4. Nozzle solution:
Clean the tanker properly
Add 30 liters petrol
10 kg compound from mixing department, cut it into small pieces
and add it to the solution.
Add more 30 liters of petrol and stir it properly.
Add 600g of resin (resin # 1068/ 1102) to 2 liters petrol and make
its mixture separate.
Then add this mixture to previous mixture.
Cover the tank and mix it for 3 to 4 hours.
Nozzle box:
Net weight = 19 kg
Gross weight = 19.5 kg
Each plastic bag = 200 nozzles
1 box = 1000 nozzles
Nozzle coating:
Use nozzle coating conveyer not hands
Arrange the nozzles in the tray and pass it over the conveyer
The nozzles are coated with solution
The nozzle is first blow with high air to remove excess solution
on nozzles
Put coated nozzle in the tray and rub solvent oil dipped brush
Put this tray in box for 5 to 10 min
Temperature in the box is 60 degrees
Cover box properly safe from powder
Don’t use the nozzle after 2 to 3 days and return it for coating
again
5. 6 men are present (4 for entering and arranging in trays, 2
collecting after coating)
Handles are there for setting solution flow.
Pressure air is applied for removing extra solution from nozzle.
Temperature of heater is 85 degrees centigrade (summer) and 95
to 100 degrees centigrade (winter)
Check is made to confirm that the solution is applied at the edges
of the nozzle
Approx. 3 min and 10 sec for one round
55 to 60 nozzles in one tray
Compound from mixing departments comes once in a day
Viscosity of nozzle solution:
The viscosity is checked by the container emptying time. For new
nozzle the time must be 40 to 42 sec.
For rework nozzle the time is 35 to 38 sec.
After one round the viscosity must be 41, 42 sec
After 2000 nozzles check again the viscosity by time
measurement.
10000 nozzles can be applied with each 15 kg basket.
Viscosity time decreases by adding petrol. It must be less than 42
sec.
6. Dye section:
Total men =9
Splicing dye making:
If the dye becomes soft or becomes round replace it.
Send it to the dye section
Burn dye with fire at extreme temp and leave it for 10 to 15 min.
Don’t use cold water the dye will deform
On cooling apply a buff with brush.
Then clean it with MEK (colorless solution) solution.
Then apply grey camlok 205 and keep it for drying for 10 min
Then apply black camlok 220 and leave it for 10 min
Then take the dye to curing press
Set the metal strip in dye mold and fix rubber on it and keep it in
for curing.
The curing time is 4 min.
Press steam pressure 5 to 7 kg/cm2
Die curing temp 150 degrees centigrade
Take out the dye after 4 min and place it in dye section
The rubber to be applied is pale grape rubber and mixture is added in
mixing department.
7. Green tube area:
Shifts = 3
Production officer per shift = 1
Foreman per shift =1
Workers per shift = 160 to 170
Compound used:
TB400 is used for making tubes.
TB400 and recycled tubes are added on warming mills.
The tube to be recycled is stretched to check whether it is cured or not.
Warming mills:
Size:
The warming mills are 22 x 60.
Temp:
The temp to be maintained is maintained (50 degrees on first two mills,
70 degrees on the next two mills, then 80 degrees at the tube extruder)
Cooling:
Fresh water is added in the mills for cooling purpose. The rpm of the
two rollers is not same so that nipping action is easier and one roller
towards the operator is at high temp while the other roller is at low
temp.
8. Capacity:
The capacity of mills is 120 kg.
Nip:
Their nip is 5mm.
Cooling:
The temperature of water of one roller is higher than the other. The
roller towards operator is at low temp so that the compound does not
stick to it. The temp of 2nd roller is higher its water flow is a little less
than the other.
When started after long time the rollers are run for 20 minutes to heat
them up to proper temp.
Mill operation:
1. Take of the tag of the compound and collect it in bin
2. Put the compound on mill for warming
3. Apply cut 4 to 6 times
4. Height of the compound on mills must not be greater than 12
inches
5. Adjust nip so that rubber sheet gauge is 10 to 12 mm
6. Transfer compound to next step when temperature reaches 80 +-
5 degree centigrade
Mill instructions:
Clean machine and check it by on/off
Check the reverse forward jog
Check the break of mill
Check the supply of water for cooling
There must be no oil or grease leakage
9. Keep the pan clean
Record the date and weight of pallet before use
Keep the tag in bin
Cut the compound 4 to 6 times by the mill knife
The height of compound over mills must not be greater than 12
inches
The nip must be set so that gauge of sheet is 10 to 12 mm
Shift the compound to next phase when 80+ - 5 degree
centigrade.
Sieving extruders:
Two sieving extruders are present to keep the compound filtered from
external metal particles. First extruder has capacity of 450 kg/ hour
while the other has capacity of 1600 kg / hour. So mostly only one is
used.
