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8/14/2019 Multiplex extruder

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Tyre Technology For eFFecTive producTion

Multiplex Extrusion Lines


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in pArTnerShip WiTh induSTry

KraussMaei is a premium partner

or the plastics and rubber processing industries

worldwide

Electrical / electronicsMedical / pharmaceuticalConstructionWhite goodsAutomotive

Whatever you aim to achieve in plastics or rubber

processing, KraussMaei is your partner. We are

the only company with intensive expertise across

the three main engineering felds. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

ra f a a

Our Injection Moulding Technology Division

supplies machines and systems or standard and

special applications, very large machines and ully

automated solutions. Our main markets are in the

automotive, packaging, electrical, electronics, medi-

cal technology and consumer goods industries.

Our Reaction Process Machinery Division supplies

machines and complete systems or processing

polyurethanes and other reactive materials.

Completing our product portolio, Tooling

Technologies supplies oam moulds, cutters and

routers. Our customer base is wide, with a ocus

on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems or compounding, or pipe,

prole and sheet extrusion, physical oaming, and

the production o technical rubbers and inter-

mediates or tire production. Machinery rom the

companys range rom single extruders to

complete extrusion lines is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, urniture and packaging.

p f pasts

We are the people or plastics. We are your

partners rom the rst exploratory discussion,

through development to commissioning, servicingand operating your system, and nal disposal. At all

times, you are assured o outstanding competence

in planning and engineering, as well as reliable and

ast spare parts, service and support.

A a f stms

We put our expertise to work or your success.

With machine ranges engineered or modularity,

we can deliver application-specifc solutions

based on our wide range o standard modules and

specially engineered solutions. This strategy oers

customers technical and cost advantages.

cs t stms a t w

As an international company, KraussMaei has a

presence in all the major markets or the plastics

and rubber processing industries and employs over

3,000 people worldwide. Our sales and service

network keeps us close to all our customers around

the world.


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Packaging

Combining excellent product quality with

maximum production output Multiplex

extrusion lines

As an expert partner for the tyre manufacturing

industry; KraussMaffei Berstorff delivers complete

leading-edge systems for the production of tyre

components. Our goal is to offer the made-to-measure

solutions you need to succeed in todays fast moving

competition.

In our product portolio you fnd Multiplex extrusion

lines with the highest output-rates in the market.

Proven engineering power, unrivalled technological

expertise, numerous patented developments and

active participation in the production processes of

the tyre manufacturers testify to the innovative

character of our machinery and made us what we

are today: the world leader in this technology.


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Seite Multiplex Extrusion Lines

MulTiplex exTruSion lineS

High technology, high quality, high output

The automotive vehicle tyre is a high-perormance

precision unit. The requirements o saety, com-

ort, economy and environmental compatibility

demand a high level o quality in every single tyre

component.

For the manuacturer, this means the application o

technologies, which combine excellent quality with

high output.

KraussMaei Berstors response to this challenge

is the delivery o complete high-tech extrusion lines

or the production o tyre components.

Our know-how matured over decades, our own

patented developments and our active participationin the innovative processes o the tyre manuacturers

all go to make us an expert partner or the industry.

The demands and expectations o our customers

are met with closely-targeted advice, highly-develo-

ped project management methods, computer-aided

component design and state-o-the-art manuactu-

ring and application-specic commissioning.

Our Technical Centres oer practical pre-contract

support with production-scale machinery and labo-

ratories with inspection and testing acilities. Trials

are conducted under real conditions to secure the

basis or each investment. The result is customer

satisaction right rom the outset.

High-tech extrusion lines with the highest output

rates conrm our position as the world leader in

this technology as all the signicant manuacturersproduce their tyres on KraussMaei Berstor

machinery.

Tread

Capply

Belt layer 1

Belt layer 2

Sidewall

Bead

Tread compound

Undertread

compound

Sidewall

compound

Rim cushion

Carcass

Innerliner

Apex

Bead wire


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Preline Seite

MulTiplex uniTS For pre-ASSeMbly

Pre-assembly: precision in detail

Pre-assembly defnes the level o the production

technology. This is because pre-assembly of

passenger car and truck tyres utilises al l the

reserves o rationalisation, whilst simultaneously

raisng the tyre component quality to a high level.

