全鋼子午胎的加工工藝及輪胎新技術(shù)

1、15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 1 An Introduction on Processing of TBR Tire& New Tire Technology全鋼子午胎的加工工藝及輪胎新技術(shù)全鋼子午胎的加工工藝及輪胎新技術(shù)RheinchemieMario Negri 馬旅歐馬旅歐15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 2 Content內(nèi)容內(nèi)容1. Major

2、 differences in tire structure and performance between truck bus radial (TBR) and cross-ply tire (TBB). 全鋼子午胎全鋼子午胎(TBR)和斜交胎和斜交胎(TBB)在結(jié)構(gòu)與性能方面的主要差別在結(jié)構(gòu)與性能方面的主要差別2. An introduction on TBR tire production line. 全鋼子午胎生產(chǎn)線的介紹全鋼子午胎生產(chǎn)線的介紹3. Main problems and counter-measures against those problems in the proc

3、ess of TBR tire production. 全鋼子午胎生產(chǎn)過(guò)程中的主要問題及補(bǔ)救措施全鋼子午胎生產(chǎn)過(guò)程中的主要問題及補(bǔ)救措施4. Material Characteristics of TBR tire components. 全鋼子午胎構(gòu)件材料的特性全鋼子午胎構(gòu)件材料的特性5. New Tire Technology 輪胎新技術(shù)輪胎新技術(shù)15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 3 Bias vs RadialBias-PlyRadial15. August 2003 20

4、20/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 4 Major difference in Structure between Truck bus radial and cross-ply tire全鋼子午胎和斜交胎在結(jié)構(gòu)方面的主要差別全鋼子午胎和斜交胎在結(jié)構(gòu)方面的主要差別 Truck Bus Cross Ply Tire 斜交胎斜交胎 Truck Bus Radial Tire 全鋼胎全鋼胎 Carcass 胎體胎體 Textile Cord 8 Ply 8 8 層纖維簾線層纖維簾線 Steel Cord 1 Ply 1 層鋼

5、絲簾線層鋼絲簾線 Belt 帶束層帶束層 Textile Cord 2 Ply 2 層纖維簾線層纖維簾線 Steel Cord 4 Ply 4 層鋼絲簾線層鋼絲簾線 15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 5 Main differences in tire performance between TBR and TBB tire全鋼子午胎與斜交胎在性能方面的主要差別全鋼子午胎與斜交胎在性能方面的主要差別050100150ABRASIONRESISTANCE 耐磨性耐磨性BELT EN

6、DURANCE帶束層耐久性帶束層耐久性ROLLING RESISTANCE滾動(dòng)阻力滾動(dòng)阻力NOISE 噪音噪音HANDLINGPROPERTIES操作性能操作性能TBBTBR15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 6 Temperature rise in tire shoulder area according to tire sizes during tire running 在運(yùn)行過(guò)程中胎肩部位的升溫隨輪胎規(guī)格變化的情況在運(yùn)行過(guò)程中胎肩部位的升溫隨輪胎規(guī)格變化的情況0204060

7、8010012014016060708090km/hrC1000-20 TubeBias11-22.5 Tubeless1000R20 Tube11R22.5 TubelessRadial15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 7 PROCESSING EQUIPMENT加工設(shè)備加工設(shè)備 PROCESSING EQUIPMENT 加工設(shè)備加工設(shè)備1. Extruding 擠出擠出 Tread / Base / Tread Wing : 8”x 4.5”x 3.5” 胎面胎面/基部基部/

8、翼部翼部 Side-wall / Shoulder Pad : 8”x 6” 胎側(cè)胎側(cè)/胎肩墊膠胎肩墊膠 Rim-Strip / Apex Strip : 6”x 4.5” 耐磨膠條耐磨膠條/三角膠條三角膠條 Belt Edge Cushion : 3.5” 帶束層邊緣緩沖層帶束層邊緣緩沖層 Apex (Upper / Lower) : 4.5”x4.5” 型膠（上部型膠（上部/下部）下部） + Assembler 成型機(jī)成型機(jī) 2. Calendering 壓延壓延 2-1) Steel Carcass 鋼絲胎體鋼絲胎體 Steel Cal. Line + Steel Radial Cutt

