+7 Logo: A Article Number = The development of the domestic automotive industry has brought about a boom in the tire market, and tire quality and performance have also become the focus. During the tire vulcanization process, the curing press is shaped. Therefore, the research and development of new energy-saving technologies for tire shaping vulcanizing machines6, and the transformation of traditional equipment to improve the performance of the equipment, reduce energy consumption, save energy, reduce production costs, has important significance for the development of the entire tire industry.

In view of the problems such as large energy consumption and low equipment utilization rate of existing tire shaping vulcanizing machines, this article first summarizes and summarizes existing tire vulcanizing machine energy-saving technologies, then analyzes and explains the shortcomings of these technologies, and finally analyzes new tires. The energy-saving technology of stereotyped vulcanizing machine puts forward the prospect.

1 tire shaping vulcanization machine energy-saving technology 1.1 thermal system improvement Yang Ju, etc. By installing only the pneumatic shut-off valve between the left and right air intake pipe of the thermal system, using the same gas source to control the movement between the valve and the nitrogen valve, you can Effectively prevents nitrogen from entering the steam line. At the same time, a pneumatic valve control unit is again set up to control the intake pressure keeping valve and the exhaust pressure keeping valve with two control units. By using this method, the shaping pressure of the left and right glue can be arbitrarily adjusted, thereby greatly reducing the pleats and large edges. The number of tires at the same time can fully play the role of a variety of pressure control valve, greatly reducing the occurrence of string pressure phenomenon. At the same time, due to the effective and reasonable opening and closing of the pressure control valve, the leakage of nitrogen to the main exhaust pipe and the nitrogen recovery pipe is greatly reduced.

Zhao Chao et al. mentioned in his patent that the electronic heating device was added to the vent of the hot air circulation system of the tire shaping vulcanizer. The electronic heating device is located on the supporting frame of the tire, and the supporting frame is close to the bottom of the vulcanization tank and is opposite to the ventilation opening of the hot air circulation system. The electronic heating device is mainly composed of an electric heat pipe rack, a junction box, an electric heat pipe and a heat pipe, and the electric heat pipe. Surrounded by heat pipes. At the same time, a temperature probe is placed on the side wall of the vulcanization tank, which is connected with the temperature control system of the tire shaping vulcanizer. When pressurized, the hot air starts to circulate, the electronic heating device is energized, and the electric heating tube group is heated. The compressed air driven by the hot air circulation system flows in the sulfidation tank to make the temperature inside the mold uniform. Based on the temperature reflected by the temperature probe, the temperature control system ensures that the pressure and temperature in the autoclave are kept constant to achieve the desired vulcanization. This method has the advantages of rapid temperature increase, precise temperature control and short curing time.

In his patent, Yin Qiwang mentioned a system for rapid recovery of hot water for curing tire curing presses. It consists of a hot water circulation loop for tire rubber and a hot water recovery loop inside the rubber. The hot water circulating circuit is composed of a deoxygenated hot water tank, a water pump and a tire rubber, and the deaerators are connected by a pipeline in turn. The hot water recovery circuit is another line connecting the tire rubber and the deaerator, the tire rubber is connected to the steam pipeline, and the hot water tank is used as an overflow device of the hot water recovery circuit, ie, is set on the hot water recovery circuit. The branch pipelines are connected to the hot water tank, and a three-way control valve that receives the overflow signal of the oxygen removal hot water tank is provided at the branch point. The device can maintain the balance of water in the hot water system, shorten the cycle of tire vulcanization, and improve work efficiency.

Although these methods have a positive effect on the basis of the original, but considering that the thermal system of the tire shaping vulcanizer is extremely large, improving it is a complicated project, and it consumes a lot of manpower, time, and financial resources. If you want to find leaks in thermal piping in a short period of time and make timely repairs, it is difficult to do.

