INDUSTRIAL PRACTICAL TRAINING REPORT GENERAL TYRE AND RUBBER COMPANY:

General Tyre & Rubber Company of Pakistan (GTR) was established in 1963 General Tyre International of America with a capacity of 150,000 Tyres per annum. This plant starts its production in 1964. In 1969, General Habib Ullah Khan Khattak took up the charge of the company as chairman. Some major Milestone achieved by GTR are: Investment of 520mn enhances the capacity up to 60,000 Tyres in the year 1985. Start manufacturing for the racing cars and export it to UK in the year 1986. Enhanced capacity to 80,000 tyres / yr in the year 1992. Production of Radial tyres was started in the year 1994. Production increases up to 955,047 in the year 2003. Certified by ISO 9001-2000 in the year 2004. Manufacturing increased to 13 lac tyres per annum in the year 2005. Manufacturing increased to 15lac tyres per annum in the year 2006. Target to increase 19lac per annum in the year 2008. Now Manufacturing increased to 2,000,000 tyres per anum.

COMPANY VISION
To be the leader in Tyre technology by building the company image through Quality improvement, competitive prices, warranty coverage, Costumer satisfaction, and meeting social obligation.

MAJOR DEPARTMENTS OF GTR:

 Quality Assurance (Q.A) Quality Control (Q.C) Administration Industrial Engineering Tyre Engineering Planning & Control Electrical Maintenance Mechanical Maintenance Instrumentation Industrial Relations Compounding
Head Office

Safety

TYRE MANUFACTURING IN GTR:

1.Radial tire manufacturing starts with many kinds of raw materials: pigments, chemicals, some 30 different kinds of rubber, cord fabrics, bead wire, etc. The process begins with the mixing of basic rubbers with process oils, carbon black, pigments, antioxidants, accelerators and other additives, each of which contributes certain properties to the compound. These ingredients are mixed in giant blenders called Banbury machines operating under tremendous heat and pressure. They blend the many ingredients together into a hot, black gummy compound that will be milled again and again. 2. The cooled rubber takes several forms. Most often it is processed into carefully identified slabs that will be transported to breakdown mills. These mills feed the rubber between massive pairs of rollers, over and over, feeding, mixing and blending to prepare the different compounds for the feed mills, where they are slit into strips and carried by conveyor belts to become sidewalls, treads or other parts of the tire. Still another kind of rubber coats the fabric that will be used to make up the tire's body. The fabrics come in huge rolls, and they are as specialized and critical as the rubber blends. Many kinds of fabrics are used: polyester, rayon or nylon. Most of todays passenger tires have polyester cord bodies. 3. Another component, shaped like a hoop, is called a bead. It has high-tensile steel wire forming its backbone, which will fit against the vehicle's wheel rim. The strands are aligned into a ribbon coated with rubber for adhesion, then wound into loops that are then wrapped together to secure them until they are assembled with the rest of the tire. Radial tires are built on one or two tire machines. The tire starts with a double layer of synthetic gum rubber called an innerliner that will seal in air and make the tire tubeless. 4. Next come two layers of ply fabric, the cords. Two strips called apexes stiffen the area just above the bead. Next, a pair of chafer strips is added, so called because they resist chafing from the wheel rim when mounted on a car. The tire building machine pre-shapes radial tires into a form very close to their final dimension to make sure the many components are in proper position before the tire goes into the mold. 5. Now the tire builder adds the steel belts that resist punctures and hold the tread firmly against the road. The tread is the last part to go on the tire. After automatic rollers press all the parts firmly together, the radial tire, now called a green tire, is ready for inspection and curing. 6. The curing press is where tires get their final shape and tread pattern. Hot molds like giant waffle irons shape and vulcanize the tire. The molds are engraved with the tread pattern, the sidewall markings of the manufacturer and those required by law. Tires are cured at over 300 degrees for 12 to 25 minutes, depending on their size. As the press swings open, the tires are popped from their molds onto a long conveyor that carries them to final finish and inspection