KraussMaei Berstor machines are designed in

concept to meet the special demands o the manu-

acture o semi-fnished components. Duplex,

Triplex and Quadroplex extrusion sets guarantee

precise combination o the dierent components,

totally ree o air inclusions. The end result is

always more than the sum o the individual parts

here is component technology in perection,

allowing signicant rationalisation by reducing

the number o working stages on the tyre buildingmachines.

Extrusion Passenger TruckExtrusion Passenger TruckHead Product car tyres tyresHead Product car tyres tyres

DuplexDuplex Sidewall + rim strip Cap + base

2-component apex

TriplexTriplex Cap, base, wings Cap, base, cushion Black sidewall, rim strip, shoulder pad

QuadroplexQuadroplex Cap, base, wings, cushion

2 x cap, base, wings White sidewall, rim strip, shoulder pad Cap CushionWings Base


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Seite

MulTiplex lineS

Quality and perormance

without compromise

All tyre makers are seeking ever-tighter manu-

acturing tolerances, whilst throughput rates are

steadily rising.

KraussMaei Berstor extrusion lines are concei-

ved or high product quality and maximum output

and are equipped with extruders o dierent types

(GE-SC or GE-KS) and sizes.

The modular design makes or rapid recongura-

tion to suit the mode o operation Mono, Duplex,

Triplex or Quadroplex.

KraussMaei Berstor Multiplex extrusion sets are

designed in a piggy-back arrangement to achieve

the highest product quality through symmetrical

material fow in the head. In addition, the compact

design makes or real space savings. A urther

eature to satisy the quality requirements is the

special design o the fow channels in the extrusion

head. These ensure a very gentle, even material

transer rom the round section at the extruder

outlet to the rectangular fat orm o the prole. In

addition, the changes in direction o the material

fow in the fow channel are kept to a minimum.

All stages o the process are controled by a monito-

ring system, thus ensuring operational security.

Throughput rates o up to 10,000 kg/h or about

30,000 passenger car treads per day are achieved

with these modern extrusion lines.

Flow channels in the Multiplex extrusion head

Pre-assembly o a

Multiplex extrusion set

Multiplex Lines


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Preline Seite


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MulTiplex exTruSion heAdS And ToolS

Versatile and efcient:

systemised head operation

The range o dierent tyres dictates the require-

ments or changing the compound, dimensions

and programs run on any production line, whilst

the extrusion head determines the quality and

eciency o the tyre production.

Multiplex extrusion heads rom KraussMaei

Berstor represent the state o the art with

working widths up to 850 mm or up to 2 treads

in one production pass

locking orces up to 10,000 kN

connection o up to our extruders o dierent

types and sizes

To achieve rapid change times or dierent prole

dimensions, KraussMaei Berstor have two

solutions:

Casset te changer unit on the operator side,

consisting o a housing and a vertical sliding unit

on either cassette. One housing is in production,

whilst the other is in the preparation position.

Double wedge comb to shorten change o the

nal die without changing the splice bar. While

the outer wedge comb is opened, the inner one

holds the housing and splice bar closed against

the head.

This minimises scrap and allows rapid restart o

production.

The upper and lower parts o the head can be ope-

ned separately to acilitate cleaning when changing

the compound and to accelerate the changeover.

Multiplex extrusion heads and tools


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Easy to clean: extrusion head in opened position Multiplex extrusion head with cassette changer unit


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Width

measurement

Accelerator roller train

with blow-o jets

Cutting machine skive

Multiplex

extrusion set

Take-o roller train

with marking unit

Continuous length

weighing scale

and width scanner

Prole

scanner

MulTiplex coMpleTe lineS

System technology at a stroke

The better the individual process stages t together,

the more secure is the fow o the production.

KraussMaei Berstor designs complete line con-

cepts to attain perect interplay o all components

under changing parameters.