1.2 Adding Energy Saving and Thermal Insulation Devices Xie Yizhong mentioned in his published patent that there are several thermal insulation devices on the upper periphery of the upper heating plate and the lower heating plate of the vulcanizer mold, and the outer periphery of the mold is also provided with thermal insulation. Device. Similar insulation devices can greatly reduce the thermal energy loss of the vulcanizer, save energy, and can greatly reduce the ambient temperature of the vulcanization plant and improve the working environment. This thermal insulation method is accomplished through a first vacuum or air insulation device, which isolates heat by 70% 8°%, and the remaining heat is isolated and exchanged by the second lane of glass fiber and polyester. Hot plate to complete. When the temperature inside the vulcanizing machine is about 20°C, this method can ensure that the temperature of components exposed on the surface of the vulcanizer frame and the like is not higher than 45°C. The heat insulating material mentioned in this method is polyester fiberglass. Glass fiber is a macromolecular substance, and although the layer can be tightly laminated, the gap between the molecules is still large. Such a structure will weaken the thermal insulation of the polyester glass fiber, and due to the volume of the vulcanizing machine. It is usually relatively large, the cost of configuring the insulation material for the entire vulcanizing machine is high, and it is difficult to retrofit the entire vulcanizing plant.

1.3 Changing the Heating Method In his patent application, Kim Shu-Ming mentions that the heating plate of the vulcanizer is replaced with an electromagnetic heating vulcanization mold. The principle of electromagnetic heating is to generate an alternating magnetic field under the action of alternating current through an electromagnetic coil wound outside a vulcanization mold. The alternating magnetic field directly generates a loop through a steel mold and forms a spiral-shaped induced current in the mold. The energy is directly converted into heat energy to heat the mold by the resistance of the steel mold. This method has the advantages of high heat conversion efficiency, rapid heating, safety and energy saving, and prevention of electromagnetic leakage. The disadvantage is that the unit price of the electromagnetic heater is high, and the replacement cost after damage is too high, and because it belongs to a new product, the corresponding national standard is also Without the introduction of electromagnetic radiation, the intensity of electromagnetic radiation generated when electromagnetic waves were heated did not pass the test, so it was unclear whether its electromagnetic radiation intensity was acceptable and whether long-term use was harmful to the human body.

In his patent, Zhao Hongji et al. mentions a far-infrared heating device that includes a can body and a locking device. The far-infrared device is located in the tank as an external source of temperature energy. The device has low energy consumption, low pollution, and high energy efficiency.

In his patent, Miao Shengrong et al. mentioned an electric thermostatic energy-saving tire vulcanizing mold, in which the electric heater was used as an internal mold, a layer of heat insulation was added between the internal and external molds, and electric constant temperature, timing and fault alarms were used. The use of this device can ensure the quality of vulcanization. It can be used for tire retreading, but it can also be used for tire manufacturing and repair. It has strong practicality and eliminates the phenomena of “live and cooked” in the product, but it keeps constant temperature consumption in the tire vulcanization process. The power is large, affecting the overall energy savings.

1.4 Improvement of the hot plate mechanism of the tire shaping vulcanizer Li Ting mentioned in its patent that a tire shaping vulcanizer energy-saving hot plate mechanism is composed of a support plate and a heat transfer plate, the support plate is located above the heat transfer plate, and the heat transfer plate A heater is arranged on the heater and a vacuum layer and a reflective layer are arranged between the support plate and the heater from top to bottom. The vacuum layer can block the way the heater transfers heat to the support plate, thereby reducing heat loss; the reflective layer can reflect heat back to the surface, and the reflected heat can be transferred by the heat transfer plate for heating the tire. Therefore, the device can make full use of the heat generated by the heater, which can effectively improve the efficiency of energy use.

Li Jian et al. mentioned in his patent that a monolithic hot plate mechanism for a tire shaping and vulcanizing press consists of an upper main plate, a lower main plate, a connecting pipe and a grommet. The upper and lower main plates are circular ring plates of the same diameter, and the lower main plate has inner surfaces. The same height, outer ring, inner flange, ribs, and bosses that mate with the upper plate. The heights of the outer flange, the inner flange, the ribs and the boss are the same. The lower main board is matched with the upper main board, and the ribs and the bosses are fixedly connected with the main board. The two connecting pipes are located between the upper and lower main boards and are fixed with the upper and lower main boards. Connect and insert the ring into the inner ring holes of the upper and lower boards, and connect them with the upper and lower boards. The device contains few components and the assembly process is simple. The upper and lower mainboards form curved steam passages between the bosses and the ribs to ensure good heat transfer of the steam, and the device has good sealability, which is favorable for improving the quality of tire vulcanization.

