Radial tire molding modular production line and production process thereof

Abstract

The application discloses a radial tire forming modular production line, which comprises a forming drum device, a tire body forming system and a 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 respectively arranged on the front and rear sides of the forming drum base, the tire body forming system synthesizes a tire body semi-product on the forming drum, the tread forming system synthesizes a tread semi-product after the belt drum, and the forming drum machine box and the belt drum machine box transport the tire body semi-product and the tread semi-product to the combined forming device for rolling and forming. The application utilizes the mathematical differential principle to standardize the minimum units of each part of the tire, and then utilizes the mathematical integral principle to utilize the standardized minimum units to perform superposition according to the shapes of the parts by using an algorithm, and finally produces a tire embryo. The scheme can improve the production efficiency, reduce the production cost and has a wide application prospect.

Description

Technical Field

[0001] This invention relates to the field of tire manufacturing technology, specifically to a modular production line for radial tire forming and its manufacturing process. Background Technology

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

[0003] Utility model patent CN201913813U discloses an intensive, ultra-large-scale, high-performance radial tire production system for passenger cars, comprising a three-story building. The first floor sequentially includes 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 shipping area. The second floor sequentially includes a compound rubber storage area, a semi-finished product production area, a tire blank painting area, a tire blank storage area, and a finished tire storage area. The semi-finished product production area is equipped with multiple triangular rubber bonding machines and multiple steel wire bead extrusion and rolling production lines. The third floor includes a tire edge grinding area, a tire inflation area, and a tire repair area. The semi-finished product extrusion and calendering area includes at least one sidewall three-compound extrusion production line and multiple tread composite extrusion production lines. The system includes: multiple cold-feed extruders, multiple inner liner calendering production lines, multiple hot refining mills, at least one fiber cord calendering production line, multiple padding finishing machines (17 and 18), multiple slitting 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, with the first-stage and second-stage forming machines configured in pairs, arranged in 2-6 rows, with 6-20 sets per row, and a tire blank conveying device between every two rows of radial tire first-stage and second-stage forming machines. The tire blank conveying device has an elevator at its end, which connects to the tire blank storage area on the second floor. To the right of the tire blank storage area is the tire blank spraying area, equipped with multiple tire blank spraying machines. To the left of the tire blank storage area is the finished tire storage area, which contains a finished tire conveying system and multiple tire polishing machines and local repair vulcanizing agents. The vulcanization area includes multiple tire dual-mold vulcanizing machines arranged in an array and multiple tire blank carts for transporting tire blanks. A monorail electric hoist is located at the front end of each tire dual-mold vulcanizing machine, connected to the elevator. The tire dual-mold vulcanizing machines are arranged in 6-12 rows, with 10-24 machines per row. A connecting device is provided between every two rows of tire dual-mold vulcanizing machines. The system includes a finished product belt conveyor, with an inclined belt conveyor at the end; the finished product inspection area includes a tire trimming machine, a visual inspection machine, multiple tire uniformity testing machines, and a tire dynamic balance testing machine. The tire trimming machine and visual inspection machine are set up as a unit, with the tire trimming machine immediately connected to the inclined belt conveyor and the visual inspection machine adjacent to it. The multiple tire uniformity testing machines and tire dynamic balance testing machines are located in the middle of the finished product inspection area; the storage, transportation, and shipping area is equipped 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, and the width is ≥190 m. The temperature in the forming area is controlled at 23℃ ±5℃, and the humidity is controlled at ≤70%.

[0004] While this solution utilizes a large-scale production system, facilitating flexible layout and technological upgrades of process equipment, and eliminating the need for outdoor transportation of semi-finished products, thus shortening transportation distance and time and avoiding pollution from sunlight, ultraviolet rays, and dust during open-air transportation, the solution requires significant investment and places a heavy burden on enterprises. Furthermore, traditional processes also require a large number of non-standard auxiliary equipment to support production, further increasing the enterprise's production costs. Summary of the Invention

[0005] To address the problems raised in the background, this solution provides a modular radial tire forming production line and its production process, which can adapt to the diverse, flexible, complex processes and the production of less common tire models, thereby improving production efficiency and reducing production costs.