Based on our wide experience, we bring together

all elements o the production line into a systemised

technological solution. From the eed units to the

wind-ups everything rom one single source.

Each part mates with the next and every compo-

nent o the line can be matched to the process-tech-

nical requirements o compound and dimensional

changes or changes rom cut piece to wind-up

operation. The interace-ree conguration o the

machinery ensures constant product quality at

maximum capacity utilisation.

Feed units with

metal detectors

automatic setting o the eed rate

simple service and maintenance

Gauging instruments

continuous weight per meter and weight per piece or

precise weight measurement

width measurement beore and ater the cooling unit

prole scanning or continuous monitoring o the geometry

length measuring units or monitoring the cut prole lengths


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Manual pick-o roller train

cut-piece operation

Reject roller train Cross-cutting unit

Wind-up stations

Spray cooling

Marking units or

printing o coloured stripes

printing o identication codes

imprints o numbers and letters

Cementing station

to increase adhesion o the

splice suraces

Cutting units (Skiver)

fying cut or start/stop cut or cut-piece

operation with the highest cut quality,

length precision and maximum cut rates

per minute, rotary cutting or wind-up

operation

Wind-up operation

cassette winders

spool winders

Cut-piece operation

manual pick-up roller train

automatic booking system

Cooling systems

units or spray or immersion cooling


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Seite

conTrol And AuToMATion

Multiplex Extrusion Lines

Planning and construction o the electro-techni-

cal equipment or the extrusion lines are carried

out in modular form to the latest standards.

Customised confgurations can be quickly created

without problems.

The extruder motors are equipped with micropro-

cessor drives, digital actual value access and bus

connector set point provision. This technology

ensures a high degree o repeatability, exact regu-

lation and dynamic screw speed control. All this

has a direct infuence on the quality o the extruded

prole. KraussMaei Berstor developed control

sotware mimimises start-up scrap and keeps the

extruded profle within the prescribed dimensi-

onal and weight tolerances during production.

The system continuously reads the weight and

the dimensions o the prole as well as the screw

speed and the stock pressure and temperature in

WIN CC (Win NT)

11 22

33 44

55

66 7788

99

10101212 1313

1111

1414 1515 1616

1717

1818 1919

2020

2121

2222

2323

each extruder. I the actual process values deviate

rom the set points, the process parameters are

corrected individually or, depending on their

proportion o infuence on the prole components,

o all extruders. Auxiliary drives are equipped

with low-maintenance three-phase standard motors

and vector-controlled requency converters. Non-

contact sensing systems such as CCD cameras and

ultra sonic sensors and special digital dancer-type

regulators provide tension-ree material transport.

Each system is provided with a digital sotware con-

trol, which guarantees optimal speed matching with

its adjacent downstream drive. The PLC automation

units o the individual machines are networked via

TCP/IP with each other and with the visual display.

Operator-riendly visualisation and easy-to-use

recipe management acilitate fexible production

planning, high product quality, minimal start-up

scrap and rapid changeovers.

Control and automation


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Seite

Service

Host

Modem

4 Switch

OPC server

6 Main operator panel

7 Operator box head Ethernet TCP/IP

9 Probus DB

Extruder control

Terminal- and

operator-boxes

Feeding or

extruder 4

Feeding or Mini RH

4 Head

Terminal- and

operator-boxes

6 PLC customer

communication

7 Probus DB

AC Drive with

pulse generator

Extruder 4

9 AC drive withpulse generator

Mini Rollerhead

Heating controller

Camera

Scale

AC Vectordrive

with pulse generator

Downstream ...n

roller-heAd lineS

Tandem operation or

maximum precision

Roller-Head technology rom KraussMaei

Berstor combines precision and economy into one:

close-tolerance work or the production o innerliners

and ller strips. The rubber compound is plastied

in the extruder and ed directly to the roll gap o

the two-roll calender via a wide-slot extrusion die.

The calender calibrates the web exactly to the preset

nal thickness. This process avoids the ormation

o a rolling ball in the calender and thus the risk

o air inclusions. The narrowest o tolerances over

the entire web width and optimal homogeneity o

the compound ensure the perect tyre innerliner and

ller strip.

