Unvulcanized Rubber Dielectric Quality Inspection
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Solution Overview
Problem
Current methods for inspecting the compounding ratio of unvulcanized rubber materials are complex, time-consuming, and cannot be performed on the production line, affecting the quality and productivity of rubber products.
Innovation Solution
A quality inspection method and system that uses a dielectric constant measurement device and calculator to determine the compounding ratio of the compounding agent in unvulcanized rubber materials, allowing for rapid and easy assessment on the production line by calculating and adjusting the ratio of vulcanizing compounding agents based on detected dielectric constants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods (oxygen flask combustion method or sodium peroxide melting method) are used to determine the compounding ratio of sulfur in unvulcanized rubber material, then measurement precision can be achieved, but the inspection process becomes complex and time-consuming, and cannot be performed on the production line
Solution Approach 1:
The patent replaces complex chemical inspection methods (oxygen flask combustion, sodium peroxide melting) with a physical measurement method using dielectric constant measurement. This substitution eliminates the need for complex chemical procedures, long inspection times, and specialized equipment, enabling simple, rapid dielectric constant measurements to be performed directly on the production line while maintaining accurate determination of sulfur compounding ratios
Solution Approach 2:
The patent changes the measurement parameter from chemical analysis to dielectric constant measurement. By measuring the dielectric constant of the unvulcanized rubber material and correlating it with the sulfur compounding ratio, the system achieves accurate quality determination through a simple physical parameter that can be measured rapidly without complex procedures
2Measurement precision
If traditional inspection methods are used, then measurement precision can be achieved, but productivity decreases due to long inspection time and inability to perform inspection on the production line
Solution Approach 1:
The patent replaces time-consuming chemical inspection methods with rapid dielectric constant measurement, enabling quality inspection to be performed continuously on the production line without stopping or slowing down production, thereby maintaining measurement precision while dramatically improving productivity
Solution Approach 2:
The patent enables continuous quality inspection on the production line by using dielectric constant measurement that can be performed rapidly and repeatedly as material passes through the production process, eliminating the need for batch sampling and laboratory analysis, thus maintaining both measurement accuracy and continuous production flow
3Difficulty of detecting and measuring
If ultrasonic wave attenuation method is used to detect contaminants in unvulcanized rubber material, then detection capability for contaminants is achieved, but the method cannot determine whether the compounding ratio of the compounding agent is appropriate
Solution Approach 1:
The patent changes the measurement parameter from ultrasonic wave attenuation to dielectric constant. The dielectric constant is sensitive to the composition and compounding ratio of materials, enabling the system to determine whether the compounding ratio of sulfur and other agents is appropriate, while also being capable of detecting contaminants through their effect on the overall dielectric properties
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
Enables the rapid determination of the acceptability of the compounding ratio, ensuring the production of unvulcanized rubber materials with appropriate compounding ratios, thereby improving the quality and productivity of rubber products.
Implementation Method 1
based on a dielectric constant of an unvulcanized rubber material in which a compounding agent of predetermined type is mixed with unvulcanized rubber, calculating a compounding ratio of the compounding agent to the unvulcanized rubber material
Data Source
AI summary
Provided are a quality inspection method and a quality inspection system for unvulcanized rubber material. A final dielectric constant measurement device detects the dielectric constant of a final rubber material in which a compounding agent of predetermined type is mixed with unvulcanized rubber, and a calculator calculates a compounding ratio of the compounding agent to the final rubber material based on the detected dielectric constant, determines whether or not the calculated compounding ratio is in a preset compounding reference range, displays a determination result on a monitor, and adjusts a ratio of the compounding agent fed into an extruder to the unvulcanized rubber such that the calculated compounding ratio is within the compounding reference range.