全鋼子午胎的加工工藝及輪胎新技術

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全鋼子午胎的加工工藝及輪胎新技術RheinchemieMario Negri 馬旅歐馬旅歐15. August 2003 2022-5-7 Folie: 1 Content內容內容1. Major 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

2、斜交胎和斜交胎(TBB)在結構與性能方面的主要差別在結構與性能方面的主要差別2. An introduction on TBR tire production line. 全鋼子午胎生產線的介紹全鋼子午胎生產線的介紹3. Main problems and counter-measures against those problems in the process of TBR tire production. 全鋼子午胎生產過程中的主要問題及補救措施全鋼子午胎生產過程中的主要問題及補救措施4. Material Characteristics of TBR tire components.

3、全鋼子午胎構件材料的特性全鋼子午胎構件材料的特性5. New Tire Technology 輪胎新技術輪胎新技術15. August 2003 2022-5-7 2Bias vs RadialBias-PlyRadial15. August 2003 2022-5-7 3Major difference in Structure between Truck bus radial and cross-ply tire全鋼子午胎和斜交胎在結構方面的主要差別全鋼子午胎和斜交胎在結構方面的主要差別 Truck Bus Cross Ply Tire 斜交胎斜交胎 Truck Bus Radial Ti

4、re 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 2022-5-7 4Main 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050100150ABRAS

5、IONRESISTANCE 耐磨性耐磨性BELT ENDURANCE帶束層耐久性帶束層耐久性ROLLING RESISTANCE滾動阻力滾動阻力NOISE 噪音噪音HANDLINGPROPERTIES操作性能操作性能TBBTBR15. August 2003 2022-5-7 5Temperature rise in tire shoulder area according to tire sizes during tire running 在運行過程中胎肩部位的升溫隨輪胎規(guī)格變化的情況在運行過程中胎肩部位的升溫隨輪胎規(guī)格變化的情況02040608010012014016060708090km

6、/hrC1000-20 TubeBias11-22.5 Tubeless1000R20 Tube11R22.5 TubelessRadial15. August 2003 2022-5-7 6PROCESSING EQUIPMENT加工設備加工設備 PROCESSING EQUIPMENT 加工設備加工設備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/翼部翼部 Side-wall / Shoulder Pad : 8”x 6” 胎側胎側/胎肩墊膠胎肩墊膠 Rim-Strip / Apex Strip

7、 : 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 成型機成型機 2. Calendering 壓延壓延 2-1) Steel Carcass 鋼絲胎體鋼絲胎體 Steel Cal. Line + Steel Radial Cutter & Splicer 鋼絲壓延生產線鋼絲壓延生產線+鋼絲子午線裁斷機和接合機鋼絲子午線裁斷機和接合機 2-2) Steel Belt &a

8、mp; 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鋼絲壓延生產線鋼絲壓延生產線+鋼絲斜裁機和接合機鋼絲斜裁機和接合機 * For more details, discuss with machinery manufacturer 詳細信息請與設備生產商聯系詳細信息請與設備生產商聯系15. August 2003 2022-5-7 7TBR TIRE PRODUCTION LINE 全鋼子午線輪胎生產線全鋼子午線輪胎生產線 15. August 2003 2022-5

9、-7 8Steel Cord Calender Line鋼絲壓延生產線鋼絲壓延生產線15. August 2003 2022-5-7 9Single Stage Building Machine for Truck-Bus Radial Tire全鋼子午胎一段成型機全鋼子午胎一段成型機15. August 2003 2022-5-7 10Cutting & Splicing Machine for Steel Radial Carcass鋼絲子午胎胎體的裁斷及接合機鋼絲子午胎胎體的裁斷及接合機15. August 2003 2022-5-7 11Assembling process o

10、f Bead and Apex胎圈和三角膠的復合胎圈和三角膠的復合15. August 2003 2022-5-7 12Assembling plate for dimensional stability of Apex in extruding process 在擠出過程中保持三角膠尺寸穩(wěn)定性的復合平臺在擠出過程中保持三角膠尺寸穩(wěn)定性的復合平臺15. August 2003 2022-5-7 13Creel 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 w

11、ire corrosion 室內濕度越低越好，以避免室內濕度越低越好，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 2022-5-7 14Metallic Cord Inlet in the Calender壓延機鋼絲簾線入口壓延機鋼絲簾線入口15. August 2003 2022-5-7 151-3) Measures to reduce irregular arrangement of

12、 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 procedure should be needed for arranging hundreds of steel cords just before starting calendering. 開始壓延前，應在錠子室內正確的排列好上百根鋼絲簾線開始壓延前，應在錠子室內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 2022-5-7 16Major Manufacturing Problems and Measures of TBR

13、Tires全鋼子午胎的主要的生產問題及措施全鋼子午胎的主要的生產問題及措施15. August 2003 2022-5-7 171-1) 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 2022-5-7 181-2) 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Edge gum width should be controlled during ca

14、lendering在壓延過程中，應該控制邊布膠的寬度在壓延過程中，應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程中也應控制接合部位的鋼絲之間的距離另外在胎體簾布接合過程中也應控制接合部位的鋼絲之間的距離 Splicing point接合點接合點 Normal 正常正常 Too wide 太寬太寬 15. August 2003 2022-5-7 191-4) Measu

15、res 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,在輪胎成型過程中在輪胎成型過程中1.Butt splice of carcass ply be recommended for carcass quality 為了保證胎體的質量，建議進行對縫結合為了保證胎體的質量，建議進行對縫結合2. The amount of overlap be minimized for Belt splice (max. 1 cords) 帶束層結合過程中鋼絲搭

