Elastomeric Extrusion Through Gear Pumps for Consistent Product Weight
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Solution Overview
Problem
Existing extrusion processes for elastomeric materials in tire production suffer from variability in flow rate and weight of the extruded semi-finished product due to changes in viscosity caused by temperature fluctuations and thermal inertia, leading to structural defects and inconsistent deposition on forming supports.
Innovation Solution
A method to control the inlet pressure of the gear pump based on the exit pressure to maintain a constant pressure difference, ensuring a consistent flow rate and weight of the extruded semi-finished product by adjusting the inlet pressure within a predetermined range to compensate for viscosity variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the extrusion process uses conventional pressure control without compensation, then the equipment operation is simple, but the flow rate and weight of the extruded product vary due to viscosity changes
Solution Approach 1:
The patent implements a feedback control system where the actual inlet pressure is continuously measured and compared with the target inlet pressure, and the discrepancy is used to adjust the screw rotational speed to maintain consistent flow rate despite viscosity variations
Solution Approach 2:
The patent replaces purely mechanical pressure control with a hybrid system that incorporates sensors and computational algorithms to dynamically adjust operational parameters based on real-time pressure measurements
2Productivity
If the inlet pressure is increased to maintain flow rate, then the flow rate consistency improves, but the risk of material degradation and equipment damage increases
Solution Approach 1:
The patent employs dynamic adjustment of screw rotational speed based on real-time pressure feedback, allowing the system to adapt to changing material properties and operating conditions without applying excessive or harmful pressures
Solution Approach 2:
The patent changes the operational parameter (screw rotational speed) dynamically in response to measured pressure conditions, optimizing the extrusion process to maintain flow rate while preventing material degradation through controlled pressure levels
3Productivity
If the extrusion speed is increased to improve productivity, then the output increases, but the viscosity variations and flow rate inconsistency worsen
Solution Approach 1:
The feedback control system continuously monitors inlet pressure and adjusts screw rotational speed to compensate for viscosity changes, enabling high-speed extrusion while maintaining consistent product weight and dimensions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures a stable and repeatable extrusion process by maintaining a constant flow rate and weight of the semi-finished product, reducing defects and enhancing process reproducibility.
Implementation Method 1
a method to control the inlet pressure of the gear pump based on the exit pressure to maintain a constant pressure difference
Implementation Method 2
an extrusion screw rotatably mounted inside the hollow body... moves the elastomeric material from the upstream end portion of the hollow body to a downstream end portion of the hollow body
Implementation Method 3
changes in viscosity caused by temperature fluctuations
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a method for extruding a semi-finished product made of elastomeric material, wherein an elastomeric material is fed to an inlet channel (20a) of a gear pump (20) with an inlet pressure value and dispensed through an exit channel (20b) of the gear pump (20) with an exit pressure value greater than the inlet pressure value. The method comprises detecting the exit pressure value and adjusting the operation of said gear pump (20) so as to maintain a predetermined pressure difference between said exit pressure and said inlet pressure based on the detection of the exit pressure value. The aforementioned method is used in a process for building a tyre for vehicle wheels.