CN115416192A - Intelligent control rubber vulcanization process, method and system - Google Patents
Intelligent control rubber vulcanization process, method and system Download PDFInfo
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- CN115416192A CN115416192A CN202211255886.5A CN202211255886A CN115416192A CN 115416192 A CN115416192 A CN 115416192A CN 202211255886 A CN202211255886 A CN 202211255886A CN 115416192 A CN115416192 A CN 115416192A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D30/00—Producing pneumatic or solid tyres or parts thereof
- B29D30/06—Pneumatic tyres or parts thereof (e.g. produced by casting, moulding, compression moulding, injection moulding, centrifugal casting)
- B29D30/0601—Vulcanising tyres; Vulcanising presses for tyres
- B29D30/0606—Vulcanising moulds not integral with vulcanising presses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2030/00—Pneumatic or solid tyres or parts thereof
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Abstract
The invention provides an intelligent control rubber vulcanization process, a method and a system, relating to the technical field of rubber production; providing a new vulcanization process, wherein equivalent vulcanization time is used as an index for measuring vulcanization completion, when the process is applied, firstly, preparing a sample under the equivalent vulcanization time calculated theoretically to optimize and obtain standard equivalent vulcanization time, then preparing a vulcanized finished product according to the data, and then reversely calibrating and marking the equivalent vulcanization time on the vulcanized finished product by adopting results verification modes such as dissection, phased array detection and the like until the equivalent vulcanization time of the product meeting a preset standard is obtained; and then propose the vulcanization procedure that corresponds respectively to different moulds, different glue kind, can not only intelligent control demolding, and realize the holistic intelligent control of vulcanization process.
Description
Technical Field
The invention relates to the technical field of rubber production, in particular to an intelligent control rubber vulcanization process, method and system.
Background
The over-vulcanization phenomenon generally exists in thick products such as tires, vulcanization temperature measurement is necessary, and a vulcanization process condition which enables the vulcanization degree of each part of the thick products to be matched reasonably is formulated according to the over-vulcanization phenomenon, so that the purposes of saving energy, reducing consumption and improving product quality are achieved.
The rubber vulcanization temperature is a basic condition for rubber vulcanization reaction, and directly influences the rubber vulcanization speed and the product quality, so that the accurate control of the temperature in the vulcanization process has important production significance. Currently, a vulcanization thermodetector is mainly used for measuring the temperature change in the vulcanization process; in China, a plurality of manufacturers produce the vulcanization temperature measuring instruments, such as an intelligent vulcanization temperature measuring instrument which is researched and developed by Beijing rubber industry research and design institute and takes a single-board computer as a core, and a simple type temperature measuring instrument and a high-grade vulcanization temperature measuring instrument which are researched and developed for solving the problem of the single-board type vulcanization temperature measuring instrument. The former has the advantages of low price, accurate temperature measurement, long service life and the like; the latter uses the notebook computer as the host computer, and is matched with 24-way thermocouple for temperature measurement, and has the advantages of convenient operation, no need of using alternating current as the power supply, perfect data processing system, high test data precision, database form storage and the like. 1.0 version tire vulcanization thermodetector, 2.0 version tire vulcanization thermodetector and 3.0 version tire vulcanization thermodetector are developed from 20 years by southern China university, wherein the 3.0 version tire vulcanization thermodetector comprises a notebook computer, an imported data collector, an alternating current power supply and a direct current power supply, and a C + + is adopted as a development tool and an object-oriented programming technology, so that a novel distributed computer temperature measurement system is formed, the temperature of each part at different moments can be measured simultaneously in the vulcanization process, meanwhile, the equivalent vulcanization time of each part, the optimal vulcanization time of a workshop and the like can be calculated, and the equivalent vulcanization effect can be calculated by using temperature measurement storage discs or temperature-time data of other sources; and 3.1 edition and 3.2 edition tire vulcanization thermoscope, almost can accomplish the whole tasks of vulcanizing temperature measurement and vulcanization calculation two part technique automatically, have been adopted by many enterprises such as south China rubber tire limited company, zhujiang tire limited company, baoli tire company, zhou Zhongzhe rubber limited company, shandong Chengshan tire group limited company, guizhou tire group limited company at present.
