Extrusion Lines for Performance Tire Manufacturing

A company of ThyssenKrupp Technologies

ThyssenKrupp Elastomertechnik
1

TK

Extrusion Lines for Performance Tire Manufacturing

Extrusion lines with cold feed pin-type extruders and hydraulic extrusion heads offer the latest and most successful concept for the automobile, light truck and truck tire production at present. ThyssenKrupp Elastomertechnik designs, supplies and erects complete extrusion lines for the production of all tire components such as treads, sidewall and apex strips and innerliners. Further we have extrusion lines for the production of tubes and technical rubber articles in our program. Besides we are experienced in modifying, re-equipping and renewing existing extrusion lines. Along with our standard program we also manufacture extrusion lines according to customer-specific data.

Upstream Equipment Extruders Cold and warm feed extruders by ThyssenKrupp Elastomertechnik are used world-wide in all areas of caoutchouc processing. Pin-Type Extruders Characteristics and Advantages Maximum output Excellent homogeneity of the material, low shearing forces and low outlet temperature Extremely economical Compact design High extruder torque ensures that even hard rubber compounds can be processed Extremely effective temperature monitoring for precise heat transfer in the temperature control zones Well-dimensioned pins which avoid pin damage and

achieve good shearing results in the material The CAD/CAE-optimized extrusion screw design takes into account the properties of the material for all materials (SBR, NR, SR, Silica etc.) Computer-aided extrusiondata-expert system by Krupp Elastomertechnik for evaluation of output data on the basis of material data Especially designed extrusion screw zones ensure intensive homogenizing of the extrudate Exacting production tolerances of the extrusion screws result in lower material reflux and higher, constant pressure build-up The special feed roller design ensures minimum material loss at the feed roller (0.05%)

Triplex Extrusion Line with Feeders and Cooling Conveyors

Pin-Type Extruders of a Triplex Extrusion Set KGS 200/150/90

Pin-Type Extruders - Dimensions ThyssenKrupp Elastomertechnik constructs extruders with an extrusion screw diameter of D = 60, 90, 120, 150, 200 mm and 250 mm. The extrusion screws are available in lengths of 12xD, 14xD and 16xD. Extrusion screw length = 12xD For preheating the material which is fed to the calender with reduced number of pins. Back pressure before the screw tip: 20 to 50 bar Extrusion screw length = 14xD For bulk profile strips with low requirements for material homogeneity. Back pressure before the screw tip: 50 to 100 bar Extrusion screw length = 16xD For automobile and truck profiles and other state-of-theart extrusion components. The following refers to all sizes: The geometry of the extrusion screw, the used material, allocation and number of pins as well as the screw length depend on the respective application.
KGS 200/16 with Head locked by C-Clamp

Single Extruder KGS 150

Single Extruder KGS 90 for Apex

Pork Chop Extruder KGS 250

Pin Type Extruder KGS 200 with a Special Head for Rectangular Profiles

KGS Extruder Type 60 90 120 150 200 250

Ration length: Screw dia. (L/D) 12/14 12/14/16 12/14/16 12/14/16 12/14/16 12/14/16

Pins

Output*)

Max. speed**)

Drive Rating

Max. Torque**) kNm 5 10.5 25 48 115 200

Heating Cooling

kg/h 5x6 5/6/7x8 6/8x8 6/8x8 6/8/10x12 7/9/10x12 230 600 1000 1800 3200 5000

min-1 65 60 55 50 32 28

(approx.) kW 30 60 110 235 310 510

3 3 3/4 3/4 4 4

*) = Depending of rubber compound and profile cross section **) = Depending of required max. speed and torque values

Extruder / Extrusion-Heads
Simplex Duplex Triplex Quadruplex Rollerhead

Maximal Extrusio n

MW 300 MW 450

MW 650

MW 800

MW 1000

Compound and Shape of Profile

Extrusion-Lines Sidewall Tread Tub Innerliner

Extruders Special Applications Warm feed extrusion Strainer extruder Pelletizer Calender feeding Simplex profile extrusion such as innerliners, tube production Multiplex profile extrusion for vehicle tire components (duplex, triplex, quadruplex)

Extrusion Head The extrusion head is the core of an extrusion line. The design of the extrusion head with the channels and tools has great influence on the production output of the line and quality of the product. We are able to adjust the extrusion channels and the tools exactly to the respective application and its conditions. Extrusion Head with patented interlocking System Characteristics and Advantages The world-wide patented hydraulic hammer-head interlocking system offers easy access to each channel for cleaning and maintenance.

Individual interlocking systems in the top and bottom head part allow quickest change of materials. The hammer-head system meets the highest requirements, withstands the highest internal pressures, is safe, durable, space-saving, effective and free of wear. Besides, the design ensures a high standard as far as safety and precision are concerned. Dimensions and Configurations For all profiles used for tire production, ThyssenKrupp Elastomertechnik can provide an extrusion head. The extrusion heads are designed for pressures of up to approx. 350 bar. We provide extrusion heads for all profile sizes so that the entire

spectrum from small automobile tire treads up to wide truck tire treads, i.e. up to 1100 mm, is covered. We construct extrusion heads with a base width of 500, 650, 800, 1000, and 1200 mm. We supply simplex, duplex, triplex and quadruplex extrusion heads. For optimum durability at small dimensions, we manufacture the head parts of forged highgrade steel. Thus, the construction is robust and at the same time, the operating and maintenance staff can easily access the extrusion head from all sides.

