全钢子午胎的加工工艺及轮胎新技术.ppt

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1、AnIntroductiononProcessingofTBRTire&NewTireTechnology全钢子午胎的加工工艺及轮胎新技术全钢子午胎的加工工艺及轮胎新技术RheinchemieMarioNegri马旅欧马旅欧15.August 2003 2021/11/1 2021/11/1 1Content内容内容1.Majordifferencesintirestructureandperformancebetweentruckbusradial(TBR)andcross-plytire(TBB).全钢子午胎全钢子午胎(TBR)和斜交胎和斜交胎(TBB)在结构与性能方面的主要差别在结构与性

2、能方面的主要差别2.AnintroductiononTBRtireproductionline.全钢子午胎生产线的介绍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全钢子午胎构件材料的特性5.NewTireTechnology轮胎新技术轮胎新技术15.Augu

3、st 2003 2021/11/1 2021/11/1 2Bias vs Radial15.August 2003 2021/11/1 2021/11/1 3MajordifferenceinStructurebetweenTruckbusradialandcross-plytire全钢子午胎和斜交胎在结构方面的主要差别全钢子午胎和斜交胎在结构方面的主要差别15.August 2003 2021/11/1 2021/11/1 4MaindifferencesintireperformancebetweenTBRandTBBtire全钢子午胎与斜交胎在性能方面的主要差别全钢子午胎与斜交胎在性能方

4、面的主要差别15.August 2003 2021/11/1 2021/11/1 5Temperatureriseintireshoulderareaaccordingtotiresizesduringtirerunning在运行过程中胎肩部位的升温随轮胎规格变化的情况在运行过程中胎肩部位的升温随轮胎规格变化的情况15.August 2003 2021/11/1 2021/11/1 6PROCESSINGEQUIPMENT加工设备加工设备PROCESSINGEQUIPMENT加工设备加工设备1.Extruding挤出挤出Tread/Base/TreadWing:8”x4.5”x3.5”胎面胎面

5、/基部基部/翼部翼部Side-wall/ShoulderPad:8”x6”胎侧胎侧/胎肩垫胶胎肩垫胶Rim-Strip/ApexStrip:6”x4.5”耐磨胶条耐磨胶条/三角胶条三角胶条BeltEdgeCushion:3.5”带束层边缘缓冲层带束层边缘缓冲层Apex(Upper/Lower):4.5”x4.5”型胶（上部型胶（上部/下部）下部）+Assembler成型机成型机2.Calendering压延压延2-1)SteelCarcass钢丝胎体钢丝胎体SteelCal.Line+SteelRadialCutter&Splicer钢丝压延生产线钢丝压延生产线+钢丝子午线裁断机和接合机钢丝子

6、午线裁断机和接合机2-2)SteelBelt&SteelChafer钢丝带束层钢丝带束层及及钢丝子口钢丝子口SteelCal.Line+SteelAngleCutter&Splicer钢丝压延生产线钢丝压延生产线+钢丝斜裁机和接合机钢丝斜裁机和接合机*Formoredetails,discusswithmachinerymanufacturer详细信息请与设备生产商联系详细信息请与设备生产商联系15.August 2003 2021/11/1 2021/11/1 7TBRTIREPRODUCTIONLINE全钢子午线轮胎生产线全钢子午线轮胎生产线15.August 2003 2021/11/1

7、 2021/11/1 8SteelCordCalenderLine钢丝压延生产线钢丝压延生产线15.August 2003 2021/11/1 2021/11/1 9SingleStageBuildingMachineforTruck-BusRadialTire全钢子午胎一段成型机全钢子午胎一段成型机15.August 2003 2021/11/1 2021/11/1 10Cutting&SplicingMachineforSteelRadialCarcass钢丝子午胎胎体的裁断及接合机钢丝子午胎胎体的裁断及接合机15.August 2003 2021/11/1 2021/11/1 11Ass

8、emblingprocessofBeadandApex胎圈和三角胶的复合胎圈和三角胶的复合15.August 2003 2021/11/1 2021/11/1 12AssemblingplatefordimensionalstabilityofApexinextrudingprocess在挤出过程中保持三角胶尺寸稳定性的复合平台在挤出过程中保持三角胶尺寸稳定性的复合平台15.August 2003 2021/11/1 2021/11/1 13CreelforMetallicCordSpools钢丝帘线锭子架钢丝帘线锭子架1.Lowerhumidityinsidecreelroombebette

