COMPLETE SYSTEM UP TO 63″

A) PRODUCTION EQUIPMENT

Position 1) Inspection machine
Position 2) Robot Skiving Machine 63”
Position 3) Sherographic machine 63”
Position 4) Shaving, polishing machine and grooving machine
Position 5) Cyclone and dust collector
Position 6) Gluing machine

Posizione 7) Extruder construction machine
Posizione 8) Autoclave
Posizione 9) Finishing and Painting of Tire Holders + Airless Tank
Posizione 10) Stand for Tires
Posizione 11) Production Tools and Accessories Kit
Posizione 12) Recommended spare parts

B) ACCESSORIES

Position 13) Steam boiler
Position 14) Air compressors
Position 15) Air tanks (2000 Lt)
Position 16) Water pumps

Download complete plant 63″

Posizione 1) Inspection machine
N.1 MGT tyre stand Hercules Plus, for tyres up to 63″

– This tyre stand is used for internal and external spot repairs.
– The machine can lift the tyre up to the required height and allow easy inside and outside operations.
– It is equipped with tyre rotation controlled by a foot pedal, the tyre speed is controlled by inverter.
– It’s designed for tyres up to 63” bead diameter.
– Total installed power 10 KW

Position 2) Robot Skiving Machine 63”
N.1 REN63 OTR Robot anthropomorphic (6 Axis) Skiving / Grooving machine for tyres up to 59/80 R 63” and 70/70 R 57” with following features:

– Steel structure with spindle with interchangeable mandrel;
– Robot anthropomorphic with “High Speed” tools driving motor with 18 KW installed power, water cooled and complete with water chiller;
– N°4 types of programs for skiving installed on board robots;
– Braking system for tire locking during skiving and grooving operation;
– Covered tool holding rack with 11 positions; – Safety fences;
– Electric box with air conditioning device and with components and cables UL Listed;
– Electric installation following LME and ANSI robotic standards;
– Safety Certification as per LME rules;
– Use and maintenance manual in English language;
– 3 working tools:
– 1 conical tool 32 mm diameter;
– 1 conical tool 50 mm diameter;
– 1 conical tool 80 mm diameter;
– 500 inserts for each tool (total 1500 inserts);
– Set of metric wrenches;

Sets of bead plates:
– 24”
– 29”
– 33”
– 39”
– 45”
– 51”
– 57”
– 63”.

Position 3) Sherographic Machine 63”
N.1 SE3 63” Sherographic machine for tyres up to 59/80 R 63” and 70/70 R 57” with following features:

– High strength special steel construction;
– machine mounted on anti-vibration systems;
– hydraulic cylinders for opening the hood of the machine;
– robotic system for handling control sensors;
– High precision 3D laser sensor;
– large-capacity vacuum pump;
– PC with 19″ touch screen;
– Three editable password levels (operator, maintenance, service);
– possibility of changing the size of the minimum test section to be worked;
– Security for access to hazardous areas with safety nets and safety barriers;
– User-friendly graphical interface and machine management software;

Anthropomorphic robot handling 3D sensor

Old version axis system

New special camera 3D

Position 4) Machine for shaving/ polishing and groove
N1. MGT One 63” OTR Cnc Controlled (5 Axis) Peeling / Buffing / Grooving machine for tyres up to 59/80 R 63” and 70/70 R 57” with following features:

– Reinforced exclusive inclined tyre holding frame, design for easy loading / unloading;
– of the tyre by overhead crane or forklift (not offered);
– High resistance linear ball bearings and trolleys;
– Sumitomo gear boxes;
– Tyre holding group with bead plates (low pressure inflation), tyre driving by brushless motor;
– The bead plates are moved by hydraulic cylinders;
– Hydraulic tyre lifting device to load / unload the tyre, on floor level;
– Exclusive 4 axis tooling frame (3 positions Peeling/Buffing/Grooving);
– 5 inches peeling gauge;
– Rockwell Allen Bradley Control Logix Plc and Kinetic 6000 Cnc;
– Exclusive Touch Screen PC with Lan Connection, Ethernet Connection and USB Port for NetCam Connection;
– Manual buffing arm;
– Software developed on Rockwell Allen Bradley ladder language;
– Total installed power 80 KW;