9、er & Splicer 鋼絲壓延生產(chǎn)線鋼絲壓延生產(chǎn)線+鋼絲子午線裁斷機(jī)和接合機(jī)鋼絲子午線裁斷機(jī)和接合機(jī) 2-2) Steel Belt & Steel Chafer 鋼絲帶束層鋼絲帶束層 及及 鋼絲子口鋼絲子口 Steel Cal. Line + Steel Angle Cutter & Splicer鋼絲壓延生產(chǎn)線鋼絲壓延生產(chǎn)線+鋼絲斜裁機(jī)和接合機(jī)鋼絲斜裁機(jī)和接合機(jī) * For more details, discuss with machinery manufacturer 詳細(xì)信息請(qǐng)與設(shè)備生產(chǎn)商聯(lián)系詳細(xì)信息請(qǐng)與設(shè)備生產(chǎn)商聯(lián)系15. August 2003 202

10、0/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 8 TBR TIRE PRODUCTION LINE 全鋼子午線輪胎生產(chǎn)線全鋼子午線輪胎生產(chǎn)線 15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 9 Steel Cord Calender Line鋼絲壓延生產(chǎn)線鋼絲壓延生產(chǎn)線15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 10 Sin

11、gle Stage Building Machine for Truck-Bus Radial Tire全鋼子午胎一段成型機(jī)全鋼子午胎一段成型機(jī)15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 11 Cutting & Splicing Machine for Steel Radial Carcass鋼絲子午胎胎體的裁斷及接合機(jī)鋼絲子午胎胎體的裁斷及接合機(jī)15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri

12、 Folie: 12 Assembling process of Bead and Apex胎圈和三角膠的復(fù)合胎圈和三角膠的復(fù)合15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 13 Assembling plate for dimensional stability of Apex in extruding process 在擠出過(guò)程中保持三角膠尺寸穩(wěn)定性的復(fù)合平臺(tái)在擠出過(guò)程中保持三角膠尺寸穩(wěn)定性的復(fù)合平臺(tái)15. August 2003 2020/5/9 2020/5/10 2020/5/10

13、 * 2022-3-4 Mario Negri Folie: 14 Creel for Metallic Cord Spools鋼絲簾線錠子架鋼絲簾線錠子架1. Lower humidity inside creel room be better against wire corrosion 室內(nèi)濕度越低越好，以避免室內(nèi)濕度越低越好，以避免 鋼絲腐蝕鋼絲腐蝕2. Thicker shaft for spool recommended to avoid the crooked shaft. 建議錠子的軸粗一些，以避建議錠子的軸粗一些，以避 免彎曲免彎曲15. August 2003 2020/5

14、/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 15 Metallic Cord Inlet in the Calender壓延機(jī)鋼絲簾線入口壓延機(jī)鋼絲簾線入口15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 16 1-3) Measures to reduce irregular arrangement of cord 減少鋼絲簾線不規(guī)則排列的方法減少鋼絲簾線不規(guī)則排列的方法Inside Creel Room Proper proced

15、ure should be needed for arranging hundreds of steel cords just before starting calendering. 開始?jí)貉忧埃瑧?yīng)在錠子室內(nèi)正確的排列好上百根鋼絲簾線開始?jí)貉忧?，?yīng)在錠子室內(nèi)正確的排列好上百根鋼絲簾線 Spools 鋼絲錠子鋼絲錠子15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 17 Major Manufacturing Problems and Measures of TBR Tires全鋼子午胎的主要的

16、生產(chǎn)問題及措施全鋼子午胎的主要的生產(chǎn)問題及措施15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 18 1-1) Measures to reduce irregular arrangement of cord 減少鋼絲簾線不規(guī)則排列的方法減少鋼絲簾線不規(guī)則排列的方法15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 19 1-2) Measures to reduce irregular arran