Except that the vulcanization temperature can be accurately measured in the rubber vulcanization process, other processes mainly adopt a mode of firstly calculating through an empirical formula, reproducing field verification and then curing. Therefore, since this method lacks scientific method certification, the following problems may occur during vulcanization, including: 1) In order to ensure that the product is not lack of sulfur, the vulcanization time set by the vulcanization process is longer, and the over-vulcanization of the product is common; 2) The first mould vulcanization process of the product occasionally has errors, so that the product is scrapped or degraded for use; 3) When the temperature of the machine table fluctuates, the vulcanization time cannot be accurately given; 4) When the rubber temperature and the mold temperature change, the vulcanization time can be increased or shortened only according to experience, and occasionally, the phenomenon of under-sulfur of the product can occur.
Disclosure of Invention
Compared with the traditional vulcanization process, the vulcanization time is used as the basis for completing vulcanization, the standard equivalent vulcanization time value is optimized to be used as the index for completing vulcanization, the demolding is intelligently controlled, and the quality of vulcanized products is remarkably improved.
In order to achieve the above purpose, the invention provides the following technical scheme: an intelligent control rubber vulcanization process, comprising the following steps:
1) The equipment pretreatment comprises the steps of additionally arranging a temperature measurement module and a lower die warning module corresponding to a temperature measurement line on hardware of the vulcanizing machine, and additionally arranging a temperature correction function of the temperature measurement module, a temperature comparison function of the same temperature measurement point and an automatic lower die function reaching preset conditions on software of the vulcanizing machine;
2) The mold pretreatment comprises the steps of determining the position information of a plurality of temperature measuring points in the product vulcanization process, and sequentially arranging temperature measuring holes at the corresponding positions of the product mold;
3) Acquiring the real-time temperature of each temperature measuring hole in the vulcanization process of the product;
4) Preparing a sample of the rubber seed product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of a vulcanized finished product prepared by the rubber seed under a corresponding mold;
5) Repeatedly executing the steps 2) to 4) on different rubber types and different molds to obtain standard equivalent vulcanization time for preparing vulcanized finished products by using different rubber types under different molds;
6) And executing a vulcanization process and an automatic lower die molding process of a vulcanized finished product according to the set rubber type and the set die and the corresponding standard equivalent vulcanization time.
Further, the method also comprises the following steps:
7) And (4) carrying out result verification analysis on the vulcanized finished product, and dynamically adjusting the standard equivalent vulcanization time under the vulcanization working condition according to the analysis result until the finished product reaches the preset standard.
Further, the process of determining the position information of the plurality of temperature measuring points in the product vulcanization process in the step 2) is as follows:
simulating the vulcanization process of any rubber product in a set mold by using three-dimensional software according to the vulcanization temperature field;
calculating the activation energy of each simulation point in the vulcanization process, and determining the most difficult vulcanization point of the product in the vulcanization process;
and determining the most difficult vulcanization point as the position of the temperature measuring hole.
Further, the specific process of performing the vulcanization process in the step 6) includes:
setting the vulcanization temperature in the vulcanization process, a temperature threshold value for starting vulcanization, standard equivalent vulcanization time and a period for automatically acquiring the real-time temperature of each temperature measuring hole;
when the real-time temperature of each automatically acquired temperature measuring hole reaches a set threshold value, starting vulcanization;
automatically calculating the equivalent vulcanization time in the vulcanization process according to the real-time temperature of each temperature measuring hole acquired in a set period;
when the calculated equivalent vulcanization time reaches the standard equivalent vulcanization time, stopping vulcanization;
and sending a control command to the vulcanizing machine so as to enable the vulcanizing machine to automatically demould.
Further, the real-time temperature of each temperature measuring hole in the product vulcanization process in the step 3) is measured by a K-type thermocouple.
Further, the process of optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the step 4) comprises the following steps:
dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear;
when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon;
optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
Further, the step 7) of performing result verification analysis on the vulcanized finished product includes:
dissecting the vulcanized finished product, and carrying out performance tests on the finished product, wherein the test contents comprise tensile strength, tear strength, specific gravity and DIN abrasion;
and determining the vulcanization degree of the vulcanized finished product, including testing whether the first mold product has an under-sulfur or over-sulfur phenomenon by using a phased array.
Further, the temperature threshold for the initiation of vulcanization is 90 ℃.
