工艺技术_全钢子午胎的加工工艺及轮胎新技术

AnIntroductiononProcessingofTBRTire NewTireTechnology全钢子午胎的加工工艺及轮胎新技术 RheinchemieMarioNegri马旅欧 Content内容 1 Majordifferencesintirestructureandperformancebetweentruckbusradial TBR andcross plytire TBB 全钢子午胎 TBR 和斜交胎 TBB 在结构与性能方面的主要差别2 AnintroductiononTBRtireproductionline 全钢子午胎生产线的介绍3 Mainproblemsandcounter measuresagainstthoseproblemsintheprocessofTBRtireproduction 全钢子午胎生产过程中的主要问题及补救措施4 MaterialCharacteristicsofTBRtirecomponents 全钢子午胎构件材料的特性5 NewTireTechnology轮胎新技术 15 August20032020 2 18 2 MarioNegri 15 August20032020 2 18 MarioNegri Folie 3 BiasvsRadial MajordifferenceinStructurebetweenTruckbusradialandcross plytire全钢子午胎和斜交胎在结构方面的主要差别 15 August20032020 2 18 4 MarioNegri MaindifferencesintireperformancebetweenTBRandTBBtire全钢子午胎与斜交胎在性能方面的主要差别 15 August20032020 2 18 5 MarioNegri Temperatureriseintireshoulderareaaccordingtotiresizesduringtirerunning在运行过程中胎肩部位的升温随轮胎规格变化的情况 15 August20032020 2 18 6 MarioNegri PROCESSINGEQUIPMENT加工设备 PROCESSINGEQUIPMENT加工设备1 Extruding挤出Tread Base TreadWing 8 x4 5 x3 5 胎面 基部 翼部Side wall ShoulderPad 8 x6 胎侧 胎肩垫胶Rim Strip ApexStrip 6 x4 5 耐磨胶条 三角胶条BeltEdgeCushion 3 5 带束层边缘缓冲层Apex Upper Lower 4 5 x4 5 型胶 上部 下部 Assembler成型机2 Calendering压延2 1 SteelCarcass钢丝胎体SteelCal Line SteelRadialCutter Splicer钢丝压延生产线 钢丝子午线裁断机和接合机2 2 SteelBelt SteelChafer钢丝带束层及钢丝子口SteelCal Line SteelAngleCutter Splicer钢丝压延生产线 钢丝斜裁机和接合机 Formoredetails discusswithmachinerymanufacturer详细信息请与设备生产商联系 15 August20032020 2 18 7 MarioNegri TBRTIREPRODUCTIONLINE全钢子午线轮胎生产线 15 August20032020 2 18 8 MarioNegri SteelCordCalenderLine钢丝压延生产线 15 August20032020 2 18 9 MarioNegri SingleStageBuildingMachineforTruck BusRadialTire全钢子午胎一段成型机 15 August20032020 2 18 10 MarioNegri Cutting SplicingMachineforSteelRadialCarcass钢丝子午胎胎体的裁断及接合机 15 August20032020 2 18 11 MarioNegri AssemblingprocessofBeadandApex胎圈和三角胶的复合 15 August20032020 2 18 12 MarioNegri AssemblingplatefordimensionalstabilityofApexinextrudingprocess在挤出过程中保持三角胶尺寸稳定性的复合平台 15 August20032020 2 18 13 MarioNegri CreelforMetallicCordSpools钢丝帘线锭子架 1 Lowerhumidityinsidecreelroombebetteragainstwirecorrosion室内湿度越低越好 以避免钢丝腐蚀2 Thickershaftforspoolrecommendedtoavoidthecrookedshaft 建议锭子的轴粗一些 以避免弯曲 15 August20032020 2 18 14 MarioNegri MetallicCordInletintheCalender压延机钢丝帘线入口 15 August20032020 2 18 15 MarioNegri 1 3 Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法 InsideCreelRoomProperprocedureshouldbeneededforarranginghundredsofsteelcordsjustbeforestartingcalendering 开始压延前 应在锭子室内正确的排列好上百根钢丝帘线Spools钢丝锭子 15 August20032020 2 18 16 MarioNegri MajorManufacturingProblemsandMeasuresofTBRTires全钢子午胎的主要的生产问题及措施 15 August20032020 2 18 17 MarioNegri 1 1 Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法 15 August20032020 2 18 18 MarioNegri 1 2 Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法 Edgegumwidthshouldbecontrolledduringcalendering在压延过程中 应该控制边布胶的宽度Otherwise thefollowingwidedistancebetweencordsatthespliceareaappearsinsplicingprocessofcarcassply 另外在胎体帘布接合过程中也应控制接合部位的钢丝之间的距离Splicingpoint接合点Normal正常Toowide太宽 15 August20032020 2 18 19 MarioNegri 1 4 Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法 IntheprocessoftireBuilding 在轮胎成型过程中Buttspliceofcarcassplyberecommendedforcarcassquality为了保证胎体的质量 建议进行对缝结合2 TheamountofoverlapbeminimizedforBeltsplice max 1cords 带束层结合过程中钢丝搭接的数量尽量少 最多1根 15 August20032020 2 18 20 MarioNegri 2 AirtrapproblemsnearthespliceareaofInner inerfor100 ButylappliedtoInner linercompound100 丁基胶内衬层搭接部位的存气问题 2 1 Measurestoreducetheairtrap Inner linerbecutwithhotknifebylowerthan30 内衬层应用热刀以小于30度的角度裁断2ndinner liner第二层内衬层Lowerthan30degree小于30度 