全鋼子午胎的加工工藝及輪胎新技術(shù)

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) Rheinchemie Mario Negri 馬旅歐馬旅歐 15. August 2003 Mario Negri Folie: 2 Content 內(nèi)容內(nèi)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

2、(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 process of TBR tire production. 全鋼子午胎生產(chǎn)過程中的主要問題及補(bǔ)救措施全鋼子午胎生產(chǎn)過程中的主要問題及補(bǔ)救措施 4. Material Characteristics of TBR tire com

3、ponents. 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 Mario Negri Folie: 3 Bias vs Radial Bias-Ply Radial 15. August 2003 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 Cros

4、s 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 Mario Negri Folie: 5 Main differences in tire performance between TBR and TBB tire 全鋼子

5、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 0 50 100 150 ABRASION RESISTANCE 耐磨性耐磨性 BELT ENDURANCE 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 HANDLING PROPERTIES 操作性能操作性能 TBB TBR 15. August 2003 Mario Negri Folie: 6 Temperature rise in tire shoulder area according to tire sizes during tire running

6、在運(yùn)行過程中胎肩部位的升溫隨輪胎規(guī)格變化的情況在運(yùn)行過程中胎肩部位的升溫隨輪胎規(guī)格變化的情況 0 20 40 60 80 100 120 140 160 60708090 km/hr C 1000-20 Tube Bias11-22.5 Tubeless 1000R20 Tube 11R22.5 Tubeless Radial 15. August 2003 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

7、 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(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 St

8、eel Cal. Line + Steel Radial Cutter & 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)信息請與設(shè)備生產(chǎn)商聯(lián)系詳細(xì)信息請與設(shè)備生產(chǎn)

9、商聯(lián)系 15. August 2003 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 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 Mario Negri Folie: 10 Single 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 Mario

10、 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 Mario Negri 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 Mario Negri Folie: 13 Assembling plate for dimensional stability of Apex in extruding process

11、 在擠出過程中保持三角膠尺寸穩(wěn)定性的復(fù)合平臺在擠出過程中保持三角膠尺寸穩(wěn)定性的復(fù)合平臺 15. August 2003 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

12、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 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 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 procedure should be needed for

13、arranging hundreds of steel cords just before starting calendering. 開始壓延前，應(yīng)在錠子室內(nèi)正確的排列好上百根鋼絲簾線開始壓延前，應(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 Mario Negri Folie: 17 Major Manufacturing Problems and Measures of TBR Tires 全鋼子午胎的主要的生產(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 Mario Negri Folie: 18 1

14、-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 Mario Negri Folie: 19 1-2) 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 calendering 在壓延過程中，應(yīng)該控制邊布膠的寬度在壓延過程中，應(yīng)該控制邊布膠的寬度 Otherwi

15、se, 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(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程中也應(yīng)控制接合部位的鋼絲之間的距離 Splicing point接合點(diǎn)接合點(diǎn) Normal 正常正常 Too wide 太寬太寬 15. August 2003 Mario Negri Folie: 20 1-4) Measures to reduce irregular arrangement of c

16、ord 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(zhì)量，建議進(jìn)行對縫結(jié)合為了保證胎體的質(zhì)量，建議進(jìn)行對縫結(jié)合 2. The amount of overlap be minimized for Belt splice (max. 1 cords) 帶束層結(jié)合過程中鋼絲搭接的數(shù)量盡量少（最多帶束層結(jié)合過程中鋼絲搭接的數(shù)量盡量少（最多1根）根）

17、15. August 2003 Mario Negri Folie: 21 2. Air trap problems near the splice area of Inner-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 2n

18、d 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. August 2003 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 accelerator system

19、 (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(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) I

20、nner-liner 內(nèi)襯層內(nèi)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 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 H

21、igher adhesion 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 Mario Negri Folie: 24 MATERIAL CHARATERISTIC OF RAD

22、IAL 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 con

23、tact area between tire 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(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應(yīng)具有低生熱

24、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 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 Mario Negri Folie: 26 Different Market Needs (1) 不同市場需求不同市場需求 USAEUROPEJAPAN before

25、1992 after 1992 W-grip Wear RR low high high high average low high low high W-grip Wear RR average high high high average high high low high 15. August 2003 Mario Negri Folie: 27 Radial 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 po

26、wer, 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 Mario Negri Folie: 28 Radial 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

27、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 胎面使用壽命長胎面使用壽命長 Direct extrusion 直接擠出直接擠出 15. August 2003 Mario Negri Folie: 29 Target for the Green Tire 0 50 100 150 Noise Skid Resistance AbrasionHandling Proper

28、ties Rolling 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 Mario Negri Folie: 30 Up to 35 % reduced rolling resistance with SiO2 Up to 5 % less fuel consumption per car or approx. 2 billion litres of fuel savings per year in Germany alone Green Ti

29、re 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2020億升的燃料億升的燃料 15. August 2003 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 Temperatu

30、re Tan Delta 和和 Tg之間的關(guān)系之間的關(guān)系 0 0 0-60 -60-60303030707070110110110 o o oC C C -100-100-100 101010-1 -1-1 101010-2 -2-2 abrasionabrasionabrasionice-gripice-gripice-grip wet-wet-wet- gripgripgrip rollingrollingrolling resist.resist.resist. high speedhigh speedhigh speed perform.perform.perform. 1 1 1 t

31、an d d ideal SBR 1721 Tg SBR 1721 15. August 2003 Mario Negri Folie: 32 Different 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 80 85 90 95 100 105 110 115 120 125 130 8090100110120130140150160 Rolling Resistance Traction better Silica Technology Replacement and R/LT Europe and NA

32、Europe OE Tyres NA OE Tyres NA Different Market Needs (2), 不同市場需求（不同市場需求（2） 15. August 2003 Mario Negri Folie: 33 Tread TechnologyPolymer Type RR Coefficient CB and E-SBRSBR 1712/211.2 - 1.1 CB and S-SBRVSL 2525-0 modified better 1.1 - 1.0 CB/silica and E-SBRSBR 1712/211.0 - 0.9 silica and E-SBRSBR

33、1712/210.95 - 0.8 silica and S-SBRVSL 5025-1 VSL 5025-1 HM modified better 0.8 - 0.6 Tread 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 Mario Negri Folie: 34 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

34、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 BR high cis Nd-BR Li-BR S-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 -100 Traction Glass Temperature Tg 15. August 20

35、03 Mario Negri Folie: 35 A Recommendation 建議建議 For the overseas and domestic OE requirements, 對于國內(nèi)外廠家的要求：對于國內(nèi)外廠家的要求： the evaluation of tread compound with 20- 50 phr of solution SBR VSL 5025-1 in the absence and presence of silica is recommended to enhance both the traction performance and low rolli

36、ng 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(dòng)阻力改善牽引性能及滾動(dòng)阻力 15. August 2003 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 fo