The invention also discloses an intelligent control rubber vulcanization method, which comprises the following steps:
obtaining standard equivalent vulcanization time for preparing vulcanized finished products by different rubber types in different molds;
preparing a vulcanized finished product according to the standard equivalent vulcanization time;
performing result verification analysis on the vulcanized finished product in a finished product dissection and phased array detection mode, wherein the result verification analysis comprises performance test and vulcanization degree judgment on the finished product;
calibrating the standard equivalent vulcanization time according to the analysis result until the finished product prepared under the standard equivalent vulcanization time after calibration reaches the preset standard;
the standard equivalent vulcanization time is obtained through the following process: preparing a sample of the rubber product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of preparing a vulcanized finished product by the rubber under a corresponding mold; the optimization process comprises the following steps: dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear; when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon; optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
The invention also discloses an intelligent control rubber vulcanization system, which comprises a vulcanizing machine, a plurality of dies, a plurality of K-type thermocouples and an intelligent control system loaded on the vulcanizing machine;
a plurality of temperature measuring holes are formed in any one of the dies, and the K-type thermocouples are installed in one-to-one correspondence with the temperature measuring holes; the K-type thermocouple is connected with the intelligent control system through a signal and used for sending real-time temperature data of the temperature measuring hole to the intelligent control system;
a vulcanization program and an automatic lower die program for producing different rubber type vulcanized finished products by using each die are preset in the intelligent control system, and any vulcanization program comprises a preset vulcanization temperature, a temperature threshold value for starting vulcanization, standard equivalent vulcanization time and a period for automatically acquiring real-time temperature of each temperature measuring hole;
when a mold and a rubber seed in the vulcanization process are selected, the preparation of a vulcanizing machine is completed, a vulcanization program corresponding to the mold and the rubber seed is selected through an intelligent control system to start vulcanization, and the vulcanization program is ended until the vulcanization reaches the standard equivalent vulcanization time preset by the program; the intelligent control system automatically starts a lower die program after the vulcanization program is finished, and the automatic lower die of the vulcanized finished product is finished;
wherein the standard equivalent cure time for any procedure is obtained as follows:
preparing a sample of the rubber seed product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample, and obtaining the standard equivalent vulcanization time of the rubber seed for preparing a vulcanized finished product under a corresponding mold;
the process for optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample comprises the following steps:
dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear or not;
when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon;
optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (5) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
According to the technical scheme, the technical scheme of the invention has the following beneficial effects:
compared with the prior art which adopts the vulcanization time as the index of the completion of vulcanization and takes the equivalent vulcanization time as the index of the completion of vulcanization, the process can effectively prevent the occurrence of under-vulcanization of the product and reduce the proportion of over-vulcanization of the product. When the method is applied specifically, firstly, a sample is prepared and optimized through equivalent vulcanization time under theoretical calculation to obtain standard equivalent vulcanization time, then, a vulcanized finished product is prepared according to the data, and then, the equivalent vulcanization time is reversely calibrated and labeled by adopting result verification modes such as dissection, phased array detection and the like on the vulcanized finished product until the equivalent vulcanization time of the product meeting the preset standard is obtained; and then propose the vulcanization procedure that corresponds respectively to different moulds, different types of glue, can not only intelligent control demolding, and realize the holistic intelligent control of vulcanization process.
In addition, compared with the method that vulcanization thermometers are adopted by all domestic and foreign famous rubber factories to optimize vulcanization time and the vulcanization thermometers are realized through a buried wire method, the method is easy to cause the phenomenon of data abnormity in the vulcanization process; the scheme adopts a thermocouple form to replace a wire embedding method, and adopts a vulcanization process intelligent control system to control the equivalent vulcanization time of each product, thereby effectively reducing the occurrence of abnormal data and ensuring the data stability of the intelligent control system.
After the vulcanization process disclosed by the invention is implemented, the average vulcanization time of most vulcanized products can be successfully saved by 10%, and about 15% of energy cost is saved every year; namely, the invention can ensure the improvement of the quality stability of the vulcanized product, and simultaneously can reduce the production cost, improve the productivity of the workshop and the competitiveness of enterprises, reduce the energy consumption and reduce the pollution.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent.
The foregoing and other aspects, embodiments and features of the present teachings will be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of specific embodiments in accordance with the teachings of the present invention.
