TIRE TECHNOLOGY & PCR TYRE BUILDING

CEAT LTD

Making Mobility Safer & Smarter. Everyday.

INDEX

▪ Basics of Tyre

▪ Tire Construction

▪ Tyre Components

▪ Tire Manufacturing process

▪ Tyre Building Machine

▪ First Stage Tyre Building

▪ Second Stage Tyre Building

2
 BASICS OF TIRES

3
DEFINITION OF TIRE

TOROIDAL shape

PRESSURE CYLINDER mechanically

LONG CHAIN MACROMOLECULES

chemically of same or different types of
elastomers
A pneumatic tire is a toroidal
shaped flexible high performance
composite membrane capable of
containing air or Fluid under COMPOSITE structure with different materials
pressure when mounted on
suitable rim.
KEY FUNCTIONS OF THE TIRE
PRIMARY FUNCTIONS PERFORMANCE REQUIREMENTS

RIDE COMFORT LANE CHANGE BEHAVIOUR DRY BRAKE

PASS-BY NOISE LIFE/DURABILITY

WET BRAKING

IN CABIN NOISE FUEL EFFICIENCY

VEHICLE PULL
5
Tire Classification
 TYRE CONSTRUCTION
RADIAL VS BIAS CONSTRUCTION

7
RADIAL & BIAS TIRES

8 Friday, April 3, 2020

TIRE CONSTRUCTION – BIAS & RADIAL TIRE
Difference in Footprint
Outcome
BIAS CONSTRUCTION
Construction Comparison

• Safety :
• Better Foot Print
• Load ability:
• Stronger structure
Sidewall and tread flex together Bias
• Comfort :
• Spring like Sidewall

RADIAL CONSTRUCTION • Economy:

• Less Fuel
consumption due
to less movement
of Tread elements

Tread stable in spite of Radial

Moving sidewall
 TYRE COMPONENTS
TIRE COMPONENTS & MATERIALS

10
 RADIAL TIRE COMPONENTS
TREAD

GROOVE CAP STRIP

BELT

BODY PLY

INNERLINER

SIDEWALL BEAD APEX

BEAD

RIM CUSHION

11 Friday, April 3, 2020

Introduction to Tyre Material Technology

Polymers Fillers Chemicals Fiber Steel

• NR,BR,SBR • Silica, • Curatives • Nylon6, • Steel
Carbon • Protection N66 Cords
• Nano Fillers • Process • Polyester • Bead Wire
Aids • Rayon

Compounding Raw Materials Reinforcement Materials

12 Friday, April 3, 2020

INNER LINER

 MATERIAL: Made of natural & synthetic rubber such

as halobutyl rubber

LOCATION: innermost part of the tire

FUNCTION: Assures air retention in tubeless tires. Air

retention ensures even tire wear, good mileage and
durability

14 Friday, April 3, 2020

BENEFITS OF TUBELESS TIRES

• In Tubeless tyres a layer of Butyl SAFETY

No risk of tube bursts leading to lower chances of accidents and
rubber tube is prepared conjoined in fatalities.

the factory itself.

EASE OF REPAIR
• No need for a separate tube. Puncture repair is easy and quick as wheel dismounting is not required.
This ensures a lower downtime of the vehicle.

COMFORT AND CONVENIENCE

Slow air loss in case of puncture enables us to ride to the nearest
service station.

HIGHER FUEL EFFICIENCY

Fuel efficiency due to low friction loss

LOW MAINTENANCE COST

Because of low chances of rim damage due to slow air loss or damage
to disc brakes while mounting and dismounting.
BODY-PLY
 MATERIAL: Rubber coated fabric (Polyester/ Nylon)

FUNCTION: Gives the tire its basic strength and

structural integrity

DIRECTION: Cords lie from Bead to Bead(radially)

LOCATION: on top of the innerliner /

squeegee and extend around the bead

 KEY CHARACTERISTICS: Cords are under tension

(strength).