Xu Muxian et al. in his patent mentioned a labyrinth drilling hot plate of a tire shaping vulcanizing machine. The lower hot plate adopts integral processing: outer ring grooves are machined in the outer edge of the annular plate, and the outer ring groove is used externally. The outer closed ring is closed, and the outer ring groove is divided into a divergent steam-distribution annular groove and a steam-collecting annular groove by a partition plate; the inner ring groove is radially processed in the middle of the annular plate body, and the inner ring groove outer periphery is closed inside. The ring is closed, and the inner ring groove is divided into a plurality of diversity steam ring grooves by a partition plate. The diversity steam ring groove communicates with the steam flow channel; an air inlet and a return air opening are provided at the outer edge of the outer closed ring. The device is easy to process, does not leak easily, the temperature is uniform, the deformation is small and the production is safe.

Although these methods are greatly improved in terms of energy saving, the hot plate mechanism of the tire shaping vulcanizer can only improve the heating condition of the contact portion of the tire with the hot plate, and there is no obvious improvement in the heating away from the hot plate portion, and the tire is heated. Non-uniformity has not been significantly improved.

1.5 Other energy-saving methods 1.5.1 Improvement Vulcanizer Vacuum exhaust pipe uses a nitrogen vulcanization process to produce semi-steel radial tires. During the production process, dynamic water is used to pump vacuum through the ejector. Vacuum backwater is discharged into the low water tank through the pipeline, and is sent back to the circulating water pool for recycling. Due to factors such as small slope, long pipeline, and small diameter of backwater pipelines, most vulcanizers are difficult to vacuum, vacuuming takes a long time, power water is wasted, and equipment production efficiency is low.

A drainage hole is drilled in the exhaust wall of the center mechanism gland. When the upper ring rises, the accumulated water in the upper cavity of the water tank will be discharged by the drainage hole in advance, and will not come in contact with the plastic lower chuck, thus greatly reducing the number of Secondary steam volume. Although scaling of vulcanizer pipes and valves is not a common phenomenon, scaling of some exhaust pipes is very serious. This problem can be solved by unblocking the rubber exhaust pipes. The internal orifices of the water-conducting holes and the water guiding rods of the central mechanism greatly reduce the effective diameter due to fouling, resulting in a lower vacuum speed. This problem can be solved by unblocking the plastic exhaust pipe. At the same time, it is also possible to increase the vacuum exhaust passage of the vulcanizer. When improving the vacuum of the former vulcanizing machine, only one channel of the exhaust pipe is used for vacuum exhausting of each varnish. Once the channel is fouled or blocked, the vacuum speed of the varnish will be reduced, and the vacuum pumping time will be prolonged. Production has an impact. Add root pipes to the left and right glue inlet pipes and install a pneumatic shut-off valve. The two valves share the air supply with the vacuum valve and open or close at the same time. After adding two valves, when the vacuum is used, the remaining air in the glue can enter the main exhaust passage of the vulcanizer at the same time through the air intake pipe and the exhaust pipe, so that each glue has two exhaust passages at the same time during vacuuming. Because the diameter of the main channel is larger than the diameters of the rubber inlet pipe and the exhaust pipe, the vacuum speed of the improved vulcanizing machine is obviously increased, and the purpose of rapid vacuum is achieved. Because the vacuum pumping energy consumption is only 1/3 of the traditional power water pumping vacuum energy consumption, for this purpose, the vacuum pumping method is changed to vacuum pumping, which can shorten the vacuum pumping time and improve the production efficiency of the vulcanizer. , but there are still individual vulcanizers that are difficult to vacuum.

1.5.2 Electron Beam Radiation Vulcanization Electron beam radiation vulcanization is a commonly used technique for polymer processing. This technology is mainly used for the cross-linking of polyethylene (PE) and polyvinyl chloride (PVC) cables, as well as the polymerization of coatings and adhesives.

The application of electron beam radiation technology in the rubber industry has not received the same attention in the plastics industry, but some important studies using electron beam radiation vulcanization and modified elastomers are also being carried out simultaneously.

