belt for tyre industry
DESCRIPTION
fajas para la industria de neumaticosTRANSCRIPT
GB
Belts for the Tyre industry
Belting solutions for: • Rubber compound handling • Extrusion and rubber calendaring• Non vulcanised rubber transport • Finished tyre handling
11
Ammeraal Beltech is a leading ma-nufacturer of Process and Conveyor belting and has a unique reputation for developing innovative solutions for belting applications.
Manufacture of a tyre not only requires the latest technology, precision instruments and qualified people but also requires qualified suppliers.
We at Ammeraal Beltech are able to offer a full range of belting products to meet the ever-increasing perfor-mance demands and to provide well considered solutions for all belting processes in the tyre industry.
Content
Introduction
Process steps in green tyre production
Mixing and Batch-off
Extrusion and Calendaring
Handling of finished tyres
Special applications
Our product portfolio
Process and Conveyor belts
Modular belts
More of our products
At your service
...................................................................... 2
........................................................ 3
............................................... 4
................................................ 5
.......................................................... 6
.............................................. 7
.................................................................... 8
........................................................ 9
................................................................ 10
2
Providing quality and innovation
Ammeraal Beltech continues to prove its commitment to a combination of quality and innovation through the ongoing introduction of new materials. Working together with our customers and leading research institutions, we have developed a large number of alternative solution concepts.
With the unique product portfolio of Ammeraal Beltech fabric based Process and Conveyor belts, as well as Modular belts, High performance flat belts, and Timing belts, we provide the best tech-nical belting solution for tyre processing: from mixing raw materials via semi-fini-shed products and green tyre production to vulcanisation.
3
Process steps in green tyre production
Mixing is the first of many important processes in tyre manufacturing and is typically a batch operation with each batch producing more than 200 kilo-grams of rubber compound.
In the Banbury mixer, rubber bales are mixed with many chemicals, to precise specifications, to become the building block of each component of the tyre. As mixing is the first step of a long process, quality of process is of utmost impor-tance.
The mixing temperature can rise up to 180° Celsius and the operation is accomplished in two stages to prevent damaging of the compound.
For handling of high temperature sticky rubber compound, our Silam belts provide excellent release due to the highly non-stick top cover surface
Mixing
Once the mixing is completed, the batch is unloaded from the mixer and sent through a series of process steps to form it into a continuous sheet.
The batch-off process involves dipping, cooling, drying and stacking of rubber strips and slabs.
The slab is then transferred to other areas for bead wire assembly, inner liner calendaring, steel belt and fabric cord calendaring, and tyre tread and sidewall extruding.
Batch-off
The best solution for dip tank appli-cations is our F53 modular belt which offers improved process reliability and easy mainte-nance.
For batch-off appli-cations we are able to offer our coated and impregnated fabric based belts for long belt life
›› ››
Our famous Hot Stock & Water belts are used for inclined conveying of rubber
4
Extrusion is one of the most important operations in the tyre manufacturing process since it processes most of the rubber produced from the mixing ope-ration and then prepares various com-ponents for the ultimate tyre building operation.
Mixed rubber sheets are heated on mills, cut into narrow strips and force-fed through precision dies by powerful screw driven extruders. Tread slabs, sidewall, apex, and other thick compo-nents are precision manufactured in the extrusion process. This process must be strictly controlled to ensure the consis-tent manufacture of the component and the uniformity of the final product. Precision take-off conveyors, cooling stations, and cutting equipment are also required for this process.
For efficient coo-ling of extruded uncured rubber our Modular belts offer the best technical and cost effective solution.
Extrusion
Calendaring is the process by which a mixed rubber compound coating is applied to fabrics such as polyester, nylon, rayon, aramid, or steel cords, to form composite sheets of rubber coated material.
Precise control of the process is required to ensure uniform coating of the fabric or steel material, as well as an overall consistent thickness of the final sheet. This material is fed through cutting machines to form the cut, to rigid spe-cifications to form the body plies, steel belts, and fabric reinforcing materials of the tyre. Strict control of this process is required to ensure quality and a uniform final product.
Cutting to precise measurements is critical for quality, uniformity of final product, and overall cost control and profitability. These „products“ are then supplied to the tyre building machines.