Tread Production with Shrinkage Conveyor

Sidewall Production for Passenger Cars with a Triplex Extrusion Line

Self Threading for Sidewall Strips

Sidewall Transition

Tools Replaceable channel inserts are available for the production of diverse profiles with one extrusion head. Already the channel inserts start forming the profile. The profile tools consist of a precisely manufactured cassette body, the profile die and the final die. The handling of the cassette is very easy. The interlockings for the tools in the extrusion head are designed in such a way that it is possible to replace the final die when the cassette remains in the extrusion head. Cassette changing: Manually, possibly with a hoist One or two cassettes fastened to the extrusion head with swivel arms Semi-automatic cassette changing device Displacing the cassettes between stock and extrusion head with hydraulic cylinders

Rollerhead Extruder Unit for PC-Innerliner

Examples of existing Extrusion Sets Simplex and duplex profile extrusion heads (bolted or hydraulically locked) Apex extrusion heads (simplex, duplex) Calender feeding, roller head, pork chop, strainer, pelletizer Tube extrusion head

Triplex Extrusion Set

Downstream Equipment The downstream equipment of the ThyssenKrupp Elastomertechnik extrusion lines offers all components required for the production of treads and sidewall strips in different variants. Examples: Feeding conveyors for extruders Metal detector Marking the contaminated material and manual cutting out or automatic cutting out the contaminated material Speed adjustment of the feeding conveyor with a position control for the material loop or the regulating balancer in front of the extruders hopper Easy, practical handling of the feeding conveyor Take-away conveyor / takeaway roller conveyor with a power-driven head roller, if necessary, with a swivelaway part to ensure easy access to the extrusion head Shrinkage roller conveyor definite or variable shrinkage
Wind-ups for Dual Sidewalls Shuttle Conveyor for Wind-up Dual Sidewalls

Dual Wind-up Station for Innerliner

Wind-up Systems for Tread and Sidewall

Transition for Single Strip to Wind-up

Measuring devices Continuous scale one scale or two scales side by side Width measuring device upstream and downstream the cooling line Profile measuring device (laser scanner) - online or offline Checkweigher Length measuring device Marking devices Stripe marking device Code marker - writing or imprinting Calender Stitchers Cementing devices Bottom cementing device Tread-end cementing device Cooling lines Immersion cooling and/or spray cooling, Manual or automatic threading, cooling system
Transport of Tread through Cooling Line Transition of Sidewall to Cooling Tank No. 2

Entrance of Tread into the Cooling Line

Speed Control by Dancer Roller

Skivers Rotating skiver or cutting blade Booking devices for material Wind-up stations winding the material on reels or in cassettes Devices for automatic booking of the cut material strips

Sidewalls entering the Wind-ups

Transition of single Tread into Incline Conveyor

10

Characteristics The material is to be transported through the extrusion line tension-free as far as possible. Dancer rollers are installed between the conveyors. The tension arising in the material when cooling down is reduced at these transfer points by changing the length. The speed of the conveyors is adjusted to the length change by controlling the position of the dancer rollers. The load of the dancer rollers on the material can be adjusted to the respective product, i.e. the load is a parameter in the recipe which is stored in the PLC. ThyssenKrupp Elastomertechnik constructs servo-controlled skivers for cutting the tread for

automobile, light truck and truck tires which can perform up to 28 cuts/min with a mechanical cut precision of 0.5 mm. We supply booking systems which are adjusted to the respective mode of operation. They include manual removal via simple reel winders and efficient cassette winding systems up to entirely automatic booking-wagon feeding conveyors. Electrical System Control and monitoring of the extrusion line with programmable logical controlers (PLC) Data management (input,

output, evaluation) with a visualization system on a PC Graphical representation of the extrusion line and display of the most important process data Output of the process data either graphically or in tables Acquisition, representation and filling of events, messages and alarms Recipe management: all input data (set values, tolerances etc.) for the extrusion line are stored in a recipe with reference to products, for production, the values are transferred from the recipe to the PLC Evaluation and filing of the process data for quality assurance Management of user authorizations

Quality assurance of our products for the products of our customers! In our company we apply a certified quality management system the requirements of which are regularly checked and optimized on the basis of the standards DIN EN ISO 9001 (quality assurance) and EN 729-2 (welding engineering). The latest audits were successfully performed in 2001 and certified respectively.

Innerliner Extrusion Line

11

ThyssenKrupp Elastomertechnik GmbH Gummimischtechnik Asdorfer Strae 60 D-57258 Freudenberg P.O. Box 11 80 D-57251 Freudenberg Tel.: +49 (2734) 4 91-0 Fax: +49 (2734) 4 91-1 50 e-mail: vertrieb@tkt-elf.thyssenkrupp.com www.thyssenkrupp-elastomertechnik.com
12

ThyssenKrupp Rubber Machinery, Inc. 1701 N. Topeka Blvd. P. O. Box 82 50 Topeka, Kansas 66608 Tel.: +1 (785) 235 23 36 Fax: +1 (785) 235 13 31 e-mail: sales@tkrmusa.com ThyssenKrupp Rubber Machinery, Inc. 1010 West Main Street Kent, Ohio 44240 Tel.: +1 (330) 678 11 18 Fax: +1 (330) 673 28 65 e-mail: sales.kent@tkrmusa.com
47/1/0686 e2 080210 T

ThyssenKrupp Elastomertechnik GmbH Kautschuktechnik Seevestrae 1 D-21079 Hamburg P.O. Box 90 05 52 D-21045 Hamburg Tel.: +49 (40) 77 179-0 Fax: +49 (40) 77 179-3 25 e-mail: vertrieb@tkt-elh.thyssenkrupp.com www.thyssenkrupp-elastomertechnik.com

ThyssenKrupp Belisce Elastomertechnik d.o.o. Trg Ante Starcevica 1 p.p. 51 - 52 31551 Belisce, Kroatien Tel.: +385 (31) 663-416 Fax: +385 (31) 662-916