Tire Building Machines
Unistage Tire Building Machine PCR/LTR-1+2
The tire building process
Process sequence (Unistage)
Step 1
Carcass building by use of pre-assembled innerliner, abrasion strip and sidewalls (PA), body ply. Manual bead loading, automatic bead setting.
Step 2
Belt building with cap ply /JLB and tread. Manual tread loading and splicing. Option: reel tread processing and manual splicing. (Step 2 synchronized with steps 1 and 3)
Step 3
Automatic shaping and assembly of the carcass and the belt package, stitching. Manual green tire removal. Option: automatic removal of green tire.
Operating personnel:
1 operator
tire design:
- radial tires (textile cord)
- 1/0 or 2/0 ply turn-up mode
- unistage process
- including 2 belt plies (steel cord)
- cap ply or jointless band (JLB), TOS and SOT tire construction
To meet our customers' expectations, every tire building machine
must be able to produce a large amount of different tire types and
sizes while making a change of dimensions within minutes possible.
The tough requirements of everyday production call for a rugged
machine which is wear-resistant and easy to maintain. Know-how and
experience gained over decades have enabled us to design machines which
are up to the task.
The PCR/LTR-1+2 has following advantages:
- automatic pusher/bead setting system, PLC-controlled
- short stop periods due to tooling components which fit several tire dimensions
- individually adjustable pusher forces and movements
- increased production stability through fault diagnosis system
- increased production output through optimized operating cycles
Product quality
The automation of all essential work steps such as component length cutting, feeding, positioning, and splicing make the outstanding quality of the assembled green tires possible. Length deviations caused by the material used are automatically corrected by adjusting the feeding and drum speed to guarantee product tolerances to within fractions of one millimeter. All machine components comply with tire industry quality standards.
Performance
The PCR/LTR-1+2 tire building machine can produce up to 1,400 green tires per day. The high degree of automation allows even larger output quantities in correlation with an optimization of production logistics. This is achieved by meshing individual production steps and through the high speed of up to 60 m/min with which the tire components are transported and applied (up to 400 m/min of JLB).
Retooling time
Short retooling times are made possible through tire recipes stored in the PLC. These recipes contain all essential parameters for automatic production of individual tire types and sizes. A further reduction of retooling time can be achieved during change of dimension by using variable toolings.
Machine logistics
Enhanced output performance through
- large material rolls supplied by customer
- material cassette systems
- personnel to (un)load the materials
- optimization of existing logistic systems through better cooperation between customer/supplier
Highlights of the new PCR/LTR-1+2 control system
The modular control system is programmed to meet today's demands, such as
- digital technology
- bus system technology
- hardware and software modularly implemented according to TBM- function, programmed according to IEC 61131-3
- intelligent HMI- and diagnosis systems
- digital servo drives
- high degree of availability
- menu-guided recipes
- intelligent fault handling systems
- communication (PC) with the higher ranking computer systems
1 Belt building machine
- precision drive with AC servomotor
- compact design, low space requirements
- belt building drum with two lateral setting positions for fast and precise belt component assembly
2 Belt building drum
- infinitely variable diameter setting for various tire sizes
- all belt building drum segments equipped with magnets which hold the first and second belt ply
- diameter can be changed by using a set of slip-on segments
3 Automatic belt server with customized let-off station(s)
- for steel cord belts
- automatic precision splicing
- belt ply placement monitored by CCD camera systems
- compensation of belt tip deviations
- stop and alarm messages for unacceptable material deviations
- automatic change of tire size via PLC tire menu
4 Automatic ply server for assembled innerliner (PA) and one or two carcass plies (BP)
- automatic cutting of pre-assembled innerliner and carcass ply to pre-determined lengths
- automatic length checks to regulate the feeding speed and to control the splice width
- automatic width measurement
- automatic center control of components via CCD camera systems
- automatic component application and splicing via multidisc roll
- automatic adjustment of the carcass splice distances
- large reel let-off stations
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1 Belt building machine |
3 Automatic belt server with customized let-off station(s) |
5+6 Transfer station with transfer ring
- infinitely variable automatic adjustment to the belt diameter
- high repetitive accuracy of transfer ring positioning by mechanical locking when the belt is being transferred from the belt building drum to the tire building drum
7 Bead setting & pushing device
- the beads are centered and precisely set by a bead setting device integrated in the transfer unit
- a mechanically adjustable pusher device guarantees precise symmetrical turnover; parameter settings are used to adjust the pusher forces
8 Tire building unit
- precision drive with AC servomotor
- standard flange seat for various tire building drums
- compact design, low space requirements, good accessibility
9 Tire building drum
- diameter-limited bead clamping system ensuring true running
- adjustable in width by spacer
- short changing times due to the drum's symmetrical structure
- internal precision spindle for width adjustment
- "sidewall over tread" and "tread over sidewall" assembly methods
- customized drum systems with six, four, two bladders or without bladders available
4 Automatic ply server for assembled innerliner (PA) and one or two carcass plies (BP)
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5-7 Transfer station with transfer ring / Bead setting & pushing device |
8 Tire building unit |
11 Reel tread server
- precision guidance of tread ensured by center or edge control
- mechanical height adjustment to the belt building drum diameter
15 Automatic reel tread
- automatic centering, length measuring, ultrasonic cutter
- placement of tread from the top
16 JLB server-tension control
- narrow cap strip (jointless band) can be processed, various winding patterns, freely programmable<
17 Automatic cap ply server
- cap ply can be processed as required
19 Chafer server
- for textile and steel cord material
19.1 Cushion strip server
- automatic application and cutting of cushion strip material
11 Reel tread server
15 Automatic reel tread cutting
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JLB applicator |
16 JLB |
