DESIGN OF GEAR UNIT ASSEMBLY IN TYRE CURING PRESS FOR OFFLINE TESTING

PRESENTED BY PRABAKARAN.G SADHASIVAM.S SHEIK FAREETH.A VIGNESH.M

INTERNAL GUIDE: Mr.K.RAJMOHAN,M.E.,

ASSISTANT PROFESSOR, UCEP.

EXTERNAL GUIDE: Mr.T.M.MOHAMED IBRAHIM,

ASST.GENERAL MANAGER, DESIGN R&D AND ENG., LARSEN&TOUBRO LTD.

 L&T is a well Established Organization for manufacturing Rubber Processing Machineries. L&T Rubber Processing Machinery is located in Vedal near Kanchipuram. The Main Production of this plant is Tyre Curing Press with various sizes. Rubber Processing Machinery has over three decades of experience in producing world class machinery . Rubber Processing Machinery is accredited with ISO 9001: 2000 Quality Management System and ISO 14001: 2004 Environmental Management System.
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 The Machineries are manufactured and distributed to various tyre companies like MRF, TVS, CEAT,etc

L&T is the major production company in manufacturing of Tyre

Curing Press. In Vedal plant, Tyre Curing Press is manufactured in different sizes (upto 118 inches). From 40 to 90 inches tyres are used in road vehicles such as car, load vehicles, truck etc.

Above 90 to 118 inches are used in mining purpose and these tyres
are not used in road ways.
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ABSTRACT
Our Project Abstract is to Design a Movable Gear Unit Assembly of Tyre Curing Machinery for Offline Testing . In Existing System, Tyre Curing Press has a fixed Gear Unit Assembly coupled with Induction Motor. In this machinery, the Gear Unit Assembly is the major part and plays a vital role because it stimulates all the functions of machineries. In General, all the parts of presses are assembled and resulted in testing. During Testing Condition in-case any problem occurs in the Gear Unit the entire gear unit setup has to be disassembled which leads to wastage of Production Time. Considering this issue we are planned to design a movable gear unit for separate testing purpose.

TYRES MEANT FOR.!

Everyone knows what a tyre is and what its for. Its a black donut made of rubber, placed on a vehicle so the driver can transport himself and his cargo from point A to point B. The tire has to allow for easy steering, braking and cornering. It must provide for a comfortable, safe ride. It needs to be durable. And thats about the extent of what most of us know.
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 Actually, a tyre is an advanced engineering product made of a lot

more than rubber.

Fiber, textile, and steel cord are just some of the components that go into the tyres inner liner, body plies, bead assembly, belts, sidewalls,

and tread.
As you can imagine, the manufacture of this complex product is, well, complex.

It requires the latest technology, heavy equipment, precision

instruments andmost importantlyqualified people.
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CURING PROCESS:
Tyre curing process is one of process which plays a major role in Preparation of Tyres. The process of hardening the soften material (Rubber) is called as Curing. Tyre manufacturing process involves many stages. In those stages, curing is a very important process. In tyre manufacturing process, curing is achieved by means of TYRE CURING PRESS.
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Process of curing:

TYRE CURING PRESS:

Tyre curing presses are completely self-contained equipment. They require only power supply and curing media connection. Automatic lubrication systems eliminate the need for manual lubrication.

Automatic controls can be furnished for controlling the mould steam

temperature and also controlling & sequencing inflation steam/hot air and vacuum.
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TYPES OF TYRE CURING PRESS:

The types of Tyre Curing Press are, Mechanical Type, Hydraulic Type and Bladder type.

