Gear Pump Extruder Control for Rubber Strip Sizing
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Solution Overview
Problem
Existing rubber strip manufacturing devices with adjustable gear pumps take a long time to switch between different belt layer sizes, resulting in periods of non-productivity and inconsistent rubber strip quality due to the lack of real-time control over extruder settings.
Innovation Solution
A device with a pressure sensor connected to a control unit to adjust the gear pump speed based on measured pressure and a measuring unit using a laser and camera to measure rubber strip height and width, allowing for precise control of the extruder and faster switching between sizes, along with a controllable pull-out unit and adjustable buffer rollers to manage demand variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gear pump speed is adjusted manually for different belt layer sizes, then the device can produce different sizes of rubber strips, but the switching time increases and productivity decreases
Solution Approach 1:
A control unit receives feedback signals from measuring devices that detect the dimensions of the rubber strip, and automatically adjusts the gear pump speed accordingly. This closed-loop feedback system eliminates manual intervention and enables rapid switching between different rubber strip sizes while maintaining consistent quality standards.
Solution Approach 2:
The gear pump speed is made dynamically adjustable through electronic control rather than fixed manual settings. The control unit can rapidly modify pump speed parameters in response to different production requirements, enabling the system to adapt quickly between different belt layer sizes without prolonged setup times.
2Adaptability or versatility
If the extruder settings are changed for different rubber strip sizes, then the device can accommodate various product specifications, but the quality consistency deteriorates during transition periods
Solution Approach 1:
Measuring devices continuously monitor the rubber strip dimensions and provide feedback to the control unit. This real-time feedback ensures that quality standards are maintained during size transitions, as the control unit can make precise adjustments to the gear pump speed to compensate for any variations and maintain consistent rubber strip quality.
Solution Approach 2:
The control unit is pre-programmed with optimal gear pump speed settings for different rubber strip sizes. Before switching between sizes, the system can pre-load the appropriate parameters, ensuring that quality consistency is maintained from the moment the transition begins, rather than requiring manual adjustment during the process.
3Manufacturing precision
If a gear pump with adjustable speed is used, then the dosage of rubber can be controlled accurately, but the device complexity increases
Solution Approach 1:
The control unit automatically manages the gear pump speed adjustments based on feedback from measuring devices, eliminating the need for complex manual adjustment mechanisms. This automated feedback system simplifies the overall device complexity while maintaining accurate dosage control, as the electronic control replaces what would otherwise require complex mechanical adjustment systems.
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
Ensures reproducible rubber strip quality and rapid adaptation to different sizes, maintaining consistent production while allowing for larger variations in demand and supply, with improved adherence to the cord material.
Implementation Method 1
the device is provided with a pressure sensor for measuring the pressure at the end of the conveying screw of the extruder, and for emitting a pressure signal indicative of the measured pressure
Implementation Method 2
a measuring unit using a laser and camera to measure rubber strip height and width
Data Source
AI summary
Device (1) for manufacturing a rubber strip material comprising cord material. The device comprises an extruder (4) with an integrated gear pump (13) with adjustable pump speed and with a conveying screw for extruding unvulcanised rubber around the cord material for the purpose of producing a continuous rubber strip. The device furthermore comprises a control unit (15) for adjusting the pump speed of the gear pump, a measuring unit (16) for measuring the height and the width of the rubber strip and for emitting a measuring signal indicative of the measured height and width. The measuring unit can be connected to the control unit for adjusting the pump speed of the gear pump for emitting the measuring signal to it, wherein the pump speed of the gear pump can be controlled by the control unit at least based on the measuring signal.