16 Friday, April 3, 2020

BEAD
 MATERIAL: Made of several turns and layers
of bronze coated steel wire and coated with rubber

 SHAPE: Comes in a variety of shapes (Square/

Rectangular/ Circular/ Hexagonal)

 LOCATION : Between Innerliner & Bodyply

 FUNCTION : Ensures that the tire sits firmly

on the rim & help disperse impact shocks

INTERFACE FUNCTION: Part of the air retention

system in tubeless tires (together with innerliner /
squeegee)
17 Friday, April 3, 2020
BEAD FILLER

MATERIAL: Made of a hard rubber

LOCATION: Above the bead

PRIMARY FUNCTION: Reduces flex in the bead

area and influences the amount of distortion in the
sidewall

SECONDARY FUNCTIONS: Influences steering

precision, driving stability and how the tire deflects
under load

INTERFACE FUNCTION: Ensures smooth body

ply contour
18 Friday, April 3, 2020
BELT
 MATERIAL: Twisted steel cords coated with brass
and embedded in rubber

LOCATION: At least 2 belts running

circumferentially around the tire

DIRECTION: Run at an angle to the direction of

motion. The direction is placed opposite to each
other to increase strength and stability.

FUNCTION: Gives the tire its basic strength and

structural integrity

19 Friday, April 3, 2020

SIDEWALL/ RIMSTRIP
 MATERIAL: Sidewall is made of soft rubber
compound and rim strip is made of hard rubber
compound
LOCATION: Flex zone- sensitive area of the tire

PRIMARY FUNCTION OF SIDEWALL: Absorbs

shocks and Influence ride comfort

KEY CHARACTERISTICS OF SIDEWALL : Highly flexible

component and good weather resistance

KEY CHARACTERISTICS OF RIM STRIP: prevent damage

by rubbing against the rim

20 Friday, April 3, 2020

TREAD
 Part of the tire that Tread  Compounds plays a
makes contact major role in:
with the  acceleration
road surface  rolling resistance
 braking
RibsRibs  steering
 tire wear
Blocks
Blocks

Sipes
Sipes  Tread Pattern
 has ribs, blocks &
sipes
 helps dissipate water
and promotes
Tread
Tread Pattern
Pattern
traction

21 Friday, April 3, 2020

TREAD PATTERN DESIGN BASICS
STRUCTURE TYPE SEASON TYPE SYMMETRY TYPE TERRAIN TYPE

LUG ROUGH
TERRAIN
SUMMER SYMMETRY

RIB
ALL TERRAIN

WINTER ASYMMETRY

SEMI LUG HIGHWAY

TERRAIN
ALL SEASON DIRECTIONAL
22
 TYRE MANUFACTURING PROCESS

23
Tyre Manufacturing Process Summary
Preparation Tyre Components Building & Inspection
Raw Materials Banbury
Mixer Fabric Cord
Calendering
Fabric Tyre
Rubber Bales Ply Cutting Building

Tyre
Curing
Chemicals
Steel Belt
Calendering Visual
Inspection
Steel Belt
Cutting
Raw Materials Balance
Fabric Cord Bead Inspection
Assembling

Tread & Sidewall Force & Moment

Textiles Extruding Inspection

X-Ray
Inspection
Innerliner
Bead & Calendering
Steel
Belt Steel Cord Finished Tyre
Technologies in tire making

•Technology of mixing Raw

Mixing Materials for Rubber compound.

Calendarin •Technology of Calendaring of

Tyre Manufacturing g Carcass material.
Process

•Technology of making
Extrusion continuous profiles for
sidewall and tread.
•Technology of Assembling of
Tyre components and making
Building Green Tyre.

Tyre •Technology of tyre moulding /

Curing
Curing process.

