輪胎行業(yè)設(shè)備方案

輪胎行業(yè)設(shè)備方案2Copyright?2009RockwellAutomation,Inc.Allrightsreserved.21.輪胎生產(chǎn)過程中設(shè)備簡述2.輪胎成型機應(yīng)用介紹3.裁斷機應(yīng)用介紹3子午線輪胎斷面結(jié)構(gòu)圖Copyright?2009RockwellAutomation,Inc.Allrightsreserved.34子午線輪胎斷面結(jié)構(gòu)圖Copyright?2009RockwellAutomation,Inc.Allrightsreserved.45輪胎的生產(chǎn)過程Copyright?2009RockwellAutomation,Inc.Allrightsreserved.56工序一：密煉工序密煉工序把碳黑、天然/合成橡膠、油、添加劑、促進劑等原材料混合到一起，在密煉機里進行加工，生產(chǎn)出“膠料”的過程Copyright?2009RockwellAutomation,Inc.Allrightsreserved.67工序二：膠部件準(zhǔn)備/工段三:胎圈成型Copyright?2009RockwellAutomation,Inc.Allrightsreserved.7原胎圈是由許多根鋼絲掛膠以后纏繞而成的。用于胎圈的這種膠料是有特殊性能的，當(dāng)硫化完以后，膠料和鋼絲能夠緊密的貼合到一起。相關(guān)設(shè)備:鋼絲纏繞機8Copyright?2009RockwellAutomation,Inc.Allrightsreserved.8在這個工序里，簾布將被裁斷成適用的寬度并接好接頭。簾布的寬度和角度的變化主要取決于輪胎的規(guī)格以及輪胎結(jié)構(gòu)設(shè)計的要求膠部件準(zhǔn)備工序工序二：膠部件準(zhǔn)備/工段四:簾布相關(guān)設(shè)備:

90度簾布裁斷機9工序二：膠部件準(zhǔn)備/工段五:三角膠貼合Copyright?2009RockwellAutomation,Inc.Allrightsreserved.9在這個工段里，擠出機擠出的三角膠條將被貼合到胎圈上。相關(guān)設(shè)備:三角膠貼合機10工序二：膠部件準(zhǔn)備/工段六:帶束層Copyright?2009RockwellAutomation,Inc.Allrightsreserved.10這個工序是生產(chǎn)帶束層的。在錠子間里，許多根鋼絲通過穿線板出來，再和膠料同時穿過口型板使鋼絲兩面掛膠。掛膠后帶束層被裁斷成規(guī)定的角度和寬度。寬度和角度大小取決于輪胎規(guī)格以及結(jié)構(gòu)設(shè)計的要求。

所有的膠部件都將被運送到“輪胎成型”工序，備輪胎成型使用。相關(guān)主要設(shè)備:小角度度簾布裁斷機11工序三：輪胎成型輪胎成型工序輪胎成型工序是把所有的半成品在成型機上組裝成生胎，這里的生胎是指沒經(jīng)過硫化。生胎經(jīng)過檢查后，運送到硫化工序。Copyright?2009RockwellAutomation,Inc.Allrightsreserved.1112工序四：硫化硫化工序生胎被裝到硫化機上，在模具里經(jīng)過適當(dāng)?shù)臅r間以及適宜的條件，從而硫化成成品輪胎。硫化完的輪胎即具備了成品輪胎的外觀—圖案/字體以及胎面花紋?，F(xiàn)在，輪胎將被送到最終檢驗區(qū)域了。Copyright?2009RockwellAutomation,Inc.Allrightsreserved.1213工序五/六：最終檢驗工序/輪胎測試

在這個區(qū)域里，輪胎首先要經(jīng)過目視外觀檢查，然后是均勻性檢測，均勻性檢測是通過“均勻性實驗機”來完成的。均勻性實驗機主要測量徑向力，側(cè)向力，錐力以及波動情況的。均勻性檢測完之后要做動平衡測試，動平衡測試是在“動平衡實驗機”上完成的。最后輪胎要經(jīng)過X-光檢測，然后運送到成品庫以備發(fā)貨。在設(shè)計新的輪胎規(guī)格過程中，大量的輪胎測試就是必須的，這樣才能確保輪胎性能達(dá)到政府以及配套廠的要求。

