| With the development of tire industry, especially the rapid development of meridian tire in China, more and more capsules are wanted in the tire industry, which raises higher requirements for the tire capsules on the quality and production technology. Currently, the domestic large enterprises have their tires capsule production factory. However, with the intensification of economic development in China, many professional capsule manufacturers start to provide capsule for tire manufacturers. At present, there are more than 20 national professional capsules manufacturers, which can basically satisfy the demand for tire capsule factory. In the capsule manufacturing process, 95% of them adopt the Compression Moulding production process. Few manufacturers use the Hydraulic Injection. There are many shortcomings in the traditional Compression Moulding molding method: difficult to improve the quality; with low production efficiency, complex process and energy-wasting. There are two-step processes in the traditional Hydraulic Injection molding method—first plasticizing and then rationing. The shortcomings are as follows: the injection device is complex with difficult processing and high cost; it injects so less that it is not suitable for large size capsule injection.Professor Lv Boyuan, Extrusion Engineering Research Laboratory of Qingdao University of Science and Technology, have made great effort and further study on the extrusion of the rubber injection molding technology. To solve the problems above, Professor Lv proposed one-step injection molding technology– merging two step plasticizing and injection in the traditional process into a single one. Advantages of One-step Injection Molding: Molded production is homogeneous and compact; the required equipment is simple with low investment, and its products can be suitable for large-capacity injection. This method is now introduced to the tire capsule manufacturing company. The original injection molding flat-type vulcanizing machines are rebuilt, so that the production problems with which manufacturers now faced can be solved. In this context, we have designed three-position tire capsule one-step injection molding vulcanizing technology and equipment.In the issue—"three-position tire capsule one-step injection molding techniques and equipment ", we have done lots of important researches and finally got the following results:1,The three-station one-step injection molding technology is applied to the tire capsule manufacture for the first time at home and abroad. What is more, we rebuilt the original vulcanizing equipment of which the enterprises are now in possession, thus improving the low quality in traditional molding capsules producing. In addition,we realize the sustainable use of equipment resources, while drive the technology of capsule production to the world's leading level.2,In the design, one-step injection process, the world's leading technology, is applied to capsule production. We adopt a method of the vertical injection, just plus underlying flow-channel plates and device to the original capsule mold, with the original mold structure of the upper and lower die and the core model remaining the same; then the Compression Mould can be transformed into a Injection Mould. Such a method is generally or universally applicable: it is not only available to the reconstruction to the type A and B in the bias tire, but also the type RA, RB, RC, RAB in the meridian capsule mold.3,In this design, the structure design of the transmission is rational. Self-cooled direct current motor and speed reducer with Double Enveloping Arc Surface join together directly, with characteristics like small in size, large loading, steady operation, low noise, long life and high efficiency. It will be an important development in technological innovation for rubber injection machine drive system.4,In this design, The Theoretical Analysis on the various performance parameters of the screw is discussed and its overall design is studied, which make the screw section meet the pressure required for the one-step injection process.5,The design adopt a helical gear feeding device in the injection molding machine. On one hand, it can ensure the rubber feeding continuously and effectively; on the other hand,it forces the rubber feeding into the barrel, which can push the feed forward powerfully and increase the injection pressure effectively.6,The design will turn mechanical quantificational rubber injection approach into a informational one. A pressure sensor is installed in the head to detect injection pressure information real-timely, and inspect the information back to the lamination machine instantaneously. When the injection press reaches the parameters set value, the injection machine will stop injecting.7,The design make a successfully application of CAE technology—Finite element method. By using finite element analysis software ANSYS, We provide a cooling - heating temperature field analysis on the important control system for injection machine. According to the results, we made a reasonable improvement and optimization for the injection barrel structure in pertinence, thus improving the reliability of design.8,The design offers a structural design of the capsule injection molding vulcanizing set and integrates two-dimensional design software—AutoCAD and 3D design software—Pro / E approach, which is intuitive, simple. Finally, we adopt three-dimensional animation and simulation software 3DS MAX and set up a full set of equipment process motion simulation, thus making sure of the rationality of the full set of our design.In a word, three-location tire campus one-step injection of vulcanizing equipment possesses widespread prospect in the development and application, I am sure that it will bring obvious social efficiency and the economic efficiency.
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