Drawings
The figures are not intended to be drawn to scale with true references. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a rubber vulcanization process technology route intelligently controlled by the present invention;
FIG. 2 is a flow chart of the intelligent control rubber vulcanization method of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the drawings of the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the described embodiments of the invention without any inventive step, are within the scope of protection of the invention. Unless defined otherwise, technical or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
The use of "first," "second," and similar terms in the description and claims of the present application do not denote any order, quantity, or importance, but rather the terms are used to distinguish one element from another. Similarly, the singular forms "a," "an," or "the" do not denote a limitation of quantity, but rather denote the presence of at least one, unless the context clearly dictates otherwise. The terms "comprises" or "comprising," and the like, mean that the elements or components listed in the preceding list of elements or components include the features, integers, steps, operations, elements and/or components listed in the following list of elements or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof. "upper", "lower", "left", "right", and the like are used only to indicate relative positional relationships, and when the absolute position of the object to be described is changed, the relative positional relationships may also be changed accordingly.
The vulcanization process based on the prior art is based on the fact that the vulcanization time is used as the basis for completing vulcanization, the vulcanization process except the vulcanization temperature can be monitored, other process parameters mainly depend on production experience, and the results are verified and improved; therefore, the phenomena of over-vulcanization, under-vulcanization, scrapping or degraded use of the first mold product and the like generally exist in the conventional process of deducing the vulcanization time through temperature monitoring. Therefore, the invention aims to provide an intelligent control rubber vulcanization process, a method and a system, the process accurately monitors the temperature of the vulcanization process through thermocouple temperature measurement on one hand, and adopts equivalent vulcanization time as an index for judging vulcanization completion on the other hand, so that the problems are effectively reduced, and the vulcanization process corresponding to the vulcanization process can be intelligentized.
The following describes a process, method and system for intelligently controlling rubber vulcanization according to the present invention in more detail with reference to the embodiments shown in the drawings.
Referring to fig. 1, when the intelligent control rubber vulcanization process disclosed in the embodiment of the present invention is executed, an equivalent vulcanization time (EQT) value is used as an index for completing vulcanization, and the process includes the following steps of basic data preparation, software development, hardware modification of a vulcanizer, and process verification, and finally implements the intelligent control vulcanization process, and specifically includes the following steps:
1) The equipment pretreatment comprises the steps of additionally arranging a temperature measurement module and a lower die warning module corresponding to a temperature measurement line on hardware of the vulcanizing machine, and additionally arranging a temperature correction function of the temperature measurement module, a temperature comparison function of the same temperature measurement point and an automatic lower die function reaching preset conditions on software of the vulcanizing machine;
2) The mold pretreatment comprises the steps of determining the position information of a plurality of temperature measuring points in the product vulcanization process, and sequentially arranging temperature measuring holes at the corresponding positions of the product mold;
3) Acquiring the real-time temperature of each temperature measuring hole in the vulcanization process of the product;
4) Preparing a sample of the rubber product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of preparing a vulcanized finished product by the rubber under a corresponding mold;
5) Repeatedly executing the steps 2) to 4) on different rubber types and different molds to obtain standard equivalent vulcanization time for preparing vulcanized finished products by using different rubber types under different molds;
6) According to the set rubber type and the set mould, executing a vulcanization process and an automatic lower mould process of a vulcanized finished product according to the corresponding standard equivalent vulcanization time;
7) And (4) carrying out result verification analysis on the vulcanized finished product, and dynamically adjusting the standard equivalent vulcanization time under the vulcanization working condition according to the analysis result until the finished product reaches the preset standard.
The steps 1) and 2) mainly realize the processes of software research and development and hardware transformation of the vulcanizing machine, and the sequence of the steps can be freely adjusted in the actual implementation process. Specifically, on hardware, the temperature measuring module is used for monitoring the temperature of the colloid in the vulcanization process in real time, and the lower die warning module is used for prompting the lower die; in software, the temperature correction function of the temperature measurement module and the temperature comparison function of the same temperature measurement point are both used for eliminating environmental interference and measuring the temperature of the temperature measurement point more accurately.