[0006] The technical solution adopted by this invention to solve its technical problem is as follows: a modular production line for radial tire forming, including a forming drum device, a tire carcass forming system, and a tread forming system; the forming drum device includes a forming drum base, a forming drum housing, a belt drum housing, and a combined forming device, the combined forming device being installed in the middle of the forming drum base, dividing the front part of the forming drum base into a tire carcass forming station, and the rear part of the forming drum base into a tread forming station, the tire carcass forming system and the tread forming system being respectively arranged in the tire carcass forming station and the tread forming station. The forming drum machine box and the belt drum machine box are respectively located on the front and rear sides of the forming drum base. The forming drum base is provided with an X-axis slide rail. The forming drum machine box and the belt drum machine box are slidably mounted on the X-axis slide rail. The forming drum and the belt drum machine box are respectively provided with a forming drum and a belt drum. The tire body forming system synthesizes the tire body semi-finished product on the forming drum. After the tire tread forming system synthesizes the tire tread semi-finished product on the belt drum, the forming drum machine box and the belt drum machine box can respectively transport the tire body semi-finished product and the tire tread semi-finished product to the combined forming device for roll forming.

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

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

[0009] Furthermore, the combined molding device includes a combined pressure roller, a forming pressure roller, and a preformer. The combined pressure roller is installed in the middle of the forming drum base, the forming pressure roller is located directly above the combined pressure roller, and the preformer is located 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 tire carcass assembly smoothly from the bonding drum to the molding drum during the molding process, ensuring the precise positioning of the tire carcass and the tire bead.

[0011] Furthermore, the forming drum device also includes a light scale, which is set at the tread forming station and is used for the production of radial tires. The light scale is adjusted vertically and longitudinally to ensure the fit between the tread and the rim, and 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 conveyor, which is connected to the transfer ring.

[0013] Furthermore, the belt extrusion coating device includes a spindle frame, an extruder, a cooling device, a material storage and cutting device, a belt layer guiding device, and a belt feeding frame. The steel wires are initially radially arranged and sorted on the spindle frame to form a steel wire strip, which enters the extruder. Inside the extruder, rubber compound is applied around the steel wires, and the strips are extruded to form a flat steel wire strip coated tire belt layer with steel wires as the radial skeleton material and rubber compound as the connecting material. The tire belt layer extruded from the extruder passes through the cooling device to reduce the high temperature generated during extrusion, and then enters the material storage and cutting device. After passing through the belt layer guiding device and the belt feeding frame, the strips are wound and compounded on the belt drum.

[0014] Furthermore, the tread forming system also includes a crown belt fiber cord laying and extrusion coating device.

[0015] This solution also discloses a radial tire forming production process, which, based on the aforementioned modular radial tire forming production line, performs the following steps:

[0016] The sidewall rubber wrapped on the molding drum by the left and right sidewall extrusion winding devices is combined with the inner liner extrusion winding device, the bead protector extrusion device, and the cord fabric fixed-length cutting and splicing device through cord fabric splicing and fixed-length cutting with the inner liner tire body, and then bonded together with the sidewall rubber on the molding drum. After buckling and wrapping, the tire body semi-finished product is pressed on the molding drum.

[0017] The belt extrusion coating device cuts the belt to a fixed length and then enters the crown belt rubber cooling section, storage section, cutting section and secondary storage section. It then works with the tread extrusion winding device and the wing rubber extrusion winding device to wind and form a composite tread semi-finished product on the belt drum.

[0018] Then, the forming drum machine box and the belt drum machine box are controlled to move on the X-axis slide rail to transport the semi-finished tire body and the semi-finished tire tread 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 machine and sends it to the tire blank special transfer vehicle.

[0019] The beneficial effects of this invention are as follows: The production line designed here is mainly used for radial tire manufacturing. The modules of the whole machine are perfectly integrated yet can operate independently. Specification switching is quick and convenient. The whole machine adopts information-automated control operation, and the remaining rubber material is displayed in real time on the visual digital display screen of each component, reminding the rubber material preparation personnel to be ready in advance. The production line designed here integrates extruders, cord cutting machines, crown strips, etc., eliminating the need for cord calendering equipment and tread / pad rubber extrusion equipment, resulting in low equipment investment costs. Based on the principles of advanced mathematics calculus, the latest unit is standardized, and various specifications of products are ultimately unified into a minimum unit for production. This not only significantly reduces the storage and circulation of semi-finished products during the production process, but also eliminates potential quality hazards that may arise during the storage of semi-finished products, and saves the investment required for a large number of non-standard auxiliary equipment in traditional processes. The production line designed here is flexible in its process. The parameters of the tire tread, sidewall, and crown belt can be directly modified on the equipment according to the process requirements. It requires less labor costs. The tire tread, sidewall, and crown belt are wound online without joints, resulting in better uniformity and dynamic balance performance. The production process is streamlined, making it suitable for customized production of small batches and multiple varieties. The equipment is integrated, reducing the need for material process control. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall horizontal structural layout of the present invention;