Both proles are doubled with the highest centricity

and absolutely blister-ree.

Roller-Head lines


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Rely on us or a ast and competent response to

all your service needs anywhere in the world.

Whatever you need rom troubleshooting or

training to spares or repairs were on the job.

Were dedicated to supplying service quality on a

par with the outstanding quality o our machines

and systems. We oer ar more than spare parts

and hotlines. Well work with you to choose thebest and most cost-eective solution or your

production. Well help you test new applications

and well plan customized service packages.

A s

Our service oering is broad. Well congure your

system, install and commission it, train your sta,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. Youll nd us ast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

I necessary, well get a technician to you quickly.

Remote diagnosis, interacing directly with your

machines control system, can be a practical

alternative. Spares or all important wear parts are

available at short notice. Were continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution or your business.

cstm tas a tt tst a

The Extrusion Division operates a test lab in Ger-

many and USA tted with the latest machinery and

equipment. We can run trials and ne-tune pro-

cesses on your behal. We can work with you to test

and evaluate processes, machines and equipment in

order to identiy the best approach or a particular

project. Our highly-qualied application engineers

are there to help you.

Ta wt as tt

Courses are held in our lab and training centre,

or, optionally, on your premises. We oer

clearly-structured basic and advanced training in

operation, process control and maintenance or

KraussMaei extrusion systems. On request, well

plan and hold special courses on topics o your

choice. All participants spend a high proportion

o their training working hands-on with original

KraussMaei Berstor machines. A well-structured

training program produces skilled operators and

technicians, which will positively impact your up-

time and productivity.

Service WorldWide

Service, support and spare parts when you

need them, where you need them


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Krauss Maei Italiana S.r.l.

Rezzato, Italy

Phone: +39 030 2590707

Fax: +39 030 2592369

Email: [email protected]

BKM Servicegesellschaft OOO

KraussMaei Berstor

Moscow, Russia

Phone: +7 495 9377554

Fax: +7 495 6265745


Krauss Maei Corporation

Florence, USA

Phone: +1 859 2834376

Fax: +1 859 2830290


Krauss Maei Mexico

Mexico City, Mexico

Phone: +5281 15211604

Fax: +5255 53081727


Krauss Maei do Brasil Ltda

So Paulo, Brazil

Phone: +55 11 56412273

Fax: +55 11 56419337


KraussMaei Co., Ltd.

Shanghai, China

Phone: +86 21 58682662

Fax: +86 21 58681173


Krauss Maei Asia Pacifc Pte. Ltd.

Singapore

Phone: +65 65 535828

Fax: +65 64 550419


Contacting us by postContacting us by post

I you need to contact any o our

international service or spare parts teams

by post, use this address:

cstm Scstm S

KraussMaffei Berstorff GmbHKraussMaffei Berstorff GmbH

An der Breiten Wiese 3-5An der Breiten Wiese 3-5

30625 Hannover30625 Hannover

GermanyGermany

Worldwide hotlineWorldwide hotline

numbersnumbers KraussMaeiBerstor GmbH

Hannover, Germany

Customer Service

Phone: +49 511

5702-533

Email: service-ext.

ha@kraussmaffei.

com

Phone rubber

technology: +49 172

511 9620

Phone plastics

technology: +49 172

511 9621

Phone service

hotline: +49 172 511

9623


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KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

KassMaff bstff gmh

An der Breiten Wiese 3-5 30625 Hannover

Phone +49 511 5702-0 Fax +49 511 5619-16

www.kraussmaffei.com

As an expert partner or the tyre manuacturing

industry; KraussMaei Berstor delivers complete

leading-edge systems or the production o tyrecomponents. Our goal is to oer the made-to-

measure solutions you need to succeed in todays

ast moving competition. In our product portolio

you fnd Multiplex extrusion lines with the highest

output-rates in the market. Proven engineering

power, numerous patented developments and active

participation in the innovative processes o the tyre

manuacturers testiy to the innovative character

o our machinery and made us what we are today:

the world leader in this technology.