The mesh size used is 0.05 mm.
Sheeting mills is used to make sheets of refined compound. After
sheeting let the compound for cooling.
Sieving extruder process:
Clean the machine properly
Check machine by on/off
Check water supply to it for cooling
Clean the extruder head
Clean the head by the mesh of 0.05 mm
Open the slug so it becomes cool from inside
10. The slug weight must be 10 to 12 kg
Make sheet by sheeting mill
Hang the sheet on racks for cooling
The operator must check the speed and scorching of slug and
clean head accordingly
Warming mill 1:
Size: (22 x 60)
1st
roller rpm = 12 rpm
2nd
roller rpm = 10 rpm
Warming mill 2:
Size: (22 x 60)
1st
roller rpm = 9 rpm
2nd
roller rpm = 8 rpm
Sheeting mill:
Size: (16 x 48)
Left roller rpm = 15 rpm
Right roller rpm = 12 rpm
Sieving extruder:
Rpm = 42 rpm
Temp= 105 degrees centigrade
Pressure = 2.4 MPa
Two heads are present. One is used at a time. The head is replaced
after 30 min to avoid overheating.
11. Warming mill 3:
Size: (22x 60)
Left roller = 12 rpm
Right roller = 13 rpm
Warming mill 4:
Size: (22 x 60)
Left roller = 10 rpm
Right roller = 12 rpm
Feeding conveyer:
One from mill 3 and one comes from mill 4.
Feeding extruders:
Two feeding extruders are present. One is supplying to two tube
extruders. While second is supplying to three tube extruders.
Tube extruder 1 and 2:
On starting the extruder is run without dye to heat it up. Then the dye
is fitted according to size. The width of the tube is set by adjusting the
studs attached to the four sides.
12. Powdering inside tube:
Powder is fed from above chamber to flow inside tube operated by
motor so that the tube does not stick from inside. Soap stone powder is
used. The motor is operating for feeding powder. The suction pump is
also attached to collect the excess powder.
The FRL (filter, regulator, lubricator) is attached to the powder pump.
The air pressure is applied through it to the powder pump.
Blue paint bottle:
Paint bottle is present for applying a blue line on the tube.
Cooling:
Water and air cooling is done. The water is flown by pipes on the hot
tube. The fans are also present for cooling.
Drying:
The tube is dried by heaters and blowers so that water is removed.
Cutter:
The electric cutter is present for cutting tube after specific length. It is
operated by the sensor which detects the space between tubes and
cause the cutter to rotate and cut the tube. The sensor is placed at
specific length so that length of tube is set accordingly. The cutter and
the colour bottle are both pneumatic operated.
Cut knife voltage = 230 V
13. Colour marking:
Colour is marked over every tube of the conveyer. Every conveyer is
given a specific colour. It is done to detect the fault easily.
Nozzle hole:
A hole in the tube is made for fitting nozzle. This is done by the punch.
Care is taken so that the hole is made only in the upper surface of tube
only. Then the nozzle is attached on the hole by the suction punch.
Both these devices are operated by the second sensor placed
afterwards. It also detect the gap between tubes.
Dig hole voltage= 230V
When the punch is applied the conveyer is lifted upwards.
On punch 3 CAMS are used. One is for suck operation, 2nd throws the
suck piece, 3rd is the lock to stop the punch.
Koruda solenoid valves are used to control vacuum pump for these
operations.
Powdering:
Then powder is applied on the surface by air so that the tubes don’t
stick with each other.
Collecting:
The tubes are collected at the end and placed in shelves.
15 in each shelf (big tube)
30 in each shelf (small tube)
If the tube has some problem it is dropped in basket at the end of
conveyer. Its nozzle is plucked and sent backed for rework.
14. Cooling of extruder:
In tube extruder a motor is present for water supply to heat exchange
with oil.
Temperature:
Compound temp on sieving extruder head 110 degrees.
Tube extruder 3, 4, 5:
The same process is done till drying as 1 and 2 extruder.
The change is that the nozzle hole and the nozzle s fixed before cutting
tube.
Here the powder is applied by mixed in water. And then after
procedure is same.
Colour markings:
1st
conveyer = no colour
2nd
conveyer = white colour
3rd
conveyer = green colour
4th
conveyer = blue colour
5th
conveyer = yellow colour
15. Sensor names on conveyer:
Two sensor pairs are used on conveyer:
E3S-2LE4 (TRANSMITTER)
E3S-2DE4 (RECEIVER)
E3S-5LE4 (TRANSMITTER)
E3S-5DE4 (RECEIVER)
Weight of tube:
The weight of tube is checked. It must be according to given standard. If
less then there is some problem with dye.
A single motor is present for conveyer movement.
Thickness:
The thickness of tube must be uniform all around. The tube must be
checked after time to time for its length and thickness with gauge.