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

[0022] Figure 3 This is a schematic diagram of the molding drum device of the present invention;

[0023] Figure 4 This is a flowchart of the radial tire molding production process of the present invention. Detailed Implementation

[0024] The present invention will be further described below with reference to embodiments. It is worth noting that these specific embodiments are merely representative examples of the present invention, and the specific methods, apparatus, conditions, materials, etc., exemplified are not intended to limit the present invention or the corresponding specific embodiments. Furthermore, descriptions of orientation in the text are... Figure 1 As a reference standard, the front and rear sides of the molded drum base mentioned in the text refer to respectively Figure 1 Position in the top-bottom direction.

[0025] Modular production line for radial tire forming, such as Figures 1-3 As shown, the system includes a forming drum device 1, a tire carcass forming system, and a tread forming system. The forming drum device 1 includes a forming drum base 11, a forming drum housing 12, a belt drum housing 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 located directly above the combined pressure roller 14, the preformer 16 is located behind the combined pressure roller 14, and the transfer ring 17 is installed behind the preformer 16. The transfer ring 17 is used to transfer the tire carcass components during the forming process, smoothly transferring the tire carcass from the bonding drum to the forming drum, ensuring accurate positioning of the tire carcass and the bead. The combined molding device divides the front part of the molding drum base 11 into a tire body molding station and the rear part of the molding drum base 11 into a tread molding station. The tire body molding system and the tread molding system are respectively arranged in the tire body molding station and the tread molding station. The molding drum machine box 12 and the belt drum machine box 13 are respectively arranged in front and rear of the molding drum base 11. The molding drum base 11 is provided with an X-axis slide rail. The molding drum machine box 12 and the belt drum machine box 13 are slidably mounted on the X-axis slide rail. The molding drum machine box 12 and the belt drum machine box 13 are respectively provided with a molding drum 121 and a belt drum 131. The tire body molding system synthesizes the tire body 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 machine box 12 and the belt drum machine box 13 can respectively transport the tire body semi-finished product and the tread semi-finished product to the combined molding device for roll forming.

[0026] Furthermore, the tire body forming system includes an inner liner extrusion and winding device 21, a bead protector extrusion device 22, a cord fabric fixed-length cutting and splicing device 23, a left tire sidewall extrusion and winding device 24, and a right tire sidewall extrusion and winding device 25. The left tire sidewall extrusion winding device 24 and the right tire sidewall extrusion 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 winding work on the forming drum 121. The inner liner extrusion winding device 21, the bead protector extrusion device 22, and the cord fabric fixed length cutting and splicing device 23 are arranged in the left empty space in front of the forming drum base 11. The inner liner extrusion winding device 21, the bead protector extrusion device 22, and the cord fabric fixed length cutting and splicing device 23 are connected to the forming drum device 1 through the foot feeding device 26. The foot feeding device 26 includes a tire body feeding frame and a material transfer roller installed on the tire body feeding frame to transport the materials output by the inner liner extrusion winding device 21, the bead protector extrusion device 22, and the cord fabric fixed length cutting and splicing device 23 to the forming drum 121 to synthesize the tire body semi-finished product. The tread forming system includes a crown belt fiber cord laying 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, while the belt extrusion coating device is arranged on the left side of the rear side of the forming drum base 11. The crown belt fiber cord laying and extrusion coating device 30 is located at the position of the cord fixed length cutting and splicing device 23. The belt extrusion and coating device includes a spindle frame 33, an extruder 34, a cooling device 35, a material storage and cutting device 36, a belt layer guide device, and a belt feeding rack 37. Steel wires undergo initial radial arrangement and organization on the spindle frame 33 to form a steel wire strip, which then enters the extruder 34. Inside the extruder 34, rubber compound covers the steel wires, extruding to form a flat steel wire strip coated tire belt layer with steel wires as the radial skeleton material and rubber compound as the connecting material. The tire belt layer extruded from the extruder 34 passes through the cooling device 35 to reduce the high temperature generated during extrusion, and then enters the material storage and cutting device 36. It is then wound and composite-formed on the belt drum via the belt layer guide 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, with a #1 belt layer guide device and a #2 belt layer guide device respectively at one end of each rack.

