Tire Manufacturing Research Articles

Climate change management in manufacturing industry: a greenhouse gas inventorisation and mitigation approach

PurposeIndustries worldwide have been striving to serve the increasing demand of consumers alongside providing importance to environmental issues. Yet, there are concern-raising changes on the planet, such as greenhouse gas (GHG) emissions resulting in a temperature rise. India remains a vital party of the United Nations Convention on Climate Change. Henceforth, the paper aims to study the increased emissions of GHG in Puducherry, an Indian Union Territory that faces tremendous pressure owing to its denser population.Design/methodology/approachThe research is designed as a case study conducted in a tyre manufacturing unit in Puducherry. The industrial sector was chosen, as it is the largest contributor (78%) of the total GHG emissions. Case studies were chosen to analyse the GHG emissions and the effects of implementing the policies and imposing interventions over time. The identified areas of improvement, proposed changes and the implemented ones with the results over a three-year period have been discussed.FindingsThe present study’s GHG inventorisation for Puducherry paved the way for preparing mitigation and adaptation plans. A total of 21 and 48 changes were incorporated to conserve fuel and power, respectively. A significant 11% reduction in power consumption and 1,113,008/litres of furnace oil was achieved. This translates to 5,115 tCO2 and 3,306 tCO2, respectively.Practical implicationsThis research will help to improve the importance of climate change management in the manufacturing sector, and it will pave the way for achieving effective sustainable practices.Originality/valueSuch case studies could cumulatively impact the policy directives/ interventions on GHG emissions. Though this seems a small leap, putting them into practice at firm levels would contribute significantly towards achieving Sustainable Development Goals.

Optimization and improving of the production capacity of a flexible tyre painting cell

AbstractOptimization of industrial processes is a constant concern and a main task for many companies in several industry sectors. Based on optimized solutions, the company can decrease manufacturing costs, lead times or, more generally, increase benefit. However, when developing a new process, you must be sure that the new solution will add more value to the initial solution. This, among many others, is one of the main reasons why companies opt, in addition to experimentation, for the use of tools that allow for the virtual prototyping, simulation, and integration of complex and sophisticated processes. Experimentation requires approximation testing, searching for the ideal values of quantity, temperature, etc.; simulation provides industrial processes with test support ranging from flows to robotic systems such as the intelligent software. This simulation software allows to develop programs, add Computer Aided Design (CAD) layouts, and simulate the cycle times of the different tasks to be performed. In this paper, an experimental approach is presented with atomization and fan spray pressure as the study basis and a simulation of the robot-based handling solution used in a tyre production line. The result is an improvement of the painting process, optimisation of the amount of fluid deposited on the tyre, of the processed product, as well as of the running times of the robot.

Explainable attention-based fused convolutional neural network (XAFCNN) for tire defect detection: an industrial case study

Ensuring tire quality is crucial in the manufacturing industry, particularly for race cars, where defective tires present a significant safety risk. Visual inspection for defects in tires is crucial; however, identifying defects in complex, textured tires has been proven to be a challenging task. This paper tackles this challenge by introducing XAFCNN, an Explainable Attention-based Fused Convolutional Neural Network for tire defect detection. XAFCNN’s novel architecture, including a Special Attention Module (SAM) and custom CNN structure, coupled with Grad-CAM visualization, prevents overfitting, enhances local feature mapping, enables detection of small defects, and proffers valuable insights into the model’s reasoning, enabling confident interpretation of its predictions. The model was trained on a dataset from a leading global tire manufacturer, including 38,710 x-ray images of defective tires and 83,985 defect-free tire images, covering 15 defect types and 50 design patterns. The results demonstrate the model’s exceptional performance compared to literature, achieving a recall rate of 86.85%, a precision of 98.5%, an F1 score of 92.31%, and an overall accuracy of 95.40%. This research, with its substantial dataset and high-performing model, advances automated tire defect detection, satisfying the industry’s need for accurate and reliable inspections, ultimately enhancing human safety.

