1、CALENDERING 壓延 LEVEL 1 第一級 MICHELIN Asia Pacific WELCOME歡迎您In this Calendering course , we will spend an hour together. 我們將在此一同進(jìn)行一小時(shí)的壓延課程。We wont teach alone but with your questions. What do you want to see? 我們將根據(jù)你的問題而不是單純的講授。你想了解什么？This course is primarily theoretical. 此課程是初級理論課程。Practical workshop

2、 exercises are limited due to time and the size of the group.因時(shí)間及資源局限車間實(shí)習(xí)內(nèi)容有限。Course Objectives課程目的 Define the Calendering Basics定義壓延基礎(chǔ)1 - Material (Rubber, Raw Fabric, steel cable)1 原材料（膠，簾線，鋼絲）2 - Calendering ( Equipment, Process, Products)2 - 壓延（設(shè)備，工藝，產(chǎn)品）MATERIAL 原材料For Fabric making we use three

3、 primary materials生產(chǎn)簾布產(chǎn)品使用三種主要原料Rubber To form the outside surface of the fabric so it will bond with the other products in the tire and to hold the other materials in the fabric in the correct position.膠- 形成簾線產(chǎn)品的外表面使簾線產(chǎn)品能夠在輪胎內(nèi)與其它產(chǎn)品相結(jié)合，并使其它原材料附著在簾線產(chǎn)品上的正確位置。Raw Textile To give strength and flexibilit

4、y to the fabric.原始簾線 賦予簾線產(chǎn)品張力與彈性Steel Cable To give even more strength with flexibility to the fabric. For use in zones of the tyre where exceptional stress occurs and for tyres carrying heavy loads鋼絲線 - 賦予簾線產(chǎn)品更大的彈性張力。用于輪胎中承受額外沖擊力的區(qū)域，也用于輪胎的承重。Rubber 膠In order for the Rubber to conform to the shape w

5、e wish it to take, so it will correctly surround, adhere to and impregnate the other materials in the fabric，it must have certain viscous-elastic properties.為了使橡膠符合我們所期望得到的形狀，以便它能夠在簾線產(chǎn)品中正確的纏繞、附著、填充其它原材料，它必須擁有一定的粘連特性。Plasticity When deformed (rolled flat) the material maintains its deformed (flat) sh

6、ape塑性 當(dāng)形變時(shí)（片狀卷曲）原材料保持它的形變形態(tài)（平片狀）Elasticity When deformed the material returns to its original shape.彈性 當(dāng)形變時(shí)原材料會返回到它的原始狀態(tài)Fluidity - The ability of the material to flow under pressure流動性 - 原材料在受壓時(shí)流動的能力Rubber 膠Elasticity is a natural property of rubber but how do we create the level of fluidity and pla

7、sticity required? 彈性是橡膠的天然性能, 但是我們?nèi)绾蝸慝@得所需的流動性和塑性呢？ By working and homogenizing the rubber by tearing and friction:通過撕扯和摩擦使橡膠運(yùn)轉(zhuǎn)、均勻 ： with a plastifier 塑煉機(jī) a feeder mill 開煉機(jī) This must happen before calandering or rolling of the material can take place. 必須在壓延或卷取之前進(jìn)行。Rubber 膠Working of the Rubber 原料的加工T

8、wo functions:兩個(gè)作用：Mix and blend rubber into a uniform mass 使橡膠混煉攪拌成一個(gè)均勻的整體Shear and break long molecular chains in its structure 剪切打斷其結(jié)構(gòu)中的大分子鏈Blending 混煉Blending different batches of the same compound:將同一種膠的不同批次進(jìn)行混煉：Reduces rheological variation (viscosity, plasticity, etc) that is inherent in the b

9、atch due to the variability of the raw materials and mixing process. 降低每批次由于原材料和密煉過程造成的固有的流變性的變化（粘性、塑性、等）Assures homogeneous dispersion of raw materials (ingredients and flow characteristics) delivered to the Calender. 保證提供給壓延機(jī)的膠料的均勻分散（成分和流動性）Allows us to use non-conform (but non scrap) batches from