[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. The light scale is adjusted vertically and longitudinally to ensure the fit between the tread and the rim, and 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 conveyor 19, which is connected to the transfer ring 17.

[0029] Furthermore, the forming drum device 1 also includes multiple sensor modules, which are arranged at different positions on the forming drum base 11 and correspond to different tire body forming system equipment and tire tread forming system equipment, respectively.

[0030] In this embodiment, the radial tire forming modular production line adopts a modular design, including at least one set of modular production equipment. Each set of equipment consists of multiple modules, which can be quickly disassembled and combined, and can be flexibly adjusted according to market demand. The equipment modules include a power module, an execution module, a sensing module, and a control system module. The control system adopts a distributed control structure to achieve intelligent control of the equipment modules. The entire machine adopts the technical principles (application of advanced mathematical calculus theory) and production processes.

[0031] This embodiment of the modular radial tire forming production line is mainly used for radial tire manufacturing. The modules of the whole machine are perfectly integrated yet can operate independently. Specification switching is quick and convenient. The whole machine adopts information-automated control operation, and the remaining rubber material is displayed in real time on the visual digital display screen of each component, reminding the rubber material preparation personnel to prepare in advance. Its equipment performance parameters are shown in Table 1 below, and its main functions are shown in Table 2 below.

[0032] Table 1

[0033]

[0034] Table 2

[0035]

[0036] The modular radial tire forming production line in this embodiment completely abandons the extrusion, calendering, and cord cutting processes in the traditional large-scale mass production of tires. It eliminates the need for fiber cord calendering equipment and small extrusion equipment such as tread / pad rubber. This not only significantly reduces the storage and transfer of semi-finished products during the production process, but also eliminates potential quality hazards that may arise during the storage of semi-finished products. Furthermore, it saves the investment required in traditional processes, such as cord calendering machines, three-component extrusion production lines, crown belt slitting machines, as well as the necessary workers and auxiliary tooling. The investment in this equipment is only one-third of that of the traditional method.

[0037] This solution also discloses a radial tire forming production process, based on the aforementioned modular radial tire forming production line, such as... Figure 4 As shown, perform the following steps:

[0038] S1. The tire body forming system produces a semi-finished tire body on the forming drum 121. Specifically, the sidewall rubber wrapped on the forming drum 121 by the left sidewall extrusion winding device 24 and the right sidewall extrusion winding device 25, the inner liner extrusion winding device, the bead protector extrusion device, and the cord fabric fixed-length cutting and splicing device are combined with the inner liner tire body through cord fabric splicing and fixed-length cutting. They are then bonded together with the sidewall rubber on the forming drum 121 and formed. After buckling and wrapping, the semi-finished tire body is pressed on the forming drum (tire body composite forming). During the production process, the forming drum machine box 12 can automatically control its movement position according to the process sequence to cooperate with each device to complete the work.

[0039] S2. The tread forming system produces semi-finished tire carcasses in the belt drum 131. Specifically, after the belt is cut to a fixed length and enters the crown belt cooling section, storage section, slitting section and secondary storage section, the belt extrusion coating device works with the tread extrusion winding device and the wing rubber extrusion winding device to wind and composite form the semi-finished tread (tread composite forming). During the production process, the belt drum housing 13 can automatically control its movement position according to the process sequence to cooperate with each device to complete the work. The crown belt fiber cord arrangement and the winding tension of the extrusion coating device 30 are controlled at 10~40N±2N.

[0040] S3. Then control the forming drum machine box 12 and the belt drum machine box 13 to move on the X-direction slide rail, transport the semi-finished tire body and the semi-finished tire tread 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 machine and sends it to the tire blank special transfer vehicle.

