摘要
由于我国现代化步伐的飞速前进,汽车产业的迅速发展,现在越来越需要大量高质量的轮胎。而拥有高质量的轮胎成型硫化设备才能保证高质量轮胎的生产,即轮胎成型硫化设备的水平决定着轮胎生产的水平。当今社会主要的轮胎成型的方法有缠绕法、模压法、离心浇铸聚氨酯法等。但这些设备和成型方法仍存在一些亟待解决的问题:第一缠绕法和模压法都属于一种将预先制好的胶片进行贴合的工艺,其使用设备多、消耗能量大,制造工艺复杂、且制品胶层之间致密性差,易出现脱层现象,胎冠使用寿命短;二是因材料的特殊性聚氨酯轮胎内生热现象严重且不易导热,并且其抗拉伸、抗撕裂、耐磨性和抗滑性能差,由于这些不足的存在,阻碍了聚氨酯轮胎的进一步推广。
本设计深入研究了各种轮胎成型设备的性能和特点,结合青岛科技大学高分子加工机械研究所现有的专利和技术,全新设计了三工位一步法注射轮胎成型硫化机组。以此使轮胎制品拥有“高质、高效、低成本、低能耗”的优势,从而进一步满足了市场的需求。本文的主要研究成果如下:
(1)首次将一步法注射技术应用于注射轮胎胎冠,大幅度提高轮胎的表面质量和整体胎体的使用寿命,从而提高了轮胎的整体性能和生产效率。
(2)注射轮胎成型硫化机组具有三工位一体式结构,整套设备可以在三工位同时进行注射、硫化和脱模等工作,极大的提高了生产效率,实现了连续化生产。并且可以在不超过设计的锁模力下更换不同的模具,可以应用在大、中、小型模具的注射成型硫化。
(3)在本次设计开放式轴承座和弹簧缓冲装置,提高了压力传感器的可靠性和控制精度,解决了电动螺旋锁模机构偶尔卡死时无法卸载的难题。
(4)注射口开在专门的流道板上,故而整个压合力均作用在流道板上,而流道板通向下模的方向又是向上的,这样解决了传统注射口开在模具上模具容易移位的问题,从而使得在合模时不会造成合模力偏心。注射口下移到单独的流道板可以使胶料在模具中自下而上流动,从而避免偏心和漏胶。
(5)轮胎顶出装置采用了机械传动和电磁传动相结合的方式,开创了硫化机历史上的先河。通过电磁离合器的采用可以使得顶出电机和上面的合模电机独立工作,效率更高,且操作更加简便。
(6)设计了三工位的横向移动装置,采用了高精度滚珠丝杠导轨副、齿轮齿条作为传动装置,确保注射装置在移动中能够实现高精度的可靠定位。
(7)本次设计中采用了先进的传感技术。压力传感器可以准确的控制注射压力,压合力和锁模吨位,提高精度,进而提高轮胎整体的质量。
(8)运用传统设计、三维造型设计和三维过程模拟、有限元分析相结合的方式,从而减少了设计制造时间、降低了成本、可提前对样机先评估,为产品的开发提供了检验手段。
总之,三工位一步法注射轮胎成型硫化机组属于轮胎制造行业内首次创新设计,在设备方面具有:生产效率高,工作精度高,生产连续化、操作自动化的特点;在制成品方面具有:轮胎整体胶料结合更加致密,轮胎整体寿命大幅度提高。因而本次设计具有当今社会成型轮胎设备所不具备的多种优点,具有明显的创新性。
Because the development of the modern society is so rapid, the car industry has grown so large. So the requirement of the tire has become more and more and the need of it’s quality become higher and higher.. So we must have the the high-quality Vulcanized rubber molding equipment to guarantee the High-quality tire. In other words, the level of the Vulcanized rubber molding equipment is controling the level of the tire production. There are three main methods at present, including winding, molding, centrifugal casting method method and so on. However, these methods still have so many problems,firstly, both winding and molding methods is a kind of procedure which join the tire and the prepared rubber sheet together. These technics use a lot of equipments, cost a large amount of energy and use such complexed manufacture procedure. The compactness between rubber layers is not tight, so the layers usually fall off very easily when the tire working. Secondly, because only the special material can suit the centrifugal casting, and this material stretch resistance, tear resistance, abrasive resistance, skid resistance is relatively poor. All these disadvantages prevent the development of the centrifugal casting.
In order to adapt to the market which requires high quality, high efficiency, low cost, low power for the tire. This thesis researches deeeply about the characteristic and performance of all kinds of tire vulcanization molding equipment. After that, we combine that with the patent and technology of Qing Dao University Science & technology’s macromolecule mechanic research center. Then we design the new three stations one step injection molding vulcanization. the main achievement of this paper are as below:
(1) One-step injection molding technique is used in the injection tire for the first time which improves the quality of the tire surface and the the whole tire. So this method improves whole performance and running efficiency of the system greatly.
(2) Thanks to the three-station integral structure, the whole equipment not only stresses rationally, deforms little but also has highly working precision, compact structure and small occupation area. This equipment can applied for the small, medium, big product at the same time. It can injection, vulcanization mold uploading at three station. So its characteristic is continuous production and automation
(3) The design of the open bearing chock and the spring buffer The pressure sensors’s control and the reliability has been increased and the problem of unable unloading when the electrical spiral clamping device is jammed accidentally has been solved because of the design of the open bearing chock and the spring buffer.
(4) The injection hole is setted in the special plate, so the whole press act on the plate, the fluent of the rubber from the plate up to the lower plate. This design solves the problem of the force of the tooling problem which made the tooling move so that circumference force become equality. This method made the rubber flow from the downward to the top freely incase eccentric leak rubber.
(5) The equipment of knocking out combined the mechanic and electromagnetism which is totally new. Via magnetic clutch made the top motor and lower motor operate separately, so the whole machine become more efficiency and operate freely.
(6) I designed three statiom movement equipment which use high precise ball screw. pinion and rack to make sure the machine can located itself precisely.
(7) The machine uses advanced digital sensing technology which can control inject pressure force, clamp force, and it improve the precise of the machine and made the time perfect.
(8) The traditional design method, three-dimensional forming design and together with three-dimensional process simulation is used in this paper,cuts off the time of the design, lower the cost, we can evaluation the product before we made it, this technology can provide the measure of examine.
In summary, there are so many advantages in the three-station injection tire molding vulcanization which the others don’t have, and obviously, it is innovative.
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