We have implemented laser measurement of width and thickness in the manufacturing process of Rubber Sheeting and Rubber FLOORING on the calender.
Due to this year's increase in sales Rubber Sheets and Rubber Flooring We have increased production capacity while focusing on increasing productivity and continuously improving the quality of manufactured products. Our production mainly focuses on specialized products with high quality standards and tight dimensional tolerances. We manufacture products dedicated to the needs of our customers.
In order to meet high market demands, we have started a multi-stage modernization of one of our calendars, from which the production process of Rubber Sheeting and Rubber Flooring begins. We are aware that full control over the quality of the manufactured products and the reduction of factors that disrupt the process, such as human error or instability of processing parameters, can be achieved mainly through automation of the process. Therefore, we first implemented a control and measurement system on the calender. It is an automatic laser geometry meter for rubber lifts that scans the thickness and width of blanks with a resolution of 0.01mm. The device uses a differential laser measurement method with a non-contact electronic head. The online system monitors the entire width and length of the rubber blank and sends information about defects to a computer in real time, activating an alarm. All measurement records are also archived, which allows us to work on continuous improvement of the production process.
The second step in the modernization of the calender unit was to increase the dimensional stability of the rubber lifts by automating the way the confection is wound. Eliminating the manual adjustment of the system allowed us to calendrate blanks at a speed synchronized with the operation of the entire calender unit. This action had a direct impact on reducing the dimensional discrepancies of the lifts.
During this stage, we also focused on coupling the operation of the cooling device with the operation of the automatic winder, measuring the temperature of the rubber lifts during the calendering process itself and after dimension stabilization, i.e. after cooling.
The next stage of the investment, which we are planning for next year, will be a change in the way we control the calender unit and feedback the operation of the measuring system with a new control system. In view of the numerous types of specialized Rubber Compounds, we are also considering thermostatting the calender roller system in order to have full control over the processing of semi-finished Rubber Sheeting and Flooring.
Above, an example of a readout of a measurement record of a semi-finished product for the production of CWT compound Rubber Sheets. A view of the trend, that is, a cross section of the material on a length scale, or number of scans, and a bird's-eye view.
Iga Korczynska
I studied Materials Engineering and Chemical Technology at the Faculty of Chemistry of the Technical University of Lodz. My studies prepared me very well for work in the Industries. They mainly focused on learning around elastomers. Both theses written
at the Institute of Polymer and Dyestuff Technology of the Polish Academy of Sciences are devoted to unconventional crosslinking systems for rubber mixtures. I have been working at BZPG „Stomil” S.A. since 2016, first in the Research and Development Department as a Technologist, and currently I am the Head of the Rubber FLOORING and RUBBER FLOORING Production Plant.