當(dāng)輪胎被正式投入生產(chǎn)之后，我們?nèi)詫⒗^續(xù)做輪胎測試來監(jiān)控輪胎的質(zhì)量，這些測試與放行新胎時所做的測試是相同的。用于測試輪胎的機器是“里程實驗”，通常做的實驗有高速實驗和耐久實驗Copyright?2009RockwellAutomation,Inc.Allrightsreserved.1314Copyright?2009RockwellAutomation,Inc.Allrightsreserved.142.輪胎成型機應(yīng)用介紹Agenda15Copyright?2009RockwellAutomation,Inc.Allrightsreserved.15Agenda2.1成型機簡介16DifferentTBMsfordifferentprocess&differenttypeoftire乘用/輕卡子午線輪胎全自動一次法成型機AutomaticUnistagePassenger/LightTruckRadialTBM乘用/輕卡子午線輪胎一段成型機1stStage&2ndStagePassenger/LightTruckRadialTBM兩鼓全鋼載重一次法成型機2-DrumsUnistageAll-steelRadialTruckTBM三鼓全鋼載重一次法成型機3-DrumsUnistageAll-steelRadialTruckTBM三鼓子午線工程胎一次法成型機3-DrumsUnistageAll-steelRadialOTRTBM四鼓子午線工程胎一次法成型機4-DrumsUnistageAll-steelRadialOTRTBM巨型全鋼工程子午線輪胎一次法成型機

AutomaticUnistageOTRTBM

...…輪胎制造過程的重要設(shè)備-成型機17Copyright?2009RockwellAutomation,Inc.Allrightsreserved.17成型機的性能要求HigherrequirementoncontrolsystemofTBM自動化程度高節(jié)省勞動力提高產(chǎn)品質(zhì)量生產(chǎn)效率高控制各工序時間縮短停機再啟動周期靈活性變更輪胎規(guī)格工藝調(diào)整精度直接影響輪胎質(zhì)量18成型機的控制特點分析Copyright?2009RockwellAutomation,Inc.Allrightsreserved.18成型機的控制特點集合多種控制形式離散控制：繁復(fù)的邏輯和時序控制，包括工藝流程，各部件的時序動作及邏輯配合，數(shù)字量輸出的控制(指示燈，氣動原件，燈標(biāo)步進電機，糾偏系統(tǒng)……)，模擬量控制:溫度控制，壓力控制，張力控制運動控制：多軸協(xié)動控制，對精度,速度,同步性均有要求。包括定長，電子齒輪，電子凸輪，插補等運動（旋轉(zhuǎn)鼓，傳送帶，JLB排線，送料…….）傳動控制：多臺變頻,變速控制（料卷導(dǎo)開，裁刀運動……..）安全控制：光幕，急停，拉線，地毯……網(wǎng)絡(luò)技術(shù)的應(yīng)用及對第三方設(shè)備的兼容人機界面，I/O，變頻，燈標(biāo)、閥島、糾偏系統(tǒng)……I/O總數(shù)較多，站點分散，類型多DI，DO，AI，AO，SSI，IK……性價比要求高功能完善的人機界面報警，配方……19Copyright?2009RockwellAutomation,Inc.Allrightsreserved.19Agenda2.2成型機解決方案–RA集成架構(gòu)20成型機解決方案–RA集成架構(gòu)211.GUARDLOGIX集成安全控制器它具備ControlLogix控制器的全部功能，可實現(xiàn)順序控制，傳動控制，運動控制和過程控制的原有要求，并同時具有SIL3安全特性，這有助于確保安全控制。其雙處理器架構(gòu)（1oo2）和單一集成的軟件開發(fā)，占有絕對優(yōu)勢。