6 of 11
TYRE BUILDING MACHINE (TBM)

▪ UNISTAGE

▪ TWO STAGE-(12”-16”), (14”-20”)

i) First stage - Carcass

ii) Second stage – Green Tyre
MAJOR PARTS - FIRST STAGE TYRE BUILDING MACHINE
MAJOR PARTS - FIRST STAGE TYRE BUILDING MACHINE
1. Carcass Drum

2. Servicer Trays ( Inner Liner, Ply, Side Wall )

3. Service or Cassette Stations

4. Head Stock

5. Tail Stock

6. Top Roll / Sponge Roller

7. Roll Round Device or Back stitcher

8. Bottom stitcher
9. Contour or Front Stitcher
10. Bead Centering Device Left/Right

11. Bead Fixing Unit Left/Right

12. Bead Stoppers

13. Bead Spacers

14. Turn Up Bladder Assembly Left/Right

15. Magnetic Rings Left /Right

16. Turn Up Rings Left / Right

17. Operator Interface (PLC)

MAJOR PARTS SECOND STAGE TYRE BUILDING MACHINE
MAJOR PARTS SECOND STAGE TYRE BUILDING MACHINE

1. Belt & Tread Drum (B & T Drum)

2. Shaping Drum
3. Transfer Ring (T-Ring)
4. Shaping Stitcher
5. Tread Applicator
6. Breaker Servicer Trays
7. Cap ply Loading Station
8. Cassette Loading Stations
9. B & T Side Interface
10. Shaping Drum/Expander Drum Side Interface

11. Belt Tip Centering Unit

How to build a good tyre ?
▪ Centered loading of plies on the servicer

▪ Guide light setting as per the specification.

▪ Ply to be spliced with 3-6mm without any wrinkle

▪ Bead application on the static condition of the drum

▪ Stitching of the off components in the specified stitching pressure.

▪ Breaker application as per guide light.

▪ Tread application following guide light and splicing 0 to -2mm

▪ Sidewall application as per guide light and uniform stretching of sidewall.

Important quality parameters

▪ Centering of components

▪ Machine setting for tool positions and tool movement

▪ Stitching pressure

▪ Bead tool difference

▪ Turret tension of liners

▪ Drum lateral and radial runout

▪ Bead placing squareness and concentricity

TYRE BUILDING MACHINE
General Description General Description

▪ First Stage Tyre Building Machine the following components are assembled.
❑ Inner liner
❑ Ply
❑ Bead
❑ Sidewall

✓ The final product is CARCASS.

▪ In Second Stage the following components are assembled with Carcass :
❑ Belt
❑ Cap Strip
❑ Tread

✓ The final product is GREEN TYRE.

❖ The GREEN TYRE is then transferred to curing to make a TYRE.

FIRST STAGE TYRE BUILDING MACHINE
Lay Out Of First Stage TBM
Lay Out Of First Stage TBM

Head Stock

Carcass
Drum

Tail Stock

Let off Applicator

station Tray
Assembly
Assembly Of First Stage TBMAssembly Of First Stage TBM

First Stage Tyre

Building
Machine

Main Machine Servicer

Head Stock Tail Stock Applicator Tray Let off Station

Sub-Assembly Of First Stage TBM Sub-Assembly Of First Stage TBM

▪ Carcass Drum
▪ Servicer Trays ( Inner Liner, Ply, Side Wall )
▪ Service or Cassette Stations
▪ Head Stock
▪ Tail Stock
▪ Top Roll / Sponge Roller
▪ Roll Round Device or Back stitcher
▪ Bottom stitcher
▪ Bead Centering Device Left/Right
▪ Bead Fixing Unit Left/Right
▪ Turn Up Bladder Assembly Left/Right
▪ Magnetic Rings Left /Right
▪ Turn Up Rings Left / Right
▪ Operator Interface (PLC)
Main Machine First Stage TBM Main Machine First Stage TBM

Turn Up Turn Up Finger

support Ring Ring Assembly

Carcass
Drum

Bead Bladder Bottom

Centering Assembly Stitcher
Unit
Tail Stock Assembly Tail Stock Assembly

Turn Up Turn Up
support Ring Ring

Finger
Assembly

Bead
Centering Bladder
Unit Assembly
Head Stock Assembly Head Stock Assembly

Turn Up
support
assembly

Carcass Bladder Finger

Drum Assembly Assembly
Let Off Station Let Off Station

Ply 2 let off

Ply 1 let off
IL let off

Sidewall let
off
Stitcher Assembly Stitcher Assembly

RRD
Stitcher
Disk
Stitcher
Carcass Drum Carcass Drum

▪ CARCASS DRUM :

