Rubber Mixing Water Control via Spray and Aspiration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of rubber mixtures for vehicle tires is challenged by the sensitivity of mixture properties to water content, which can compromise the quality of the finished tire due to improper temperature and water management during the mixing process.
Innovation Solution
A process and system that control the addition of water in a rubber mixture by spraying and aspirating water vapors during the mixing cycle, using predetermined data to adjust water flow rates and air flow to achieve target temperature and water content values, ensuring precise control and prevention of premature vulcanization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water is added to cool the rubber mixture during mixing, then the temperature control is improved, but the water content control becomes problematic and compromises tire quality
Solution Approach 1:
The invention changes the parameters of water application by controlling the amount, timing, and distribution of water sprayed onto the rubber mixture. The system uses multiple spray bars with adjustable water flow rates to precisely control water addition, transforming the cooling process from a粗放 approach to a precisely controlled parameter-based system that maintains both temperature and water content within target ranges.
Solution Approach 2:
The invention implements a feedback control system that continuously monitors temperature and water content during the mixing process. Sensors detect actual values and the system automatically adjusts water spray rates and aspiration power to maintain target values, resolving the contradiction by using feedback to simultaneously control both temperature and water content precision.
2Productivity
If spray and aspiration equipment is used to cool the mixture, then the cooling efficiency is improved, but the control complexity increases
Solution Approach 1:
The invention divides the spray and aspiration system into multiple independent segments - several spray bars with individual water flow control and multiple aspiration zones with independent power adjustment. This segmentation allows localized control of cooling in different regions of the mixer, improving overall cooling efficiency while enabling manageable control through modular adjustment of each segment rather than controlling the entire system as one unit.
3Stability of the object's composition
If repeated rolling is performed to plasticize the mixture, then the mixing quality is improved, but the temperature rises causing premature vulcanization
Solution Approach 1:
The invention applies preliminary cooling action before the temperature rise becomes problematic. Water is sprayed onto the rubber mixture at controlled intervals during the rolling process, and aspiration removes excess heat and moisture proactively. This preliminary cooling prevents the temperature from reaching the premature vulcanization threshold while the rolling continues to achieve proper mixing homogeneity.
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 the rubber mixture reaches optimal temperature and water content before vulcanization, maintaining tire quality and reducing cycle times, thereby enhancing productivity while preserving the beneficial properties of the rubber.
Implementation Method 1
spraying water whose vapors are evacuated controllably
Implementation Method 2
vapors are evacuated controllably by at least one aspiration system
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A process for controlling the addition of water in a rubber mixture produced during a mixing cycle in which the rubber mixture is transported in the form of a continuous sheet and along at least a portion of which at least one spray system sprays water that is controllably evacuated by at least one aspiration system, comprising: obtaining data unique to each rubber mixture that includes at least a predetermined water flow rate delivered by the spraying system, a predetermined air flow rate delivered by the aspiration system and target values of temperature and water content for the rubber mixture; detecting an amount of water added at an elapsed during the mixing cycle; using the detected amount of water to predict values of temperature and water content for the rubber mixture at the end of the mixing cycle in progress; comparing the target values and the predicted values; and between successive mixing cycles, adjusting the actual water flow rate when a comparison indicates non- equivalence.