The traditional layer-laying method and the set-up method on the tread production of engineering machinery tires have poor compactness and single product, especially when producing large-size tires, the labor intensity is extremely great. Most of the foreign countries use engineering machinery tire tread winding machine to wrap the tread. The typical tread winding machine has the ALPHA-R tread winding machine of the Italian Malangoni company. The domestic bias tire tread winding machine can not be wrapped around the sidewall, and there is still a gap in shape, quality and production efficiency. This paper briefly introduces the quality and shape control of tread winding of BTXC-3 engineering machinery tires produced by Chemical Baichuan Automatic Control Co., Ltd.
Production Process
The tread winding is generally composed of five steps of extrusion, conveying, pressing, cooling and winding of the rubber. The process and control system of the domestic bias tire tread winding machine are similar.
Winding quality control
The winding quality of the tread is one of the most important parameters. If the mass is small, the green tire may not fill the mold or appear porous or even hollow when vulcanized; if the quality is too large, the winding time and the rubber compound are wasted. BTXC-3 engineering mechanized tire tread winding machine can control the tread quality error within 2%~5%. The tread winding quality is mainly controlled by the upper machine and PLC.
Open the upper machine control software Twister of BTXC-3 engineering machinery tire tread winding machine, select the menu process parameter management / process parameters, pop up the recipe selection dialog box shown in Figure 2, select the existing recipe and modify or create a new recipe. Considering the tread winding process should be modified and added by special personnel. To ensure the safety of the process parameters, after selecting or creating new process parameters, the password verification dialog box will pop up, and the user can input the correct account number and password before setting the parameters. Enter the correct password and enter the process parameter setting interface as shown in Figure 3.
The tread winding shape can be set in the process parameter setting interface. The winding shape is mainly determined by the number of winding segments, the height and the number of layers (the left and right limit points of the inner layer must be included by the left and right limit points of the outer layer), and the zero line of the thickness in FIG. 3 is The outer diameter of the carcass, the shape curve of the outermost layer and the diameter of the green tire determine the volume of the winding. When the formulation of the rubber is stable, the theoretical winding quality can be obtained according to the density of the rubber.
Click on the blue part of the upper part of the dialog box to bring up the Curve Node dialog box, enter the thickness value and the distance from the midpoint and the thickness correction value, then click the Add, Modify and Delete buttons below the dialog box to add, modify or delete the node ( Clicking on an existing node can modify or delete an existing node, otherwise the Modify and Delete buttons will automatically be grayed out. Since the curve is symmetrical about the centerline of the tire, it is only necessary to set the curve on one side of the tire. When multi-layer winding, the program will automatically generate the similar curve of the next layer according to the curve of the first layer. If the automatically generated node is not ideal, you can click this point to modify the value. Compared with the ALPHA-R tread winding machine, the shape parameter setting of the BTXC-3 tread winding machine is simpler, more convenient and more intuitive than the command input operation.
After the shape is determined, when the fine adjustment is needed, the thickness compensation parameter can be adjusted, and the actual winding thickness is the difference of the input thickness compensation parameter. Especially after working in the production line for a period of time, due to climate change, mechanical wear and other reasons, the winding quality may have a large change compared with the initial setting. In this case, only the thickness compensation parameters need to be slightly modified, and the process curve node does not need to be re-modified.
The PC software can estimate the quality of the entangled compound according to the parameters of the winding curve, the blank and the material density input by the customer. The density parameter can be modified when changing the compound formulation to properly estimate the quality of the winding.
Winding shape control
Accurate measurement of the actual winding thickness is the key to ensure the shape and quality of the winding. BTXC-3 engineering machinery tire tread winding machine uses cylinder, slide ball bearing and measuring mechanism to calculate the winding thickness. The measuring mechanism is shown in Figure 4. When the strip is wound for one week, the diameter of the green tire becomes larger, the slider supporting the measuring head retreats, and the analog quantity change generated by the measuring mechanism is fed back to the computer through the high-speed counter and the thickness variation is calculated. When the quality of the strip is stable, the winding quality is proportional to the winding volume, and the winding thickness can ensure the winding quality. The PLC compares the required thickness and measured thickness of a certain point in the axial direction of the winding drum in real time. When the thickness does not meet the requirements, the winding machine runs at a slow speed, and immediately moves to the next winding point when the thickness reaches the requirement.
In order to ensure the winding accuracy, there are the following points to be aware of.
(1) Measuring head telescopic cylinder pressure
When the pressure of the telescopic cylinder of the measuring head is large, the roller of the measuring head is pressed into the rubber strip more, and the actual winding thickness is larger than the measured value, so the easier the measuring head is to expand and contract, the better. If the expansion is easy and the thickness is slightly changed, the measuring head can be retracted or extended, and the thickness change can be immediately fed back to the computer. The test results show that the telescopic pressure of the measuring head should not be higher than 4.5Mpa, and the smaller the better.