The pneumatic solenoid valves are present at start of conveyer to move
up and down the start of conveyer.
All the cooling is done by fresh water.
The faulted green tubes are sent back to warming mills.
Many warming mills are used to make the compound soft and do
more production in less time.
The nozzles before applying are refreshed by solvent oil. And kept
in bulb heated area.
Green tube width is set by conveyer speed.
The whole conveyer is run by a single motor. Adapter is used to
convert the motion of motor by 90 degrees.
The tube has two sides rim side and crown side.
16. Tube extruders motor specs:
Extruder # rpm power current
1 980 55 KW 94.8 A
2 990 75 KW 141 A
3 980 55 KW 94.8 A
4 980 55 KW 94 A
5 1500 55 KW 101 A
Tube extruder working:
1. Clean the machine properly
2. Check water supply
3. Without head heat the extruder by entering compound
4. Heat the dye in heating chamber before fitting
5. Set the proper dye according to size
6. Feed butyl by feeding conveyer
7. With the screw rotate compound so that the compound comes
outward
8. With the help of stud set the thickness of tube
9. When set start the powder and vacuum
10.Set the speed of conveyer to set the width of tube
11.Start cooling water on conveyer
12.Start cutter after setting length
13.Start blower for drying
14.Check length of tube according to specs
15.Apply nozzle automatically not by hands
16.Weight the tube at the end
17.Check off set and holder alignment
18.Book tube on trolleys.
19.Check shrinkage after 15 min on shelf
17. Record kept of green tube:
Compound temp at warming mill
Compound temp at tube extruder head
Tube size
Conveyer speed
Air pressure at soap stone(3 MPa)
Tube width
Tube length
Tube shrinkage factor(less than 30 mm)
Thickness(crown)
Thickness(base)
Thickness folding 1
Thickness folding 2
Tube weight
Nozzle distance with nearly edge
18. MC splicing:
Size Total presses temperature
2.50-18 2 330 to 350
2.50-17 12 330 t0 350
3.00-18 1 360
3.00-17 1 320
3.50-8 1
1.35-10 1 280
4.00-8 2 290
2.25-17 2 330 to 350
The temp of some presses are less so that the piece doesn’t stick to the
machines.
Splicer operation:
1. Check all the machines properly
2. Apply powder at ends of green tube
3. Set dye in tube according to size
4. Set temp 200 to 300 degrees
5. Pressure must not be less than 6.5 kg/cm2
6. Apply joint after proper setting of tube
7. Don’t joint undersize tube
8. Don’t joint oversize tube
9. Clean the dye
10. Cutters are cleaned by wood piece
11. Hang tube on chilling unit
The splicing presses have bolts which are for leveling. The dye is
leveled so that the joint is perfect.
19. MC tube Curing:
Presses= 144
The tube is placed on the former and inflated. It is placed for
some time to inspect it.
The joint leak, body thin, leak due to nozzle and other faults
are checked.
Body thin problem mostly occurs in stock and it is sent back.
In one press there are two molds in MC tube.
The tubes are kept in the press for 2 to 3 minutes in MC tube
presses. The molds open automatically after specified time.
The steam traps are used to avoid water entering with steam.
The direct bypass valves are also used.
Three pipelines are coming to every press
1. Air pressure line
2. Low pressure steam line
3. High pressure steam line
On average 30 tubes are made per hour
Each operator operates two presses
Total 144 presses are present (24 sets of 6 presses per set).
All the presses in MC tube are hydraulic. 1 hydraulic pump for 6
presses is used.
Approximately 30 presses are given to rickshaw tube.
20. Supply:
The three pipes are given to each press:
High pressure steam
Low pressure steam
Air pressure
The high pressure is provided by series connection to molds.
The inside low pressure is given to each mold separately.
MC tube curing operation:
1. Put tubes on former
2. 3 to 5 psi pressure t0 inflate it.
3. Check tube if leak then pull out its nozzle and send it to
rework
4. Internal and external pressure must be according to
specifications.
5. Set tube in mold of press properly.
6. Set curing time and temperature according to specs.
7. Check if inside pressure is on and light is operated.
8. Apply next tube on former during curing of 1st tube.
9. Check tube after curing again.
Types of molds:
1. Plain mold:
The plain mold press ha less space between the
two molds of presses.
21. 2. Jacket type mold:
In jacket type mold the jacket like structure is present across
the molds. The spacing between molds is greater as
compared to plain molds.
Types of presses:
1. Hydraulic presses:
The MC tube department all the presses are hydraulic and
are operated by oil pressure.
2. Pneumatic presses:
The car tube presses are pneumatic and are overall operated
by air pressure.
3. Mechanical presses:
The tractor and truck tyre presses are mechanical in nature
and are mechanically operated. In mechanical presses the
lock is present with the motor gear to stop the main motor.
