Tires are the only thing connecting the vehicle and the road, making them fundamental to the safety of a vehicle or aircraft. This importance is reflected in the laborious and complex nature of their production process. Ensuring production runs smoothly and safely requires robust and intelligent drive solutions. We understand how important production reliability, outstanding quality and energy-efficient drive and control technology are for tire production.
Mixers
Since tires – or specific types of tires – have to exhibit certain characteristics, tire manufacturers use a variety of rubber mixtures. In addition to natural and synthetic rubber, various materials and additives are included in these mixtures to give the tires the desired characteristics. A single tire mixture can contain up to 45 different base materials, which are combined in the mixer – a kind of kneading machine that applies pressure and heat. The resulting mixture is then stretched into a long strand of rubber using an extruder, cooled and stored temporarily awaiting further processing.
Normally, special gear units from SEW EURODRIVE are used for this.
Your benefits:
- Customized solution: individual, robust special gear units, e.g. as replacement gear units in case of service incidents
- Wide range of options and flexibility: multi-shaft inputs and outputs, individual steel welded housing designs or special gearings, and much more
- Designed and built by application-specific experts
Extruders
The extruder pulls the rubber belt produced in the mixer – which emerges from the mixer in a plastic state – into a screw press. The press then molds the belt into a continuous strip.
Normally, helical gear units / bevel-helical gear units of the X.. series in extruder design are used for this.
Your benefits:
- Extruder-specific solution
- Robust and powerful gear units offering fine graduation (23 sizes with a torque range from 6.8 to 475 kNm)
- Wide range of options: cooling, sealing systems, motor connection, and much more
- Customer-specific gear unit interfaces to the machine
Extruder cooling line / downstream
As it passes through the extruder cooling line, the rubber belt – which is still warm – is checked to determine its weight per meter and cooled in an immersion bath.
Our MOVIGEAR ® in sizes 2-4 are normally used for this.
Your benefits:
- Maximum energy efficiency as a result of the high level of integration of the synchronous motor, gear unit and control technology (delivering energy savings of > 40%) and high overload capacity (350%)
- Significantly lighter than alternative gear motors with asynchronous motors
- Universal mounting position
- Significant reduction in variants and cables
- Simple and safe cabling thanks to connector technology
- Setting ranges > 1:2000 possible
Core winder
This part of a tire is responsible to a large degree for running characteristics and stability. It consists of a rubber base into which steel is incorporated. The tire core is produced in the core winder before the various layers of textile and steel cord are applied around it.
Our DRC motor is ideal for this process.
Your benefits:
- Maximum energy efficiency due to the synchronous motor (energy savings of > 40%)
- Significant reduction in variants and cables
- Compact design frees up space
- Extremely simple and safe cabling thanks to connector technology
Calender / cap strip system
The calender is where ready-made steel and textile threads are embedded into one or more layers of rubber. To achieve this, the threads are unwound from the continuous strip and fed into the calender using special spooling devices.
A calender is a typical application for several of our products: DRN motor,X gear unit / P-X gear unit
- Your benefits with the DRN brake motor
- The motor offers a highly reliable safety function thanks to the integrated SEW brake. The calender rollers are brought to a halt within an angle of up to 30°, even when running at full speed.
- The benefits of the X gear unit
- Robust and powerful gear units offering fine graduation
- Wide range of options: cooling, sealing systems, motor connection, and much more
- Customer-specific gear unit interfaces to the machine
- The benefits of the P-X1KP gear unit
- Space-saving thanks to directly mounted planetary gearmotor
- High flexibility for machine optimization (11 sizes with a torque range from 25 to 500 kNm)
- Cost reduction due to inexpensive and compact stand-alone planetary gear unit solution
- Wide range of options: cooling, sealing systems, torque support, and much more
However, the textile threads can also be integrated into the rubber inside a cap strip system rather than a calender – in which case the threads are sheathed while being continuously pulled through the head of an extruder. They are then wound on cooling rollers, which lowers their temperature and prevents the rubber sheathing from sticking.
This is an ideal area of application for our MOVIGEAR ® in the sizes 2-4
Your benefits:
- Maximum energy efficiency due to the synchronous motor (energy savings of > 40%)
- Overload capacity: 350%
- Significantly lighter than alternative asynchronous gear motors
- Option of universal mounting position for drives
- Significant reduction in variants and cables
- Extremely simple and safe cabling thanks to connector technology
- Setting ranges > 1:2000 possible
Cutting machine
To ensure a tire exhibits certain running characteristics and a certain stability, the fabric specially woven from the individual textile or steel threads must be cut to certain lengths. This is done in the aptly named cutting machine.
