Optimization of equipment and fine modification process to lay a solid foundation for comprehensive production and efficiency increase

Since 2014, the market competition of all steel radial tire has become increasingly severe. With overcapacity, the sales of medium and high-grade products with certain price advantages in the market are becoming more and more obvious. It is urgent to produce high-quality products efficiently, and the quality of tire largely depends on its process equipment. Therefore, the investment and selection of equipment has become the top priority, The company has successively introduced key equipment for tire production from Italy, Japan and other countries and regions. These world-class process equipment have become a powerful guarantee for the production of high-quality tires. Shandong Hongyu Rubber Co., Ltd. has fully considered and implemented the technical innovation and the selection and configuration of phase II equipment.

1、 Key equipment

1. Japan Shengang internal mixer

The company purchased two internal mixers of Japan Shengang, one is bb430, which is used for the production of rubber compound, and the other is bb305, which is used for the production of final rubber compound. Kobelco is one of the world's famous internal mixer manufacturers. Among the tire manufacturing plants in Asian countries, the internal mixer accounts for nearly 70% and the equipment performance is very superior.

Bb430 adopts 6wi rotor, which is a patented product of Japan Shengang. The internal mixer equipped with this rotor has obvious advantages over the traditional two edge and four edge rotors in terms of mixing efficiency and mixing quality. Using the rotor, the white carbon black can reach 90 parts. The rotor is the general rotor of Goodyear factories all over the world and the main rotor of Zhengxin company.

The bb305 internal mixer adopts 4wn rotor, which is also a patented product of Japan Shengang. The low temperature effect of the rotor is very obvious, the production capacity is large, and the white carbon black can reach 120 parts. It is a universal rotor used by Sumitomo and Dunlop all over the world.

2. Automatic rubber turnover device of open mixer

The lower auxiliary machine of bb305 Shengang internal mixer is equipped with 2 sets of 710 and 1 set of 550 open mixer, which is used for unloading. Two sets of automatic rubber turnover devices are configured between the three open refiners. The operation of the device greatly improves the operation safety of operators, saves manpower, accurately realizes the automatic rubber turnover times specified in the process, and ensures the rubber mixing quality.

2、 Technological innovation

In order to meet the needs of the development of production technology, the equipment department of the company carries out technical innovation on the equipment in a planned, focused and step-by-step manner on the premise of achieving practical benefits according to the impact of equipment, product quality, quantity, cost, production safety, energy consumption and environmental protection.

1. The new rear pressing device of three drum forming machine is selected. The original rear pressing device adopts the form of traditional three groups of dynamic pressing rollers. Now the latest four groups of dynamic pressing rollers are selected, which has a significant effect on improving the pressing efficiency and ensuring the pressing quality, especially the pressing quality of tire shoulder and rubber core.

2. Gradually reducing the number of mechanical drums and increasing the number of capsule drums have an obvious effect on solving the problems of "solar umbrella" and sidewall bulging, and improving the quality of reverse packaging.

3. Reforming the power water valve group of the flexible die of the vulcanizer can not only reduce the power water loss caused by the overflow of the flexible die, but also completely remove the equipment damage caused by the cut-off of the air source during the mold closing overflow, reduce the equipment failure rate and save the maintenance cost.

4. The vacuum pumping pipeline in the thermal pipeline shall be reconstructed, and at least 1 minute can be saved for each boiler tire; The 0-bar exhaust valve is transformed from a three-way pneumatic cut-off valve to a two-way pneumatic cut-off valve, which greatly reduces the occurrence of curve tire with low tire pressure caused by 0-bar exhaust valve leakage.

5. The steam condensate is recycled and used for office and dormitory heating in winter, which can save about 350 tons of standard coal every winter; At the same time, 153000 tons of tap water can be saved every year after all production.

Equipment is the basis for the survival, development and growth of production enterprises. With the progress in the technical field and the increasing requirements for the performance of tire products, Shandong Hongyu Rubber Co., Ltd. has widely applied various new technologies, new processes and new concepts to the tire production process, which has played a good role in improving and improving the safety, reliability and economy of the equipment. At the same time, in order to better adapt to the development of the current situation, the company's equipment management has changed from static management to dynamic management, constantly update the concept of equipment management, comprehensively improve the production efficiency and management level of the enterprise, give full play to the equipment efficiency of the enterprise, and implement the concept of general mobilization to manage the equipment, so as to achieve the goal of optimal comprehensive efficiency of the equipment.