After the automation transformation of the rubber mixing production line, the comprehensive production efficiency can be improved by 30% to 60%. The extent of the improvement depends on the proportion of manual operation in the original production line, the accuracy of process control, and the adaptability of the transformation plan.
1, The core source of efficiency improvement
(1) Optimization of measurement and feeding accuracy
The measurement error of manual ingredients is usually 2%~5%, while the measurement error of automated weight loss scales can be controlled within ± 0.5% to avoid rework caused by raw material waste or ratio deviation
The timing control of linkage batching and feeding eliminates the waiting time loss of manual material replacement and feeding, and shortens the pre waiting time of single batch mixing by more than 30%. (II) Closed loop control of process parameters
The temperature, rotor speed, and rubber discharge time parameters of the internal mixer and open mixer are automatically adjusted by PLC, eliminating the parameter fluctuations caused by manual operation (usually ≥ ± 5 ℃ or ± 5rpm), and reducing the defective rubber mixing rate from 5% to 8% to 1% to 2%
The linkage of automatic glue dispensing and post-processing avoids the cooling waiting time of manual glue dispensing, shortens the mixing cycle of a single batch by 15%~25%, and releases the efficiency of personnel operation
The manual operation of a single mixing production line requires 3-4 people, which can be reduced to 1-2 people after automation, eliminating production interruptions caused by manual fatigue and improving the stability of continuous operations. Secondly, key conditions affecting the degree of improvement
The original production line foundation: an extensive production line with more than 70% manual labor, with an improvement rate of 50% to 60%; A partially automated production line has been established, with an increase of approximately 30% to 40%
Adaptability of the transformation plan: The full process linkage transformation (including measurement, mixing, and subsequent molding connection) has a 15% to 20% increase in improvement compared to single point automation transformation (only replacing measurement equipment)
Supporting management system: The production line connected to the MES system can achieve optimized scheduling, full process traceability, and an additional 5% to 10% improvement in comprehensive efficiency. 3. Practical application reference (publicly available statistics of the domestic rubber products industry from 2022 to 2024)
Half steel radial tire rubber material mixing production line: After automation transformation, the single shift production capacity has been increased from 12 tons to 19-21 tons, and the comprehensive efficiency has been improved by about 58%
Special sealant mixing production line: After renovation, the defect rate has been reduced from 7% to 1.5%, the single batch cycle has been shortened by 22%, and the comprehensive efficiency has been improved by about 45%. Safety precautions: After automation renovation, it is necessary to ensure that the electrical circuit complies with GB 50054 "Design Specification for Low Voltage Power Distribution", the PLC control system needs to be calibrated regularly, the ventilation equipment in the mixing workshop needs to be linked with production to avoid the accumulation of high-temperature exhaust gas, and the operation needs to be carried out by certified electricians and equipment maintenance personnel.