Our DRC motors are normally used for conveyor systems and our servo gearmotor, comprising a helical-bevel gear unit and a DRL asynchronous servomotor, for the knife unit
The benefits of DRC
- Maximum energy efficiency due to the synchronous motor (energy savings of > 40%)
- Significant reduction in variants and cables
- Compact design frees up space
- Extremely simple and safe cabling thanks to connector technology
The benefits of DRL
- Reliable control, as a load of up to 3 to 4 times the nominal motor torque in relation to the motor shaft can be achieved
- Excellent speed quality due to a compact unit comprising gear unit and robust asynchronous servomotor
- Reduced circumferential backlash, high efficiency levels and high-endurance gearing
Tire building machine
Producing new tires (as opposed to retreaded tires) is a complex process for the various tire manufacturers because the end product must exhibit the characteristics outlined above, but tires are also needed in different types and sizes. The framework for a tire comprises up to 25 individual components.
The carcass layers form the basis onto which the steel belt layers are applied. Most tires consist of two carcass layers, two steel belt layers and two textile cord layers, which are then covered by the tread. To ensure the tire is securely mounted onto the rim, a steel belt is processed into the bead, which works with the tension on the tire to keep everything securely fixed.
The various components are assembled in the tire building machine.
Our servo gearmotor, comprising a B.SF helical-bevel servo gear unit and a synchronous CMP servomotor, are used in this process.
- The benefits of B.SF
- Low rotational clearance thanks to the high torsional rigidity of the gearing geometry
- Large gear ratio range thanks to the helical gear input stage combined with a hypoid output stage
- A perfect combination with the B5 mounting flange
- The benefits of CMP
- Highly dynamic performance
- Precise positioning using an integrated encoder
- Powerful brake
Curing press (mechanical)
Before the green tire is "baked" into a finished tire through prolonged exposure to heat and pressure in the curing press, it is sprayed with a special liquid to ensure the components bind properly. Following vulcanization, the tire has assumed its final form, and the plastic rubber has been elasticized.
Once it is fully formed, the tire is imprinted with markings on its sidewall and given its final tread pattern in the press. A distinction is made between positive tread patterns (tread bars) and negative tread patterns (tread grooves). These bars and grooves form the thread and vary, for example, between summer and winter tires.
This is where our CMP servomotors and helical-bevel gearmotors come in, the former used in the lifting drive and the latter as auxiliary drives.
The benefits of the CMP motor:
- Highly dynamic performance
- Precise positioning using an integrated encoder
- Powerful brake
- Tailor-made drive solutions
Inspection
Before we can have tires fitted in our trusted workshop, each tire must undergo various quality checks at the manufacturer's premises, the first of which is a visual inspection during which experts check the tires for visible faults. Machines are used to test the uniformity of tires and check for characteristics such as radial run-out. Invisible areas are also inspected using X-rays before the tire production process is complete. Naturally, only tires that have passed all quality checks are permitted to leave the factory.
BS.F gear units, CM3C motors and our ECDriveS ® are often used in this process.
The benefits of our ECDriveS ® and ECDriveS ® controllers:
- Application module for green tire handling – moving green tires safely from place to place to prevent dents and indentations (also runs during PLC timeout)
- Control options: PROFINET ® , EtherCAT ® , EtherNET/IP TM , binary, etc.
- Positioning possible using an integrated encoder
- Starting torque and power rating exceed market standard
- Electronic nameplate: The profile is automatically downloaded following replacement
- Condition monitoring can be implemented (e.g. temperature)
- The benefits of B.SF
- Low rotational clearance thanks to the high torsional rigidity of the gearing geometry
- Large gear ratio range thanks to the helical gear input stage combined with a hypoid output stage
- A perfect combination with the B5 mounting flange
- The benefits of CM3C
- Space-saving installation thanks to compact design and direct gear unit mounting
- Use of motors with simple and cost-saving single-cable technology
- Powerful spring-loaded brakes with an increased working capacity
- Auto-tuning using the electronic nameplate
Gantry robot
Gantry robots are often used in the tire industry when temporarily storing and sorting unmachined and finished parts.
We can offer special solutions for these gantry robots with our machine automation systems. Whether it's control technology with our MOVIAXIS ® and MOVI-PLC ® power, or helical-bevel gear units and CMP motors, we can provide you with a complete solution.