7. If anything is wrong with the tire if anything even seems to be wrong with the tire, even the slightest blemish it is rejected. Some flaws are caught by an inspector's trained eyes and hands; others are found by specialized machines. Inspection doesn't stop at the surface. Some tires are pulled from the production line and X-rayed to detect any hidden weaknesses or internal failures. In addition, quality control engineers regularly cut apart randomly chosen tires and study every detail of their construction that affects performance, ride or safety. 8. This is how all the parts come together: the tread and sidewall, supported by the body, and held to the wheel by the rubber-coated steel bead. But whatever the details, the basics are fundamentally the same: steel, fabric, rubber, and lots of work and care, design and engineering

MANUFACTURING AREAS IN GTR:

There are 3 major areas: Area-1(Blue) Area-2(Green) Area-3(Yellow)

AREA-I
Its the initial area for tyre building process. Here the Fabric of different tyre is prepared by the specification provided by the Q.C. Fabric selection is an important process that assures long lasting life of a tyre. Area 1 consists of: 1) Mixing (BN# 1, 2, 3 and 4) 2) Dual Extruder and its mills 3) Four Roll Calendar and its mills 4) Triplex Machine 5) Refiner MIXING It is the process in which the rubber, carbon, oil and pigments are blended according to specification suiting the type of compound specified for different components of the tyre. The above are fed in an internal mixture and mixed for a specified period of time. RAW MATERIALS Major raw materials used are: 1) 2) 3) 4) 5) 6) Natural rubber Synthetic rubber Carbon black Silicon dioxide Processing oil (aromatic oil or rubber process oil) Pigments

A COMPLETE PROCESS OF A BATCH MAKING

Carbon

OIL

Mixer

Small component +

Dump Mill

Sheeter Mill

Cooling Rack

Batch Off

PROCESS: The process consists of two steps; a master batch is mixed first, is cooled and allowed proper aging before curatives are added in the second stage which is done at lower temperatures and for shorter duration and is called Finish batch. First we do the weight of master batches as per specifications. The sheets are then fed into the Banbury through hopper door. After mixing, it is dropped on dump mill after it come on sheeter mill and then passed through soap solution tank and cooled in cooling line. The fabric is then properly tagged and accumulated in the storage area. The fabric is used according to requirement. This process of coating fabric with rubber is called calendaring and is performed on 4-Roll Calendar.

BANBURY MACHINE:
It is a commonly used machine to produce such goods as automobiles tyre and tubes, rubber mechanical goods and insulated wires. There are two mixer machines at Banbury: 1) HF-270 2) F-270 3) Kneader Machine 1 4) Kneader Machine 2 They produce Master and Finish Batches. In Master Batch rubber sheets are produce and in finish batch rubber sheets and different pigments enters into the mixer.

STEPS FOR MIXING A BATCH IN BANBUARY

RAM DOWN CARBON IN RAM IN OIL UP

FEED DOOR OPEN

RUBBER FEED

RAM DOWN

RAM UP/ DOWN SEVERALTIME

DROP DOOR DUMP MILL: OPEN

Its used to produce Finish batch, here the Master Batch is mixed with some amount of a chemical to make smooth bands. The temperature at the Dump mill is nearly 120oC.

SHEETER MILL
It is used to make sheets. After making sheets it come on Take off Conveyer and pass through Soap water. Then send in Cooling Rack, after cooling rubber sheet Batch off through Batch off Unit. Take Off Conveyer. Soap Tank. Cooling Rack. Batch off Unit

ELECTRICALLY COMMUNICATION SYSTEM OF HF-270 Recipe Computer

Profibus Com3 com4 com5 com6

CNCC PLC S7 300

CPU 315 2 DP

Profibus

IM 365 S

P1

P2

P3

P4

INPUTS

OUTPUTS

Profibus

UTHS PLC S7 300

CPU 314
MEMORY CARD

IM 365 R

MPI
M

OIL SCALE DISPLAY GUAGE

RUBBER SCALE DISPLAY GUAGE

CARBON SCALE DISPLAY GUAGE

RUBBER SCALE COMPUTER TERMINAL DISPLAY

UTHS PANEL HMI

DP

DUMP MILL SHEETER MILL

THE PLCs USED IN GTR

In production areas of GTR following Brands are used on different machines. 1) ALLEN BRADLLEY (502,503 ) 2) SIEMENS (S7-400,300,200)

3) HONEYWELL 4) GEM 80 5) LENZE

Operational Sections of a PLC CPU

Output Peripherals: Monitor Input Memory Building Alterable FixedProcessor Power Battery Printers commands: Modules-Logic Electricalup Memory Supply Back Recorders Keyboard AC Power Power -Diagram -Logic-Clock Etc. -Numeric -Edit -Etc