Prioritization of Volatile Organic Compound Reduction in the Tire Manufacturing Industry through Speciation of Volatile Organic Compounds Emitted at the Fenceline

Volatile organic compounds (VOCs), with their ubiquitous presence across numerous global industries, pose multifaceted challenges, influencing air pollution and health outcomes. In response, countries such as the United States and Canada have implemented fenceline monitoring systems, enabling real-time tracking of organic solvents, including benzene. Initially, this focus was predominantly placed on the petroleum refining industry, but it has gradually been broadening. This investigation seeks to identify and analyze the specific VOCs produced in the tire manufacturing sector by utilizing both active and passive monitoring methodologies. The findings of the present study aim to recommend prioritized reduction strategies for specific VOCs. Percentage means the ratio of VOCs detected at the research site. At research target facility A, active monitoring demonstrated the presence of Methylene chloride (20.7%) and Carbon tetrachloride (15.3%), whereas passive monitoring identified Carbon tetrachloride (43.4%) and m,p-Xylene (20.8%). After converting these substances to their equivalent concentrations, we found a noteworthy correlation between the active and passive methodologies. At research target facility B, active monitoring detected n-Pentane (45.5%) and Isoprene (11.4%), while passive monitoring revealed Toluene (21.3%) and iso-Hexane (15.8%). Interestingly, even at sites like warehouses and test tracks where VOC concentrations were projected to be low, we observed VOC levels comparable to those in process areas. This underlines the fact that the dispersal of VOCs is considerably influenced by wind direction and speed. Specifically, in the tire manufacturing industry, emissions of Xylene and 3-Methylhexane, both having high photochemical ozone creation potential (POCP), contribute significantly to air pollution. However, the overall detection concentration in the tire manufacturing industry was detected at a low concentration of less than 2 μg/m3. This is less than 9 μg/m3, which is the standard for benzene, which has strong carcinogenicity regulations. This suggests that additional research is needed on synthetic rubber manufacturing rather than tire manufacturing.

Advancing mechanical performance in sustainable engineering: Synergistic effects of graphene oxide/nano‐silica hybrid nanofiller via latex coagulation in natural rubber composites

AbstractThis research investigates the utilization of a hybrid nanofiller comprising graphene oxide (GO) and amine‐modified nano silica in natural rubber matrix via the latex stage coagulation method. The resulting novel composite materials were characterized comprehensively for their static and dynamic mechanical properties. The hybrid nanofiller exhibited excellent dispersion within the rubber latex, facilitating the formation of a well‐interconnected network structure. The formed network resulted in remarkable improvements in tensile strength, elongation at break, and modulus of the composites. Dynamic mechanical analysis revealed that the hybrid filler (GO/nano‐silica hybrid (GO/NS)) could effectively reinforce the rubber matrix by constraining the mobility of rubber chains, leading to increased stiffness and mechanical strength. In fact, the confinement effect of the nanofillers has been carefully evaluated from dynamic mechanical spectroscopy. The increased glass transition temperature of the rubber nanocomposites specifies the restricted segmental mobility of the rubber chains. Moreover, the hybrid composites displayed significantly low rolling resistance, particularly GO/NS 2 (31% reduction), indicating their potential application as tire treads for fuel‐efficient and green tire manufacturing. The mechanical and rolling resistance properties achieved in these composites can be attributed to the efficient dispersion of the GO/nano‐silica hybrid(GO/NS) nanofiller and the resulting network formation within the rubber matrix. Findings emphasized the composites' viability as sustainable and eco‐friendly tire materials, potential for enhanced fuel efficiency, and reduced environmental footprint in tire manufacturing technology.Highlights The hybrid nanofiller (GO/nano silica hybrid) exhibited excellent dispersion within the rubber latex, leading to the formation of a well‐interconnected network structure. The resulting network structure significantly improved the tensile strength, elongation at break, and modulus of the composite materials. Dynamic mechanical analysis demonstrated that the hybrid filler effectively reinforced the rubber matrix, increasing stiffness and mechanical strength by constraining the mobility of rubber chains. Our hybrid composites displayed a remarkable reduction in rolling resistance, particularly GO/NS2, with a 31% reduction, indicating their potential application as tire treads for fuel‐efficient and green tire manufacturing. The study emphasized the composites viability as sustainable and eco‐friendly tire materials, offering potential benefits for enhanced fuel efficiency and reduced environmental footprint in tire manufacturing technology.