In this embodiment, compare in the mode of the vulcanization thermoscope that the tradition adopted and the method of burying the line monitoring temperature, this scheme confirms earlier the mode that the temperature measurement point adopted thermocouple fixed point temperature measurement again, and this mode effectively avoids the temperature measurement line can appear the drunkenness in the vulcanization process and leads to the problem that the vulcanization time can't be accurately obtained to the data abnormity, and the equivalent vulcanization time of every product can be accurately controlled to the thermocouple form.
In the scheme, the process of determining the position information of a plurality of temperature measuring points in the product vulcanization process in the step 2) comprises the following steps: simulating the vulcanization process of any rubber product in a set mold by using three-dimensional software such as ANSYS simulation software according to the vulcanization temperature field; calculating the activation energy of each simulation point in the vulcanization process, and determining the most difficult vulcanization point of the product in the vulcanization process; and determining the most difficult vulcanization point as the position of the temperature measuring hole. Optionally, a plurality of temperature measuring holes can be selected when the temperature measuring holes are selected, and by setting an activation energy threshold, each simulation point exceeding the threshold is taken as a hard-to-cure point and is respectively selected as a temperature measuring point. During optional temperature measurement, a plurality of thermocouples can be placed in one temperature measurement hole, and the temperature of the point is measured, so that temperature abnormity can be further eliminated and corrected in the step 3).
Known thermocouples are used as temperature sensing elements, which can convert temperature signals into thermoelectric force signals, and can display the measured temperature by a proper conversion instrument; the thermoelectric effect is the basic principle of thermocouple temperature measurement. The thermocouple is a closed loop formed by two wires made of different metal materials, and two ends of each wire are not arrangedAt the same temperature, a thermoelectric potential e is generated in the loop 0 ,e 0 Is a function of the temperature at the junction of two different metals, and the value can be directly used as the output value of the temperature. In the vulcanization thermo-detector, the thermocouples mainly used are of three types of T, J and E, wherein the T-type thermocouple is most commonly used in the vulcanization thermo-detector of the tire, because the T-type thermocouple is the one with the highest accuracy grade of the three thermocouples, and has high sensitivity and good reproducibility. In the application, the thermocouple is a K-type thermocouple, which is low in price, and has the advantages of good linearity, large thermoelectromotive force, high sensitivity, good stability and uniformity, strong oxidation resistance and the like.
When the device is installed, the thermocouple is suspended in the air through the steel needle and sent into the temperature measuring hole, and the temperature of the thermocouple is uploaded to control software of a vulcanizing machine in real time. In specific implementation, because the acquired real-time temperature may have deviation due to new equipment or mechanical errors, correction needs to be performed, the correction mainly adopts a manual mode, usually a temperature measuring element is arranged on the outer side of the vulcanizing machine, and data of the temperature measuring element is compared with real-time thermocouple temperature measuring data; during correction, the position of the thermocouple is adjusted mainly according to the deviation between the temperature measurement data of the thermocouple and the temperature measurement data at the outer side.
The basic data preparation is mainly applied to the step 4) and the step 5), and comprises the following steps: optimizing the activation energy of each rubber seed, optimizing the equivalent vulcanization time of each rubber seed product, and optimizing the equivalent vulcanization time of each rubber seed bubble vanishing point; wherein, the activation energy of the rubber seeds is optimized by an Arrhenius formula, and the equivalent vulcanization time is obtained by calculating the activation energy of the rubber seeds and a variable formula (1) of the Arrhenius formula:
wherein E represents activation energy, kJ/moL; t is a unit of 0 A temperature threshold, K, indicating the onset of vulcanization; t represents the vulcanization temperature, K; r represents a gas constant; t is t * Represents the equivalent cure time, s; t represents the vulcanization time, s.
Specifically, the process of optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon comprises the following steps: dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear; when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon; optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (5) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard. The process is adopted to optimize equivalent vulcanization time for samples made of different rubber types and different molds, and standard equivalent vulcanization time is obtained.
During actual optimization, the vulcanization time corresponding to the equivalent vulcanization time is calculated in advance by prolonging the theory when the first mold is used for preparing the sample, so that no air bubbles exist in the product, the vulcanization time is shortened gradually until the air bubbles appear on the product section, and the disappearance time corresponding to the disappearance of the air bubbles at the critical point is adjusted and found gradually.