2.安全分布式I/O在控制和監(jiān)視復(fù)雜的安全系統(tǒng)回路的同時還具有傳統(tǒng)分布式I/O的所有優(yōu)點。安全I/O模塊更易于在相同的接線上集成安全和標(biāo)準(zhǔn)控制。雙通道模塊支持模塊用于Categroy4和SIL3應(yīng)用。與GUARDLOGIX完美配合成型機解決方案–RA集成架構(gòu)22RA全系列安全產(chǎn)品激光掃描器安全光幕安全地毯安全PLC急停&信號門開關(guān)非接觸型開關(guān)密鑰切換開關(guān)安全接觸器安全繼電器拉線開關(guān)安全變頻器安全使能開關(guān)安全邊緣23機械安全實例24輪胎成型機

25全自動一次法成型機安全地毯邊緣開關(guān)激光掃描儀安全行程開關(guān)安全地毯安全行程開關(guān)26全自動一次法成型機安全光幕安全行程開關(guān)非接觸式門開關(guān)拉線急停27成型機解決方案–RA集成架構(gòu)3.帶有GuardMOTION的KiNETIX?6000伺服驅(qū)動器安全停車功能在不切斷整個系統(tǒng)供電的情況下完成。驅(qū)動器的輸出可以禁止并消除電動機轉(zhuǎn)矩，提供安全性和最大機器可用性。安全停車功能已通過TüV認(rèn)證，并符合EN-954-1Category3和IEC-61508SIL3關(guān)于安全停車和預(yù)防意外重啟動應(yīng)用的要求。28Objectbasedtagv.straditionalPLCaddressmappingObjectsconsistingof

IO,VFD,servodrive,instructionetc方案亮點29方案亮點OptionalmultipleprogramminglanguageLadderSFCSTFBD30Completeinstructionofmotion,drive,discrete,SIL3safetyetc34Motioninstructionsembedded方案亮點31Completeinstructionofmotion,drive,discrete,SIL3safetyetcESTOP EmergencyStop/急停DIN DualInput/雙輸入RIN RedundantInput/冗余輸入ROUT RedundantOutput/冗余輸出LC LightCurtain/光簾ENPEN EnablePendant/使能墜FPMS FivePositionModeSelector/五位選擇開關(guān)方案亮點3200010203COMCOMT0T1M04050607COMCOMT2T3M00010203COMCOMCOM00010203COMCOMCOMCOMCOMFDBK2+FDBK2-FDBK1+FDBK1-SAFETYEN2+SAFETYEN-24V+24_COMSAFETYEN1+Safe-offConnectorKinetix6000DriveOSSD1OSSD224V+NCNC方案亮點33方案亮點34Copyright?2009RockwellAutomation,Inc.Allrightsreserved.34Agenda2.3.成型機典型控制環(huán)節(jié)35KeyApplication1:Cutting裁切IntermittentcuttingStage-1Axis1&2stopStage-2Axis1&2startatthesametimeandtrytorunatthesamelinespeedStage-2(VelocitySych.From0toV1)Step1:speedofAxis1&2increasefrom0toV1Step2:Axis1&2runatV1continuouslytillsensordetectthecuttingmaterialStage-3(PositioncontrolbaseonV1)AfterStage-2step2,Positionsych.(axis1&2)Whenreachthesettingposition,axesdeceleratetostopandwaitingfornextcycleRemarks:inthestage2,cuttingmaterialsometimesskidsonbelt(axis1),sointhisphaseweneedmakesureaxis1hasthesamevelocityasaxis2atanytime.36KeyApplication1:Cutting裁切功能塊Master/SlaveLinearaxisHoming:Active/ImmediateThesensorshouldbeahigh-speedsensorandwiredintoMasterAxisDrivermoduleI/OportasRegistrationsignal.IncludeMSO/MAFRMDR(fornextPos.Registration)MRP(RedefinecurrentPos.=0)MAM1(ensuresensordetectedmaterial)MAM2:AbsolutePos.Movement(Registration_position+Fixed_distance)37KeyApplication2:Winding收卷total3typesmaterialswillbetransporttowindontheBigrollerEachmaterialwillbewindedontherolleronlyonecircleV2islinespeedontherollerAnytimeweneedmakesurethatV1=V2Duringwinding,thediameterofrollerwillbechangedMasteraxis=FeedingSlaveaxis=Winding38JLBWinding39MasterisWindingAxis;unitDegUnwindofMasteraxis=360Degree.SlaveisFeedingaxis;unitmmKeyApplication2:Winding