Applying a System of Systems Perspective to Hyundai‐Kia's Virtual Tire Development

ABSTRACTSystems engineering has become important in almost every complex product manufacturing industry, especially automotive. Emerging trends like vehicle electrification and autonomous driving now pose a system of systems (SoS) engineering challenge to automotive OEMs. This paper presents a proof‐of‐concept (PoC) that applies a top‐down SoS perspective to Hyundai‐Kia Motor Corporation's (HKMC) virtual product development process to develop a performance‐critical component of the vehicle, the tire. The PoC demonstrates using the Arcadia MBSE method to develop a consistent, layered, vehicle architecture model starting from the SoS operational context down to the lowest level of system decomposition in the physical architecture thereby capturing top‐down knowledge traceability Using the concept of functional chains, several vehicle performance views are captured that serve as the basis for architecture verification orchestration across engineering domains using a cross‐domain orchestration platform thereby validating key vehicle/tire performance metrics that influence the tire design parameters. Preliminary results of the study show that applying a method‐based modeling approach could provide several benefits to HKMC's current product development approach such as reduced time to model, SoS knowledge capture and reusability, parameter/requirement traceability, early performance verification, and effective systems engineering collaboration between the OEM, tire design supplier, and tire manufacturers.

Are volatile methylsiloxanes in downcycled tire microplastics? Levels and human exposure estimation in synthetic turf football fields

Downcycled rubber, derived from end-of-life tires (ELTs), is frequently applied as crumb rubber (CR) as infill of synthetic turf in sports facilities. This practice has been questioned in recent years as numerous studies have reported the presence of potentially hazardous chemicals in this material. CR particles fall into the category of microplastics (MPs), making them possible vectors for emerging micropollutants. A preliminary study where volatile methylsiloxanes (VMSs) were found in CR originated the hypothesis that VMSs are present in this material worldwide. Consequently, the present work evaluates for the first time the levels and trends of seven VMSs in CR from synthetic turf football fields, while attempting to identify the main sources and impacts of these chemicals. A total of 135 CR samples and 12 other of alternative materials were analyzed, employing an ultrasound-assisted dispersive solid-phase extraction followed by gas chromatography–mass spectrometry (GC–MS), and the presence of VMSs was confirmed in all samples, in total concentrations ranging from 1.60 to 5089 ng.g−1. The levels were higher in commercial CR (before field application), a reflection of the use of VMS-containing additives in tire production and/or the degradation of silicone polymers employed in vehicles. The VMSs generally decreased over time on the turf, as expected given their volatile nature and the wearing of the material. Finally, the human exposure doses to VMSs in CR (by dermal absorption and ingestion) for people in contact with synthetic turf in football fields were negligible (maximum total exposure of 20.5 ng.kgBW−1.year−1) in comparison with the European Chemicals Agency (ECHA) reference doses: 1.35 × 109 ng.kgBW−1.year−1 for D4 and 1.83 × 109 ng.kgBW−1.year−1 for D5. Nevertheless, more knowledge on exposure through inhalation and the combined effects of all substances is necessary to provide further corroboration. This work proved the presence of VMSs in CR from ELTs, another family of chemical of concern to take into account when studying MPs as vectors of other contaminants.

Soft-sensor estimation via parameter fitting and dynamic optimization in an experimental batch butadiene homopolymerization reactor

In this work, we address modeling and experimental tasks to develop an industrial process for the anionic polymerization of butadiene, which is a key compound used in the production of high-performance tires. The aim of this study was to determine the processing conditions that lead to the efficient manufacturing of polybutadiene. Accordingly, an experimental polymer reaction facility was constructed to record both butadiene conversion and temperature profiles. A first-principles dynamic mathematical model was developed to track the measurement variables as best as possible. To improve the tracking of recorded variables, some process variables were deployed as manipulated variables. Because good experimental tracking was not acceptable, we used the soft-sensor approach to estimate some additional degrees of freedom. The estimation task was performed by describing the problem as a dynamic optimization problem. The results clearly show that the optimization and control tasks of butadiene polymerization reaction facilities are demanding and require good experimental information to develop reliable mathematical models that can be leveraged to speed up the development of such industrial polymerization systems.