Calendaring
A wide range of abrasion resistance belts with non-stick properties are available for infeed/outfeed and cutting applications
›› ››
5
Handling of finished tyres
The highly robotic tyre building machine assembles all the extruded, calendared and wound precision components to form the green tyre. The assembly pro-cess must be exacting, as any error here will negate the quality of the individual components, and is magnified in the finished tyres quality, uniformity and performance. This process may be fully automated, or operator driven, depen-ding on the types of building equipment chosen.
Curing is the final step in the manuf-acturing process, where the green tyre is exposed to very high temperatures and pressure, while being captured in an aluminium or steel tyre mould. The pressure/heat causes the tyre to flow to the shape dictated by the mould shape, while the heat completes all the chemical bonds required to form the adhesion that holds the green components toge-ther. Heat drives the final formulation of compounds in this process, allowing the tyre to perform as intended in the field.
For handling of green tyres before vulcanising we advise our Modular belt RAM 208
Tyre building & curing
When the vulcanising process is comple-ted finished tyres are loaded onto a long conveyor which carries them to final finishing and inspection.
Inspection is the last step in the ma-nufacturing process and is important in ensuring quality of both performance and safety.
Tyre inspection includes: trimming, visu-al inspection, X-ray inspection, balance (weight and uniformity) inspection.
Inspection
Modular belts with lateral rollers for loading side ways are used for trans-port from vulcanis-ing to final stages
››
To assist in positio-ning the finished tyre in the centre of the conveyor, Ammeraal Beltech has developed direction rollers for use with Solid Top Modular belts.
6
Special applications
Wind up systems are a critical part of the extrusion process, since the pro-ducts need to be wound up with the highest accuracy to avoid stretching and to maintain other critical parameters.
Due to our expertise in the field of tyre manufacturing we fully understand the requirements of wind-up systems.
Wind-up systems
After a tyre passes these rigorous inspections, it is stored in fully automa-ted storage buildings, where high tech handling systems organise them.
Warehouse tyre storage system
We are able to provide wind-up belts and fabrics with guiding strips or flat belts up to a length of 200 meters.
Within the storage system our abrasion resistant Ropanyl belts with their high flexibility are often utilised.Wind up systems
with Flexam and Fabric belts are used for treads, sidewalls and body plies.
7
Our product portfolio
The comprehensive range of Ammeraal Beltech Process and Conveyor belting is regarded as one of the most firmly established within the entire belting industry.
A wide range of raw materials and pro-duction methods is available to satisfy ever increasing demands, such as high temperature resistance, higher speeds, increased flexibility and durability, more stringent international standards, and many more.
Ammeraal Beltech is able to offer a full range of high quality, light weight conveyor belts in silicone, rubber, PVC and PU material for every step in your production process. We have the technology and experience to fulfil your most demanding material handling needs, efficiently and effectively.
ProfilingAmmeraal Beltech has developed a comprehensive range of profiled belts, capable of meeting all the requirements of industry in respect of efficient pro-duct handling. Practically every Ammeraal Beltech belt can be em-bossed with one of our available profiles, while specific requirements can be developed in close co-operation with the customer.
FabricationOur belts can be made endless by means of various splicing methods. Semi-fini-shed products are customised to exact requirements at local sites. Belts can be fitted with accessories such as carriers, ropes and corrugated sidewalls, made endless and engineered with holes and grooves.
Process and Conveyor belts
Products Main features Customer benefits Application indication
Silam belts (Silicone coated)
• Excellent non-stick• High temperature resistance• Suitable for fasteners or thermoplastic splice
• Highest rubber quality• Very good rubber release• Long belt life• Less downtime• Less maintenance costs
• Rubber mixing• Batch-off
Fabric and Ropanol belts(Bare fabric or PU impregnated fabric)
• Excellent non-stick• Low friction coefficient• Highly abrasion and cut resistant
• Good rubber release• Reliable product flow• Reduced belt wear
• Rubber mixing• Batch-off• Extrusion
Flexam belts(PVC coated)
• Different profiles available• Available in antistatic
• Cost efficient• Reliable conveying
• General use
Ropanyl belts(TPU coated)
• Longitudinal flexible• Abrasion resistance
• Compact conveyor design• Long belt life
• Calendaring• Storage
One of our more successful profiled belt is the Flexam with A18 Fine square pyramid.