MasterisVirtualAxis;unitsencondSlaveiswindingaxis;unitmmMakesurethatthematerialswillbestretchedequablyateachpoint.40V1V2CalculatedataofFirstmaterialWindingParameter:D0(diameterofbigroller)D1(thicknessoffirstmaterial)D2(thicknessofSecondmaterial)D3(thicknessof3rdmaterial)StartWindsignalMastervelocityParameter:Lengthof3kindsofmaterialsbycustomerAftereachwind,thereisaangel.KeyApplication2:Winding41KeyApplication3:TransferRingPositionShapingDrumB&TDrumCarcassDrumCarcassRingB&TRingWaitingPositionCarcassPositionShapingPositionB&TDrumPositionWaitingPositionMAMMAJMAMMAJMAMMAJTorqueLimit42Copyright?2009RockwellAutomation,Inc.Allrightsreserved.42Agenda2.4.模塊化編程43S88ProcessOrientedProgramStructure:

Unit,EquipmentModule,ControlModuleCM2CM1EM7CM2CM1EM6CM2CM1EM5CM2CM1EM4CM3CM2CM4CM1EM1CM1EM3CM2CM1EM2UNIT44TailSupportILConveyorCarcassDrumPLYConveyorStitcherLaserMarkTransferRingTireunloadShapingDrumStitcherTPConveyorTPDrumClampRingUNIT1CM4CM1EM1CM2CM1EM2CM3CM2CM1EM3CM2CM1EM4CM2CM1EM5CM2CM1EM6CM2CM1EM6S88ProcessOrientedProgramStructure:

TBMExle45S88ProcessOrientedProgramStructure:

TBMExleCM2CM1EM5CM2CM1EM4CM3CM2CM4CM1EM1CM1EM3CM2CM1EM2UNIT1UNIT1_BuildingStation1forAuto/SemiAuto/ManualStation2forAuto/SemiAuto/ManualInterlockingorhandshakingCommandSequencing1UNIT1_BuildingSequencing246TodeploypowerprogrammingforTBM

Step1:tounderstandmachineflowLevel1:UnitLevel2:StationFrontRackFirstStage_CarcassBuildingPLY(A)ConveyorILConveyorILLetOffPLY(N)ConveyorPLY(N)LetOffPLY(A)LetOffS-WallConveyorS-Wall(L)LetOffS-Wall(R)LetOffLevel3:EquipmentCarcassDrumNetherStitcherXStitcherYStitcherCarcassConveyorLevel4:ActuatorServomotorValveclutch47Level1:UNIT1_CarcassBuildingAutoLevel3:EquipmentModuleControlInterfaceCarcassDrumNetherStitcherXStitcher

YStitcher

CarcassConveyorLevel4:ControlModuleCM04AutoAxisCM10FResetCM21Enable

CM22Home

CM23Move

CM24Gear

CM27Jog

CM33Stop

CM35Disable

CM31StatusLevel2:StationModel&SequencingILConveyorS-Wall(R)LetOffResettingIdleRunningStoppedStoppingAbortingAbortedCarcass&ShapingDrumManualApplyPAApplyNPLYApplyAPLYBeadLoadShapingRemoveAutoControlSequenceManualControlCommandTodeploypowerprogrammingforTBM

Step2:totransferthemachineflowtoPPS01S02S10OperationModeEM10EM11EM13EM12EM14S01-Sq1S01-Sq2BladderUPStitchingSWApp48TodeploypowerprogrammingforTBM

Step3:toget1ststationdone(Confidential–ForInternalUseOnly)Copyright?2007RockwellAutomation,Inc.Allrightsreserved.48Level1WholeUnitOperationLevel3EquipmentModuleControlInterfaceLevel2StationModel&SequencingLevel4SingleActionExecuting49Level2StationModel&Sequencing

St