Electron beam radiation vulcanization technology refers to the irradiation of high-energy electron beams emitted by electron accelerators to semi-finished tire components, such as ply and airtight layers, to ionize, activate and cross-link the rubber compounds. It can be used to vulcanize rubbers of different thicknesses. Articles, whether or not they contain a vulcanizing agent. In the rubber industry, this technology is mainly used for the presulfiding of different components in rubber products and composite products before final vulcanization. Compared to other thermal chemical crosslinking methods, the process of electron beam radiation cross-linking is very clean, consumes less energy, allows faster processing speeds, and can be operated at room temperature, effectively increasing green strength and avoiding material waste. At the same time, the curing time can be shortened and the production efficiency can be improved.

The electron beam radiation vulcanization apparatus includes an electron accelerator for generating a high-energy electron beam and a down beam apparatus thereof. The problem of electron beam radiation vulcanization is how to control the depth dose distribution of the electron beam and the average absorbed radiation energy of the irradiated material, increase the utilization efficiency of the electron beam, and prevent radioactive pollution and radiation damage. Therefore, in the rubber industry, the industrialization of electron beam radiation technology has not received wide attention from various countries, especially in developing countries.

1.5.3 Shortening warm-up time Lu Lin et al. in his patent mentioned the existing tire shaping vulcanizer with a gas dispersion baffle. The baffle is located in the flow channel opposite to the steam inlet, which can ensure that the superheated steam is evenly distributed and changes. The trend of past flow, and can prevent the local heating of the mold. At the same time, the preheating time of the mold can be greatly reduced, the uniformity of the tire heating can be improved, and the uneven heating and temperature increase of different parts of the mold can also be improved.

2 Existing problems The current weaknesses of various energy-saving technologies are mainly manifested in the following aspects.

In the tire vulcanization process, there is a longer vulcanization induction period and a pre-sulfurization period. This stage does not require too high a temperature and pressure, and the existing tire vulcanization technology consumes a large amount of energy at this stage. The existing tire vulcanizer technology adopts steam-heated rubber vulcanization, and there is a large temperature difference on the surface of the rubber, resulting in uneven tire vulcanization. In order to ensure that the tire is fully vulcanized, only the vulcanization time can be extended, thereby increasing the energy consumption.

(3) The low energy conversion rate of the steam heating method and the poor thermal conductivity of the rubber vulcanization method fundamentally limit the further development of the tire vulcanization energy-saving technology.

Although the above-mentioned improved technologies have obvious energy-saving effects, the impact of vulcanizer performance on the quality of tire vulcanization products is not considered. Only by thoroughly understanding the interdependence between the two can we fundamentally improve the energy efficiency of tire vulcanizers. Reduce tire vulcanization energy consumption.

3 Technical Outlook To reduce the cost of transformation, ensure good energy-saving effects, greatly improve the quality and performance of tires, and look forward to the future development of tire shaping vulcanizers, mainly in the following aspects.

Develop tire pre-vulcanization technology. Before the tire is put into the steam chamber for vulcanization, it is often left unused on the tire retainer. If the tire is heated during this time, the preheating temperature is reached, and then the vulcanization is performed in the steam chamber, the vulcanization time can be greatly reduced, and It also promotes the uniformity of tire vulcanization.

Existing rubber vulcanization technology improves temperature uniformity. Nowadays, small tires are mainly vulcanized with steam added with nitrogen. Since gas diffusion is significantly stronger than that of liquid, the temperature unevenness of the upper and lower sidewalls is improved. However, due to the presence of condensed water at the bottom of the rubber, the temperatures of the upper and lower sidewalls are not Uniformity is still evident. As the core part of the tire shaping vulcanizing machine, at the same time directly controlling the vulcanization process of the tire, the improvement of the central mechanism can significantly improve the overall heat transfer effect in the tire shaping vulcanizer rubber, thereby reducing the temperature difference between the upper and lower sidewalls and shortening the vulcanization time. , reduce energy consumption.

The direct compression vulcanization technology of the existing vulcanization method is completely denied. Nowadays, the inhomogeneity of rubber heat transfer and the difference in neutrality are considered to be the main reasons leading to the failure of tire quality. At the same time, its short life and high replacement cost. Therefore, the existing rubber vulcanization method is negated, and it is necessary to propose a structure replacement adhesive to provide the temperature and pressure required for tire vulcanization.

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