10、 mixing.允許我們使用密煉來的不同的批次（但不是報(bào)廢料）。WIG-WAG Blending To Feed a Plastifier塑煉機(jī)擺片喂料123A Plastifier塑煉機(jī)It is necessary that our “Plastifier” prepares the compound for Calendering.需要使用“塑煉機(jī)”為壓延機(jī)準(zhǔn)備混煉膠。Operating procedures are important because they:操做程序非常重要因?yàn)樗鼘ⅲ?Create as uniform a homogeneous mix as possible 制

11、出盡可能均勻的膠料 Create a level of fluidity and plasticity that will allow the rubber to calender with the steel or textile correctly. 制出擁有流動性和塑性標(biāo)準(zhǔn)的膠料使其可與鋼絲簾線或簾布簾線正確壓延到一起。THE COMPONENTS OF PLASTIFIERS塑煉機(jī)的部件Cylinder (feeding, working)汽缸 （喂料，運(yùn)轉(zhuǎn)）Screw ( 2 basic types many variations)螺桿 （兩種基本類型- 多種變化）Blade (to

12、 cut the rubber into lumps）刀片 （將膠料切成小塊）Screw 螺桿Pin Barrel Cylinder for Plastifier塑煉機(jī)的銷釘套筒The feeder Mill also prepares the compound for Calendering.開煉機(jī)也為壓延機(jī)準(zhǔn)備混煉膠。Operating procedures on the feeder mill are also very important because they:開煉機(jī)的操做程序也非常重要因?yàn)樗鼘ⅲ?Help create as uniform a homogeneous mix a

13、s possible 幫助制出盡可能均勻的膠料 Help creates a level of fluidity and plasticity that will allow the rubber to calender with the steel or textile correctly. 幫助制出擁有流動性和塑性標(biāo)準(zhǔn)的橡膠使其可與鋼絲簾線或簾布簾線正確壓延到一起。HOT FEEDER MILL 熱喂料開煉機(jī)Temperature has to be controlled around 26c溫度必須控制在 26c 左右This is for the Fabric not the work

14、ers! 這是為了簾線而不是操作者！But the workers get the benefit!但是操作者受益！FABRIC WORKSHOP 簾線壓延車間 Humidity has to be controlled at = (To support the cylinders)支架(支撐套筒)Cylinders ( 2, 3 or 4)輥筒 (2，3 或 4)Motor ( 1 or 4)電機(jī) (1 或 4)Gearbox (Fixed ratio or adjustable with 4 motors)變速箱 (4 臺電機(jī)組成速率固定或可調(diào))Pressure & Guide rolle

15、rs (before & after calender)壓力和傳動輥 (在壓延機(jī)前、后)Cylinder nip adjustment devices. (Cyls. 1,2 & 4)輥距調(diào)節(jié)裝置 (輥筒 1，2 & 4)Calendering Process 壓延過程Hot Calendering Textile & Metallic熱壓延簾線和金屬DENSITY = No. cords in 10cm (Between 48 and 136)密度 = 10cm內(nèi)的簾線根數(shù)（在48和136之間）SYMMETRY 對稱性For METALIC 對金屬線而言:Pace 中心間距 ( 0,7 to

16、 2,5 mm)BRIDGE 橡膠橋01-01 DEFINITION 定義01 CALENDER TISSUE 壓延簾布TISSUE THICKNESS 簾布厚度(Between 0,3 to 2,5 mm) (Skim Thickness 1,7 to 0.2 mm )(在 0,3 到 2,5 毫米之間) (膠片厚度 1,7 到 0.2 毫米 )TISSUE WIDTH: between 900 & 1460mm簾布寬度： 900 到 1460mm01-03 VERIFICATION ASPECT 外觀檢查MISSING SKIM 缺膠（露簾線）MISSING OR MISPLACED CA

17、BLE 簾線缺失或錯(cuò)位 （稀開）CURED LUMP 膠燒塊BAD EDGE 邊料（逃皮）OTHER VERIFICATION 其它檢測-TACK 黏度- LIFTING EDGE 邊部翹起02 SCHEMATIC OF A TYPICAL MIXED CALENDER LINE 典型混煉壓延生產(chǎn)線示意圖 FROM 150 to 250 m IN LENGTH 長度從 150 米 到 250 米CALENDER壓延機(jī)COOLING CYLINDERS冷卻輥WINDUP卷取UNWINDING POST TRAME簾線導(dǎo)開支架CREEL ROOM 2nd FLOOR二樓錠子房OBJECTIVE 目