Investigate How CEAT Manages its Raw Materials, Production Processes, and Distribution Channels

The research paper aims to provide a comprehensive understanding of CEAT's supply chain management practices, focusing on three critical areas: raw materials management, production processes, and distribution channels. The combination of primary and secondary data collection methods ensures a robust and nuanced exploration of these aspects. The primary data collection involves interviews with key personnel directly engaged in CEAT's supply chain operations. This approach offers firsthand insights into the company's strategies, challenges, and successes in managing raw materials, optimizing production, and streamlining distribution channels. These interviews provide a qualitative dimension to the research, offering a deeper understanding of the day-to-day decision-making processes within CEAT's supply chain. Complementing the primary data, secondary data collection involves an extensive review of existing literature, company reports, and industry publications. This approach allows for a broader contextualization of CEAT's practices within the global tire manufacturing sector. By benchmarking against industry best practices, the study can identify areas where CEAT excels and areas for potential improvement. The paper's structure facilitates a systematic exploration of CEAT's supply chain, starting with an overview of the company's supply chain structure. This sets the stage for a detailed examination of how CEAT manages its raw materials, delving into procurement strategies ensuring a stable and reliable supply chain. The investigation then shifts to production processes, assessing the adoption of technology, implementation of quality control measures, and the overall operational efficiency in tire manufacturing.

Enhancing third-party logistics providers partnerships: An approach through the D.L.A.R.C.S supply chain paradigm

The effective selection of third-party logistics providers (3PLs) is crucial for achieving optimal supply chain performance. This study addresses the challenge of 3PL selection by adopting the comprehensive Digital, Lean, Agile, Resilient, Circular, and Sustainable (D.L.A.R.C.S) supply chain paradigm, which encompasses dimensions vital for managing modern supply chains, including digital, lean, agile, resilient, circular, and sustainable aspects. Recognising the interconnectedness of these dimensions, this paradigm emphasises their collective importance in enhancing supply chain operations. Utilising fuzzy SWARA (Step-wise Weight Assessment Ratio Analysis) and BWM (Best Worst Method) techniques, the study evaluates and ranks 3PLs based on their performance within these dimensions. The analysis reveals pivotal criteria such as purchasing price, transportation cost, removal of wastes, service costs, reduction in costs, and crisis and risk management as paramount considerations in the 3PL selection process. These criteria not only provide specific insights but also serve as a foundation for a data-driven approach to decision-making. This research, beyond offering strategic alignment insights for outsourcing, contributes substantively to the broader discourse on supply chain management. The methodology employed in this study integrates diverse dimensions, offering a robust framework for 3PL selection, thereby enhancing operational efficiency and sustainability across industries. The findings offer valuable insights for tyre manufacturers seeking to optimise their logistics operations within the D.L.A.R.C.S. framework, contributing to the advancement of supply chain management in the tyre industry and beyond.

Sliding friction of a pillar array interface: part I.

Biology is replete with examples, at length scales ranging from the molecular (ligand-receptor binding) to the mesoscopic scale (wing arresting structures on dragonflies) where shape-complementary surfaces are used to control interfacial mechanical properties such as adhesion, friction, and contact compliance. Related bio-inspired and biomimetic structures have been used to achieve unique interfacial properties such as friction and adhesion enhancement, directional and switchable properties. The ability to tune friction by altering surface structures offers advantages in various fields, such as soft robotics and tire manufacturing. Here, we present a study of friction between polydimethylsiloxane (PDMS) samples with surfaces patterned with pillar-arrays. When brought in contact with each other the two samples spontaneously produce a Moiré pattern that can also be represented as an array of interfacial dislocations that depends on interfacial misorientation and lattice spacing. Misorientation alone produces an array of screw dislocations, while lattice mismatch alone produces an array of edge dislocations. Relative sliding motion is accompanied by interfacial glide of these patterns. The frictional force resisting dislocation glide arises from periodic single pillar-pillar contact and sliding. We study the behavior of pillar-pillar contact with larger (millimeter scale) pillar samples. Inter-pillar interaction measurements are combined with a geometric model for relative sliding to calculate frictional stress that is in good agreement with experiments.

Storms mobilize organophosphate esters, bisphenols, PFASs, and vehicle-derived contaminants to San Francisco Bay watersheds.

