Electromagnetic heating module for capsule vulcanizing machine
By combining an inner ring electromagnetic heating component and a temperature sensor, the problems of uneven temperature and high energy loss during tire vulcanization are solved, achieving efficient and energy-saving bladder vulcanization and improving the bladder's service life and safety.
Patent Information
- Application Number
- CN202511927714.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-19
- Publication Date
- 2026-02-24
AI Technical Summary
Existing tire vulcanization processes suffer from problems such as long vulcanization time, large temperature differences, uneven product quality, low number of uses, and high energy loss. Furthermore, steam vulcanization poses safety hazards and has low energy utilization.
The capsule employs a combined structure consisting of an inner electromagnetic heating assembly, a core mold, an outer electromagnetic heating assembly, a magnetic field isolation barrier, and a shell. Combined with a temperature sensor, it achieves synchronous heating and real-time temperature control of the inner and outer sides of the capsule, ensuring that the vulcanization temperature accuracy is within ±1℃.
It achieves improved temperature uniformity and energy efficiency during the capsule vulcanization process, reduces vulcanization time by more than 20%, saves more than 50% of energy, and improves capsule lifespan and safety.
Smart Images
Figure CN121552574A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of electromagnetic heating technology, specifically relating to an electromagnetic heating module for a capsule vulcanizing machine. Background Technology
[0002] In tire production, the bladder is the core component of the tire vulcanizing machine. Its performance directly determines the tire vulcanization quality, production efficiency, and production cost, making it the "core carrier" of the tire vulcanization process. High-quality bladders result in higher vulcanization cycles and lower production costs. For decades, both domestic and international bladder vulcanization has used steam vulcanization. However, steam can cause water residue in the lower mold half after mold closing, leading to uneven temperature during vulcanization. Traditional steam vulcanization relies on indirectly measuring the vulcanization temperature by measuring the return water temperature, resulting in significant temperature measurement errors and an inability to adjust the vulcanization temperature in a timely manner. Therefore, the existing steam vulcanization methods suffer from significant temperature measurement errors. Problems such as long vulcanization time, large temperature difference (±5℃), uneven tensile strength, poor product quality, and low number of uses mean that the number of times a capsule can be used is usually limited to a safe range. However, uneven tensile strength can lead to premature damage to localized areas of the capsule, which can easily cause tire failure and injuries from the high-temperature medium inside the capsule spraying out of the vulcanizing machine during use, posing a significant safety hazard. At the same time, the boiler has a 90% heat utilization rate, steam transportation has a 10% heat loss, mold and machine have a 20% heat loss, condensate carries away 20%, and steam is only used for vulcanized products at a rate of only 40%, resulting in a final energy utilization rate of only 40%, which is a huge energy loss. Summary of the Invention
[0003] This invention aims to provide an electromagnetic heating module for a capsule vulcanizing machine, which ensures uniform tensile strength of capsules, reduces vulcanizing time, improves vulcanizing efficiency, and solves the problems of long vulcanizing time, large temperature difference, uneven product properties, low number of uses, and high energy loss caused by steam vulcanization of capsules.
[0004] Therefore, the technical solution adopted by this invention is as follows: an electromagnetic heating module for a capsule vulcanizing machine, comprising, from the inside out, an inner ring electromagnetic heating component, a core mold, an outer mold, an outer ring electromagnetic heating component, a magnetic field isolation barrier, and a shell, wherein the core mold and the outer mold are in a closed state and a cavity for placing the capsule is provided between them; the inner ring electromagnetic heating component and the outer ring electromagnetic heating component are respectively matched with the shape of the core mold and the outer mold; the inner ring electromagnetic heating component includes a core mold coil mounting bracket and a core mold coil spirally mounted on the core mold coil mounting bracket, thereby providing heating for the inner side of the capsule. The core mold includes an upper core mold and a lower core mold, and the outer mold includes an upper outer mold and a lower outer mold. The inner side of the core mold and the outer side of the outer mold are symmetrically provided with blind holes for mounting temperature sensors, and are equipped with temperature sensors. The outer ring electromagnetic heating assembly includes an upper mold coil mounting bracket, a lower mold coil mounting bracket, an upper mold coil spirally mounted on the upper mold coil mounting bracket, and a lower mold coil spirally mounted on the lower mold coil mounting bracket, thereby providing temperature for vulcanization on the outside of the capsule. The shell includes an upper shell and a lower shell.