Sets of bead plates:
– 25” steel plates (pair)
– 29” steel plates (pair)
– 33” steel plates (pair)
– 35” steel plates (pair)
– 39” steel plates (pair)
– 45” steel plates (pair)
– 49” steel plates (pair)
– 51” steel plates (pair)
– 57” steel plates (pair)
– 63” steel plates (pair)

Position 5) Cyclone and dust collector
Cyclone and Dust Collector:

Application
Removal of rubber crumb dust and fume from the equipment listed as per your new factory layout.
Method
We anticipate installing a centralised dust/fume extraction system comprising of a Cyclofilter and exhaust fan set. A main header transport duct will provide suction to each collection point and remove the
dust/fume directly at source, minimising contamination into the work area. The main extraction plant would be installed external to the factory and the exhausted cleaned air vented to atmosphere via the Cyclofilter. Each connection to the extraction point would be designed for maximum capture this may require some modification work to existing hoods and machine guards. The system has been sized from information presented by you and includes maximum air volumes and pressures listed below.

System volume 12.000 cubic metres/hour.

Motor power 30 Kw

Electrical voltage 400 Volt – 50 Hz

System comprises:
n.1 Cyclo-Filter

The filter is complete with the following:

– Special filter using 104 sleeves for 125 square metres of filter area
– Clean compressed air on request average use 30 nmc/hour when required
– 285 x 500 Rotary valve with 1.1 kW electric motor
– Access ladder and supporting structure included
– Main body of 2 mm panel
– Main control panel and automatic filter cleaning module
– Fan unit complete with electric motor 30 Kw – 2800 rpm
– Shank inlet and flanged outlet
– Access door and outlet outlet
– V-belt transmission and transmission protection
– Motor and sliding guides
– Fire-fighting device
– Electrical equipment
– Standard painting
– Total installed capacity 30 KW

Position 6) 6.1 Incollatrice (cabina + serbatoio airless + stand)
Spray Booth

Technical Specifications
Spray booth to cement the tyre.
We quote for the supply of 5 mt. width x 4 mt. deep x 5 mt. height, spray booth.
The booth on the top is equipped with a split of 300 x 2500 mm. to allow loading and unloading the tyre on tyre stand.
The total air volume handled by the system would be approximately 45.000 m³/hour.
The booth is manufactured from formed galvanised sheet steel in a panel form.
It is complete with all fixing nuts and bolts, suction on the back of booth by two hoppers with two belt drive axial type fan sets.
N.5 rows of Andreae paper filter, n.3 neon lights, electric equipment for fan sets.

Motor power n.2 electric motors of 7,5 kW – 1400 rpm each one

Electrical voltage 400 Volt – 50 Hz

System volume 12.000 cubic metres/hour.

Motor power 30 Kw

Electrical voltage 400 Volt – 50 Hz

System comprises:
n.1 Cyclo-Filter

The filter is complete with the following:

Position 6) 6.2 Airless tank (with mixing device) for bonding
Airless Tank

Ideal for spraying the special adhesive solution, to protect buffed tyre surfaces from oxidation.
Guarantees a uniform solution and application of a constant and minimum thickness of mastic.
Complete with a mixer to ensure adhesive solution uniformity.
Operated with air compressed driven pump.
No contact between air compressed and the adhesive solution.

Position 6) 6.3 Pneumatic stand for gluing machine
Tyre stand MGT Hercules Mini35 Hyd, for tyres up to 35”

– This tyre stand is used to keep the tyre during cementing cycle.
– The tyre stand is placed inside the spray booth.
– The machine can lift the tyre up to the required height.
– It is equipped with tyre rotation controlled by a foot pedal, the tyre speed is controlled by inverter.
– It’s designed for tyres up to 63” bead diameter.
– Total installed power 10 KW

Position 7) Extruder Builder Machine (with 127 mm cold feed pin type extruder)
N.1 MGT Optima 51” OTR Cnc Controlled (4 Axis) Extruder builder machine
(with 127 mm pin type cold feed extruder) for tires up to 36.00 R 51” and 45/65 R 45” with following features:

– Optima 5 inches (127 mm) diameter “Cold Feed Pin Type” extruder, with ratio diameter/length 1:16;
– DC motor for extruder speed adjustment (135 kw);
– Rockwell Reliance D.C. driver Flexpack 3000;
– 4 temperatures control zones (nr.1 screw – nr.2 feeding roll + 1ST half barrel – nr.3 2ND half barrel – nr.4 extruder head + calender);
– Reinforced exclusive inclined tyre holding frame, design for easy loading / unloading of the tyre by overhead crane (not offered);
– High resistance linear ball bearings and trolleys;
– Tyre holding group with bead plates (low pressure inflation), tyre driving by AC motor;
– The bead plates are moved by hydraulic cylinders;
– Exclusive 3 axis strip application unit, with calender rollers and strip supporting device;
– Hydraulic tyre lifting device to load / unload the tyre, on floor level;
– Rockwell Allen Bradley Control Logix Plc and Kinetic 6000 Cnc and brushless motors, with inverters for tyre rotation and calender for speed control;
– Exclusive Touch Screen PC with Lan Connection, Ethernet Connection and USB Port for NetCam Connection;
– Software developed on Rockwell Allen Bradley ladder language;
– Water Chiller MK 35;
– Total installed power 200 KW;

Sets of bead plates:
– 25” steel plates (pair)
– 29” steel plates (pair)
– 33” steel plates (pair)
– 35” steel plates (pair)
– 39” steel plates (pair)
– 45” steel plates (pair)
– 49” steel plates (pair)
– 51” steel plates (pair)
– 57” steel plates (pair)
– 63” steel plates (pair)

Position 8) Autoclave
Autoclave AIM 4.400 x 4.000 mm. with direct steam for tyre vulcanization

Autoclave body
It consists of an electro-welded cylindrical body with an elliptical bottom at the rear end, and an elliptical bottom that moves forward.
The body is completed by a series of support saddles suitably sized and suitable to support the frame of the autoclave, the load coming from the material to be processed and the required service connections.
Opening/closing of autoclave door
The closure system is equipped with a sealing seal with lip profile made of special silicone compound.
The movement of the door opening and closing system and the safety lock shall be effected by a hydraulic system.
The door of the autoclave is supported by a special support that allows the perfect closure/ opening with minimal space. The left or right opening will be finalized when ordering. The security lock, designed by Italmatic, will ensure the max. security over time.

Heating system	STEAM
Fluid	Direct Steam
Useful internal diameter	3.000	mm
Useful length of the rotative hanging system	3.000	mm
Useful internal length	3.000	mm
Highly Insulating with external protection coat	60	mm
Maximum working pressure	7,8	bar
Working pressure	6	bar
Maximum adjustable working temperature	170	bar
Project rules	VSR / EN 13445
Structural certification	CE PED 97/23
Quality certification	UNI EN ISO 9001:2008
Certification	Any certification on request
Under flux welding according to rules	VSR-288
Construction material	P355 NH
Radiographies covering	10%+100% cross
Supporting cradles	2	N°
Hydraulic door opening system	YES
Voltage	400/50/3	V
Body Position	Horizontal
Control board	PLC
Data Record	Included

Thermal Insulation
The outside of the autoclave will be coated by a suitable thermal insulation. Its thickness guarantees that the temperature of the external side of the autoclave is into the requested limits by the current rules, with exception of the thermal points.
The external thermal insulation will be protected by zinc-steel, particularly fixed to allow a free dilatation of the covering elements.

Valves and service piping
– Regulation valves
– Closure valves
– Piloting electro valves
– Pressure switch
– Manual exhaust valves
– Disconnection points
– By pass for pressure tests
– Pipings – Manometers
– Thermometers

Power control board
The power section, consisting of standard modular rakes of primary producers, contains all of the components needed for the power electric feeding of the different components of the plant.
Inside the boards spare spaces are foreseen, according to the current rules.
When not specified by the Customer, the colour of the control boards is grey.