-Function Status -Monitor -I/O Status -Communicate -Scratch Pad -Etc - Etc. -RAM-ROM-

The PLC CPU Processor

Print Disk Tape Display Output Input Keyboard Interface Operatingwith Fixed Display Keyboard Modules Peripherals Other Analysis Output Logic Input Error CPUs Switch Control Program Memory Clock Alterable or Memory Scan Check Setting computers

Status and Fault Displays

Fiber OOptional Cable and Connection IMultiple PLC PM ToCInputs Output InputsOptics Layout CToSystem Up to Optional To I/O Printe RecorderCPU OnePlayer Switchesor nProgramme Output Inputs Outputs uConnection oo Mile Wires Remote Input r Central ConnectionCable Contacts, dt Tape or p Coaxial Output Coils, d To r Processin Alarms, Module eeetc. p Disk u Master Monitor g rretc. Computer u t Unit t s

DUAL EXTRUDER:
In Dual Extruder we use two type of rubber material. Rubber sheets from the mixing dept are fed to the extruder. A Die is use in dual extrusion to acquire the desire shape. It produces tread for Bias tyres. Dual extruder consists of: Break down mill. Feed mill. Cold feed extruder. Inclined and declined conveyor. Separation conveyors. Cooling conveyor Cutters.

In dual extruder printer are use to mark the specifications on the tread, which provide date, size, operator code etc to point out any error occurs due to the tread in the finish area.

4-ROLL CALENDER MACHIINE:

As the name indicates, this machine contains 4 heavy rollers which rotate in opposite directions. The calendar machine is use to coat the fabric with rubber compound. Three types of calenderer product are produce, nylon, square woven and polyester. Controlling system of calendar machine contains: Photo-sensors.-To maintain the position of fabric on the rollers. Splicer. -Used to join the fabric. Tensio-meters.-Shows the load of fabric Banana-roll.-To change the Drain Per Inches (DPI) of the fabric. Accumulator.-It holds the fabric while a new roller is installing for further process.

It has 17 DC motors. All the motors work in synchronization through sensors and load cells.

Triplex Extruder Machine

In Triplex Extruder we use three type of rubber material. Rubber sheets from the mixing dept are fed to the extruders. A Die is use in Tri extrusion to acquire the desire shape. It produces tread for radial and side wall of radial tyres. Triplex extruder consists of: Feed Conveyors. Cold feed extruders. Inclined and declined conveyor. Separation conveyors. Cooling conveyor Cutters. In Triplex extruder printer are use to mark the specifications on the tread, which provide date, size, operator code etc to point out any error occurs due to the tread in the finish area.

A R E A

I I

The rubber coated fabric from Area-I is then send to Area-II for the production of Radial and Passenger Tyres. Following process are performed in Passenger Tyre area. 1) Stock preparation 2) Bead and BandBuilding.

3) TyreBuilding.

STOCK PREPARATION In stock preparation the necessary and small components of a tyre are prepared. Here Biascutting machines (FC-2, FC-3,FC-4) are use for cutting the rubber coated fabric with certain angle and size. Since length varies for different tyres, Photo-eye is use to sense the cutting length of the rubber. Counter meter are used to cut the cloths at a certain distance.

This department deals with prepation of necessary components required for a tyrebuilding .it is further divided into: 1) Bias cutting 2) Bead forming 3) Band building 4) Sqeegee application (SQ-1). 5) Cap ply forming 6) Slittering (FS-1).

TYRE BUILDNG In tyre building Plies are wrapped around a metallic drum, the wrapping of the no. of plies varies according to vehicle type. Beads are set to the end of the drum and covered by the end of the plies. Then tread is wrapped around these plies to give the assembled tyre unit. These treads are designed in the curing section.