18、的: TO DELIVER THE RAW TEXTILE TO THE CALENDER : WITHOUT POLUTION, CORRECTLY CENTERED, WITH THE CORRECT WIDTH, WITHOUT WATER POLUTION, WITH THE CORRECT TENSION. 將簾線原料傳遞至壓延機(jī)：無污染，正確居中，寬度正確，無水污染，張力正確。 WITH THE ABILITY TO CHANGE THE RAW FABRIC ROLL WITHOUT STOPPING THE CALENDER. 能夠使壓延機(jī)在不停止工作情況下更換原材料簾線03

19、UNWINDING POST TRAME 導(dǎo)開架LET OFF導(dǎo)開JOINING PRESS接頭機(jī)COMPENSATOR儲布器BANANA ROLLERS FOR EXTENDING AND GUIDING THE RAW TEXTILE香蕉輥以展開并引導(dǎo)原材料簾線UNWINDING CAPSTAN放線絞盤 OBJECTIVE : * TO DELIVER THE CABLE TO THE CALENDER :WITHOUT POLUTION, CENTERED, WITHOUT CROSSED CABLES, WITH THE CORRECT TENSION.目的：將鋼絲線傳遞至壓延機(jī)：無污

20、染，居中，無交叉線，張力正確。04 METALLIC BOBBIN RACK 金屬線軸架Bobbin Rack 錠子支架1120 Bobbins 1120 個(gè)錠子PREPARATION TABLE 準(zhǔn)備臺(single layer) （單層）JOINING PRESS接頭機(jī)OBJECTIVE : TO DELIVER THE RUBBER INTO THE CALENDER NIPS: AT THE CORRECT TEMPERATURE, WITH THE CORRECT PROPERTIES, IN THE CORRECT FORM: 目的：將膠料傳送至壓延機(jī)輥筒之間：一定的溫度，特性，形

21、態(tài)。05 RUBBER MIXING 混煉膠05 - 01 IN GENERAL 一般而言 MIXING & HOMOGENIZING BY PLASTIFIER通過塑煉機(jī)混合& 均質(zhì)化MORE HOMOGENIZATION AND MAKING THE CORRECT FORM FOR FEEDING進(jìn)一步均質(zhì)化并形成正確形態(tài)以便喂料FEEDING THE CALENDAR BANKS喂料至壓延主機(jī)05-03 REHEATING RUBBER 重新加熱膠料- PIN BARREL PLASTIFIER 銷釘膛筒05 -04 FEEDER 開煉機(jī)EBLENDER ROLLER攪拌輥RUBBER

22、 ARRIVES AS PORK CHOPS FOR MOREHOMOGENIZATIONAND WORKING膠料以膠塊的形式進(jìn)入，以便其更加均勻和易加工FEED BAND TO CALENDER供壓膠條給壓延機(jī)To CALENDER供給壓延機(jī)06 CALENDERING 壓延1234PRESSURE ROLLER TEXTILE簾線壓力輥TISSUE CALENDERING POINT簾布壓延點(diǎn)RUBBER BANK FOR UPPER SKIM生產(chǎn)上膠片的堆積膠RUBBER BANK FOR BOTTOM SKIM生產(chǎn)下層膠片的堆積膠NIP ADJUSTMENT AND CROSS AX

23、ES輥距校正和軸交叉OPERATOR操作者06-01 TEXTILE 簾線Measure Skim Thickness : PSIT膠片厚度測量裝置 ：PSITAir Bubble Pricker劃泡針EDGE TRIMMING膠邊清理裝置06-02 METALLIC 金屬1234PACE/PRESSURE ROLLER METALLIC金屬間距/壓力輥TISSUE CALENDERING POINT簾布壓延點(diǎn)RUBBER BANK FOR UPPER SKIM生產(chǎn)上層膠片的堆積膠RUBBER BANK FOR LOWER SKIM生產(chǎn)下層膠片的堆積膠NIP ADJUSTMENT AND CR

24、OSS AXES輥距調(diào)和軸交叉調(diào)節(jié)OPERATOR操作者TRIMS膠邊清理06-03 FUNCTION OF AUXILLARY EQUIPMENT ON THE CYLINDERS輥筒上的輔助設(shè)備的功能1342TISSUE NIP 簾線間隙THICKNESS MEASURE UPPER SKIM.上層膠片厚度測量ADJUSTMENT TOP SKIM.上層膠片調(diào)節(jié)ADJUSTMENT BOTTOM SKIM下層膠片調(diào)節(jié)THICKNESS MEASURE LOWER SKIM.下層膠片厚度測量CYLINDER 3 FIXED3#固定輥筒06-06 DIFFERENT TYPES OF CALE