As mentioned above, step 6) is essentially realized as an automated vulcanization program, and the corresponding vulcanization process data is converted into an automatically executed vulcanization program according to the optimized standard equivalent vulcanization time; the specific process comprises the following steps:
setting the vulcanization temperature in the vulcanization process, a temperature threshold value for starting vulcanization, standard equivalent vulcanization time and a period for automatically acquiring the real-time temperature of each temperature measuring hole; when the real-time temperature of each automatically acquired temperature measuring hole reaches a set threshold value, starting vulcanization; automatically calculating the equivalent vulcanization time of the vulcanization process according to the real-time temperature of each temperature measuring hole acquired in a set period; when the calculated equivalent vulcanization time reaches the standard equivalent vulcanization time, stopping vulcanization; and sending a control command to the vulcanizing machine so as to enable the vulcanizing machine to automatically demould. When the vulcanizing program is set in the vulcanizing machine, the production is strictly carried out according to the process.
Wherein, the temperature threshold value for starting vulcanization is conventionally set as 90 ℃, the period for automatically acquiring the real-time temperature of each temperature measuring hole is generally set as 60s, and the equivalent vulcanization time is calculated by the above-mentioned variable (1).
Step 7) realizing a continuous optimization process of the standard equivalent vulcanization time, wherein the process is generally carried out in a laboratory; the verification process comprises the following steps: dissecting a vulcanized finished product, and performing performance test on the finished product by adopting the existing method, wherein the test contents comprise tensile strength, tear strength, specific gravity and DIN abrasion; determining the vulcanization degree of a vulcanized finished product, wherein the vulcanization degree comprises testing whether the first mold product has an under-sulfur or over-sulfur phenomenon by using a phased array; because the bubble disappearance phenomenon optimization standard is adopted to achieve equivalent vulcanization time, the phased array test is mainly used for testing whether the product has a sulfur shortage phenomenon.
According to the intelligent control rubber vulcanization process disclosed by the invention, the vulcanization time is not taken as a basis for completing vulcanization, the EQT value is optimized to be used as an index for completing vulcanization when the vulcanization process is formulated, the demolding is intelligently controlled, and the intelligent control of the vulcanization process is realized for the first time; the implementation of the process can not only improve the quality stability of the vulcanized product, reduce the production cost, but also improve the workshop productivity and the enterprise competitiveness.
For example, from the aspect of instrument cost, the cost required for realizing EQT analysis by a commercially available vulcanization thermometer in the prior art is about 20 ten thousand per meter, and the cost required for optimizing the EQT and analyzing by using the thermocouple temperature measurement of the present solution is about 5000 yuan per meter, which effectively saves the cost. Secondly, from the energy perspective, the process can reduce the average vulcanization time of most products by 10 percent, and can save the energy consumption of the average vulcanization time by 10 percent on the premise of reducing the average vulcanization time by heating with natural gas; finally, from the social perspective, less energy is consumed to effectively reduce environmental pollution.
In another embodiment of the present invention, as shown in fig. 2, a method for intelligently controlling rubber vulcanization is provided, which comprises:
obtaining standard equivalent vulcanization time of preparing vulcanized finished products by different rubber types under different molds; preparing a vulcanized finished product according to the standard equivalent vulcanization time; performing result verification analysis on the vulcanized finished product in a finished product dissection and phased array detection mode, wherein the result verification analysis comprises performance test and vulcanization degree judgment on the finished product; calibrating the standard equivalent vulcanization time according to the analysis result until the finished product prepared under the standard equivalent vulcanization time after calibration reaches the preset standard;
the standard equivalent vulcanization time is obtained through the following process: preparing a sample of the rubber product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of preparing a vulcanized finished product by the rubber under a corresponding mold; the optimization process comprises the following steps: dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear; when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon; optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
As an optional embodiment, the intelligent control rubber vulcanization system comprises a vulcanizing machine, a plurality of molds, a plurality of K-type thermocouples and an intelligent control system loaded on the vulcanizing machine;
a plurality of temperature measuring holes are formed in any one of the dies, and the K-type thermocouples are installed in one-to-one correspondence with the temperature measuring holes; the K-type thermocouple is connected with the intelligent control system through a signal and used for sending real-time temperature data of the temperature measuring hole to the intelligent control system;