▪ This is radial expansion drum in which all the first stage tyre
building components are assembled in a sequence to get a final
product - CARCASS.
Applicator Tray AssemblyApplicator Tray Assembly

▪ SERVICER TRAYS (INNER LINER, BODY PLY, SIDE WALL)

▪ Servicer Trays serve the purpose of transporting the material ( Inner Liner, Ply,
Sidewall) from the let off station to drum for assembling purpose. Servicer trays
consist of conveyor belts which transports the material. The length measurement
and cutting of the materials takes place automatically on these servicer trays.

Inner Liner - Auto length measurement - Rotary Speed Cutter

Body Ply - Auto length measurement - Cut by hook knife
Side wall - Auto length measurement - Cut by rotary disc cutter
Bead Centering AssemblyBead Centering Assembly

▪ BEAD CENTERING DEVICE :

▪ Consists of set of bead centering segments, each one

for the right and left side. Each set consists of six
segments of aluminum blocks which are mounted on
the bead setter unit.

▪ The bead centering unit serves the purpose of

holding and centering the bead and ensure no off
centered bead set.
Top Roller Assembly Top Roller Assembly

▪ TOP ROLL / SPONGE ROLL

▪ This is a cylindrical roller with its surface made

up of spongy material. The main function of the
top roll is to drive away the air trap between the
drum the material which is being applied. It also
serves the purpose of stitching the inner liner and
the body ply and thus leaving no air between
them.
Let off Station Let off Station

▪ SERVICE / CASSETTE STATIONS

▪ Station in which the material cassettes are

loaded or docked in. The winding and
unwinding of the material and the liner takes
place in these stations.
Roll Round Device (RRD) Back Stitcher

▪ ROLL ROUND DEVICE

▪ Two tools symmetric to drum which serve the

function of stitching the sidewall in the bead area.
Bottom Stitcher Bottom Stitcher

▪ BOTTOM / DISK STITCHER

▪ The main function of bottom stitcher is to

stitch the side wall across its width and to
remove air trap. It consists of a pair of
rubberized stitcher disc.
PLC HMI

▪ OPERATOR INTERFACE :

▪ This is a PLC controlled interface which is capable of storing up to

100 recipies. Through this screen, the operator controls and performs
the various steps and functioning of the machine
 FIRST STAGE TBM CYCLE TIME

Sidewall
Bead Insert Inner liner Ply 1 appln Bead Set Side wall Carcass
Sl. No. Cycle Time Turn up time stitching
time appln time time time appln time removal time
time
1 39.354 5.389 2.651 3.251 5.187 3.287 11.101 6.674 1.814

2 39.346 5.657 2.644 3.193 5.160 3.339 11.050 6.501 1.802

3 38.712 5.509 2.325 3.149 5.162 3.274 11.063 6.557 1.673

4 39.173 5.652 2.663 3.126 5.159 3.218 11.122 6.577 1.656

5 39.085 5.688 2.546 3.196 4.966 3.128 11.095 6.570 1.896

6 38.972 5.575 2.540 3.095 4.926 3.187 11.094 6.536 2.019

7 39.210 5.637 2.889 3.076 5.032 3.207 10.910 6.553 1.906

8 39.108 5.364 2.648 3.124 5.021 3.184 11.085 6.563 2.119

9 38.691 5.450 2.439 3.089 4.913 3.225 11.045 6.663 1.867

10 39.600 5.228 3.026 3.254 5.289 3.292 11.053 6.649 1.809

11 38.395 4.328 2.519 3.519 5.116 3.215 11.140 6.582 1.976

12 39.655 5.270 3.026 3.115 5.213 3.124 11.163 6.612 2.132

13 39.031 5.246 2.749 3.087 5.199 3.221 11.078 6.780 1.671

14 39.020 5.225 2.956 3.035 5.167 3.159 11.102 6.638 1.738

Average 39.084 5.360 2.665 3.158 5.117 3.213 11.083 6.595 1.894
SECOND STAGE TYRE BUILDING MACHINE
Lay Out Of Second Stage TBM
Lay Out Of Second Stage TBM

