Container-Frame Modular Extrusion Line for Fast On-Site Installation
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Solution Overview
Problem
Existing extrusion lines for producing tyre semi-finished products are large and difficult to assemble and transport, requiring disassembly and reassembly at the customer's site, leading to high costs and prolonged installation times.
Innovation Solution
A modular extrusion line composed of interconnecting modules, each formed by frames corresponding to international shipping container dimensions, allowing for assembly and testing at the manufacturer's site before shipment, with components installed and adjustable for precise fitting and anchoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the extrusion line is assembled in small subassemblies and shipped in multiple containers, then the device can be transported to overseas locations, but the packaging and transportation costs increase and the full volume of shipping containers is not used
Solution Approach 1:
The extrusion line is divided into modular subassemblies that can be independently packaged and transported. Each module is designed as a self-contained unit with specific functions (extrusion, cooling, cutting, etc.), allowing flexible configuration and efficient space utilization in shipping containers while maintaining transportability to overseas locations
Solution Approach 2:
The modular subassemblies are designed with universal interfaces and standardized mounting structures that allow them to be configured in different arrangements. This multi-functionality enables the same modules to adapt to various production requirements while optimizing container loading efficiency and reducing packaging waste
2Adaptability or versatility
If the extrusion line is disassembled for shipping and reassembled at the customer's site, then the device can be transported, but the assembly, activation and testing time increases to 5-6 months
Solution Approach 1:
The modular subassemblies are pre-assembled, pre-tested, and pre-configured at the manufacturer's facility before shipping. Critical components are pre-installed and calibrated, so that upon arrival at the customer's site, only final integration and connection are required, reducing on-site assembly and testing time from 5-6 months to a significantly shorter period
Solution Approach 2:
Each modular subassembly is designed as a self-contained unit with integrated control systems and self-diagnostic capabilities. The modules can autonomously perform basic activation and self-testing upon connection, reducing the need for extensive manual configuration and professional intervention during installation
3Adaptability or versatility
If the extrusion line is assembled in small subassemblies, then the device can be shipped in containers, but the complexity of assembly and activation increases at the customer's plant
Solution Approach 1:
The extrusion line is segmented into functionally independent modular subassemblies, each with dedicated control systems and standardized interfaces. This segmentation isolates complexity within individual modules while simplifying the overall system integration through uniform connection protocols and modular architecture
Solution Approach 2:
Standardized mechanical interfaces, electrical connectors, and control communication protocols serve as intermediaries between modular subassemblies. These intermediary elements provide consistent connection standards that simplify assembly procedures and reduce the complexity of integrating multiple modules, enabling straightforward plug-and-play installation
Data Source
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AI summary
The modular extrusion line intended for production of semi-finished products of tyres from high elastic compounds comprises a plurality of modules, wherein each module is formed by frame (1) dimensionally corresponding to the internal dimensions of the international shipping containers, wherein frame (1) is also the transport support. At least one technological component (2) is installed in the frame (1) of at least one module. At least one technological component (2) in the frame (1) of the at least one module has adjusting elements (3) for adjustment in at least one axis. The modular extrusion line comprises the modules of the base structure of the line, the frames (1) of which are precisely set with each other by means of setting elements (4) to form the base structure of the line, and comprises at least one module of the superstructure structure of the line. The frames (1) of the module of the base structure of the line are anchored to the floor by means of anchoring elements (5) in the horizontal plane. The frame (1) of each module of the superstructure of the line structure is interconnected with the frame (1) of at least one module of the base structure of the line by means of interconnecting elements (6) for their precise interconnection.