轮胎行业设备方案.pptx

1,罗克韦尔自动化OEM 团队,轮胎行业设备方案,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,2,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,2,1. 轮胎生产过程中设备简述,2. 轮胎成型机应用介绍,3. 裁断机应用介绍,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,3,子午线轮胎断面结构图,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,3,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,4,子午线轮胎断面结构图,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,4,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,5,轮胎的生产过程,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,5,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,6,工序一：密炼工序,密炼工序 把碳黑、天然/合成橡胶、油、添加剂、促进剂等原材料混合到一起，在密炼机里进行加工，生产出“胶料”的过程,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,6,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,7,工序二：胶部件准备/工段三:胎圈成型,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,7,原胎圈是由许多根钢丝挂胶以后缠绕而成的。用于胎圈的这种胶料是有特殊性能的，当硫化完以后，胶料和钢丝能够紧密的贴合到一起。,相关设备: 钢丝缠绕机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,8,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,8,在这个工序里，帘布将被裁断成适用的宽度并接好接头。帘布的宽度和角度的变化主要取决于轮胎的规格以及轮胎结构设计的要求胶部件准备工序,工序二：胶部件准备/工段四:帘布,相关设备: 90度帘布裁断机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,9,工序二：胶部件准备/工段五:三角胶贴合,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,9,在这个工段里，挤出机挤出的三角胶条将被贴合到胎圈上。,相关设备: 三角胶贴合机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,10,工序二：胶部件准备/工段六:带束层,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,10,这个工序是生产带束层的。在锭子间里，许多根钢丝通过穿线板出来，再和胶料同时穿过口型板使钢丝两面挂胶。挂胶后带束层被裁断成规定的角度和宽度。宽度和角度大小取决于轮胎规格以及结构设计的要求。 所有的胶部件都将被运送到“轮胎成型”工序，备轮胎成型使用。,相关主要设备: 小角度度帘布裁断机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,11,工序三：轮胎成型,轮胎成型工序 轮胎成型工序是把所有的半成品在成型机上组装成生胎，这里的生胎是指没经过硫化。生胎经过检查后，运送到硫化工序。,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,11,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,12,工序四：硫化,硫化工序 生胎被装到硫化机上，在模具里经过适当的时间以及适宜的条件，从而硫化成成品轮胎。硫化完的轮胎即具备了成品轮胎的外观图案/字体以及胎面花纹。现在，轮胎将被送到最终检验区域了。,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,12,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,13,工序五/六：最终检验工序/轮胎测试,在这个区域里，轮胎首先要经过目视外观检查，然后是均匀性检测，均匀性检测是通过“均匀性实验机”来完成的。均匀性实验机主要测量径向力，侧向力，锥力以及波动情况的。均匀性检测完之后要做动平衡测试，动平衡测试是在“动平衡实验机”上完成的。最后轮胎要经过X-光检测，然后运送到成品库以备发货。 在设计新的轮胎规格过程中，大量的轮胎测试就是必须的，这样才能确保轮胎性能达到政府以及配套厂的要求。 当轮胎被正式投入生产之后，我们仍将继续做轮胎测试来监控轮胎的质量，这些测试与放行新胎时所做的测试是相同的。用于测试轮胎的机器是“里程实验”，通常做的实验有高速实验和耐久实验,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,13,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,14,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,14,2. 轮胎成型机应用介绍,Agenda,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,15,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,15,Agenda,2.1 成型机简介,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,16,Different TBMs for different process& different type of tire 乘用/轻卡子午线轮胎全自动一次法成型机 Automatic Unistage Passenger/ Light Truck Radial TBM 乘用/轻卡子午线轮胎一段成型机 1st Stage& 2nd Stage Passenger/ Light Truck Radial TBM 两鼓全钢载重一次法成型机 2-Drums Unistage All-steel Radial Truck TBM 三鼓全钢载重一次法成型机 3-Drums Unistage All-steel Radial Truck TBM 三鼓子午线工程胎一次法成型机 3-Drums Unistage All-steel Radial OTR TBM 四鼓子午线工程胎一次法成型机 4-Drums Unistage All-steel Radial OTR TBM 巨型全钢工程子午线轮胎一次法成型机 Automatic Unistage OTR TBM . ,轮胎制造过程的重要设备-成型机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,17,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,17,成型机的性能要求,Higher requirement on control system of TBM,自动化程度高 节省劳动力 提高产品质量 生产效率高 控制各工序时间 缩短停机再启动周期 灵活性 变更轮胎规格 工艺调整 精度 直接影响轮胎质量,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,18,成型机的控制特点分析,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,18,成型机的控制特点 集合多种控制形式 离散控制 ：繁复的逻辑和时序控制，包括工艺流程，各部件的时序动作及逻辑配 合，数字量输出的控制(指示灯，气动原件，灯标步进电机，纠偏系统)，模拟量控制: 温度控制，压力控制，张力控制 运动控制： 多轴协动控制，对精度,速度,同步性均有要求。包括 定长，电子齿轮，电子凸轮，插补等运动 （旋转鼓，传送带，JLB排线，送料.） 