1stinner liner第一层内衬层 15 August20032020 2 18 21 MarioNegri MATERIALCHARATERISTICOFRADIALTIRE子午胎的材料特性 1 Forthelongerlifeoftreadcomponent 对于使用寿命长的胎面部件1 1 Toemploymediumsulfur higheracceleratorsystem 1 5 1 2 1 5phr 采用中硫高促系统 1 5 1 2 1 5phr 1 2 Tointroducehigherantioxidantlevel6PPD TMQ 2 1phr 是用高性能的防老剂 6PPDTMQ2 1phr 2 Bettercasingperformancefor2 3timesrecappingbeneededasfollows 为了获得更好的腔体性能 以能够进行2 3次的翻新 应遵循以下几条 2 1 Inner liner内衬层80 100phrofButylbemixedtoimprovegasimpermeabilityandinner linercrackresistance 使用80 100phr的丁基胶来改善密封性能及耐龟裂性能 15 August20032020 2 18 22 MarioNegri MATERIALCHARATERISTICOFRADIALTIRE子午胎的材料特性 2 2 CarcassandBeltply胎体和带束层帘布层Higheradhesionofcompoundtosteelcordberequired Thefollowingsteelwirestructurenormallybeused 胶料与钢丝应具有很高的粘合性能 一般使用下列结构的钢丝 3 9 15 0 175 1w3 0 2 6 0 35 HTforcarcassforbelt胎体带束层 15 August20032020 2 18 23 MarioNegri MATERIALCHARATERISTICOFRADIALTIRE子午胎的材料特性 2 3 Side wallcompound胎侧胶Normally60phrofBRbeingemployedtoimproveflexfatigueresistance 一般使用60phrBR来改善耐曲挠龟裂性能2 4 Rimstripcompound轮辋耐磨胶条70 80phrofBRbeingintroducedtoenhanceabrasionresistanceagainstfrictionwearonthecontactareabetweentireandvehiclerim 使用70 80phrBR来增加耐磨耗性能 以减少轮胎和轮辋接触部位的摩擦损耗2 5 ShoulderPad胎肩垫胶Lowerheatbuildupperformanceandhigherflexfatigueresistancebeingrequired Optimumvolumebeneededagainstplyseparation 应具有低生热性能和高耐曲挠龟裂性能 体积最佳化以防止帘布层剥离 15 August20032020 2 18 24 MarioNegri NewTyreTechnology新轮胎技术 Thegreentires绿色轮胎Lightweighttires轻量轮胎Colouredtires彩胎Thecompositewheel复合胎 15 August20032020 2 18 25 MarioNegri DifferentMarketNeeds 1 不同市场需求 USA EUROPE JAPAN before1992 after1992 15 August20032020 2 18 26 MarioNegri RadialTruckTyres Companyrequirements卡车子午胎 公司要求 LowermanufacturingCostsby 如何降低成本Reducedmanpower 减少人工ShortproductionCycletime缩短生产周期Consistantproductionrate quality稳定的生产速度和质量Sizechangeflexibility 尺寸变化灵活性Scrapreduction降低废品率 15 August20032020 2 18 27 MarioNegri RadialTruckTyres Trends卡车子午胎 趋势 Reducedtyrecomponents减少轮胎部件Weightreduction降低重量Lowrollingresistance降低滚动阻力Gooduniformity良好的均匀性Retreadability增加胎面翻新率Longlifetread胎面使用寿命长Directextrusion直接挤出 15 August20032020 2 18 28 MarioNegri TargetfortheGreenTire GreenTireApplication绿色轮胎应用 15 August20032020 2 18 29 MarioNegri GreenTireConcept EconomicBenefit绿色轮胎的概念 获得经济效益 使用白炭黑可使滚动阻力最多可降低30 每辆轿车的耗油量最多可节省5 仅在德国 每年可以节省20亿升的燃料 15 August20032020 2 18 30 MarioNegri PolymerPropertiesandTyrePerformance聚合物性能和轮胎性能 TanDeltaandGlassTransitionTemperatureTanDelta和Tg之间的关系 0 60 30 70 110 oC 100 10 1 10 2 abrasion ice grip wet grip rollingresist highspeedperform 1 tand ideal SBR1721 TgSBR1721 15 August20032020 2 18 31 MarioNegri DifferentRequirementsApplyforDifferentMarkets对于不同市场的不同要求 DifferentMarketNeeds 2 不同市场需求 2 15 August20032020 2 18 32 MarioNegri TreadTechnologyandRollingResistance轮胎技术及滚动阻力 15 August20032020 2 18 33 MarioNegri Structure Property Relation 2 结构与性能之间的关系 2 ImportantTyreProperties DependanceonGlassTransitionTemperature重要的轮胎性能 依赖于玻璃化温度 SSBR 25 Styrene 50 Vinyl EmulsionBR highcisNd BR Li BR S SBR 18 Styrene 10 Vinyl SBR 15 Styrene SBR1500 23 5 Styrene SBR1516 40 Styrene S SBR 34 Styrene 32 Vinyl 20 60 40 80 100 Traction GlassTemperatureTg 15 August20032020 2 18 34 MarioNegri ARecommendation建议 FortheoverseasanddomesticOErequirements 对于国内外厂家的要求 theevaluationoftreadcompoundwith20 50phrofsolutionSBRVSL5025 1intheabsenceandpresenceofsilicaisrecommendedtoenhanceboththetractionperformanceandlowrollingresistance 建议使用20 50phr溶聚SBRVSL5025 1 无论是否含有白炭黑来 改善牵引性能及滚动阻力 15 August20032020 2 18 35 MarioNegri LightWeightTyres轻量轮胎 Lightweighttyresreducerollingresistance轻量轮胎降低滚动阻力Lightweig