RADIALTYREBUILDING
Radial tyres are the improved form of Bias tyre, which are building in GTR using American Technology. They are designed to absorb shocks. For radial, polyester fabric is used because of its high M.P. Radial tyres are built in two stages. 1st Green Tyre Forming The first stage of building a radial tyre is to locate the beads onto a cylindrical flat forming drum, followed by a series of components which will form the base structure of the tyre and link the two beads together. The tubular shaped carcass is then transferred to the second stage. 2nd Green Tyre Shaping The second stage of construction begins by loading the tyre carcass onto a second drum, the tyre is the shaped and breaker belts are applied, followed by the sidewall and tread

components. At each stage of the construction great care is taken to apply pressure, with the view to expelling all air between each layer and to consolidate the assembly. STEELASTIC Here steel cords coated with Brass are used in strip making. These cords are coated with rubber and insolated with specified rubber compound. Cut at and angle (24o ,26o) with +-5% tolerance, spliced and rolled in a liner to keep freshness and free from dust. Extruder machine is used to make strips, consist of copper wire coated with rubber. Strip can be made of different sizes. No. of wires are kept constant for different sizes of the trips e.g. for 6 strip 84 wires are used. Creed room is used to store/keep the steel wires for strip making. Humidity and the temperature in the creed room are kept at a certain level, to assure the quality of the tyre. Humidity = <34% Temperature= 40oC. In steelastic following machines are used: Creel stand Cold feed extruder. Heat exchanger. Cooling drum. Cutting and splicing table. Winding unit. Gum aging

A R E A - I I I
This area is divided into two sections: 1) Curing 2) Final finish THE CURING SECTION Curing is the process of applying pressure to the green tire in a mold in order to give it its final shape, and applying heat energy to stimulate the chemical reaction between the rubber and other materials. In this process the green tire is automatically transferred onto the lower mold bead seat, a rubber bladder is inserted into the green tire, and the mold closes while the bladder inflates. As the mold closes and is locked the bladder pressure increases so as to make the green tire flow into the mold, taking on the tread pattern and sidewall lettering engraved into the mold. The bladder is filled with a recirculating heat transfer medium, such as steam, hot water, or inert gas. Temperatures are in the area of 350 degrees Fahrenheit with pressures around 350 PSI. Passenger tires cure in approximately 15 minutes. At the end of cure the pressure is bled down, the mold opened, and the tire stripped out of the mold. The

tire may be placed on a PCI, or post-cure inflator, that will hold the tire fully inflated while it cools. There are two generic curing press types, mechanical and hydraulic. Mechanical presses hold the mold closed via toggle linkages, while hydraulic presses use hydraulic oil as the prime mover for machine motion, and locks the mold with a breech-lock mechanism. Hydraulic presses have emerged as the most cost effective because the press structure does not have to withstand the mold opening pressure and can therefore be relatively light-weight. There are two generic mold types, two piece molds and segmental molds.

Final Finish After the tire has been cured, there are several additional operations. Tyre Uniformity measurement is a test where the tire is automatically mounted on wheel halves, inflated, run against a simulated road surface, and measured for force variation. Tyre balance measurement is a test where the tire is automatically placed on wheel halves, rotated at a high speed and measured for imbalance. Large commercial truck/bus tyres, as well as some passenger and light truck tyres, are inspected by X-ray machines that can penetrate the rubber to analyze the steel cord structure. In the final step, tyres are inspected by human eyes for numerous visual defects such as incomplete mold fill, exposed cords, blisters, blemishes, and others. PNEUMATIC MOTORS are also used in Area 2 in Larsen &toubroLimitted LTM Business Unit Chennai India machine and in FC4. pnuematic is sued to pass pressure to hold leather and then cut it. RS- logic 5000 is used Pneumatics is the use of pressurized gas to affect mechanical motion. Pneumatic power is used in industry, where it is common to have factory units plumbed for compressed air although other compressed inert gases can be, and are used in smaller or selfcontained systems Advantages of pneumatics 1) Cleanliness a. Air is used by a machine and is then exhausted to the atmosphere - no return line is necessary. b. Any leaks will be of air (which is much less of a problem than oil leaks in Hydraulics). 2) Availability a. Air is freely available in the pneumatics. b. Most factories are pre-plumbed for compressed air distribution - which makes it very easy to set up a manufacturing process. 3) Simplicity of Design And Control

a. Machines are easily designed using standard cylinders & other components. Control is as easy as it is simple ON - OFF type control. 4) Reliability a. Pneumatic systems tend to have long operating lives and require very little maintenance. b. Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force. 5) Storage a. Compressed Gas can be stored, allowing the use of machines when electrical power is lost. 6) Safety Very small fire hazards (compared to hydraulic oil). Machines can be designed to be overload safe.