The traditional methods of layering and setting up treads in the production of engineering machinery tires suffer from poor compaction and limited product variety, especially when manufacturing large-sized tires, where labor intensity is extremely high. Most foreign countries use tread winding machines for engineering machinery tires, such as the ALPHA-R model from the Italian company Malangoni. However, domestic bias tire winding machines lack the capability to wrap around the sidewall, resulting in gaps in shape, quality, and production efficiency. This paper provides an overview of the tread winding process and quality control for the BTXC-3 engineering machinery tires produced by Chemical Baichuan Automatic Control Co., Ltd.
The tread winding process typically involves five key steps: extrusion, conveying, pressing, cooling, and winding. The overall process and control system of domestic bias tire winding machines are quite similar. Among these, the winding quality is one of the most critical parameters. If the weight of the tread is too low, the green tire may not fully fill the mold or become porous during vulcanization; if it's too heavy, it leads to wasted time and materials. The BTXC-3 engineering machinery tire tread winding machine can maintain a tread quality error within 2% to 5%, with the winding quality mainly controlled by the upper machine and PLC.
By opening the Twister software on the BTXC-3 tread winding machine, users can access the "Process Parameter Management" menu to select or create a recipe. After selecting or creating a new recipe, a password verification dialog box appears to ensure process security. Once the correct credentials are entered, users can adjust process parameters through the interface. In this setting, the winding shape is determined by the number of winding segments, height, and layers, with the outer layer’s left and right limits covering the inner ones. The zero line in the thickness curve represents the carcass’s outer diameter, while the outermost layer’s shape and green tire diameter determine the winding volume.
Users can also modify the curve by clicking on nodes and adjusting thickness values, distance from the midpoint, and correction values. Since the curve is symmetrical, only one side needs to be set. For multi-layer winding, the program automatically generates similar curves for subsequent layers. Compared to the ALPHA-R machine, the BTXC-3 offers a more intuitive and user-friendly interface.
After determining the shape, users can fine-tune the thickness compensation parameter to adjust the actual winding thickness. Over time, due to environmental changes or mechanical wear, the winding quality may deviate from initial settings. In such cases, only minor adjustments to the thickness compensation parameter are needed, without modifying the entire curve. The PC software can estimate the compound quality based on the winding curve, blank, and material density, allowing for accurate quality prediction even when formulations change.
Accurate measurement of the actual winding thickness is crucial for maintaining shape and quality. The BTXC-3 uses a cylinder, slide ball bearing, and measuring mechanism to calculate thickness. When the tire diameter increases after one rotation, the measuring head retracts, and the analog signal is sent to the computer via a high-speed counter. The PLC continuously compares the required and measured thickness along the drum axis. If the thickness is insufficient, the machine slows down until the desired thickness is achieved.
To ensure precision, several factors must be considered:
1. **Measuring Head Cylinder Pressure**: Excessive pressure causes the roller to press deeper into the rubber, leading to inaccurate measurements. A pressure below 4.5 MPa is recommended for optimal performance.
2. **Measuring Head Offset**: The offset direction should oppose the winding direction to minimize lag. An offset of 25–40 mm is ideal for strips between 60–80 mm wide.
3. **Rubber Strips**: Proper edge alignment and guide roll tapering are essential for consistent wrapping. The lower side of the strip should always align with the far left of the guide roll.
4. **Winding Drum Axial Speed**: Too slow a speed reduces efficiency and may cause grooves, while too fast may compromise compaction and venting.
5. **Strip Thickness, Width, Temperature, and Flash**: These factors significantly impact winding quality. A width of 60–80 mm balances efficiency and control. Strip temperature must be carefully managed to avoid deformation or poor bonding. Flash edges can affect the final quality of the green tire.
By controlling the winding speed, measuring head hysteresis, and real-time thickness monitoring, the BTXC-3 ensures accurate tread quality and shape. The thickness, width, and temperature of the strip, along with flash edges, all play a role in determining the final quality of the tire. Overall, the system provides a reliable and efficient solution for engineering machinery tire production.
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