively transport the carcass semi-finished product and the tread semi-finished product to the combined molding device for rolling molding.

2. The radial tire building modular production line according to claim 1, characterized in that: The carcass forming system comprises an inner liner extrusion and winding device, a spur rubber extrusion device, a cord fabric fixed-length cutting and splicing device, a left sidewall extrusion and winding device, and a right sidewall extrusion and winding device.

3. The radial tire building modular production line according to claim 1, characterized in that: The tread molding system includes a tread extrusion and winding device, a wing rubber extrusion and winding module, and a belt extrusion and rubber coating device.

4. The radial tire building modular production line according to claim 1, characterized in that: The combined molding device includes a combined pressure roller, a molding pressure roller and a preformer. The combined pressure roller is installed in the middle of the molding drum base, the molding pressure roller is arranged directly above the combined pressure roller, and the preformer is arranged on the rear side of the combined pressure roller.

5. The radial tire building modular production line according to claim 4, characterized in that: The combined molding device further comprises a transfer ring, which is installed on the rear side of the preformer.

6. The radial tire building modular production line according to claim 1, 4 or 5, characterized in that: The forming drum device further comprises a light scale, and the light scale is arranged at the tread forming station.

7. The radial tire building modular production line according to claim 5, characterized in that: The forming drum device also includes a tire unloading roller, and the tire unloading roller is connected to the transfer ring.

8. The radial tire building modular production line according to claim 3, characterized in that: The belt extrusion and rubber coating device includes a spindle rack, an extruder, a cooling device, a material storage and cutting device, a belt layer guide device and a belt feeding rack. The steel wire completes the initial radial arrangement and sorting of the steel wire on the spindle rack to form a steel belt, which enters the extruder. In the extruder, the rubber compound is covered around the steel wire and extruded to form a rubber-coated tire belt layer of a flat steel belt with steel wire as a radial skeleton material and rubber compound as a connecting material. The tire belt layer extruded from the extruder passes through a cooling device to reduce the high temperature generated during extrusion, and then enters the material storage and cutting device, and is wound and composited on the belt drum through the belt layer guide device and the belt feeding rack.

9. The radial tire building modular production line according to claim 3, characterized in that: The tread forming system also includes a cap band fiber cord pay-out arrangement and rubber extrusion coating device.

10. A radial tire forming production process, characterized in that: The radial tire building modular production line according to any one of claims 1 to 9, performing the following steps: S1. The sidewall rubber is wound on the building drum by the left and right sidewall extrusion and winding devices. The inner liner extrusion and winding device, the bead rubber extrusion device, and the cord fabric cutting-to-length and splicing device splice and cut the cord fabric to length and laminate it with the inner liner carcass. The product is then laminated and formed together with the sidewall rubber on the building drum. After beading and turning up, the product is pressed on the building drum to form a semi-finished carcass. S2. The belt extrusion coating device is cut to length by the belt, enters the cap rubber cooling section, storage section, cutting section and secondary storage section, and then the tread extrusion winding device and the wing rubber extrusion winding device are wound on the belt drum to form a composite tread semi-finished product; S3. Then control the forming drum chassis and the belt drum chassis to move on the X-axis slide rail, transport the semi-finished carcass and tread to the combined forming device for roll forming to form a tire blank, and finally use the tire unloading robot to unload the formed tire blank from the tire machine and send it to a special tire blank transfer vehicle.

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