[0005] As a preferred embodiment of the above solution, the inner and outer electromagnetic heating components are respectively provided with mounting brackets for the temperature sensors to be inserted inward or outward. The design is reasonable and avoids positional conflicts between the temperature sensors and other components after installation.
[0006] The core mold coil mounting bracket, the upper half mold coil mounting bracket, and the lower half mold coil mounting bracket are all provided with coil through holes, so as to allow the core mold coil, the upper half mold coil, and the lower half mold coil to be spirally installed.
[0007] The upper and lower half-mode coil mounting brackets are provided with wire slots on the outer circumference for placing the temperature sensor data lines, which avoids messy wire harnesses that are difficult to organize and manage, and the structural design is reasonable.
[0008] More preferably, the core mold coil mounting frame includes a lantern-shaped skeleton structure with its upper and lower ends connected together, a reinforcing connecting plate located in the section with the largest diameter inside the skeleton structure, and an inner mold terminal block frame located on the upper part of the skeleton structure, resulting in a stable structure.
[0009] A further preferred embodiment is that the upper and lower ends of the skeleton structure are connected by annular blocks, and the reinforcing connecting plate is connected to the annular blocks at the upper and lower ends by connecting columns arranged circumferentially, resulting in a stable structure.
[0010] The inner side of the annular block at the top has pairs of mirror-image wire-passing holes. The upper part of the wire-passing holes has a wire-passing limit post mounting thread. The reinforcing connecting plate has a weight-reducing hole in the circumferential direction. The inner mold terminal block bracket is installed at the bottom of the annular block at the top and has a through hole corresponding to the wire-passing hole. The through hole corresponding to the wire-passing hole for coil wiring is set as a round hole and is provided with a coil terminal mounting plate. The through hole corresponding to the wire-passing hole for sensor wiring is set as an arc-shaped notch. Considering the different lengths and sizes of the wires, the wire-passing holes with different shapes are designed, which is ingenious.
[0011] Further preferably, the core mold coil, upper mold coil, and lower mold coil are all made of copper busbars, and the spacing between adjacent upper and lower copper busbars is 80mm to 90mm, which effectively avoids mutual interference of electric fields. The spacing between the core mold coil and the inner wall of the core mold, as well as between the upper mold coil and the lower mold coil and the outer wall of the outer mold, is 40mm to 50mm. This spacing is the optimal coupling distance under an alternating magnetic field at a frequency of 20kHz and a power of 20kW.
[0012] A further preferred embodiment is that the lower half of the outer mold edge is bent outward and upward to form a step that fits with the lower edge of the upper half of the outer mold, ensuring the sealing of the mold closing. The inner diameter of the upper half of the shell is smaller than that of the lower half of the shell, and the bottom end abuts against the lower edge of the upper half of the outer mold when the mold is closed. The edge of the lower half of the outer mold extends out of the lower half of the shell. Both the upper and lower half of the shell are provided with junction boxes. The core mold coil, the upper half of the mold coil and the corresponding temperature sensor wire harness can be led out through the junction box of the upper half of the shell, and the lower half of the mold coil and the corresponding temperature sensor wire harness can be led out through the junction box of the lower half of the shell, thereby connecting the wires in batches and making it convenient to organize and manage the wires.
[0013] A further preferred embodiment is that a central shaft is installed at the center of the bottom of the lower half of the core mold, which passes vertically through the inner ring electromagnetic heating assembly. The top of the upper half of the core mold is provided with a wire outlet hole corresponding to the wire passage hole. The top of the upper half of the core mold is provided with a threaded hole circumferentially corresponding to the top of the central shaft, so that the central shaft passes vertically through the inner ring electromagnetic heating assembly and is threadedly connected to the upper half of the core mold. The upper half of the core mold and the lower half of the core mold are installed together, which is convenient and quick to install and disassemble, and the structure is ingeniously designed.
[0014] Further preferably, the magnetic field isolation barrier is made of aluminum or copper sheet, which has low cost and good isolation effect. The core mold and the outer mold are provided with four blind holes for installing temperature sensors that are symmetrically arranged in the top, bottom, left and right, so as to facilitate one use and one spare, and avoid the situation where one temperature sensor fails.