9、ragainstwirecorrosion室内湿度越低越好，以避免室内湿度越低越好，以避免钢丝腐蚀钢丝腐蚀2.Thickershaftforspoolrecommendedtoavoidthecrookedshaft.建议锭子的轴粗一些，以避建议锭子的轴粗一些，以避免弯曲免弯曲15.August 2003 2021/11/1 2021/11/1 14MetallicCordInletintheCalender压延机钢丝帘线入口压延机钢丝帘线入口15.August 2003 2021/11/1 2021/11/1 151-3)Measurestoreduceirregulararrangemen

10、tofcord减少钢丝帘线不规则排列的方法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 钢丝锭子钢丝锭子15.August 2003 2021/11/1 2021/11/1 16MajorManufacturingProblemsandMeasuresofTBRTires全钢子午胎的主要的生

11、产问题及措施全钢子午胎的主要的生产问题及措施15.August 2003 2021/11/1 2021/11/1 171-1)Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法减少钢丝帘线不规则排列的方法15.August 2003 2021/11/1 2021/11/1 181-2)Measurestoreduceirregulararrangementofcord减少钢丝帘线不规则排列的方法减少钢丝帘线不规则排列的方法Edgegumwidthshouldbecontrolledduringcalendering在压延过程中，应该

12、控制边布胶的宽度在压延过程中，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接合点接合点Normal正常正常Toowide太宽太宽 15.August 2003 2021/11/1 2021/11/1 191-4)Measurestoreduceirregulararrangementofc

13、ord减少钢丝帘线不规则排列的方法减少钢丝帘线不规则排列的方法IntheprocessoftireBuilding,在轮胎成型过程中在轮胎成型过程中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（最多带束层结合过程中钢丝搭接的数量尽量少（最多1根）根）15.August 2003 2021/11/1 2021/11/

14、1 202.AirtrapproblemsnearthespliceareaofInner-inerfor100%ButylappliedtoInner-linercompound100%丁基胶内衬层搭接丁基胶内衬层搭接部位的存气问题部位的存气问题2-1)Measurestoreducetheairtrap:Inner-linerbecutwithhotknifebylowerthan30内衬层应用热刀以小于内衬层应用热刀以小于30度的角度裁断度的角度裁断2ndinner-liner第二层内衬层第二层内衬层Lowerthan30degree小于小于30度度1stinner-liner第一层内衬

15、层第一层内衬层15.August 2003 2021/11/1 2021/11/1 21MATERIALCHARATERISTICOFRADIALTIRE子午胎的材料特性子午胎的材料特性1.Forthelongerlifeoftreadcomponent,对于使用寿命长的胎面部件对于使用寿命长的胎面部件phr).phr)1-2)Tointroducehigherantioxidantlevel6PPD/TMQ(2/1phr).是用高性能的防老剂是用高性能的防老剂(6PPDTMQ2/1phr)2.Bettercasingperformancefor2-3timesrecappingbeneede

16、dasfollows.为了获得更好的腔体性能，以能够进行为了获得更好的腔体性能，以能够进行2-3次的翻新，次的翻新，应应遵循以下几条：遵循以下几条：2-1)Inner-liner内衬层内衬层80-100phrofButylbemixedtoimprovegasimpermeabilityandinner-linercrackresistance.使用使用80-100phr的丁基胶来改善密封性能及耐龟裂性能的丁基胶来改善密封性能及耐龟裂性能15.August 2003 2021/11/1 2021/11/1 22MATERIALCHARATERISTICOFRADIALTIRE子午胎的材料特性子

17、午胎的材料特性2-2)CarcassandBeltply胎体和带束层帘布层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。一般使用下列结胶料与钢丝应具有很高的粘合性能。一般使用下列结构构的钢丝。的钢丝。3+9+15(0.175)1w3(0.2)+6(0.35)HTforcarcassforbelt胎体胎体带束层带束层15.August 2003 2021/11/1 2021/11/1 23MATERIALCHAR