In urban to peri-urban watersheds such as those surrounding San Francisco Bay, stormwater runoff is a major pathway by which contaminants enter aquatic ecosystems. We evaluated the occurrence of 154 organic contaminants via liquid chromatography coupled to tandem mass spectrometry, including organophosphate esters (OPEs), bisphenols, per- and polyfluoroalkyl substances (PFASs), and a suite of novel urban stormwater tracers (SWCECs; i.e., vehicle-derived chemicals, pesticides, pharmaceuticals/personal care products, benzothiazoles/benzotriazoles). Time-averaged composite sampling focused on storms in highly developed watersheds over four wet seasons, with complementary sampling in less-urban reference watersheds, near-shore estuarine sites, and the open Bay. Of the targeted contaminants, 68 (21 SWCECs, 29 OPEs, 3 bisphenols, 15 PFASs) were detected in ≥10 of 26 urban stormwater samples. Median concentrations exceeded 500 ng L-1 for 1,3-diphenylguanidine, hexa(methoxymethyl)melamine, and caffeine, and exceeded 300 ng L-1 for 2-hydroxy-benzothiazole, 5-methyl-1H-benzotriazole, pentachlorophenol, and tris(2-butoxyethyl) phosphate. Median individual PFAS concentrations were <10 ng L-1, with highest concentrations for PFHxA (180 ng L-1), PFOA (110 ng L-1), and PFOS (81 ng L-1). In six of eight urban stormwater samples analyzed for 6PPD-quinone (a tire rubber-derived transformation product), concentrations exceeded coho salmon acute toxicity thresholds, suggesting (sub)lethal impacts for sensitive species. Observed concentrations were generally significantly higher in highly developed watersheds relative to reference watersheds, but not statistically different in near-shore estuarine sites, suggesting substantial transient exposure potential at stormwater outfalls or creek outflows. Results emphasized the role of stormwater in contaminant transport, the importance of vehicles/roadways as contaminant sources, and the value of monitoring broad multi-analyte contaminant suites to enable comprehensive source and toxicity evaluations.

Multi criteria decision analysis for the identification of feasible rubber waste management alternatives for tire manufacturing industry: a Sri Lankan case study with TOPSIS and SWING

Multi criteria decision analysis for the identification of feasible rubber waste management alternatives for tire manufacturing industry: a Sri Lankan case study with TOPSIS and SWING

Evaluation of Nylon 6 and Nylon 66 Cord Fabrics for Scooter Tyre Production under Different Curing Conditions

Evaluation of Nylon 6 and Nylon 66 Cord Fabrics for Scooter Tyre Production under Different Curing Conditions

Phase-II monitoring of AR(1) auto-correlated simple linear profiles in multi-stage processes (case study: tyre production industry)

Phase-II monitoring of AR(1) auto-correlated simple linear profiles in multi-stage processes (case study: tyre production industry)

Сomputational approach to thermal-stressed state modeling of tire based on the algorithm of its self-heating analysis. Part 2 – Practical results of applying the approach

Elastomers and their composites are widely used in modern innovative technology: for the production of aviation and automobile tires, anti-vibration elements (rubber, rubber-metal springs), dampers, elastomeric bearings. Also they are used in shaft suspensions, as spacers between structural parts, supporting parts and fasteners. Elastomeric elements of structures have a high dynamic load, in particular of a cyclic nature, which is accompanied by the formation of hysteresis loops and, as a result, the occurrence of the phenomenon of self-heating. An increase in temperature in the middle of materials causes significant changes in their mechanical properties, reduces strength characteristics, accelerates aging and degradation processes, and has a significant impact on fatigue processes. In addition, an increase in temperature causes an additional thermal stress state, capable of significantly changing the qualitative picture of the structure's deformation characteristics' distribution. Thus, the purpose of this study is development of approach to assessing the thermal stress state of structures made of elastomeric materials for the possibility of further analysis of its influence on the structure work as a whole. The appropriate approach was built on the basis of numerical modeling of thermal and deformation processes which takes place into the structure during operation. The proposed approach includes several related calculations by using FEM and is based on the fundamental approaches of the theories of elasticity and viscoelasticity, thermal conductivity and thermo-elasticity. Thus, the article presents an approach to the analysis of the thermal stress state of structural elements under operating conditions. This approach was applied to determine the thermo-strain-stress characteristics of a pneumatic tire and corresponding pictures of its distribution were obtained.