[0015] The beneficial effects of this invention are:
[0016] (1) Compared with the steam vulcanization method used for capsule preparation, this method uses electromagnetic heating. During the capsule vulcanization process, temperature sensors are used to collect data at various temperature points of the core mold and outer mold in real time. The internal and external heating temperatures are flexibly adjusted by analyzing and comparing the data to ensure that the vulcanization temperature control accuracy is within ±1℃, thereby ensuring excellent uniformity of tensile strength after electromagnetic vulcanization. The main reason for premature capsule failure is uneven tensile strength in different segments. Electromagnetic heating vulcanization not only solves the problem of uneven tensile strength, but also reduces the vulcanization time by more than 20%. Furthermore, electromagnetic heating saves more than 50% of energy compared to steam heating, making it highly efficient, energy-saving, and producing high-quality products.
[0017] (2) The inner ring electromagnetic heating component, core mold, outer mold, outer ring electromagnetic heating component, magnetic field isolation barrier and shell are arranged sequentially from the inside to the outside to form synchronous heating of the inner and outer rings, thereby achieving uniform heating inside and outside. The tensile strength of the capsule produced by electromagnetic heating is 6.8% higher than that of the sample produced by steam heating, and the tensile strength deviation is reduced by 45%. The overall tensile performance of the capsule vulcanized by electromagnetic heating is better than that of steam vulcanization. At present, electromagnetic heating vulcanization is generally used for tire vulcanization and planar electromagnetic heating is used. This application is for the method of heating and vulcanizing the capsule inside and outside, which can improve the overall service life and safety of the capsule.
[0018] In summary, this invention has advantages such as high efficiency, energy saving, superior product quality, and improved capsule lifespan and safety. Attached Figure Description
[0019] Figure 1 This is an exploded view of the part of the present invention.
[0020] Figure 2 for Figure 1 A magnified view of a portion of point E.
[0021] Figure 3 This is a schematic diagram of the inner ring electromagnetic heating assembly and the core mold structure.
[0022] Figure 4 This is a schematic diagram of the inner ring electromagnetic heating assembly.
[0023] Figure 5 for Figure 4 A sectional view.
[0024] Figure 6 This is a structural schematic diagram of the inner mold wiring post bracket.
[0025] Figure 7 This is a schematic diagram of the electromagnetic heating control principle. Detailed Implementation
[0026] The present invention will be further described below with reference to the embodiments and accompanying drawings:
[0027] Combination Figure 1 — Figure 7 As shown, an electromagnetic heating module for a capsule vulcanizing machine consists of an inner ring electromagnetic heating component 1, a core mold 2, an outer mold 3, an outer ring electromagnetic heating component 4, a magnetic field isolation barrier, and a shell 5 arranged sequentially from the inside out.
[0028] A cavity for placing the capsule 6 is left between the core mold 2 and the outer mold 3, which are in the closed state.
[0029] The inner ring electromagnetic heating component 1 and the outer ring electromagnetic heating component 4 are respectively matched with the core mold 2 and the outer mold 3.
[0030] The inner ring electromagnetic heating assembly 1 consists of a core mold coil mounting bracket 11 and a core mold coil 12 spirally mounted on the core mold coil mounting bracket 11, thereby providing temperature for the vulcanization of the inner side of the capsule 6.
[0031] The core mold coil mounting frame 11 consists of a lantern-shaped frame structure 111 with its upper and lower ends connected together, a reinforcing connecting plate 112 located in the section with the largest diameter inside the frame structure 111, and an inner mold terminal block frame 113 located on the upper part of the frame structure 111.
[0032] The upper and lower ends of the skeleton structure 111 are connected by annular blocks 114.
[0033] The reinforcing plate 112 is connected to the annular blocks 114 at the upper and lower ends by connecting posts 115 arranged circumferentially. The inner side of the annular block 114 at the upper end is provided with two pairs of relatively mirrored wire holes 114a.
[0034] The upper part of the wire hole 114a is provided with a wire guide post mounting thread.
[0035] The reinforcing connecting plate 112 is provided with weight reduction holes in the circumference.
[0036] The inner mold terminal block 113 is installed at the bottom of the annular block 114 located at the upper end, and a through hole 113a is provided corresponding to the wire through hole 114a.
[0037] The via 113a is configured as a circular hole corresponding to the wire hole 114a for coil routing, and is provided with a coil terminal mounting plate 113b.
[0038] The annular block 114 at the upper end has a notch for inserting the coil terminal mounting plate 113b, and the through hole 113a is set in an arc-shaped notch corresponding to the through hole 114a for the sensor wiring.
[0039] The core coil 12, the upper half-coil 43, and the lower half-coil 44 all use copper busbars, and the spacing between adjacent upper and lower copper busbars is 80mm to 90mm.