V-ropes are fitted on Flexam belts for winding applications.
8
For many years, Modular belting has been one of the basic product groups of Ammeraal Beltech.
Ammeraal Beltech provides a comple-te range of straight, radius and spiral belts suitable for numerous conveying applications. With its extensive variety of top surfaces and materials (PE, PP, AC, and Nylon), our Modular belts offer the best solution in many applications in tyre manufacturing such as dip tanks, cooling processes and finished tyre handling.
AccessoriesTogether with different supports, guide strips and sprockets, various accessories are available:• Accumulation rollers• Lateral and Position rollers• Amflights• High friction inserts
Modular belts
Products Main features Customer benefits Application indication
F 50 Series belts(flush grid)
• Non stick surface• Temperature resistance (+190°C)• Raised rib less contact area• Open surface 35%
• Good release• Long belt life• Limited contact area• Less downtime
• Rubber mixing• Batch-off
Small Pitch belts(flush grid)
• Non stick surface• Small sprocket diameters
• Good release• Long life time
• Wig wag belts
Straight belts(flush grid)
• Large open area up to 70 %• Available in one inch• Small diameters possible
• Good drainage• Less downtime• Compact conveyor design
• Cooling belts
All-In-One Series(flush grid)
• Straight and radius transport with one belt• Also possible in Helix spiral applications
• Less transfers points• Controlled conveying• Less floor space
• Curved transport• Vertical transport
Lateral roller belt(2-inch solid top)
• Low friction rollers for loading sideways (90°)
• Easy changing of transport direction• Less damaging of tyres• No conjunction of tyres
• Loading sideways
Position roller belt(2-inch solid top)
• Assist in positioning the tyre to the center of the conveyor• Adjustable in any angle in comparison with the transport direction
• Less damaging of tyres • Merging and sorting
Accumulation belts • Low pressure accumulation • Low friction• Low back pressure
• Merging and sorting
Our belts with position rollers are the ideal solution for handling of finished tyres in merge and sorting applications
Position rollers are offered in the ST62000 solid top and are adjustable in 360° degrees
Modular belts with positive drive are running with lower tension and using less energy thus resulting in a longer life. Use of modular belts in finished tyre conveying systems will automatically lead to cost savings as a result of no maintenance, easy replacement, reduced downtime of production and no jams.
The finish area of tyre manufacturing in-volves complicated logistics and requires large stock areas. Our modular belts assist in meeting high demands with:• efficient conveying system• no tracking problems• less power consumption
9
More of our products
Timing beltsIn today’s tyre industry there is a requirement for more and more synchronised conveying. Positioning is very important, particularly under high speed.
Unique Maestro splice pressMaestro splicing equipment is specially designed for joining of Ammeraal Beltech Process and Conveyor belts on site. The Maestro splice press is constructed of light weight materials allowing for easy transport around the plant. The unique Maestro concept makes Ammeraal Beltech the foremost supplier in global standardised splicing, leading to:• Improved quality and efficiency benefits• Short cycle time, approx. 10 min. or less depending on belt type • Consistent, reliable splice results and superior belt appearance • Less shrinkage of fingers, providing stronger, flatter splices• No glass fibre sheets or other splice plates necessary
A new concept for fast, reliable and effortless splicing
Woven fabric beltsIn applications where standard conveyor belts cannot be used because of small diameters, our in-house woven fabric belts are the perfect choice. These belts are made of synthetic yarns and custo-mised with a wide variety of coatings and profiles.
Silam coated woven fabric belts are the ideal solution for conveying mixed rubber slabs in applications where high temperature resistance, non stock properties, and small diameters are required.
Wear resistant flat belts Rapplon® are found in cutting applications in tyre manufacturing to provide uniform feed and precise positioning
Our timing belts with vulcanised rubber top or with splicable polyu-rethane top and Kevlar fibre are used for in-feed conveying
High performance flat beltsAmmeraal Beltech offers a complete range of quality flat belts with classical nylon core belting for power transmissi-on as well as modern belt constructions with thermoplastic inner layers.