Shaper
Assembly

Let Off Servicer

Station Assembly

BnT
Assembly
Assembly Of Second Stage TBM
Assembly Of First Stage TBM

Second Stage Tyre

Building Machine

Main Machine Servicer

B&T Drum Shaping Head Transfer Ring Applicator Tray Let off Station
Sub-Assembly Of Second Stage TBM
Sub-Assembly Of Second Stage TBM

▪ Belt & Tread Drum (B & T Drum)

▪ Shaping Drum
▪ Transfer Ring (T-Ring)
▪ Shaping Stitcher
▪ Tread Applicator
▪ Breaker Servicer Trays
▪ Cap Strip Loading Station
▪ Cassette Loading Stations
▪ B & T Side Interface
▪ Shaping Drum/Expander Drum Side Interface
▪ Belt Tip Centering Unit
 B&T Drum B&T Drum

▪ BELT & TREAD DRUM (B & T DRUM)

▪ This is a diameter adjustable drum with 32 segments on which
the breaker, cap ply & tread are applied automatically. There is
a slide and cone mechanism inside the drum, operated
pneumatically for it’s to and fro motion, which in turn makes
the Drum expand and collapse. This diameter is controlled by
the spacer, which is mounted on the control pin, connected to
the cone.

▪ The desired diameter can be obtained by fixing Recipe.

▪ The belts are centered mechanical centering system with

centering sensors. Tread are centered with auto centering
system
▪
Belt Servicer Belt Servicer

▪ Magnetic conveyor is to carry the belt from let off station to

B & T drum.
Capstrip Unit Capstrip Unit

▪ Capstrip application with auto tension controller.

Tread Applicator Tread Applicator

▪ Auto length measurement with auto centering.

Transfer Ring Transfer Ring

▪ The machine is equipped with a belt transfer ring.

The inner diameter of the belt transfer ring is
controlled pneumatically; the setting is manual.
The belt package is pneumatically clamped.
▪ If the green tyre outer diameter is outside of the
adjustment range of the belt transfer ring, a
special belt transfer ring has to be applied.
Shaping Head Shaping Head

▪ SHAPING DRUM

▪ Shaping drum consists of expandable bead holders,

which holds the carcass bead while inflation & stitching.
▪ Air comes from the inside of the shaft for carcass
inflation.
▪ A geared AC-SERVO MOTOR drives the rotation & the
drive of the spindle.
Stitcher Assembly Stitcher Assembly

▪ The stitcher station is equipped with tread and side

rolls.
▪ The travel movements of the rolls are recipe-
referenced values, their setting is motorized.
 SECOND STAGE TBM CYCLE TIME

Sl. No. Cycle Time Belt 1 Applictn Belt 2 Applictn Capply Applictn Tread Applictn Package Pick up

1 35.291 5.500 5.420 8.270 9.835 6.266

2 35.577 5.331 5.840 9.877 8.308 6.221

3 38.804 5.343 5.666 10.700 9.297 7.798

4 36.250 5.362 5.980 10.450 8.440 6.018

5 37.788 5.320 5.540 9.728 10.525 6.675

6 35.669 5.383 5.975 10.217 8.194 5.900

7 36.881 5.363 5.865 10.158 9.691 5.804

8 36.957 5.494 5.539 10.729 9.298 5.897

9 30.344 5..697 6.266 10.006 8.787 5.285

10 34.892 5.340 5.430 10.141 7.785 6.196

11 36.045 5.299 6.172 9.986 8.579 6.009

12 35.705 5.312 6.077 9.677 8.754 5.885

13 35.775 5.385 6.007 9.753 8.604 6.026

14 35.849 5.347 5.887 10.518 8.255 5.842

AVERAGE 35.836 5.368 5.803 10.027 8.883 6.113

Green Tyre
Green Tyre Storage
 THANK YOU

Making Mobility Safer

Making Mobility & Smarter.
Safer & Smarter. Everyday.
Everyday.