全钢子午胎的加工工艺及轮胎新技术

1、An Introduction on Processing of TBR Tire& New Tire Technology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RheinchemieMario Negri 马旅欧马旅欧15. August 2003 2022-5-7 Folie: 1 Content内容内容1. Major differences in tire structure and performance between truck bus radial (TBR) and cross-ply tire (TBB). 全钢子午胎全钢子午胎(TBR)和

2、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能方面的主要差别2. An introduction on TBR tire production line. 全钢子午胎生产线的介绍全钢子午胎生产线的介绍3. Main problems and counter-measures against those problems in the process of TBR tire production. 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. Material Characteristics of TBR tire components.

3、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. New Tire Technology 轮胎新技术轮胎新技术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 Truck Bus Cross Ply Tire 斜交胎斜交胎 Truck Bus Radial Ti

4、re 全钢胎全钢胎 Carcass 胎体胎体 Textile Cord 8 Ply 8 8 层纤维帘线层纤维帘线 Steel Cord 1 Ply 1 层钢丝帘线层钢丝帘线 Belt 带束层带束层 Textile Cord 2 Ply 2 层纤维帘线层纤维帘线 Steel Cord 4 Ply 4 层钢丝帘线层钢丝帘线 15. August 2003 2022-5-7 4Main differences in tire performance between TBR and TBB tire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面的主要差别050100150ABRAS

5、IONRESISTANCE 耐磨性耐磨性BELT ENDURANCE带束层耐久性带束层耐久性ROLLING RESISTANCE滚动阻力滚动阻力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02040608010012014016060708090km

6、/hrC1000-20 TubeBias11-22.5 Tubeless1000R20 Tube11R22.5 TubelessRadial15. August 2003 2022-5-7 6PROCESSING EQUIPMENT加工设备加工设备 PROCESSING EQUIPMENT 加工设备加工设备1. Extruding 挤出挤出 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” 胎侧胎侧/胎肩垫胶胎肩垫胶 Rim-Strip / Apex Strip

7、 : 6”x 4.5” 耐磨胶条耐磨胶条/三角胶条三角胶条 Belt Edge Cushion : 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) Steel Carcass 钢丝胎体钢丝胎体 Steel Cal. Line + Steel Radial Cutter & 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午线裁断机和接合机 2-2) Steel Belt &a

8、mp; Steel Chafer 钢丝带束层钢丝带束层 及及 钢丝子口钢丝子口 Steel Cal. Line + Steel Angle Cutter & 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 * For more details, discuss with machinery manufacturer 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 2022-5-7 7TBR TIRE PRODUCTION LINE 全钢子午线轮胎生产线全钢子午线轮胎生产线 15. August 2003 2022-5

9、-7 8Steel Cord Calender Line钢丝压延生产线钢丝压延生产线15. August 2003 2022-5-7 9Single Stage Building Machine for Truck-Bus Radial Tire全钢子午胎一段成型机全钢子午胎一段成型机15. August 2003 2022-5-7 10Cutting & Splicing Machine for Steel Radial Carcass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 2022-5-7 11Assembling process o

10、f Bead and Apex胎圈和三角胶的复合胎圈和三角胶的复合15. August 2003 2022-5-7 12Assembling plate for dimensional stability of Apex in extruding process 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 2022-5-7 13Creel for Metallic Cord Spools钢丝帘线锭子架钢丝帘线锭子架1. Lower humidity inside creel room be better against w

11、ire corrosion 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. Thicker shaft for spool recommended to avoid the crooked shaft. 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 2022-5-7 14Metallic Cord Inlet in the Calender压延机钢丝帘线入口压延机钢丝帘线入口15. August 2003 2022-5-7 151-3) Measures to reduce irregular arrangement of

12、 cord 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Inside Creel Room Proper procedure should be needed for arranging hundreds of steel cords just before starting calendering. 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 2022-5-7 16Major Manufacturing Problems and Measures of TBR

13、Tires全钢子午胎的主要的生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 2022-5-7 171-1) Measures to reduce irregular arrangement of cord 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 2022-5-7 181-2) Measures to reduce irregular arrangement of cord 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Edge gum width should be controlled during ca

14、lendering在压延过程中，应该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, the following wide distance between cords at the splice area appears in splicing process of carcass ply.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 Splicing point接合点接合点 Normal 正常正常 Too wide 太宽太宽 15. August 2003 2022-5-7 191-4) Measu

15、res to reduce irregular arrangement of cord 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In the process of tire Building,在轮胎成型过程中在轮胎成型过程中1.Butt splice of carcass ply be recommended for carcass quality 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. The amount of overlap be minimized for Belt splice (max. 1 cords) 带束层结合过程中钢丝搭

16、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 2022-5-7 202. Air trap problems near the splice area of Inner-inerfor100%Butylapplied to Inner-liner compound 100% 丁基胶内衬层搭接部位的存气问题丁基胶内衬层搭接部位的存气问题2-1) Measures to reduce the air trap : Inner-liner be cut with hot knife by lower than 30 内衬层应用热刀以小于内衬层