17、gement of cord 減少鋼絲簾線不規(guī)則排列的方法減少鋼絲簾線不規(guī)則排列的方法Edge gum width should be controlled during calendering在壓延過(guò)程中，應(yīng)該控制邊布膠的寬度在壓延過(guò)程中，應(yīng)該控制邊布膠的寬度 Otherwise, the following wide distance between cords at the splice area appears in splicing process of carcass ply.另外在胎體簾布接合過(guò)程中也應(yīng)控制接合部位的鋼絲之間的距離另外在胎體簾布接合過(guò)程中也應(yīng)控制接合部位的鋼絲之間

18、的距離 Splicing point接合點(diǎn)接合點(diǎn) Normal 正常正常 Too wide 太寬太寬 15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 20 1-4) Measures to reduce irregular arrangement of cord 減少鋼絲簾線不規(guī)則排列的方法減少鋼絲簾線不規(guī)則排列的方法In the process of tire Building,在輪胎成型過(guò)程中在輪胎成型過(guò)程中Butt splice of carcass ply be recommended

19、 for carcass quality 為了保證胎體的質(zhì)量，建議進(jìn)行對(duì)縫結(jié)合為了保證胎體的質(zhì)量，建議進(jìn)行對(duì)縫結(jié)合2. The amount of overlap be minimized for Belt splice (max. 1 cords) 帶束層結(jié)合過(guò)程中鋼絲搭接的數(shù)量盡量少（最多帶束層結(jié)合過(guò)程中鋼絲搭接的數(shù)量盡量少（最多1根）根）15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 21 2. Air trap problems near the splice area of Inne

20、r-inerfor100%Butylapplied to Inner-liner compound 100% 丁基膠內(nèi)襯層搭接部位的存氣問題丁基膠內(nèi)襯層搭接部位的存氣問題2-1) Measures to reduce the air trap : Inner-liner be cut with hot knife by lower than 30 內(nèi)襯層應(yīng)用熱刀以小于內(nèi)襯層應(yīng)用熱刀以小于30度的角度裁斷度的角度裁斷 2nd inner-liner第二層內(nèi)襯層第二層內(nèi)襯層 Lower than 30 degree 小于小于30度度 1st inner-liner第一層內(nèi)襯層第一層內(nèi)襯層15. A

21、ugust 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 22 MATERIAL CHARATERISTIC OF RADIAL TIRE子午胎的材料特性子午胎的材料特性 1. For the longer life of tread component, 對(duì)于使用壽命長(zhǎng)的胎面部件對(duì)于使用壽命長(zhǎng)的胎面部件 1-1) To employ medium sulfur/higher accelerator system (1.5/ 1.2-1.5 phr). 采用中硫高促系統(tǒng)（采用中硫高促系統(tǒng)（ 1.5/1.21.5p

22、hr) 1-2) To introduce higher antioxidant level 6PPD/TMQ (2/1 phr). 是用高性能的防老劑是用高性能的防老劑(6PPDTMQ 2/1phr) 2. Better casing performance for 2-3 times recapping be needed as follows. 為了獲得更好的腔體性能，以能夠進(jìn)行為了獲得更好的腔體性能，以能夠進(jìn)行2-3次的翻新，次的翻新，應(yīng)應(yīng) 遵循以下幾條：遵循以下幾條： 2-1) Inner-liner 內(nèi)襯層內(nèi)襯層 80 - 100 phr of Butyl be mixed to

23、improve gas impermeability and inner-liner crack resistance. 使用使用80-100phr的丁基膠來(lái)改善密封性能及耐龜裂性能的丁基膠來(lái)改善密封性能及耐龜裂性能15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 23 MATERIAL CHARATERISTIC OF RADIAL TIRE子午胎的材料特性子午胎的材料特性2-2) Carcass and Belt ply 胎體和帶束層簾布層胎體和帶束層簾布層 Higher adhesion