- Your benefits:
- Reliable solution from a single source (drive, inverter and controller)
- Software specially developed for this all-wheel-drive gantry application to prevent tilting and slipping
- Integrated servo gearmotors
- The benefits of CMP:
- Highly dynamic performance and precise positioning
- Powerful brake
- The benefits of MOVIAXIS ® :
- High modularity
- Suitable for customized expansion
- Simple startup
- Your benefits with MOVI-PLC ® power:
- Integrated system bus
- Control up to 64 axes with response times in the 1 ms range
- Efficient automation thanks to various performance classes
Connection conveyor technology
Roller and beltconveyors are a very simple solution for interlinking different processing stations or storage/retrieval areas.
Roller conveyors are the perfect fit for our ECDriveS ®
- Your benefits:
- Application module for green tire handling – moving green tires safely from place to place to prevent dents/indentations (also runs during PLC timeout)
- Control options: PROFINET ® , EtherCAT ® , EtherNET/IP TM , binary, etc.
- Positioning possible using an integrated encoder
- Starting torque and power rating exceed market standard
- Electronic nameplate: The profile is automatically downloaded following replacement
- Condition monitoring can be implemented (e.g. temperature)
Belt conveyors are the perfect fit for our MOVIGEAR ®
- Your benefits
- Maximum energy efficiency due to the synchronous motor (energy savings of > 40%)
- Overload capacity: 350%
- Significantly lighter than alternative asynchronous gear motors
- Option of universal mounting position for drives
- Significant reduction in variants and cables
- Extremely simple and safe cabling thanks to connector technology
- Setting ranges > 1:2000 possible
Safety first
Explosive mixtures of dust and air can form when mixing rubber and manufacturing tires. Depending on the substances involved and how fine the dust is, between 60 and 2000 grams of dust per cubic meter of air can be enough to produce a dust explosion when a suitable ignition source is present. These ignition sources can also include conventional electric drive technology.
To ensure no sparks are generated that could trigger an explosion, we consistently use explosion-proof drives in systems that are operated in these high-risk conditions. Our explosion-proof gearmotors satisfy the requirements set out in EU Directive 2014/34/EU (ATEX, formerly Directive 94/9/EC). They also comply with the IEC/IECEx and HazLoc-Na ® standards , which makes it easier to use our drive technology worldwide. We also offer degree of protection IP65/66, OS1 to OS4 surface protection and surface protection as an XCO ® drive package.
Components and technical data
Not all tires are the same
The intended purpose is key
State-of-the-art tires have become an indispensable part of road travel today. Tires directly affect the fuel consumption, noise and safety of a vehicle. They maintain their traction in the winter, even at low temperatures, and displace large volumes of water in the rain so quickly that aquaplaning does not occur and we can drive safely. It is also vital to our safety that they produce the shortest possible braking distances , while, at the same time, achieving excellent mileage , even at high ambient temperatures.
In the case of motorcycle tires , traction is extremely important – particularly when turning corners. In the case of utility vehicles , tread types are an important factor, e.g. for tractors or off-road vehicles. Truck tires must be able to accommodate high loads without suffering excessive wear. Although tires used to need an inner tube to contain the air inside them, that is no longer the case – the combination of rim, tire and valve is designed in such a way that the system is self-sealing. To achieve this, the inner surface of the tire is lined with an airtight, elastic layer of rubber.
Truck tires must also meet special requirements, especially those used in the mining of base materials – in which case the tires are larger than people, weigh several hundred kilograms and can carry loads of several metric tons. As you can see, there are various types of tire for every possible application in the tire industry depending on their ultimate intended use.
Producing new tires (as opposed to retreaded tires) is a complex process for the various tire manufacturers because the end product must exhibit the characteristics outlined above, but tires are also needed in different types and sizes. The framework for a tire comprises up to 25 individual components . And because tires are sometimes used in the most adverse conditions, the production process is subject to constant quality controls .
A tire is made up of various components. We usually devote most of our attention to the rubber of the tread, but the bead, sidewall and carcass are also integral parts of a tire. Before the tread is pressed at the very end of the tire production process, the body of the tire – the carcass – must be made first. In fact, it is this stage that determines – based on how individual layers of fabric are applied – whether the tire will be radial or bias-ply . The benefits of radial tires include low rolling resistance, which reduces fuel consumption, and better directional stability during acceleration/braking. Bias-ply tires, by contrast, exhibit better driving stability and more rigid sidewalls, which are desirable characteristics in motorcycle tires, for instance.
Data and documents
You can download comprehensive documentation here.
Brochure about the tire industry (PDF, 240 KB)
Download a poster (PDF, 1,1 MB)
Products and solutions (PDF, 10,1 MB)