Radial Tire Building Machine

[dingomex3]

Hi Everyone,
I just started to work in the tire industry and I got a project about of upgrading an old and obsolete Radial Tire Building Machine. Does anybody have experience in this kind of equipment?.

Thank you in advance.

 

[OkiePC]

My first step up in my career after being a maintenance tech was as a maintenance specialist for a tire company in the assembly department where I was tasked with overseeing the upgrades on ARF (automatic radial full-stage) tire machines. The machines under my responsibility were designed in 1979 using PLC hardware that was obsolete in 1980 and had been slowly upgraded to PLC-5.

The upgrades were so slow, that around the time I took over in 1999, we still had 19 of 36 ARFs still running on the antique ISSC hardware and decided to alter the upgrade path to Controllogix.

It has been 15 years since I left that job, but I did learn quite a bit about how those machines work. It was a brilliant equipment design they used. Each ARF could put out a tier a minute and every station of the machine was steadily moving with little to no wasted time or motion. Those machines were limited to making tires for up to 18" diameter wheels without extensive mods, so I think the company has eliminated them since I left.

 

[dingomex3]

Wow! right now I'm working in a tire maker company and I will have to upgrade their machines but I don't know anything about. Could you help me please?. Thank you !

 

[OkiePC]

You will have to be a lot more specific.

 

[parky]

Although never done a tyre machine I have over 40 years experience upgrading machinery of many types, the best thing you can do is watch the machines in operation, troll through the drawings & get very familiar with the whole system, Talk to the experienced operators their knowledge is key to how it all works, try to find out if there are any existing problems be it mechanical or electrical there is no point upgrading a machine if it's not going to work as it did in the first place, try to get the company to invest in a total refurb, even if that is after the electrical upgrade. Remember, it will probably need the safety system upgraded to meet your countries current regulations this is important as you will also be personally responsible.
One final thing, Think about improvements for example making it easier for the operator, diagnostics perhaps an HMI even if it does not already have one, this can aid operators & maintenance staff by giving current status & alarms.
Not really required, but choose a control system that could also be integrated into some sort of reporting system, management like those sort of things (with the exception of the extra cost), it could be a feather in your cap if it is agreed.

 

[Phrog30]

Let's first agree, it is a TIRE, not TYRE.

As others stated, you are going to have to get way more specific on the help you need. Start at the beginning, then work your way through.

 

[parky]

It's Tyre not tire in UK, US have used English & modified it it's the same as colour color, These words had no particular spelling until Samuel Johnson in 1755 TBH it's mainly in the US that these words are spelt that way, it has been said that here the English language was born & the Americans perfected it But then American would say that lol.

 

[dingomex3]

Thank you guys ! I really appreciate your comments. And I believe you are right, I have to get familiar with the process and operation, and all the available engineering they have (drawings, manuals, etc).
The help I'm looking for is perhaps some PLC example even if it's an old PLC platform, just to have an idea because those machines are currently working with relays and mechanical sequencers, and some Push Buttons (for example) are not being used anymore. But again, I would appreciate your help with this , maybe some examples of Control architecture, hardware, etc. Thank you everyone!

 

[parky]

Obviously you need to find out how many inputs from PB's Sensors etc. add about 20% spare (people always want extras added), same with outputs, For something like this I guess a medium sixed PLC to allow for enough memory for the program perhaps an HMI to replace some of the push buttons etc.
As far a logic goes then that is difficult but as for sequences then I certainly suggest using a word for sequences rather than bit memories it makes them easier to add extra steps, for example you can have step numbers in units of 10 so step 1 is 0, step 2 is 10 & so on if you need to add an extra step just use any number between them. see example of a simple traffic light.
Although it's in FBD you can see how it works.

 

[Jim3846]

Well if you asking for opinions.
Does the machine have to be run off then torn down at a different location? quick disconnect fittings on panel for quick tear down.
Since its tires, would the area be considered oily, dirty, nasty ash?
Put all your vfds/servo drives in a panel if thats the case.
Contrologix 16 slot rack or a compactlogix is a price point that you need to decide on?
Or maybe a standard brand in your factory that everyone has standardized?
Is there hydraulics involved since your making tires?
HMI that can take the beating of oil/dust and what not.
2 door free standing panel? or seperate panels for low voltage/high voltage/plc
Thats all i can think of?

 

[I_Automation]

For any machine I make a list of the following:


All inputs
All controlled objects (relay, valve, light, VFD, servo, latch, fan, ANYTHING)
Watch the operation of the machine and make notes of every step and action
Ask the operator(s) about anomalies and problems, and any ideas they have that would improve the operation.
Ask the maintenance tech about anomalies & feature improvements.

What the operator AND boss wants programmed in the HMI.
Ask the bosses about future features they may want added in, that would mean additional inputs, outputs and HMI features - or even an additional IO card.


For programming I write a list in Excel of every step or feature that needs included in the program. This list is not set and gets added to and some features deleted almost every day.
Also in the Excel workbook I have a sheet for IO to keep track of it and it's helpful when doing the CAD schematic, and I have a sheet of HMI tags - noting valid ranges for numerical values. (IE - heating temperature minn=180 max=550)