24、of compound to steel cord be required. The following steel wire structure normally be used. 膠料與鋼絲應(yīng)具有很高的粘合性能。一般使用下列結(jié)膠料與鋼絲應(yīng)具有很高的粘合性能。一般使用下列結(jié)構(gòu)構(gòu) 的鋼絲。的鋼絲。 3+9+15(0.175) 1w 3(0.2)+6(0.35)HT for carcass for belt 胎體胎體 帶束層帶束層15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 24 MATERI

25、AL CHARATERISTIC OF RADIAL TIRE子午胎的材料特性子午胎的材料特性 2-3) Side-wall compound 胎側(cè)膠胎側(cè)膠 Normally 60 phr of BR being employed to improve flex fatigue resistance. 一般使用一般使用60phr BR來(lái)改善耐曲撓龜裂性能來(lái)改善耐曲撓龜裂性能 2-4) Rim strip compound 輪輞耐磨膠條輪輞耐磨膠條 70-80 phr of BR being introduced to enhance abrasion resistance against fr

26、iction wear on the contact area between tire and vehicle rim. 使用使用7080phr BR來(lái)增加耐磨耗性能，以減少輪胎和輪輞來(lái)增加耐磨耗性能，以減少輪胎和輪輞 接觸部位的摩擦損耗接觸部位的摩擦損耗 2-5) Shoulder Pad 胎肩墊膠胎肩墊膠 Lower heat build up performance and higher flex fatigue resistance being required. Optimum volume be needed against ply separation. 應(yīng)具有低生熱性能和高耐

27、曲撓龜裂性能。體積最佳化以防止簾應(yīng)具有低生熱性能和高耐曲撓龜裂性能。體積最佳化以防止簾 布層剝離布層剝離 15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 25 New Tyre Technology 新輪胎技術(shù)新輪胎技術(shù)The green tires 綠色輪胎綠色輪胎Light weight tires 輕量輪胎輕量輪胎Coloured tires 彩胎彩胎The composite wheel 復(fù)合胎復(fù)合胎15. August 2003 2020/5/9 2020/5/10 2020/5/1

28、0 * 2022-3-4 Mario Negri Folie: 26 Different Market Needs (1) 不同市場(chǎng)需求不同市場(chǎng)需求USAEUROPEJAPANbefore 1992after 1992W-gripWearRRlowhighhighhighaveragelowhighlowhighW-gripWearRRaveragehighhighhighaveragehighhighlowhigh15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 27 Radial Truck

29、 Tyres : Company requirements卡車子午胎：公司要求卡車子午胎：公司要求Lower manufacturing Costs by : 如何降低成本如何降低成本Reduced man power, 減少人工減少人工Short production Cycle time 縮短生產(chǎn)周期縮短生產(chǎn)周期Consistant production rate & quality 穩(wěn)定的生產(chǎn)速度和質(zhì)量穩(wěn)定的生產(chǎn)速度和質(zhì)量Size change flexibility, 尺寸變化靈活性尺寸變化靈活性Scrap reduction 降低廢品率降低廢品率15. August 2003

30、 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 28 Radial Truck Tyres : Trends卡車子午胎：趨勢(shì)卡車子午胎：趨勢(shì)Reduced tyre components 減少輪胎部件減少輪胎部件Weight reduction 降低重量降低重量Low rolling resistance 降低滾動(dòng)阻力降低滾動(dòng)阻力Good uniformity 良好的均勻性良好的均勻性Retreadability 增加胎面翻新率增加胎面翻新率Long life tread 胎面使用壽命長(zhǎng)胎面使用壽命長(zhǎng)Direct extr

31、usion 直接擠出直接擠出15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 29 Target for the Green Tire050100150NoiseSkid ResistanceAbrasionHandling PropertiesRolling Resistance噪音噪音滾動(dòng)阻力滾動(dòng)阻力耐滑性能耐滑性能加工性能加工性能磨耗磨耗Green Tire Application 綠色輪胎應(yīng)用綠色輪胎應(yīng)用15. August 2003 2020/5/9 2020/5/10 2020/5/