(2) Offset of the measuring head and the center of the measuring head
The biasing direction of the measuring head is opposite to the winding direction, so the measuring value of the measuring head is delayed by a certain period of time from the actual thickness. The larger the offset is, the larger the hysteresis is. The thickness measurement value lags more and more when going up and down, and even the offset may occur. Too large causes the measuring head to be blocked by the rubber strip that has been wound before, and cannot move along the winding drum axially, and the groove is pressed or even bent on the winding tread; however, the measurement is too small when the offset is too small. ideal. If the width of the strip is 60~80mm, the offset is 25~40mm, and the winding effect is better.
(3) rubber strips
When the rubber is wound, the edge of the rubber strip is to ensure the wrapping effect, and the rubber strip wound at the back needs to be attached to the front rubber strip, and the rubber strip must be high and low in the width direction. As shown in Figure 6, the lower side of the strip should be on the far left of the guide roll each time. In order to ensure that the strip is edged, the guide rolls should have a suitable taper.
(4) The axial movement speed of the winding drum
If the moving speed of the winding car along the winding axis is too slow, the time for winding a single tire is long, the production efficiency is low, and there may be a small groove formed by the exhaust roller pressing on the strip for a long time, and the shape of the wrapped tread is not Smooth and coherent; but if the speed is too fast, compaction and venting are not good.
(5) Strip thickness, width, temperature and flash
The thickness, width and flash of the strip also have a large effect on the quality and shape of the winding. As shown in Fig. 6, when the strip is too thick, the volume error is large, and the exhaust effect is not good; the thickness of the strip is small and the outer strip is fine, and the excess strip is less, so the winding quality calculation is more accurate, and the exhaust effect is also better. Good, but the winding time is long and the winding efficiency is reduced. The larger the width of the strip, the higher the winding efficiency, but the more difficult it is to control the quality and shape, so the strip width is generally 60~80mm. If the temperature of the strip is too high, the rubber will be too soft, and the exhaust roller will be pressed into the inside of the strip. At the same time, after the winding is completed, the green tire shrinks greatly and is easy to be deformed; if the temperature of the strip is too low, it cannot be bonded. When the extruded strip has a flash, the winding shape will be rough and affect the overall quality of the green tire.
Control the winding speed and hysteresis of the measuring head and winding machine of the tread winding machine of engineering machinery tires, determine the winding speed according to the test and mathematical model, measure the winding thickness in real time and calculate the thickness and quality of the green tire, which can control the total winding tread Quality and make the tread shape meet the process requirements. The thickness, width and temperature of the strip during winding have a certain influence on the quality and shape of the winding, and the flash edge of the strip also affects the overall quality of the wound blank.
Production Process
The tread winding is generally composed of five steps of extrusion, conveying, pressing, cooling and winding of the rubber. The process and control system of the domestic bias tire tread winding machine are similar.
Winding quality control
The winding quality of the tread is one of the most important parameters. If the mass is small, the green tire may not fill the mold or appear porous or even hollow when vulcanized; if the quality is too large, the winding time and the rubber compound are wasted. BTXC-3 engineering mechanized tire tread winding machine can control the tread quality error within 2%~5%. The tread winding quality is mainly controlled by the upper machine and PLC.
Open the upper machine control software Twister of BTXC-3 engineering machinery tire tread winding machine, select the menu process parameter management / process parameters, pop up the recipe selection dialog box shown in Figure 2, select the existing recipe and modify or create a new recipe. Considering the tread winding process should be modified and added by special personnel. To ensure the safety of the process parameters, after selecting or creating new process parameters, the password verification dialog box will pop up, and the user can input the correct account number and password before setting the parameters. Enter the correct password and enter the process parameter setting interface as shown in Figure 3.
The tread winding shape can be set in the process parameter setting interface. The winding shape is mainly determined by the number of winding segments, the height and the number of layers (the left and right limit points of the inner layer must be included by the left and right limit points of the outer layer), and the zero line of the thickness in FIG. 3 is The outer diameter of the carcass, the shape curve of the outermost layer and the diameter of the green tire determine the volume of the winding. When the formulation of the rubber is stable, the theoretical winding quality can be obtained according to the density of the rubber.
Click on the blue part of the upper part of the dialog box to bring up the Curve Node dialog box, enter the thickness value and the distance from the midpoint and the thickness correction value, then click the Add, Modify and Delete buttons below the dialog box to add, modify or delete the node ( Clicking on an existing node can modify or delete an existing node, otherwise the Modify and Delete buttons will automatically be grayed out. Since the curve is symmetrical about the centerline of the tire, it is only necessary to set the curve on one side of the tire. When multi-layer winding, the program will automatically generate the similar curve of the next layer according to the curve of the first layer. If the automatically generated node is not ideal, you can click this point to modify the value. Compared with the ALPHA-R tread winding machine, the shape parameter setting of the BTXC-3 tread winding machine is simpler, more convenient and more intuitive than the command input operation.
