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TIRE BEAD WIRE MANUFACTURING

 

TIRE BEAD WIRE MANUFACTURING EQUIPMENT


Bead wire application

Bead wire is widely used in rubber industry:

  • for the production of bead rings of tires;
  • reinforcement of passenger cars, trucks and light truck tires to give necessary rigidity to tire beads;
  • reinforcing steel cord conveyor belts and high-pressure hoses.

Bead wire is widely used for reinforcement of cars, trucks, light truck tires, to give the necessary rigidity to tire beads.

The main reinforcing element of the bead part of tires is a bead ring made of steel wire coated with bronze to provide chemical bond with rubber. Bead wire contains of fiber stands disposed so as to provide both high strength and certain degree of flexibility needed for mounting and dismounting tires. Carcass layers are wrapped around the bead wire fixing carcass layers and holds the assembly on the wheel rim, thereby preventing the tire from rolling or sliding, providing road performance of the tire.

Bead wire for bias and bias-belted tires is used on both sides of the tire. In cast tires bead wire is used for fixing the tire to the rim.

tyre bead wire in the automotive industry tyre bead wire


Technological process of bead wire manufacturing


Ø1.55 mm~Ø1.65 mm

Wire Rod
Ø5.5~Ø6.5 mm
Mechanical descaling, electrolytic etching,
boraxing, drawing up to Ø1.55~Ø1.65 mm
Heat treatment, rinsing,
wire bronzing line
Checking, packaging
and storage




Ø0.78 mm~Ø0.96 mm

Wire Rod
Ø0.78~Ø0.96 mm
Mechanical descaling, electrolytic
etching, boraxing, drawing up to Ø2.80 mm
Heat treatment, rinsing,
wire bronzing line
Drawing up to
Ø0.78~Ø0.96 mm
Heat treatment, rinsing,
wire bronzing line
Checking, packaging
and storage


PRODUCTION EQUIPMENT AND PRODUCT SPECIFICATION

Productivity 8000 tons/ year
Bead Wire Range Ø1.55 mm~Ø1.65 mm and Ø0.78 mm~Ø0.96 mm
Power Consumption 800 kW/h
Water consumption 6 m3/h
Steam consumption 2000 kg/h
Waste water type FeSO4 waste water; CuSO4 waste water
exhaust gas vapor H2SO4
The ability of use sulfuric acid instead of hydrochloric acid.


As steel cord as bead wire are coated with an alloy that increases the strength of the connection with the tires. Special brass coatings are used almost exclusively to the steel cord and only in some cases.

Bronze coating is most common for the bead wire. Chemical formation of adhesion to brass-coated steel cord is very complex. Brass layer made of zinc and copper, and the composition gradient of the steel cord to the rubber surface are very important for this process.

Theoretically, depending on starting reactivity of the mixture brass alloy forms intermediate layers of zinc, sulphide and copper. The rates of these layers formation are determined by the initial level and durability of the connection.


Equipment for the production of bead wire

Machine name and type Qty
1. Mechanical descaling, electrolytic etching, wire boraxing line 2
2. RG155-165 straight through wire drawing machine 1
3. RG078-096 straight through wire drawing machine 2
4. Heat treatment + acid etching, wire phosphatizing line 1
5. Heat treatment + acid etching, wire bronzing line 1


Required personnel (for output of 16000 tons/year)

Technological process Working Shift Operating Personnel Total
1. Wire Drawing 4 4 16
2. Hardening + acid etching 4 4 16
3. Heat treatment + chemical coating line 4 5 20
4. Manager 1 6 6
5. Total     58



Environmental Protection

When this device operated three types of polluting waste are formed: acid vapors; waste water with acid-content; waste water coming from the brass plating line.

To eliminate acid vapors indoor air pollution control system is used.

For treatment of waste water with acid-content and waste water from the brass plating line: uniformity, neutralization, aeration, sedimentation and filtration are applied. Water can be discharged after reaching standards.

Waste water
Operational process Wastewater type Material type Concentration, mg/l Output, l/h Unloading Amount, m3
Mechanical descaling Acid waste Fe 350 2000 48
SO4 2800
Heat treatment Acid waste Fe 350 3600 86.4
SO4 2800
Wire Brozing Line Copper coating wastewater Cu 20 1500 36
Fe 20
SO4 50
Acid waste Fe 200 1000 24
SO4 1500


WASTE PICKLE LIQUOR
Operational process Dissolution type Material type Concentration, mg/l Amount
Mechanical descaling Acid Solution H2SO4 250 Change every 2 months, total volume 8 m3
FeSO4 100
Heat treatment Acid Solution H2SO4 250 Change 1 time per month, total volume 10 m3
FeSO4 120
Borax Liquor Na2B4O7 × 10H2O 170 Change 1 time per month, total volume 86 m3
Wire Brozing Line Acid Solution H2SO4 250 Change 1 time per 2 month, total volume 5 m3
FeSO4 100
Cooper sulphate solution CuSO4 × 5H2O 15 Change 1 time per month, total volume 10 m3


Acid vapors
Operational process Vapor output, m3 Number of equipment lines Total vapor volume, m3
Wire Rod Preparation 2000 2 4000
Wire Patenting 6000 2 12000
Electrolytic Etching on Wire Bronzing Line 3000 1 3000

The total vapor concentration is 18 mg/m3. After heat treatment and unloading, the concentration is 0.99 m3, which meets environmental standards.



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