传动控制 ：多台变频 ,变速控制（料卷 导开，裁刀运动） 安全控制： 光幕，急停，拉线，地毯 网络技术的应用及对第三方设备的兼容 人机界面，I/O ，变频，灯标、阀岛、纠偏系统 I/O总数较多，站点分散，类型多 DI ，DO，AI，AO，SSI，IK 性价比要求高 功能完善的人机界面 报警，配方,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,19,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,19,Agenda,2.2 成型机解决方案 RA 集成架构,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,20,成型机解决方案 RA 集成架构,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,21,1.GUARDLOGIX 集成安全控制器 它具备ControlLogix控制器的全部功能，可实现顺序控制，传动控制 ，运动控制 和过程控制的原有要求，并同时具有SIL3安全特性，这有助于确保安全控制。其双处理器架构（1oo2）和单一集成的软件开发，占有绝对优势。 2. 安全分布式I/O 在控制和监视复杂的安全系统回路的同时还具有传统分布式I/O的所有优点。安全I/O模块更易于在相同的接线上集成安全和标准控制。双通道模块支持模块用于Categroy 4和SIL3应用。与GUARDLOGIX完美配合,成型机解决方案 RA 集成架构,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,22,RA全系列安全产品,激光扫描器,安全光幕,安全地毯,安全 PLC,急停 & 信号,门开关,非接触型开关,密钥切换开关,安全接触器,安全继电器,拉线开关,安全变频器,安全使能开关,安全边缘,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,23,机械安全实例,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,24,轮胎成型机,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,25,全自动一次法成型机,安全地毯,边缘开关,激光扫描仪,安全行程开关,安全地毯,安全行程开关,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,26,全自动一次法成型机,安全光幕,安全行程开关,非接触式门开关,拉线急停,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,27,成型机解决方案 RA 集成架构,3.带有Guard MOTION的KiNETIX6000伺服驱动器 安全停车功能在不切断整个系统供电的情况下完成。 驱动器的输出可以禁止并消除电动机转矩，提供安全性和最大机器可用性。安全停车功能已通过TV认证，并符合EN-954-1 Category 3 和IEC-61508SIL3关于安全停车和预防意外重启动应用的要求。,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,28,Object based tag v.s traditional PLC address mapping,Objects consisting of IO, VFD, servo drive, instruction etc,方案亮点,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,29,方案亮点,Optional multiple programming language,Ladder,SFC,ST,FBD,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,30,Complete instruction of motion, drive, discrete, SIL3 safety etc,34 Motion instructions embedded,方案亮点,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,31,Complete instruction of motion, drive, discrete, SIL3 safety etc ESTOP Emergency Stop/急停 DIN Dual Input/双输入 RIN Redundant Input/冗余输入 ROUT Redundant Output/冗余输出 LC Light Curtain/光帘 ENPEN Enable Pendant/使能坠 FPMS Five Position Mode Selector/五位选择开关,方案亮点,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,32,FDBK2+,FDBK2-,FDBK1+,FDBK1-,SAFETY EN2+,SAFETY EN-,24V+,24_COM,SAFETY EN1+,Safe-off Connector,Kinetix 6000 Drive,OSSD1,OSSD2,24V+,NC,NC,方案亮点,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,33,方案亮点,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,34,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,34,Agenda,2.3. 成型机典型控制环节,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,35,Key Application 1: Cutting裁切,Intermittent cutting Stage-1 Axis 1&2 stop Stage-2 Axis 1&2 start at the same time and try to run at the same line speed Stage-2 (Velocity Sych. From 0 to V1) Step 1: speed of Axis 1&2 increase from 0 to V1 Step 2: Axis 1&2 run at V1 continuously till sensor detect the cutting material Stage-3 (Position control base on V1) After Stage-2 step2, Position sych. (axis 1&2) When reach the setting position, axes decelerate to stop and waiting for next cycle Remarks: in the stage 2, cutting material sometimes skids on belt (axis1), so in this phase we need make sure axis 1 has the same velocity as axis 2 at anytime.,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,36,Key Application 1: Cutting 裁切功能块,Master/Slave Linear axis Homing: Active/Immediate The sensor should be a high-speed sensor and wired into Master Axis Driver module I/O port as Registration signal. Include MSO/MAFR,MDR(for next Pos. Registration) MRP (Redefine current Pos.