a vulcanization program and an automatic lower die program for producing different rubber type vulcanized finished products by using each die are preset in the intelligent control system, and any vulcanization program comprises a preset vulcanization temperature, a temperature threshold value for starting vulcanization, standard equivalent vulcanization time and a period for automatically acquiring real-time temperature of each temperature measuring hole;
when a mold and a rubber seed in the vulcanization process are selected, the preparation of a vulcanizing machine is completed, a vulcanization program corresponding to the mold and the rubber seed is selected through an intelligent control system to start vulcanization, and the vulcanization program is ended until the vulcanization reaches the standard equivalent vulcanization time preset by the program; the intelligent control system automatically starts a lower die program after the vulcanization program is finished, and the automatic lower die of the vulcanized finished product is completed;
the standard equivalent cure time for any of the above procedures was obtained as follows: preparing a sample of the rubber seed product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample, and obtaining the standard equivalent vulcanization time of the rubber seed for preparing a vulcanized finished product under a corresponding mold; wherein, the process of optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample is as follows: dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear or not; when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon; optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
The invention combines the modification of the vulcanizing machine and the software development to realize the central control of the vulcanizing process, takes the equivalent vulcanizing time as an index for judging the vulcanizing degree, and can intelligently analyze the vulcanizing degree of the product by calculating the equivalent vulcanizing time; and then, the vulcanizing machine is communicated with a vulcanizing machine in real time, and when the product control point reaches an optimized value, the vulcanizing operation is automatically completed.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims (10)
1. An intelligently controlled rubber vulcanization process is characterized by comprising the following steps:
1) The equipment pretreatment comprises the steps of additionally arranging a temperature measurement module and a lower die warning module corresponding to a temperature measurement line on hardware of the vulcanizing machine, and additionally arranging a temperature correction function of the temperature measurement module, a temperature comparison function of the same temperature measurement point and an automatic lower die function reaching preset conditions on software of the vulcanizing machine;
2) The mold pretreatment comprises the steps of determining the position information of a plurality of temperature measuring points in the product vulcanization process, and sequentially arranging temperature measuring holes at the corresponding positions of the product mold;
3) Acquiring the real-time temperature of each temperature measuring hole in the vulcanization process of the product;
4) Preparing a sample of the rubber seed product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of a vulcanized finished product prepared by the rubber seed under a corresponding mold;
5) Repeatedly executing the steps 2) to 4) on different rubber types and different molds to obtain standard equivalent vulcanization time for preparing vulcanized finished products by using different rubber types under different molds;
6) And executing the vulcanization process and the automatic lower die molding process of the vulcanized finished product according to the set rubber type, the set die and the corresponding standard equivalent vulcanization time.
2. The intelligently controlled rubber vulcanization process of claim 1 further comprising the steps of:
7) And (4) carrying out result verification analysis on the vulcanized finished product, and dynamically adjusting the standard equivalent vulcanization time under the vulcanization working condition according to the analysis result until the finished product reaches the preset standard.
3. An intelligent controlled rubber vulcanization process according to claim 1, characterized in that the process of determining the position information of several temperature measurement points in the product vulcanization process in step 2) is:
simulating the vulcanization process of any rubber product in a set mold by using three-dimensional software according to the vulcanization temperature field;
calculating the activation energy of each simulation point in the vulcanization process, and determining the most difficult vulcanization point of the product in the vulcanization process;
and determining the most difficult vulcanization point as the position of the temperature measuring hole.
4. The intelligent control rubber vulcanization process of claim 1, wherein the step 6) of executing a vulcanization process comprises:
setting the vulcanization temperature in the vulcanization process, the temperature threshold value for starting vulcanization, the standard equivalent vulcanization time and the period for automatically collecting the real-time temperature of each temperature measuring hole;
when the real-time temperature of each automatically acquired temperature measuring hole reaches a set threshold value, starting vulcanization;
automatically calculating the equivalent vulcanization time of the vulcanization process according to the real-time temperature of each temperature measuring hole acquired in a set period;
when the calculated equivalent vulcanization time reaches the standard equivalent vulcanization time, stopping vulcanization;
and sending a control command to the vulcanizing machine so as to enable the vulcanizing machine to automatically demould.
5. An intelligent controlled rubber vulcanization process according to claim 1, characterized in that the real-time temperature of each temperature measurement hole during product vulcanization in step 3) is measured by a type K thermocouple.