18、ATERISTICOFRADIALTIRE子午胎的材料特性子午胎的材料特性2-3)Side-wallcompound胎侧胶胎侧胶Normally60phrofBRbeingemployedtoimproveflexfatigueresistance.一般使用一般使用60phrBR来改善耐曲挠龟裂性能来改善耐曲挠龟裂性能2-4)Rimstripcompound轮辋耐磨胶条轮辋耐磨胶条70-80phrofBRbeingintroducedtoenhanceabrasionresistanceagainstfrictionwearonthecontactareabetweentireandvehic

19、lerim.使用使用7080phrBR来增加耐磨耗性能，以减少轮胎和轮辋来增加耐磨耗性能，以减少轮胎和轮辋接触部位的摩擦损耗接触部位的摩擦损耗2-5)ShoulderPad胎肩垫胶胎肩垫胶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布层剥离15.August 2003 2021/11/1 2021/1

20、1/1 24NewTyreTechnology新轮胎技术新轮胎技术Thegreentires绿色轮胎绿色轮胎Lightweighttires轻量轮胎轻量轮胎Colouredtires彩胎彩胎Thecompositewheel复合胎复合胎15.August 2003 2021/11/1 2021/11/1 25Different Market Needs(1)不同市场需求不同市场需求USAEUROPEJAPANbefore 1992after 1992W-gripWearRRlowhighhighhighaveragelowhighlowhighW-gripWearRRaveragehighhi

21、ghhighaveragehighhighlowhigh15.August 2003 2021/11/1 2021/11/1 26RadialTruckTyres:Companyrequirements卡车子午胎：公司要求卡车子午胎：公司要求LowermanufacturingCostsby:如何降低成本如何降低成本Reducedmanpower,减少人工减少人工ShortproductionCycletime 缩短生产周期缩短生产周期Consistantproductionrate&quality 稳定的生产速度和质量稳定的生产速度和质量Sizechangeflexibility,尺寸变化灵

22、活性尺寸变化灵活性Scrapreduction 降低废品率降低废品率15.August 2003 2021/11/1 2021/11/1 27RadialTruckTyres:Trends卡车子午胎：趋势卡车子午胎：趋势Reducedtyrecomponents减少轮胎部件减少轮胎部件Weightreduction降低重量降低重量Lowrollingresistance降低滚动阻力降低滚动阻力Gooduniformity良好的均匀性良好的均匀性Retreadability增加胎面翻新率增加胎面翻新率Longlifetread胎面使用寿命长胎面使用寿命长Directextrusion直接挤出直接

23、挤出15.August 2003 2021/11/1 2021/11/1 28Target for the Green TireGreenTireApplication绿色轮胎应用绿色轮胎应用15.August 2003 2021/11/1 2021/11/1 29Upto35%reducedrollingresistancewithSiO2Upto5%lessfuelconsumptionpercarorapprox.2billionlitresoffuelsavingsperyearinGermanyaloneGreen Tire Concept:Economic Benefit绿色轮胎的

24、概念：获得经济效益绿色轮胎的概念：获得经济效益使用白炭黑可使滚动阻力最多使用白炭黑可使滚动阻力最多可降低可降低30%每辆轿车的耗油量最多可节省每辆轿车的耗油量最多可节省5%仅在德国，每年可以节省仅在德国，每年可以节省2020亿升的燃料亿升的燃料15.August 2003 2021/11/1 2021/11/1 30Polymer Properties and Tyre Performance聚合物性能和轮胎性能聚合物性能和轮胎性能TanDeltaandGlassTransitionTemperatureTanDelta和和Tg之间的关系之间的关系0-603070110oC-10010-110

25、-2abrasionice-gripwet-griprollingresist.highspeedperform.1tan d didealSBR 1721Tg SBR 172115.August 2003 2021/11/1 2021/11/1 31Different Requirements Apply for Different Markets对于不同市场的不同要求对于不同市场的不同要求808590951001051101151201251308090100110120130140150160RollingResistanceTractionbetterSilica Technology