Control and managing system
The control system by PLC, assuring all the following operations:
– Data recording
– Control of cycle parameters
– Indication of data running

• Manual cam for the blocking of the door connected to the pressure warning light valve to control that there is no pressure before the opening of the door
• Pneumatic cylinder which prevent the rotation of the cam which blocks the door with the autoclave under pressure
• Electric device which does not allow to pressurize if the door is not closed
• Manual button to stop the autoclave and abort the cycle in case of emergency
• Over pressure valves (Safety certificated valve)
• Atmospheric pressure switch which allows the door opening
• Analogic manometer and thermometer to visualize the pressure and the temperature inside the autoclave
• Pressure switch at max pressure to unload possible over pressure
• Thermostat at maximum temperature at manual rearmament, to abort the cycle in case of emergency of high temperature in autoclave
• Emergency Stop Push Button

N.1 Autoclave AIM 3.800 x 3.000 complete with:
• Hydraulic rotation and closure of the door
• Outside Thermal insulation
• Steam Heating inside diffuser
• Steam / air – inlet / outlet control valves
• Control power board as above described
• Control system with PLC
• Structural certification CE PED 97/23
• Quality certification UNI EN ISO 9001:2008

The technical characteristics are as described in the present offer.

N°1 – Final Cooling System with water
N°1 – Rotative hanging system (max. weight 12.000 kg), tyre loading by forklift
Optional
N.1 Carrier for the autoclave
The carrier embedded in front of the autoclave moves hooking the tyre holder from the Autoclave and inserting and withdrawing it (see drawing 4200-1 in the next page)
N°1 Any certification on request

Position 9) Stand per pneumatici di Finitura e verniciatura + Serbatoio Airless per la verniciatura
N.1 MGT tyre stand Hercules Plus, for tyres up to 63”

N°1 Airless Tank with Mixer (see position 6.2 for details)

Position 10) 10.1 Tyre Stand 35”
N.2 MGT tyre stand Hercules Mini, for tyres up to 35″

This tyre stand is used for hang the tyre during repair and filling of the skives. It is equipped with tyre rotation controlled by a foot pedal. It’s designed for tyres up to 35” bead diameter.

Position 10) 10.2 Tyre Stand 63”
N.1 MGT tyre stand Hercules Plus, for tyres up to 63”

This tyre stand is used for internal and external spot repairs.
The machine can lift the tyre up to the required height and allow easy inside and outside operations.
It is equipped with tyre rotation controlled by a foot pedal, the tyre speed is controlled by inverter.
It’s designed for tyres up to 63” bead diameter.
Total installed power 10 KW.

Position 11) Kit of production tools and accessories
kit for machinery and tyre repair, see also our accessories catalogue N.23

Position 12)
Suggested Spare Parts (for 2 years of good functioning) for:

Position 1) Inspection Machine
Position 2) Robot skiving Machine 63″
Position 3) Sherographic Machine 63″
Position 4) Peeling, Buffing and Grooving Machine
Position 5) Cyclone & Dust Collector
Position 6) Cementing Machine
Position 7) Extruder Builder Machine CNC
Position 8) Autoclaves
Position 9) Finishing & Painting Tyre Stand + Airless Tank
Position 13) Steam Boiler
Posizione 14) Air Compressor

B) ANCILLARY EQUIPMENT

Position 13) Steam Boiler
N°1 Steam Boiler type Eurosteam 1200 composted with:

N.1 Steam generator with a production of 1.200 Kg/H. at a design pressure of 12 Bar.

N.1 Water and condensate tank manufactured in carbon steel, completely insulated and with a capacity of 2.000 Lts.

N.1 Chimney of six meters formed by modules. Manufactured in carbon steel

N.1 Water treatment equipment formed by water softener (40 liters) maximum capacity 4 m3/h.

Position 14) Air Compressors
N.2 Air Rotary Screw Compressor

Rotary air compressor with air production of 5.540 Lt/min. (5,54 m3/min.) at 10 Bar, complete with special filter and post air dryer refrigerator. Installed Power 45 KW each one.

Position 15) Air Tank
N.2 Air compressed tank capacity 2000 Lts

With max pressure of 11,5 Bar and complete with safety valve, manometer and 2 inches in and out connections.

Position 16) Water Pumps
N.1 Kit of water pumps and pressure reducer for compressors and autoclave cooling

With max pressure of 11,5 Bar and complete with safety valve, manometer and 2 inches in and out connections.

Download complete plant 63″