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[15.August2003]MarioNegri[Folie:2]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.August2003]MarioNegri[Folie:3]BiasvsRadialBias-PlyRadial[15.August2003]MarioNegri[Folie:4]MajordifferenceinStructurebetweenTruckbusradialandcross-plytire全钢子午胎和斜交胎在结构方面的主要差别TruckBusCrossPlyTire斜交胎TruckBusRadialTire全钢胎Carcass胎体TextileCord8Ply8层纤维帘线SteelCord1Ply1层钢丝帘线Belt带束层TextileCord2Ply2层纤维帘线SteelCord4Ply4层钢丝帘线[15.August2003]MarioNegri[Folie:5]MaindifferencesintireperformancebetweenTBRandTBBtire全钢子午胎与斜交胎在性能方面的主要差别050100150ABRASIONRESISTANCE耐磨性BELTENDURANCE带束层耐久性ROLLINGRESISTANCE滚动阻力NOISE噪音HANDLINGPROPERTIES操作性能TBBTBR[15.August2003]MarioNegri[Folie:6]Temperatureriseintireshoulderareaaccordingtotiresizesduringtirerunning在运行过程中胎肩部位的升温随轮胎规格变化的情况02040608010012014016060708090km/hr'C1000-20TubeBias11-22.5Tubeless1000R20Tube11R22.5TubelessRadial[15.August2003]MarioNegri[Folie:7]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.August2003]MarioNegri[Folie:8]TBRTIREPRODUCTIONLINE全钢子午线轮胎生产线[15.August2003]MarioNegri[Folie:9]SteelCordCalenderLine钢丝压延生产线[15.August2003]MarioNegri[Folie:10]SingleStageBuildingMachineforTruck-BusRadialTire全钢子午胎一段成型机[15.August2003]MarioNegri[Folie:11]Cutting&SplicingMachineforSteelRadialCarcass钢丝子午胎胎体的裁断及接合机[15.August2003]MarioNegri[Folie:12]AssemblingprocessofBeadandApex胎圈和三角胶的复合[15.August2003]MarioNegri[Folie:13]AssemblingplatefordimensionalstabilityofApexinextrudingprocess在挤出过程中保持三角胶尺寸稳定性的复合平台[15.August2003]MarioNegri[Folie:14]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.August2003]MarioNegri[Folie:15]MetallicCordInletintheCalender压延机钢丝帘线入口[15.August2003]MarioNegri[Folie:16]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.August2003]MarioNegri[Folie:17]MajorManufacturingProblemsandMeasuresofTBRTires全钢子午胎的主要的生产问题及措施[15.August2003]MarioNegri[Folie:18]1-1)Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法[15.August2003]MarioNegri[Folie:19]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.August2003]MarioNegri[Folie:20]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1.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.August2003]MarioNegri[Folie:21]2.AirtrapproblemsnearthespliceareaofInner-inerfor100%ButylappliedtoInner-linercompound100%丁基胶内衬层搭接部位的存气问题2-1)Measurestoreducetheairtrap:Inner-linerbecutwithhotknifebylowerthan30º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.August2003]MarioNegri[Folie:22]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.August2003]MarioNegri[Folie:23]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.August2003]MarioNegri[Folie:24]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70-80phrofBRbeingintroducedtoenhanceabrasionresistanceagainstfrictionwearonthecontactareabetweentireandvehicleri