VARIETIES OF TYRE CURING PRESS: The varieties of Tyre Curing Press are Single Dome Type,

Double Dome type, and

Platen Type.
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Tyre curing press:

SINGLE DOME TYPE: DOUBLE DOME TYPE:

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COMPONENTS OF TYRE CURING PRESS:

Base Assembly, Top Link Sub-Assembly, Crank Gear Assembly, Cylinder Guide Assembly, Gear Unit Assembly, Steam Platen Assembly, Bottom Platen Assembly, Steam Box Sub-Assembly.
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gear unit assembly:

Gear Unit Assembly is the main component of Tyre Curing Press which plays major role is Power Transmission through out the machinery. The Gear Unit Assembly consist of Worm and Worm Wheel with Gear Case and which is coupled with the Three Phase Induction Motor. It also consists of Gear Train.`

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FUNCTION: This gear unit is used to transfer the required torque from the statorrotor assembly to the crank gear through the gear train, to provide the closing force required at the mold by mechanical toggle action by the

side link.
The gear unit consists of a worm and worm wheel which reduces the speed of the stator-rotor at the first stage in the gear train leading to the crank gear.
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 The output shaft from the gear unit will directly mount the crank gear pinion (normally for smaller size presses) or will mount an intermediate gear and pinion arrangement (for bigger size presses) in order to have a higher reduction ratio.

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EXISTING GEAR UNIT ASSEMBLY:

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 For curing process high torque is required. We know that Speed is inversely proportional to Torque. I.e. N 1/T

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TESTING CONDITIONS: In Existing System, the tyre curing press are fully assembled and suspected to testing. Those testing are done under unloading condition (Without Loading Soften Rubbers). During unload condition, there exists no problem with the machinery which is tested in the company itself after assembling the whole Tyre Curing Assembly. After supplying the tyre curing press to their customer (MRF, CEAT, etc,) testing of machinery will be done at loading condition, where soften rubbers

are placed in the tyre curing press.

During the testing, they are not comfortable with the major Gear Unit Assembly during the load condition. 18

Problems faced in existing system:

The major problems faced by the company with existing system: Wastage of production time during Assembling and Disassembling of Tyre Curing press for Gear Unit Replacement. Over current usage for the rated loading. Causes Noise Pollution.

Damages in worm wheel and smokes are produced.

These are the major problems faced by the company, but the main root causes are not known and it is tedious to sort it out. So the company has planned to test the Gear Assembly by means of Dynamometer in Offline Testing Mode

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OUR SOLUTION FOR EXISTING PROBLEM:

Due to difficulties in sorting out the exact issues with the Gear Unit

Assembly Company has decided to test the Gear Unit Assembly in

Offline Mode by means of Dynamometer. Since Dynamometer act as a Braking System by which they can attain the required Torque for testing condition. By conducting this test the exact root cause for problem can be sorted out to a certain extent. Due to the usage of Dynamometer, testing is done at low torque because

dynamometer works at certain level of torque only.

In Existing system high torque is applied to get desire result but which is not suitable for offline testing mode.
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MOVABLE GEAR UNIT ASSEMBLY:

So, we have planned to design a Movable gear Unit Assembly for offline
testing. But our Design more or less it resembles as a existing gear unit design.

In our design we are replacing the intermediate pinion by means of

intermediate gear. In the same way the position intermediate gear is replaced by

intermediate pinion to attain low torque and a coupling is attached at

both ends of the Main Shaft for replacement in case of any issues in Gear Box during testing.
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Schematic 2d diagram:

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Design of intermediate shaft:

2D VIEW: 3D VIEW:

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Design of pinion shaft:

2D VIEW: 3D VIEW:

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Design of intermediate pinion:

2D VIEW: 3D VIEW:

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DESIGN OF INTERMEDIATE GEAR:

2D VIEW: 3D VIEW:

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Design of key:
2D VIEW:
3D VIEW:

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DESIGN OF COUPLING:

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3d assembled view:

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ADVANTAGES OVER EXISTING SYSTEM:

Avoids the Wastage of Production Time. Reduces the current usage than the rated loading. Easy maintenance. Damages in worm gear and smokes produced will be reduced.

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Conclusion:
Thus by the Design Of Movable Gear Unit Assembly for
Offline testing, the problems like Wastage of production time during Assembling and Disassembling of Tyre Curing press for Gear Unit Replacement, Over current usage for the rated loading, Damages in worm gear and Noise pollution will be sorted out its root cause for those problems easily and exact solution can be given to the problems.

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THANK YOU

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