=0) MAM1(ensure sensor detected material) MAM2: Absolute Pos. Movement (Registration_position+Fixed_distance),(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,37,Key Application 2: Winding 收卷,total 3 types materials will be transport to wind on the Big roller Each material will be winded on the roller only one circle V2 is line speed on the roller Anytime we need make sure that V1=V2 During winding, the diameter of roller will be changed Master axis = Feeding Slave axis = Winding,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,38,JLB Winding,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,39,Master is Winding Axis; unit Deg Unwind of Master axis = 360Degree. Slave is Feeding axis; unit mm,Key Application 2: Winding,Master is Virtual Axis; unit sencond Slave is winding axis; unit mm,Make sure that the materials will be stretched equably at each point.,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,40,Calculate data of First material Winding,Parameter: D0 (diameter of big roller) D1(thickness of first material) D2(thickness of Second material) D3(thickness of 3rd material) Start Wind signal Master velocity,Parameter: Length of 3 kinds of materials by customer After each wind, there is a angel.,Key Application 2: Winding,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,41,Key Application 3:Transfer Ring Position,Shaping Drum,B&T Drum,Carcass Drum,Carcass Ring,B&T Ring,Waiting Position,Carcass Position,Shaping Position,B&T Drum Position,Waiting Position,MAM,MAJ,MAM,MAJ,MAM MAJ Torque Limit,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,42,Copyright 2009 Rockwell Automation, Inc. All rights reserved.,42,Agenda,2.4.模块化编程,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,43,S88 Process Oriented Program Structure: Unit, Equipment Module, Control Module,CM 3,CM 2,UNIT,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,44,Tail Support,UNIT 1,S88 Process Oriented Program Structure: TBM Example,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,45,S88 Process Oriented Program Structure: TBM Example,CM 3,CM 2,UNIT 1,UNIT1_Building,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,46,To deploy power programming for TBM Step 1: to understand machine flow,Level 1: Unit,Level 2: Station,Front Rack,First Stage _Carcass Building,PLY(A) Conveyor,IL Conveyor,IL Let Off,PLY(N) Conveyor,PLY(N) Let Off,PLY(A) Let Off,S-Wall Conveyor,S-Wall (L) Let Off,S-Wall (R) Let Off,Level 3: Equipment,Carcass Drum,Nether Stitcher,X Stitcher,Y Stitcher,Carcass Conveyor,Level 4: Actuator,Servo motor,Valve,clutch,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,47,Level 1: UNIT1_Carcass Building,Auto,Level 3: Equipment Module Control Interface,Carcass Drum,Nether Stitcher,X Stitcher,Y Stitcher,Carcass Conveyor,Level 4: Control Module,CM04 Auto Axis,CM10 F Reset,CM21 Enable,CM22 Home,CM23 Move,CM24 Gear,CM27 Jog,CM33 Stop,CM35 Disable,CM31 Status,Level 2: Station Model& Sequencing,IL Conveyor,S-Wall (R) Let Off,Resetting,Idle,Running,Stopped,Stopping,Aborting,Aborted,Carcass & Shaping Drum,Manual,Apply PA,Apply N PLY,Apply A PLY,Bead Load,Shaping,Remove,Auto Control Sequence,Manual Control Command,To deploy power programming for TBM Step 2: to transfer the machine flow to PP,S01,S02,S10,Operation Mode,EM10,EM11,EM13,EM12,EM14,S01-Sq1,S01-Sq2,Bladder UP,Stitching,SW App,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,48,To deploy power programming for TBM Step 3: to get 1st station done,(Confidential For Internal Use Only) Copyright 2007 Rockwell Automation, Inc. All rights reserved.,48,Level 1 Whole Unit Operation,Level 3 Equipment Module Control Interface,Level 2 Station Model& Sequencing,Level 4 Single Action Executing,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,49,Level 2 Station Model& Sequencing,Station 01 Operation Mode,Station 01 Production Sequence,EM Control Interface,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,50,Station Operation Mode,(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved.,51,Station Production Sequence,The operator or Engineer in