26、Replacement and R/LTEurope and NAEuropeOE TyresNAOE TyresNADifferent Market Needs(2),不同市场需求（不同市场需求（2）15.August 2003 2021/11/1 2021/11/1 32TreadTechnologyandRollingResistance轮胎技术及滚动阻力轮胎技术及滚动阻力15.August 2003 2021/11/1 2021/11/1 33Structure/Property-Relation(2)结构与性能之构与性能之间的关系（的关系（2）ImportantTyrePropert

27、ies:DependanceonGlassTransitionTemperature重要的轮胎性能：依赖于玻璃化温度重要的轮胎性能：依赖于玻璃化温度SSBR(25%Styrene,50%Vinyl)Emulsion BRhigh cis Nd-BRLi-BRS-SBR(18%Styrene,10%Vinyl)SBR(15%Styrene)SBR 1500(23.5%Styrene)SBR 1516(40%Styrene)S-SBR(34%Styrene,32%Vinyl)-20-60-40-80-100TractionGlassTemperatureTg15.August 2003 2021/

28、11/1 2021/11/1 34ARecommendation建议建议FortheoverseasanddomesticOErequirements,对于国内外厂家的要求：对于国内外厂家的要求：theevaluationoftreadcompoundwith20-50phrofsolutionSBRVSL5025-1intheabsenceandpresenceofsilicaisrecommendedtoenhanceboththetractionperformanceandlowrollingresistance.建议使用建议使用20-50phr溶聚溶聚SBRVSL5025-1(无论是否

29、含有白炭黑无论是否含有白炭黑来来)改善牵引性能及滚动阻力改善牵引性能及滚动阻力15.August 2003 2021/11/1 2021/11/1 35LightWeightTyres轻量轮胎轻量轮胎Lightweighttyresreducerollingresistance轻量轮胎降低滚动阻力轻量轮胎降低滚动阻力Lightweighttyressavematerialandthereforereducetyrematerialcost轻量轮胎节省材料因此降低成本轻量轮胎节省材料因此降低成本Lightweighttyresallowheavierwiderwheelsandlowprofil

30、etyresforimprovedappearance/performance轻量胎所使用的轮辋重且宽，轮胎断面扁平，改善了轮胎的外观及轻量胎所使用的轮辋重且宽，轮胎断面扁平，改善了轮胎的外观及性能性能15.August 2003 2021/11/1 2021/11/1 36RollingResistanceandFuelConsumption滚动阻力和燃料消耗滚动阻力和燃料消耗ActionReplacingcurrent-generationtireswithgreentiresReduceweightoftireby5%Reducetireweightby10%Increase retre

31、ading by6-8%ResultWouldcuttotalconsumptionby5percent,or1.6billiongallonsofgasolineanddieselfuelSaves32milliongallonsofcrudeoilSaves86milliongallonsofcrudeoilSaves45milliongallonsofoilTireFactorsinFuelConsumption在轮胎中影响燃料消耗的因素在轮胎中影响燃料消耗的因素措施措施结果结果使用绿色轮胎使用绿色轮胎降低降低5%消耗或节省消耗或节省16亿加仑汽油或柴油亿加仑汽油或柴油轮胎重量降低轮胎重

32、量降低5%节省节省3千千2百万加仑原油百万加仑原油轮胎重量降低轮胎重量降低10%节省节省8千千6百万加仑原油百万加仑原油胎面翻新增加胎面翻新增加6-8%节省节省4前前5百万加仑油料百万加仑油料15.August 2003 2021/11/1 2021/11/1 37TheCompositeWheel复合轮胎复合轮胎DevelopdbytheSwedishNationalRoadandTransportResearchInstitute由瑞典国家道路及运输研究所开发由瑞典国家道路及运输研究所开发Verylownoise噪音很低噪音很低30%lowerrollingresistance滚动阻力降低滚动阻力降低30%Nopuncturespossible耐刺穿性能好耐刺穿性能好Nosteelusedandverylittlerubber无钢丝，胶料使用少无钢丝，胶料使用少Noaquaplaning防滑性能好防滑性能好15.August 2003 2021/11/1 2021/11/1 3815.August 2003 2021/11/1 2021/11/1 3915.August 2003 2021/11/1 2021/11/1 40