16、接的數量盡量少（最多帶束層結合過程中鋼絲搭接的數量盡量少（最多1根）根）15. August 2003 2022-5-7 202. Air trap problems near the splice area of Inner-inerfor100%Butylapplied to Inner-liner compound 100% 丁基膠內襯層搭接部位的存氣問題丁基膠內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 內襯層應用熱刀以小于內襯層

17、應用熱刀以小于30度的角度裁斷度的角度裁斷 2nd inner-liner第二層內襯層第二層內襯層 Lower than 30 degree 小于小于30度度 1st inner-liner第一層內襯層第一層內襯層15. August 2003 2022-5-7 21MATERIAL 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, 對于使用壽命長的胎面部件對于使用壽命長的胎面部件 1-1) To employ medium sulfur/higher accelera

18、tor 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)（ 1.5/1.21.5phr) 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，以能夠進行為了獲得更好的腔體性能，以能夠進行2-3次的翻新，次的翻新，應應 遵循以下幾條：遵循以下幾

19、條： 2-1) Inner-liner 內襯層內襯層 80 - 100 phr of Butyl be mixed to improve gas impermeability and inner-liner crack resistance. 使用使用80-100phr的丁基膠來改善密封性能及耐龜裂性能的丁基膠來改善密封性能及耐龜裂性能15. August 2003 2022-5-7 22MATERIAL 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

20、 adhesion of compound to steel cord be required. The following steel wire structure normally be used. 膠料與鋼絲應具有很高的粘合性能。一般使用下列結膠料與鋼絲應具有很高的粘合性能。一般使用下列結構構 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 2022-5-7 23MATERIAL CHARATERISTIC OF RADIAL TIRE子午胎的材料特性子午

21、胎的材料特性 2-3) Side-wall compound 胎側膠胎側膠 Normally 60 phr of BR being employed to improve flex fatigue resistance. 一般使用一般使用60phr BR來改善耐曲撓龜裂性能來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 friction wear on the contact area between t

22、ire and vehicle rim. 使用使用7080phr BR來增加耐磨耗性能，以減少輪胎和輪輞來增加耐磨耗性能，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應具有低生熱性能和高耐曲撓龜裂性能。體積最佳化以防

23、止簾 布層剝離布層剝離 15. August 2003 2022-5-7 24New Tyre Technology 新輪胎技術新輪胎技術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 復合胎復合胎15. August 2003 2022-5-7 25Different Market Needs (1) 不同市場需求不同市場需求USAEUROPEJAPANbefore 1992after 1992W-gripWearRRlowhighhighhighaverage

24、lowhighlowhighW-gripWearRRaveragehighhighhighaveragehighhighlowhigh15. August 2003 2022-5-7 26Radial Truck 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 縮短生產周期縮短生產周期Consistant production rate & qu

25、ality 穩(wěn)定的生產速度和質量穩(wěn)定的生產速度和質量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 2022-5-7 27Radial Truck Tyres : Trends卡車子午胎：趨勢卡車子午胎：趨勢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 降低滾動阻力降低滾動阻力Good uniformity 良好的均勻性良好的均勻性Retreadability

26、增加胎面翻新率增加胎面翻新率Long life tread 胎面使用壽命長胎面使用壽命長Direct extrusion 直接擠出直接擠出15. August 2003 2022-5-7 28Target for the Green Tire050100150NoiseSkid ResistanceAbrasionHandling PropertiesRolling Resistance噪音噪音滾動阻力滾動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 綠色輪胎應用綠色輪胎應用15. August 2003 2022-5-7 29Up to 35 %

27、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：獲得經濟效益綠色輪胎的概念：獲得經濟效益使用白炭黑可使?jié)L動阻力最多使用白炭黑可使?jié)L動阻力最多可降低可降低30% 每輛轎車的耗油量最多可節(jié)省每輛轎車的耗油量最多可節(jié)省5%僅在德國，每年可以節(jié)省僅在德國，每年可以節(jié)省2020億升

28、的燃料億升的燃料15. August 2003 2022-5-7 30Polymer 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之間的關系之間的關系0-603070110oC-10010-110-2abrasionice-gripwet-griprollingresist.high speedperform.1tan d didealSBR 1721Tg SBR 172115. August 2003 2022-5-7 3

29、1Different Requirements Apply for Different Markets對于不同市場的不同要求對于不同市場的不同要求808590951001051101151201251308090100110120130140150160Rolling ResistanceTractionbetterSilica TechnologyReplacement and R/LTEurope and NAEuropeOE TyresNAOE TyresNADifferent Market Needs (2), 不同市場需求（不同市場需求（2）15. August 2003 2022-

30、5-7 32Tread TechnologyPolymer Type RR CoefficientCB and E-SBRSBR 1712/211.2 - 1.1CB and S-SBRVSL 2525-0modified 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 Resis

31、tance輪胎技術及滾動阻力輪胎技術及滾動阻力15. August 2003 2022-5-7 33Structure / Property - Relation (2)結構與性能之間的關系（結構與性能之間的關系（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)SB

32、R (15% Styrene)SBR 1500 (23.5% Styrene)SBR 1516 (40% Styrene)S-SBR (34% Styrene, 32% Vinyl)-20-60-40-80-100 TractionGlass Temperature Tg15. August 2003 2022-5-7 34A Recommendation建議建議For the overseas and domestic OE requirements, 對于國內外廠家的要求：對于國內外廠家的要求： the evaluation of tread compound with 20- 50 ph

33、r 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(無論是否含有白炭黑來無論是否含有白炭黑來)改善牽引性能及滾動阻力改善牽引性能及滾動阻力15. August 2003 2022-5-7 35Light Weight Tyres輕量輪胎輕量輪胎Light weight tyres reduce rolling resistance 輕量輪胎降低滾動阻力輕量輪胎降低滾動阻力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 improved appearance/performan