A wide range of cover styles ensure the best solution for various applications e.g. soft covers to protect goods, high friction covers for high efficiency or low friction cover for accumulation.
Ammeraal Beltech has standard solutions for all types of synchronised conveying, linear positioning and power transmission requirements, offering different pitches, tooth shapes, dimensions, cord and coa-ting materials. Special treatments to the belt surface such as grinding, milling or the attachment of cleats are possible.
Outstanding mechanical and chemical properties lead to high-performance operation and precision.
10
At your service
Facts & figuresAmmeraal Beltech is an international company with affiliates in 25 countries. Our products are available globally via a network of distributors and service centres in more than 150 countries.
We have 7 production plants, where incorporating R&D is an integral part, which manufacture our rolls of process and conveyor belting. More than 1,600 highly qualified employees in over 80 service centres, in close proximity to our customers, provide standard and tailor-made solutions, often combined with 24 hours service.
InnovationWithin our purpose-built R&D cen-tres we are continuously optimising and improving our products to satisfy constantly changing demands, such as higher speeds and temperatures, increased cleanability and durability, and more stringent international standards of hygiene and safety.
Because Ammeraal Beltech manages every aspect of the belting quality – from the fabric to the final fabrication – we are confident that we are able to develop the belt that meets your future needs.
Service networkWe understand the importance of kee-ping your business running and know how costly and disruptive downtime can be. That’s why we offer a service net-work worldwide, that is available round the clock at local level.
We ensure that there is an Ammeraal Beltech branch near you, so the support you receive will be fast and convenient.
Technical supportWith the on-site support of Ammeraal Beltech’s experienced team of Sales Engineers, nothing is left to a chance and ensures valuable support and your complete satisfaction. Our Product Specialist have the technical proficiency to develop a belt for most difficult operating conditions in any industry.
A sound combination of a global net-work, market segment knowledge and product management is the basis for our innovative and service orientated organisation.
10
Refe
renc
e: 4
4.0
GB
Dat
e: 0
2 / 2
006
Your global contactInternational Head Office:
Ammeraal Beltech Holding B.V.Handelsstraat 1P.O. Box 381700 AA HeerhugowaardThe Netherlands
T +31 72 5751212F +31 72 [email protected]
AustriaT +43 1 2929372F +43 1 [email protected]
BelgiumT +32 2 466 0300F +32 2 466 [email protected]
BrazilT +55 11 4655 1244F +55 11 4655 10 [email protected]
CanadaT +1 905 890 1311F +1 905 890 [email protected]
ChileT +56 266 96975F +56 266 [email protected]
ChinaT +86 21 6534 4690F +86 21 6548 [email protected]
Czech RepublicT +420 56 7330 056F +420 56 7330 [email protected]
FinlandT +358 3 278 4400F +358 3 273 [email protected]
FranceT +33 3 20 90 36 00F +33 3 20 32 29 [email protected]
GermanyT +49 4152 937-0F +49 4152 [email protected]
HungaryT +36 234 275 10F +36 234 275 [email protected]
ItalyT +39 051 660 60 06F +39 051 660 60 [email protected]
LuxembourgT +352 26 48 38 56F +352 26 48 38 [email protected]
MalaysiaT +60 3 806 188 49F +60 3 806 189 [email protected]
NetherlandsT +31 72 57 51212F +31 72 57 [email protected]
PortugalT +351 22 947 94 40F +351 22 941 30 [email protected]
SingaporeT +65 62739767F +65 [email protected]
SlovakiaT +421 2 55648541-2F +421 2 [email protected]
South KoreaT +82 31 448 3613-7F +82 31 448 [email protected]
SpainT +34 93 718 3305F +34 93 718 [email protected]
SwedenT +46 44 43015F +46 44 [email protected]
SwitzerlandT +41 55 2253 535F +41 55 2253 [email protected]
ThailandT +66 2 902 2604-13F +66 2 902 [email protected]
United KingdomT +44 1992 500550F +44 1992 [email protected]
United StatesT +1 847 673 6720F +1 847 673 [email protected]