2K Membrane Dosing System for Tire Coating

• System: 2K high-pressure diaphragm metering system with 4 metering units.
• Stock: Set of 2–4 PROMERA 430L piston accumulators for supplying up to 3 application cells with Component A (the main component of the compound).
• Material Supply: Material station with mixing and blending tanks for Component B (cross-linking agent).
• Application: Robot-assisted application using a custom-designed 2K high-pressure mixing head.
• Handling: “RDV-2” special-purpose machine for tire handling; optionally equipped with a “tire rotator” for post-processing.
• Performance: Cycle time of approximately 40 seconds per tire using a single application cell.
• Service: Turnkey project, including installation, commissioning, and on-site staff training (with production support if needed).

Overview and structure

THE SYSTEM IS DESIGNED AS A 2-COMPONENT HIGH-PRESSURE MEMBRANE DOSING SYSTEM WITH 4 PAIRS OF AXES (3 FOR COMPONENT A AND 1 FOR COMPONENT B) AND A COMMON CENTRAL HYDRAULIC SYSTEM:

• PRESSURE & TEMPERATURE:
  Due to the high viscosity of the A-component, the system is designed for pressures up to 200 bar. All parts of the A-component that come into contact with the material are heated to approximately 130°C.
• CAPACITY:
  The system features a shared central hydraulic system and achieves a discharge rate of up to approximately 3,500 ccm/minute.

Overview and structure

• The A component (main component) is usually produced on-site using an upstream extruder.
• More Flexible Production Planning Through Buffer Capacity: A set of 2–4 piston accumulators, each with a storage capacity of 400 liters, serves as a buffer and compensates for the difference between the extruder’s output and the system’s capacity. This makes it possible to operate the extruder at optimal settings.
• The storage tanks can also be filled using other methods (e.g., drum melters). They generate the necessary feed pressure of 20–40 bar for the diaphragm metering system and also reclaim recirculated material from the system.

Overview and structure

THE B COMPONENT (CROSSLINKER) CONSISTS OF A REACTIVE MATERIAL THAT IS BLENDED WITH A CARRIER SUBSTANCE.

• PREPARATION:
  Mixing takes place in a special mixing container.
• SUPPLY:The material is conveyed to a daily storage tank, from which the membrane dosing units are supplied via appropriately sized pumps. The system also reliably recovers the recirculated material.

Overview and structure

Precise application is achieved using our PROMERA 2K high-pressure mixing head, the “MiKoHD-PC10-PC15.”

• ROBOTICS:
  Use of KUKA industrial robots with KRC5 controllers (integration of other manufacturers' systems is possible).
• SAFETY & CONTROL:
  Fully integrated safety concept for robots and PLCs. The robot functions are largely integrated into the plant visualization system.

Overview and structure

The RDV-2 special-purpose machine ensures the smooth flow of tires through the system. It is equipped with two stations to optimize the use of the dosing system and the robot.