32、10 * 2022-3-4 Mario Negri Folie: 30 Up to 35 % reduced rolling resistance with SiO2Up to 5 % less fuel consumption per caror approx. 2 billion litres of fuel savings per year in Germany aloneGreen Tire Concept: Economic Benefit綠色輪胎的概念：獲得經(jīng)濟(jì)效益綠色輪胎的概念：獲得經(jīng)濟(jì)效益使用白炭黑可使?jié)L動(dòng)阻力最多使用白炭黑可使?jié)L動(dòng)阻力最多可降低可降低30% 每輛轎車的耗油量最

33、多可節(jié)省每輛轎車的耗油量最多可節(jié)省5%僅在德國(guó)，每年可以節(jié)省僅在德國(guó)，每年可以節(jié)省2020億升的燃料億升的燃料15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 31 Polymer Properties and Tyre Performance聚合物性能和輪胎性能聚合物性能和輪胎性能Tan Delta and Glass Transition TemperatureTan Delta 和和 Tg之間的關(guān)系之間的關(guān)系0-603070110oC-10010-110-2abrasionice-grip

34、wet-griprollingresist.high speedperform.1tan d didealSBR 1721Tg SBR 172115. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 32 Different Requirements Apply for Different Markets對(duì)于不同市場(chǎng)的不同要求對(duì)于不同市場(chǎng)的不同要求808590951001051101151201251308090100110120130140150160Rolling ResistanceTracti

35、onbetterSilica TechnologyReplacement and R/LTEurope and NAEuropeOE TyresNAOE TyresNADifferent Market Needs (2), 不同市場(chǎng)需求（不同市場(chǎng)需求（2）15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 33 Tread TechnologyPolymer Type RR CoefficientCB and E-SBRSBR 1712/211.2 - 1.1CB and S-SBRVSL 252

36、5-0modified better1.1 - 1.0CB/silica and E-SBRSBR 1712/211.0 - 0.9silica and E-SBRSBR 1712/210.95 - 0.8silica and S-SBRVSL 5025-1VSL 5025-1 HMmodified better0.8 - 0.6Tread Technology and Rolling Resistance輪胎技術(shù)及滾動(dòng)阻力輪胎技術(shù)及滾動(dòng)阻力15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 34

37、 Structure / Property - Relation (2)結(jié)構(gòu)與性能之間的關(guān)系（結(jié)構(gòu)與性能之間的關(guān)系（2）Important Tyre Properties:Dependance on Glass Transition Temperature重要的輪胎性能：依賴于玻璃化溫度重要的輪胎性能：依賴于玻璃化溫度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 (

38、40% Styrene)S-SBR (34% Styrene, 32% Vinyl)-20-60-40-80-100 TractionGlass Temperature Tg15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 35 A Recommendation建議建議For the overseas and domestic OE requirements, 對(duì)于國(guó)內(nèi)外廠家的要求：對(duì)于國(guó)內(nèi)外廠家的要求： the evaluation of tread compound with 20- 50

39、phr of solution SBR VSL 5025-1 in the absence and presence of silica is recommended to enhance both the traction performance and low rolling resistance. 建議使用建議使用20-50phr溶聚溶聚SBR VSL5025-1(無(wú)論是否含有白炭黑來(lái)無(wú)論是否含有白炭黑來(lái))改善牽引性能及滾動(dòng)阻力改善牽引性能及滾動(dòng)阻力15. August 2003 2020/5/9 2020/5/10 2020/5/10 * 2022-3-4 Mario Negri Folie: 36 Light Weight Tyres輕量輪胎輕量輪胎Light weight tyres reduce rolling resistance 輕量輪胎降低滾動(dòng)阻力輕量輪胎降低滾動(dòng)阻力Light weight tyres save material and therefore reduce tyre material cost 輕量輪胎節(jié)省材料因此降低成本輕量輪胎節(jié)省材料因此降低成本Light weight tyres allow heavier wider wheels and low profile tyres for imp