6. The intelligent control rubber vulcanization process of claim 1, wherein the process of optimizing the equivalent vulcanization time of the rubber product based on bubble phenomenon in step 4) is:
dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear or not;
when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon;
optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
7. The intelligent control rubber vulcanization process of claim 2, wherein the step 7) of performing result verification analysis on the vulcanized product comprises:
dissecting the vulcanized finished product, and carrying out performance tests on the finished product, wherein the test contents comprise tensile strength, tear strength, specific gravity and DIN abrasion;
and determining the vulcanization degree of the vulcanized finished product, including testing whether the first mold product has an under-sulfur or over-sulfur phenomenon by using a phased array.
8. A intelligently controlled rubber vulcanization process according to claim 4, characterized in that the temperature threshold for starting vulcanization is 90 ℃.
9. A method of intelligently controlling vulcanization of rubber, comprising:
obtaining standard equivalent vulcanization time of preparing vulcanized finished products by different rubber types under different molds;
preparing a vulcanized finished product according to the standard equivalent vulcanization time;
performing result verification analysis on the vulcanized finished product in a finished product dissection and phased array detection mode, wherein the result verification analysis comprises performance test and vulcanization degree judgment on the finished product;
calibrating the standard equivalent vulcanization time according to the analysis result until the finished product prepared under the standard equivalent vulcanization time after calibration reaches the preset standard;
the standard equivalent vulcanization time is obtained through the following process: preparing a sample of the rubber seed product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample, wherein the optimized equivalent vulcanization time is the standard equivalent vulcanization time of a vulcanized finished product prepared by the rubber seed under a corresponding mold; the optimization process comprises the following steps: dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear or not; when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon; optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
10. An intelligent control rubber vulcanization system is characterized by comprising a vulcanizing machine, a plurality of dies, a plurality of K-type thermocouples and an intelligent control system loaded on the vulcanizing machine;
a plurality of temperature measuring holes are formed in any one of the dies, and the K-type thermocouples are installed in one-to-one correspondence with the temperature measuring holes; the K-type thermocouple is connected with the intelligent control system through a signal and used for sending real-time temperature data of the temperature measuring hole to the intelligent control system;
a vulcanization program and an automatic lower die program for producing vulcanized finished products of different rubber types by using each die are preset in the intelligent control system, and any vulcanization program comprises a preset vulcanization temperature, a temperature threshold value for starting vulcanization, standard equivalent vulcanization time and a period for automatically acquiring real-time temperature of each temperature measuring hole;
when a mold and a rubber seed in the vulcanization process are selected, the preparation of a vulcanizing machine is completed, a vulcanization program corresponding to the mold and the rubber seed is selected through an intelligent control system to start vulcanization, and the vulcanization program is ended until the vulcanization reaches the standard equivalent vulcanization time preset by the program; the intelligent control system automatically starts a lower die program after the vulcanization program is finished, and the automatic lower die of the vulcanized finished product is completed;
wherein the standard equivalent cure time for any procedure is obtained as follows:
preparing a sample of the rubber product under the equivalent vulcanization time theoretically calculated, optimizing the equivalent vulcanization time of the rubber product according to the bubble phenomenon in the sample, and obtaining the standard equivalent vulcanization time of the rubber product for preparing a vulcanized finished product under a corresponding mold;
the process for optimizing the equivalent vulcanization time of the rubber seed product according to the bubble phenomenon in the sample comprises the following steps:
dissecting a sample of the glue seed product, and observing whether bubbles in the section disappear or not;
when the bubbles disappear in the section of the sample, recording the disappearance time corresponding to the bubble disappearance phenomenon;
optimizing the equivalent cure time according to the disappearance time, comprising: when the disappearance time exceeds the equivalent vulcanization time, adjusting and increasing the equivalent vulcanization time; when the disappearance time is less than the effective vulcanization time, the equivalent vulcanization time is adjusted and reduced; and (4) repeatedly executing the adjusting process until the disappearance time is consistent with the equivalent vulcanization time, and optimizing the equivalent vulcanization time to reach the standard.
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| CN113945465B (en) * | 2021-10-18 | 2023-12-22 | 哈尔滨工业大学 | Thermal simulation test method and application of high-temperature high-strength tungsten-rhenium alloy |
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