[0041] Since steps S1 and S2 in this solution are performed at different workstations, they can be carried out simultaneously without affecting each other, thus improving production efficiency.

[0042] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the description of the invention shall still fall within the scope of the patent of the present invention.

Claims

1. A modular production line for radial tire forming, characterized in that, The system includes a forming drum assembly, a carcass forming system, and a tread forming system. The forming drum assembly comprises a forming drum base, a forming drum housing, a belt drum housing, and a combined forming device. The combined forming device is installed in the middle of the forming drum base, dividing the front portion of the forming drum base into a carcass forming station and the rear portion into a tread forming station. The carcass forming system and the tread forming system are respectively arranged in the carcass forming station and the tread forming station. The forming drum housing and the belt drum housing are... The forming drum is positioned on the front and rear sides of the forming drum base. The forming drum base is equipped with an X-axis slide rail. The forming drum machine box and the belt drum machine box are slidably mounted on the X-axis slide rail. The forming drum machine box and the belt drum machine box are respectively equipped with a forming drum and a belt drum. The tire body forming system synthesizes the tire body semi-finished product on the forming drum. After the tire tread forming system synthesizes the tire tread semi-finished product on the belt drum, the forming drum machine box and the belt drum machine box can respectively transport the tire body semi-finished product and the tire tread semi-finished product to the combined forming device for roll forming. The combined molding device includes a combined pressure roller, a forming pressure roller, and a preformer. The combined pressure roller is installed in the middle of the forming drum base, the forming pressure roller is positioned directly above the combined pressure roller, and the preformer is positioned behind the combined pressure roller. The tread forming system includes a belt extrusion and coating device, which includes a spindle frame, an extruder, a cooling device, a material storage and cutting device, a belt layer guiding device, and a belt feeding frame. The steel wires are initially radially arranged and organized on the spindle frame to form a steel wire strip, which enters the extruder. In the extruder, rubber compound is applied around the steel wires, and the strips are extruded to form a flat steel wire strip coated tire belt layer with steel wires as the radial skeleton material and rubber compound as the 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. After passing through the belt layer guiding device and the belt feeding frame, the strips are wound and composite-formed on the belt drum.

2. The modular production line for radial tire forming according to claim 1, characterized in that, The tire body forming system includes an inner liner extrusion and winding device, a bead protector extrusion device, a cord fabric fixed-length cutting and splicing device, a left tire sidewall extrusion and winding device, and a right tire sidewall extrusion and winding device.

3. The modular production line for radial tire forming according to claim 1, characterized in that, The tread forming system also includes a tread extrusion and winding device and a wing rubber extrusion and winding module.

4. The modular production line for radial tire forming according to claim 1, characterized in that, The assembly molding device also includes a transfer ring, which is installed on the rear side of the preform.

5. The modular production line for radial tire forming according to claim 1 or 4, characterized in that, The forming drum device also includes a light scale, which is located at the tread forming station.

6. The modular production line for radial tire forming according to claim 4, characterized in that, The forming drum device also includes a tire unloading roller conveyor, which is connected to the transfer ring.

7. The modular production line for radial tire forming according to claim 3, characterized in that, The tread forming system also includes a crown belt fiber cord laying and extrusion coating device.

8. A radial tire forming and manufacturing process, characterized in that, The modular production line for radial tire forming according to any one of claims 1-7 shall perform the following steps: S1. The sidewall rubber wrapped on the forming drum by the left sidewall extrusion winding device and the right sidewall extrusion winding device, the inner liner extrusion winding device, the bead protector extrusion device, and the cord fabric fixed length cutting and splicing device are combined with the inner liner tire body through cord fabric splicing and fixed length cutting, and are bonded together with the sidewall rubber on the forming drum to form a semi-finished tire body after buckling and wrapping. S2. The belt extrusion coating device cuts the belt to a fixed length and then enters the crown belt rubber cooling section, storage section, cutting section and secondary storage section. It then works with the tread extrusion winding device and the wing rubber extrusion winding device to wind and form a composite tread semi-finished product on the belt drum. S3. Then control the forming drum machine box and the belt drum machine box to move on the X-axis slide rail, transport the semi-finished tire body and the semi-finished tire tread 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 machine and sends it to the tire blank special transfer vehicle.

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