17、应用热刀以小于30度的角度裁断度的角度裁断 2nd inner-liner第二层内衬层第二层内衬层 Lower than 30 degree 小于小于30度度 1st inner-liner第一层内衬层第一层内衬层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, 对于使用寿命长的胎面部件对于使用寿命长的胎面部件 1-1) To employ medium sulfur/higher accelera

18、tor system (1.5/ 1.2-1.5 phr). 采用中硫高促系统（采用中硫高促系统（ 1.5/1.21.5phr) 1-2) To introduce higher antioxidant level 6PPD/TMQ (2/1 phr). 是用高性能的防老剂是用高性能的防老剂(6PPDTMQ 2/1phr) 2. Better casing performance for 2-3 times recapping be needed as follows. 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

19、条： 2-1) Inner-liner 内衬层内衬层 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 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 胎体和带束层帘布层胎体和带束层帘布层 Higher

20、 adhesion of compound to steel cord be required. The following steel wire structure normally be used. 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) 1w 3(0.2)+6(0.35)HT for carcass for belt 胎体胎体 带束层带束层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 胎侧胶胎侧胶 Normally 60 phr of BR being employed to improve flex fatigue resistance. 一般使用一般使用60phr BR来改善耐曲挠龟裂性能来改善耐曲挠龟裂性能 2-4) Rim strip compound 轮辋耐磨胶条轮辋耐磨胶条 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) Shoulder Pad 胎肩垫胶胎肩垫胶 Lower heat build up performance and higher flex fatigue resistance being required. Optimum volume be needed against ply separation. 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

23、止帘 布层剥离布层剥离 15. August 2003 2022-5-7 24New Tyre Technology 新轮胎技术新轮胎技术The green tires 绿色轮胎绿色轮胎Light weight tires 轻量轮胎轻量轮胎Coloured tires 彩胎彩胎The composite wheel 复合胎复合胎15. August 2003 2022-5-7 25Different Market Needs (1) 不同市场需求不同市场需求USAEUROPEJAPANbefore 1992after 1992W-gripWearRRlowhighhighhighaverage

24、lowhighlowhighW-gripWearRRaveragehighhighhighaveragehighhighlowhigh15. August 2003 2022-5-7 26Radial Truck Tyres : Company requirements卡车子午胎：公司要求卡车子午胎：公司要求Lower manufacturing Costs by : 如何降低成本如何降低成本Reduced man power, 减少人工减少人工Short production Cycle time 缩短生产周期缩短生产周期Consistant production rate & qu

25、ality 稳定的生产速度和质量稳定的生产速度和质量Size change flexibility, 尺寸变化灵活性尺寸变化灵活性Scrap reduction 降低废品率降低废品率15. August 2003 2022-5-7 27Radial Truck Tyres : Trends卡车子午胎：趋势卡车子午胎：趋势Reduced tyre components 减少轮胎部件减少轮胎部件Weight reduction 降低重量降低重量Low rolling resistance 降低滚动阻力降低滚动阻力Good uniformity 良好的均匀性良好的均匀性Retreadability

26、增加胎面翻新率增加胎面翻新率Long life tread 胎面使用寿命长胎面使用寿命长Direct extrusion 直接挤出直接挤出15. August 2003 2022-5-7 28Target for the Green Tire050100150NoiseSkid ResistanceAbrasionHandling PropertiesRolling Resistance噪音噪音滚动阻力滚动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 绿色轮胎应用绿色轮胎应用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绿色轮胎的概念：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

28、的燃料亿升的燃料15. August 2003 2022-5-7 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Tan Delta and Glass Transition TemperatureTan Delta 和和 Tg之间的关系之间的关系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对于不同市场的不同要求对于不同市场的不同要求808590951001051101151201251308090100110120130140150160Rolling ResistanceTractionbetterSilica TechnologyReplacement 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 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轮胎技术及滚动阻力轮胎技术及滚动阻力15. August 2003 2022-5-7 33Structure / Property - Relation (2)结构与性能之间的关系（结构与性能之间的关系（2）Important Tyre Properties:Dependance on Glass Transition Temperature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)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建议建议For the overseas and domestic OE requirements, 对于国内外厂家的要求：对于国内外厂家的要求： 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. 建议使用建议使用20-50phr溶聚溶聚SBR VSL5025-1(无论是否含有白炭黑来无论是否含有白炭黑来)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 2022-5-7 35Light Weight Tyres轻量轮胎轻量轮胎Light weight tyres reduce rolling resistance 轻量轮胎降低滚动阻力轻量轮胎降低滚动阻力Light weight tyres save material and therefore reduce tyre material cost 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Light weight tyres allow heavier wider wheels and low profile tyres for improved appearance/performan