Type of steam trap:
1. Thermostatic trap
2. Mechanical trap
3. Thermodynamic trap
Thermodynamic traps are used here in tube. In trap circular coin like
structure is present and sits on its seat when steam is coming and
moves upwards when water is there.
22. Internal process of hydraulic press:
Air is used to control the three way solenoid valve which is used
to control different processes during operation.
A lock inner valve is also present which is used to apply high
pressure when the press is closed.
Single coil, single spring solenoid valve is used to operate 3 way
valve at the back of presses to apply pressure and release while
opening and closing of molds
First low pressure applied and the mold closes normally. Then
high pressure is applied to lock the mold tightly.
Two valves are present on each pump:
1) Vane type
2) Piston/ plunger type
Two sensors are present on presses to detect opening and closing
of molds.
A sensor also present on solenoid valve to operate it.
23. Car tube:
Number of presses:
Total 54 presses are present :
8 tractor rear (10 min curing time)
6 tractor front (6 min curing time)
2 heavy truck (10 to 12 min curing time)
38 car tube (4 min curing time)
Number of splicers:
Total 7 splicers are present.
Size of tubes:
Car tubes:
4.50-12
6.15-13
Light truck:
6.50-14
Mazda:
7.50-16
Tractor:
6.00-16(front)
7.50-16(front)
11.00-20(rear)
11.00-28
14.9-28
16.9-30
24. 18.4-30
Heavy Truck:
9.00-20
10.00-20
Lifter:
6.00-9
7.00-12
Machines in car tube:
First warming mill is present
1 sieving extruder is present
Sheeting mill is present afterward
2nd warming mill is present
Feeding mill
Two tube extruders are present
Then afterwards two conveyers are present
Tube extruder# Power rpm current
1 55 KW 980 94.8 A
2 75 KW 990 141 A
Production rate:
35 tube/ hour are made of car.
Length of tube:
The car tube is kept a bit long and cut afterwards due to
shrinkage.
25. Faults in tube:
1. Joint leak (JL)
2. Crease(C)
3. Overlap (OL)
4. Joint thin(JT)
5. Nozzle thin(NT)
6. Foreign matter(FM)
7. Nozzle open(NO)
8. Puncture(pun)
9. Under cure(UC)
10. Press fault (PF)
11. Electric fault (EF)
12. over cure (OC)
13. Oversize (OS)
14. Nozzle patch (NP)
15. Balloon
16. Balloon (repairable)
Body thin:
If the pressure is less the body thin problem occurs
Puncture:
The puncture can occur due to nozzle mark and certain other reasons
26. Press fault:
It is a mechanical fault. It occurs due to low pressure during locking
Balloon:
If the steam trap not working. Any water content in tube cause this
problem. If the thickness remain proper on deflation of tube this
balloon is repairable.
Under cure:
It looks like balloon and the thickness of tube does not remain same on
deflation. It occurs due to inside pressure not proper.
Overlap:
This occurs due to increase in length of tube
Nozzle patch:
Small opening at nozzle not easily detectable.
Crease:
This occur due to increase diameter of tube
Over cure:
This occurs when the tube is not repaired properly after recurring.
Nozzle open:
The nozzle is not properly attached and can be repaired if the area to
attach is less.
27. Packing:
Firstly silicone solution is applied to tube to make it shine.
Then the air is sucked though it.
After then valve is inserted through motor.
Then vashel and the nut is applied
Then after tightening this nut another nut and cap is applied.
Tube is folded and rubber band is applied
They are packed in cover and sealed.
50 tubes are then put in a bag and sealed by thread
On bag size of tube, date and code of senior is written.
The weight of the bag is written on it.
The card of size and bundle number is put in bag
Each tube of 2.50-17 (350 gram)
Double check tube:
Valves inserted and air inflated.
Puncture is checked by water
A little air is removed and vashel and two nuts are applied.
16, 17 number stamp s applied with yellow ink for identification of
shift.
The tubes are kept for 8 hours inflated.
The tubes are then sent to tyre department.
size Weight of tube bag.
2.50-17 18.3 to 19 kg
2.50-18 19.9 to 20.95 kg
3.00-17 21 to 22 kg
3.50-16 25 to 26 kg
4.00-8 18.35 to 18.50 kg
3.50-8 16.35 to 16.40 kg
28. Improvements:
1. The atmosphere must be adjusted by proper ventilation.
2. The dust and powder collectors must be increased.
3. The cleaning must be done by vacuum cleaners so that the dust is
not blown
4. A make up system must be implemented to all the presses. So
that the pressure during curing is not varied.
5. FRL units must be attached to every press so that it will increase
the life of presses because air is not free from water
6. The pressure supply pipes of car tube must be with roof the
connections will be easy and neat.