[0040] The distance between the core mold coil 12 and the inner wall of the core mold 2, as well as the distance between the upper half mold coil 43, the lower half mold coil 44 and the outer wall of the outer mold 3, is 40mm to 50mm.
[0041] The core mold 2 consists of an upper core mold 21 and a lower core mold 22.
[0042] A central shaft 221, which passes vertically through the inner ring electromagnetic heating assembly 1, is installed in the center of the bottom of the lower half core mold 22.
[0043] The top of the upper core mold 21 is provided with a wire outlet hole 211 corresponding to the wire through hole 114a.
[0044] The top of the upper half core mold 21 is provided with a circumferential mounting threaded hole 212 corresponding to the top of the central shaft rod 221, so that the central shaft rod 221 passes vertically through the inner ring electromagnetic heating assembly 1 and is threadedly connected to the upper half core mold 21, and the upper half core mold 21 and the lower half core mold 22 are installed together.
[0045] The outer mold 3 consists of an upper outer mold 31 and a lower outer mold 32.
[0046] The lower half of the outer mold 32 bends outward and upward to form a step that matches the lower edge of the upper half of the outer mold 31.
[0047] The inner side of the core mold 2 and the outer side of the outer mold 3 are symmetrically provided with blind holes 8 for installing temperature sensors, and are equipped with temperature sensors.
[0048] The outer ring electromagnetic heating assembly 4 consists of an upper half-mold coil mounting bracket 41, a lower half-mold coil mounting bracket 42, an upper half-mold coil 43 spirally mounted on the upper half-mold coil mounting bracket 41, and a lower half-mold coil 44 spirally mounted on the lower half-mold coil mounting bracket 42, thereby providing temperature for the vulcanization of the outer side of the capsule 6.
[0049] The inner ring electromagnetic heating component 1 and the outer ring electromagnetic heating component 4 are respectively provided with mounting brackets for temperature sensors to be inserted inward or outward.
[0050] The core mold coil mounting bracket 11, the upper half mold coil mounting bracket 41, and the lower half mold coil mounting bracket 42 are all provided with coil through holes.
[0051] The housing 5 consists of an upper housing 51 and a lower housing 52, and both the upper and lower housings are equipped with junction boxes 53.
[0052] The upper half-mold coil mounting bracket 41 and the lower half-mold coil mounting bracket 42 are provided with cable outlet slots 45 for accommodating temperature sensor data lines on their outer circumferential sides.
[0053] The inner diameter of the upper shell 51 is smaller than that of the lower shell 52, and when the mold is closed, the bottom end abuts against the lower edge of the upper outer mold 31, while the edge of the lower outer mold 32 extends out of the lower shell 52.
[0054] The magnetic field isolation barrier is preferably made of aluminum or copper sheet. Both the core mold 2 and the outer mold 3 are equipped with four blind holes 8 for installing temperature sensors that are symmetrically arranged vertically and horizontally.
[0055] First, manually fill the outer half of the mold with the adhesive material in a circular motion, and then start the mold closing process.
[0056] The rubber compound is squeezed into the mold cavity and flows into it, filling the cavity, and the vulcanization timer begins.
[0057] like Figure 7 As shown in the electromagnetic heating control principle diagram, based on the data transmitted by the temperature sensor, the PLC control mechanism analyzes, compares and adjusts the data, thereby adjusting the transmission power of the upper outer half-mold electromagnetic heating power supply 91, the core mold electromagnetic heating power supply 92 and the lower outer half-mold electromagnetic heating power supply 93 to adjust the electromagnetic heating temperature.
[0058] Since wireless temperature sensors cannot be used due to the enclosed electromagnetic field, wired temperature sensors must be used.