After the shape is determined, when the fine adjustment is needed, the thickness compensation parameter can be adjusted, and the actual winding thickness is the difference of the input thickness compensation parameter. Especially after working in the production line for a period of time, due to climate change, mechanical wear and other reasons, the winding quality may have a large change compared with the initial setting. In this case, only the thickness compensation parameters need to be slightly modified, and the process curve node does not need to be re-modified.
The PC software can estimate the quality of the entangled compound according to the parameters of the winding curve, the blank and the material density input by the customer. The density parameter can be modified when changing the compound formulation to properly estimate the quality of the winding.
Winding shape control
Accurate measurement of the actual winding thickness is the key to ensure the shape and quality of the winding. BTXC-3 engineering machinery tire tread winding machine uses cylinder, slide ball bearing and measuring mechanism to calculate the winding thickness. The measuring mechanism is shown in Figure 4. When the strip is wound for one week, the diameter of the green tire becomes larger, the slider supporting the measuring head retreats, and the analog quantity change generated by the measuring mechanism is fed back to the computer through the high-speed counter and the thickness variation is calculated. When the quality of the strip is stable, the winding quality is proportional to the winding volume, and the winding thickness can ensure the winding quality. The PLC compares the required thickness and measured thickness of a certain point in the axial direction of the winding drum in real time. When the thickness does not meet the requirements, the winding machine runs at a slow speed, and immediately moves to the next winding point when the thickness reaches the requirement.
In order to ensure the winding accuracy, there are the following points to be aware of.
(1) Measuring head telescopic cylinder pressure
When the pressure of the telescopic cylinder of the measuring head is large, the roller of the measuring head is pressed into the rubber strip more, and the actual winding thickness is larger than the measured value, so the easier the measuring head is to expand and contract, the better. If the expansion is easy and the thickness is slightly changed, the measuring head can be retracted or extended, and the thickness change can be immediately fed back to the computer. The test results show that the telescopic pressure of the measuring head should not be higher than 4.5Mpa, and the smaller the better.
(2) Offset of the measuring head and the center of the measuring head
The biasing direction of the measuring head is opposite to the winding direction, so the measuring value of the measuring head is delayed by a certain period of time from the actual thickness. The larger the offset is, the larger the hysteresis is. The thickness measurement value lags more and more when going up and down, and even the offset may occur. Too large causes the measuring head to be blocked by the rubber strip that has been wound before, and cannot move along the winding drum axially, and the groove is pressed or even bent on the winding tread; however, the measurement is too small when the offset is too small. ideal. If the width of the strip is 60~80mm, the offset is 25~40mm, and the winding effect is better.
(3) rubber strips
When the rubber is wound, the edge of the rubber strip is to ensure the wrapping effect, and the rubber strip wound at the back needs to be attached to the front rubber strip, and the rubber strip must be high and low in the width direction. As shown in Figure 6, the lower side of the strip should be on the far left of the guide roll each time. In order to ensure that the strip is edged, the guide rolls should have a suitable taper.
(4) The axial movement speed of the winding drum
If the moving speed of the winding car along the winding axis is too slow, the time for winding a single tire is long, the production efficiency is low, and there may be a small groove formed by the exhaust roller pressing on the strip for a long time, and the shape of the wrapped tread is not Smooth and coherent; but if the speed is too fast, compaction and venting are not good.
(5) Strip thickness, width, temperature and flash
The thickness, width and flash of the strip also have a large effect on the quality and shape of the winding. As shown in Fig. 6, when the strip is too thick, the volume error is large, and the exhaust effect is not good; the thickness of the strip is small and the outer strip is fine, and the excess strip is less, so the winding quality calculation is more accurate, and the exhaust effect is also better. Good, but the winding time is long and the winding efficiency is reduced. The larger the width of the strip, the higher the winding efficiency, but the more difficult it is to control the quality and shape, so the strip width is generally 60~80mm. If the temperature of the strip is too high, the rubber will be too soft, and the exhaust roller will be pressed into the inside of the strip. At the same time, after the winding is completed, the green tire shrinks greatly and is easy to be deformed; if the temperature of the strip is too low, it cannot be bonded. When the extruded strip has a flash, the winding shape will be rough and affect the overall quality of the green tire.
Control the winding speed and hysteresis of the measuring head and winding machine of the tread winding machine of engineering machinery tires, determine the winding speed according to the test and mathematical model, measure the winding thickness in real time and calculate the thickness and quality of the green tire, which can control the total winding tread Quality and make the tread shape meet the process requirements. The thickness, width and temperature of the strip during winding have a certain influence on the quality and shape of the winding, and the flash edge of the strip also affects the overall quality of the wound blank.
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