Effects of vertical load and inflation pressure on tire-soil interaction on artificial soil

Instrumented single tire soil bin testing was conducted on a rigid surface and artificial soil by vertically loading a radial tire (LT235/75R15) to two tire vertical loads (6 kN and 8 kN) inflated to three levels of tire inflation pressure (179, 241, and 283 kPa). Lowering the tire inflation pressure by 37 % resulted in 26 % (6 kN vertical load) and 39 % (8 kN vertical load) greater contact lengths (P < 0.05). The 2-D contact area on artificial soil (initial bulk density of 1.51 Mg/m3) was significantly affected (P < 0.05) by tire inflation pressure for each load case. Increasing the load significantly affected the tire’s contact length on soil (P = 0.0010); however, tire inflation pressure did not significantly affect the contact length on soil (P = 0.0609). Soil rut depth and tire-soil deformed volume were not significantly affected by vertical load and tire inflation pressure. Measured tire contact area on soil surface was 3.3 times the contact area on the rigid surface, suggesting tire-soil interaction interface properties on deformable soil are better than using the gross flat plate for evaluating low ground pressure tire technology effects on traction and reducing soil compaction.

Synergistic integration of waste fibres and supplementary cementitious materials to enhance sustainability of ultra-high-performance concrete (UHPC)

Efforts to improve the environmental sustainability of the construction industry involve exploring waste materials, environmentally friendly production processes and high performance materials like ultra-high-performance concrete (UHPC). Despite UHPC’s benefits, its widespread use is hampered by its high cost and environmental concerns. To address this, limestone filler and metakaolin were used to replace 30% of the cement, while recycled tyre steel fibres (RTSF) and production waste carbon fibres (CF) replaced the conventional factory-made fibres. Eight mixes underwent various tests in fresh state and hardened state, revealing initial negative effects of supplementary cementitious materials (SCMs) on strength and capillary absorption, which improved considerably over time. Fibres addition, especially hybrid fibres, increased strength and toughness without significantly affecting modulus of elasticity. RTSF at 1 vol% and 1.5 vol% positively impacted compressive strength and toughness, while 1 vol% CF improved flexural strength and capillary water absorption. Optimal contents varied for the hybrid fibre mixes depending on the tested property, with overall best results in compressive strength, toughness and specific energy absorption. The hybrid mixes outperformed the RTSF mixes but lagged behind the CF mixes in terms of flexural strength and capillary water absorption. A multi-criteria analysis was conducted to determine the optimum mix design, taking into account factors such as performance, cost, and environmental impact. This analysis highlighted the potential of the supplementary materials and fibres to improve the environmental and economic efficiency of UHPC while maintaining or even improving the tested properties.

Bottleneck Identification through Simulation Modelling: A Case of Solid Tire Manufacturing Sector

Abstract Businesses are constantly making productivity improvements to survive in the highly competitive marketplace. Bottlenecks have been identified as one of the main factors limiting the system performance of manufacturing firms. Thus, identifying bottlenecks in the production process is extremely important to increase productivity. Considering its importance, this case study was designed to identify causes for not meeting the tire target and determine the implications of bottlenecks in the tire manufacturing process. For this purpose, simulation analysis was carried out for the solid resilience tire-building process. Through the investigation, the cushion layer-building process was identified as the bottleneck. To validate the identified limitation, Line balancing and Pareto analysis were conducted. Analysis results confirmed the presence of a bottleneck in the cushion layer-building process. Further, to identify the root causes for not reaching the maximum tire target, Cause-and-Effect analysis and 5WHY analysis were adopted. The study revealed that inadequately maintained outdated machines and frequent power failures are the leading causes of not meeting the maximum production. By answering these issues, the target production can be increased, and the results showed the opportunity to increase the efficiency of the manufacturing process by more than 95%.

트럭 버스용 타이어(TBR)에 대한 탄소발자국 산정 및 비교

As the importance of environmental strategy is gaining weight, a number of tire manufacturers are quantifying the environmental aspect of a product in order to reduce the environmental impact of the product and devise an environmental strategy for the product. In this study, the environmental impact of truck bus radial(TBR) tire was quantified using Life Cycle Assessment(LCA) and Carbon footprint which are the two of the main methods for assessing environmental impact.