Claims
1. An electromagnetic heating module for a capsule vulcanizing machine, characterized in that: The system includes, from the inside out, an inner ring electromagnetic heating assembly (1), a core mold (2), an outer mold (3), an outer ring electromagnetic heating assembly (4), a magnetic field isolation barrier, and a shell (5). The core mold (2) and outer mold (3) are in a closed state, leaving a cavity for placing the capsule (6). The inner ring electromagnetic heating assembly (1) and outer ring electromagnetic heating assembly (4) are respectively matched to the core mold (2) and outer mold (3). The inner ring electromagnetic heating assembly (1) includes a core mold coil mounting bracket (11) and a core mold coil (12) spirally mounted on the core mold coil mounting bracket (11), thereby providing temperature for the vulcanization of the inside of the capsule (6). The core mold (2) includes an upper core mold (21) and a lower core mold (22). The outer mold (3) includes an upper outer mold (31) and a lower outer mold (32). The inner side of the core mold (2) and the outer side of the outer mold (3) are symmetrically provided with blind holes (8) for installing temperature sensors, and equipped with temperature sensors. The outer ring electromagnetic heating assembly (4) includes an upper half mold coil mounting bracket (41), a lower half mold coil mounting bracket (42), an upper half mold coil (43) spirally mounted on the upper half mold coil mounting bracket (41), and a lower half mold coil (44) spirally mounted on the lower half mold coil mounting bracket (42), thereby providing temperature for vulcanization of the outer side of the capsule (6). The shell (5) includes an upper shell (51) and a lower shell (52).
2. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The inner ring electromagnetic heating assembly (1) and the outer ring electromagnetic heating assembly (4) are respectively provided with mounting brackets for the temperature sensor to be inserted inward or outward. The core mold coil mounting bracket (11), the upper half mold coil mounting bracket (41), and the lower half mold coil mounting bracket (42) are all provided with coil through holes. The outer side of the upper half mold coil mounting bracket (41) and the lower half mold coil mounting bracket (42) is provided with a wire slot (45) for placing the temperature sensor data line.
3. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The core mold coil mounting frame (11) includes a lantern-shaped frame structure (111) with its upper and lower ends connected together, a reinforcing connecting plate (112) located in the section with the largest diameter inside the frame structure (111), and an inner mold terminal block frame (113) located on the upper part of the frame structure (111).
4. The electromagnetic heating module for a capsule vulcanizing machine according to claim 3, characterized in that: The upper and lower ends of the skeleton structure (111) are connected by annular blocks (114). The reinforcing connecting plate (112) is connected to the annular blocks (114) at the upper and lower ends by connecting posts (115) arranged circumferentially. The inner side of the annular block (114) at the upper end is provided with pairs of mirror-image wire holes (114a). The upper part of the wire hole (114a) is provided with a wire routing limit post mounting thread. The reinforcing connecting plate (112) is provided with weight reduction holes circumferentially. The inner mold wiring post bracket (115) is also provided with a wire routing limit post mounting thread. 3) Installed at the bottom of the annular block (114) at the upper end, and a through hole (113a) is provided corresponding to the wire hole (114a). The through hole (113a) is set as a circular hole corresponding to the wire hole (114a) for coil wiring, and a coil terminal mounting plate (113b) is provided. The annular block (114) at the upper end is provided with a notch for inserting the coil terminal mounting plate (113b). The through hole (113a) is set as an arc-shaped notch corresponding to the wire hole (114a) for sensor wiring.
5. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The core mold coil (12), upper half mold coil (43), and lower half mold coil (44) are all made of copper busbars, and the distance between adjacent upper and lower copper busbars is 80mm to 90mm. The distance between the core mold coil (12) and the inner wall of the core mold (2), and between the upper half mold coil (43) and the lower half mold coil (44) and the outer wall of the outer mold (3) are all 40mm to 50mm.
6. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The lower half of the outer mold (32) bends outward and upward to form a step that fits with the lower edge of the upper half of the outer mold (31). The inner diameter of the upper half of the shell (51) is smaller than that of the lower half of the shell (52), and the bottom end abuts against the lower edge of the upper half of the outer mold (31) when the mold is closed. The edge of the lower half of the outer mold (32) extends out of the lower half of the shell (52). Both the upper half of the shell (51) and the lower half of the shell (52) are provided with junction boxes (53).
7. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The lower half core mold (22) has a central shaft (221) that passes vertically through the inner ring electromagnetic heating assembly (1) installed in the center of the bottom. The upper half core mold (21) has a wire outlet hole (211) corresponding to the wire hole (114a) at the top. The upper half core mold (21) has a mounting thread hole (212) circumferentially arranged at the top of the central shaft (221) so that the central shaft (221) passes vertically through the inner ring electromagnetic heating assembly (1) and is threadedly connected to the upper half core mold (21), thus merging the upper half core mold (21) and the lower half core mold (22).
8. The electromagnetic heating module for a capsule vulcanizing machine according to claim 1, characterized in that: The magnetic field isolation barrier is made of aluminum or copper sheet, and the core mold (2) and outer mold (3) are provided with four blind holes (8) for installing temperature sensors that are symmetrically arranged in the upper, lower and left and right.