25、NDERS 不同類型的壓延機(jī) NIP POSITION CONSTANT 輥距位置常數(shù) EN L A 135 A 9012341234123412341234 NIP PRESSURE CONSTANT 輥距壓力常數(shù) 90 2X2 07 CONDITIONING LINE AFTER CALENDER壓延后生產(chǎn)線OBJECTIVE : TO TAKE TISSUE FROM THE CALENDAR, COOL IT DOWN PROGRESSIVELY, BRUSH IF REQUIRED, BREAK THE CROSS THREADS AND PLACE AIR DRAIN THREAD

26、S ON FABRIC目的：將壓延后的簾布從壓延主機(jī)到逐漸冷卻，（如果需要打毛），（打破緯線）并將排氣線加到簾布上；POST TENSION ROLLER張力輥MEASURE TISSU WEIGHT簾布測重裝置AIR DRAIN THREADS排氣線COOLING ROLLS冷卻輥08 WIND UP 卷曲OBJECTIVE : TO WINDUP FOR DELIVERY TO THE CUSTOMER GOOD TISSUE, WITHOUT FOLDS OR CREASES, THE CORRECT LENGTH, EASILY UNWINDABLE AND CAPABLE OF CH

27、ANGING THE FINISHED ROLLS WITHOUT STOPPING THE LINE.目的：在不停機(jī)的狀態(tài)下將無打褶，一定長度，易導(dǎo)開的大卷簾布交到客戶手中。COMPENSATOR儲布器DRIVE ROLLERS驅(qū)動輥WINUP卷取09-04 IDENTIFICATION & DEFECT INFORMATION TICKET 產(chǎn)品鑒定和CQ信息小票 Identification Ticket 產(chǎn)品鑒定小票Defect Information TicketCQ信息小票NOWLETSSEE ITINACTION !現(xiàn)在讓我們看一下運(yùn)轉(zhuǎn)狀態(tài)Plastifier塑煉機(jī)FEEDER

28、MILL 細(xì)煉供膠Mill for Mixing Rubber混煉膠用的細(xì)煉機(jī)Textile Wind Out Station簾布導(dǎo)開Let off compensator 導(dǎo)開儲布器Fabric Joining Press簾布接頭機(jī)Cable Bobbin Racks 鋼絲錠子架1234Rubber 膠TEXTILE orSTEELCORD簾線或鋼絲線Calendered Fabric壓延好的簾布Rubber 膠Cooling Roller 冷卻輥Compensator 儲布器.Product Windup 產(chǎn)品卷取Symmetrical Fabric 簾布對稱Quality Verific

29、ation Tools 質(zhì)量檢驗(yàn)工具This type of calender normally look similar to a fabric calender but does not have the sections for feeding in textile or cable as it is only used for Calendering flat rubber products.這種壓延機(jī)通?？雌饋砼c簾布壓延機(jī)相似但它沒有簾線或鋼絲線供料部分，因?yàn)樗皇怯脕韷貉幽z片產(chǎn)品的。It may have 2, 3 or 4 cylinders.它可以有 2，3 或 4 個(gè)圓筒。I

30、t is feeder with rubber in the same way as a fabric calender, by either a plastifier and feeder mill or breaker and feeder mills.膠料以與簾布壓延機(jī)相同的方式喂料，即或者塑煉喂料或者破膠喂料。To wind up the products it will either have a wind up table or a bobbin wind up chariot often both. 卷取產(chǎn)品時(shí)或者使用卷曲臺或者使用卷取線軸車 通常兩個(gè)均有。We also use

31、 another type of Calender in Asia called an EB CALENDER在亞洲我們還應(yīng)用另一種壓延機(jī)叫做 EB CALENDERREMEMBER WHAT IS CALENDERING記住什么是壓延The rolling of material through cylinders to form a new product原材料通過輥筒翻滾形成一種新產(chǎn)品In the case of an EB Calender this material is Rubber對 EB Calender 而言這種原材料就是膠。 WHAT IS A CALENDER? 什么是壓延機(jī)？A device that rolls the material (rubber) betw