Haifeng Automation Overall Solution for Shoe Soles
Schmerzpunkte der Industrie
01
Insufficient Production Efficiency and Stability
Die Abriebfestigkeit, Rutschfestigkeit, Stoßfestigkeit und andere Kernleistungen herkömmlicher Schuhsohlen sind unzureichend und genügen den Sicherheitsanforderungen unter komplexen Straßenbedingungen nicht. Die Abhängigkeit von der manuellen Dosierung und die unzureichende Prozesskontrolle führen zu erheblichen Leistungsunterschieden zwischen den Produkten derselben Charge und zu einer hohen Fehlerquote.
02
Imbalanced Formula Adaptability and Cost Control
It is difficult to quickly customize exclusive formulas for multiple scenarios (such as mine heavy load, low temperature, etc.), limiting adaptability. Meanwhile, traditional processes cause high pollution and significant raw material waste, and the short service life of tires leads to high comprehensive costs for customers.
03
High Technical Threshold and Implementation Difficulty
The linkage between polyurethane tire formula R&D and automated production is challenging, core technologies are hard to break through, and small and medium-sized enterprises lack mature support, making it difficult to achieve standardized and large-scale production.
Kern der Lösung
With over 30 years of profound experience in the polyurethane field, Haifeng focuses on the core needs of OTR polyurethane tires—”efficient production, precise formulas, and stable quality”. Relying on independently developed fully automated polyurethane casting equipment and precision metering systems, combined with formula customization technology and standardized production processes, we have created an integrated solution of “formula R&D support + automated production equipment + process implementation guidance”. We provide tire manufacturers with full-chain services from equipment supply to technical support, helping customers achieve standardized and large-scale production of OTR polyurethane tires, with equipment operating without failure for over 6,000 hours.
Kernlösungsmodule
Scenario-Based Custom Formula R&D
Performance-Exclusive Formulas: Specialized polyurethane formulas are developed for different application scenarios such as mine heavy load, low temperature, and corrosion, optimizing the wear resistance, damage resistance, and temperature resistance of tires. The Akron abrasion value can be as low as ≤0.15 cm³/1.61km.
Flexible Formula Adjustment: Formula components can be quickly adjusted according to customers’ specific performance requirements (e.g., enhancing load-bearing capacity for mine tires, improving low-temperature elasticity for tires in cold regions), ensuring adaptation to various harsh operating environments.
Formula Stability Verification: Rigorous multi-dimensional tests (including wear resistance, pressure resistance, and temperature resistance) are conducted on developed formulas to ensure consistent performance of finished tires, meeting industry quality standards.
Automated High-Precision Production System
Full-Process Automated Production Line
Equipped with Haifeng's independently developed high-pressure casting machines, modular molds, and vulcanization testing lines, it realizes full-automated operation of raw material mixing, casting, vulcanization, and testing processes. The metering precision is ≤±1%, and production efficiency is increased by more than 3 times.
Precision Mold Customization
Exclusive molds are customized according to the size and structural requirements of OTR tires, achieving one-time molding precision that meets design standards. This ensures consistent tire dimensions and avoids quality hazards caused by manual molding.
Modular Equipment Upgrade
To improve vulcanization efficiency, expand production scale, etc., only modular adjustments to the production line (such as adding casting stations, upgrading testing modules) are required, enabling rapid adaptation to changes in production demand.
Umfassende Qualitätsüberprüfung und Konformitätssicherung
Core Performance Inspection
Key indicators of finished tires, such as wear resistance, load-bearing capacity, and structural integrity, are inspected to ensure a product qualification rate of ≥99%, meeting customers' actual application needs.
Green Production Compliance Support
Production equipment has no pollutant emissions, and raw material utilization rate is increased by 20%, complying with environmental protection standards. It also supports the production of airless and high-load-bearing tires, adapting to customers' differentiated needs.
Intelligent Quality Inspection and Sorting
Combining visual inspection with automatic sorting, it accurately identifies surface defects and dimensional deviations of tires, automatically removing unqualified products to ensure the quality of delivered products.
Lösungswert und Auswirkungen
| Dimension | Traditionelles Verfahren | Haifeng Automatisierungslösung | Verbesserungseffekte |
|---|---|---|---|
| Produktionseffizienz | Low (relying on manual labor) | Full-process automation | Increased by more than 3 times, meeting large-scale production needs |
| Produktqualifizierungsrate | 70-80% | ≥99% | Significantly reduces rework losses and improves production efficiency |
| Formula Adaptability | Single, difficult to customize | Scenario-based customization with flexible adjustment | Adapts to various harsh operating needs and expands application scenarios |
| Raw Material Utilization Rate | Low with significant waste | High with precise proportioning | Increased by 20%, significantly reducing raw material costs |
| Equipment Stability | Prone to failure, difficult to maintain | Over 6,000 hours of trouble-free operation | Reduces downtime and maintenance losses, ensuring continuous production |
| Technical Threshold | High, difficult to break through | Standardized processes + technical guidance | Helps enterprises quickly master core production capabilities and lower entry barriers |
Prozess der Umsetzung
Nachfragerforschung
Das technische Team führt Untersuchungen vor Ort durch, um personalisierte Lösungen zu erarbeiten.
Formel und Prozessgestaltung
Vollständige Anpassung und Überprüfung der Machbarkeit durch das F&E-Zentrum.
Geräteanpassung/Transformation und Inbetriebnahme
Das Werk schließt die Produktion ab, und die Ingenieure führen die Installation und Inbetriebnahme vor Ort durch.
Kleinserien-Versuchsproduktion
Das technische Team verfolgt und optimiert die Parameter.
Vor-Ort-Installation und Massenproduktion
Implementierung der Produktionslinie und Beginn der Massenproduktion unter technischer Anleitung.
Unterstützung bei Qualitätsinspektion und Zertifizierung
Hilfestellung beim Ausfüllen von Prüfungs- und Zertifizierungsanträgen.
Betrieb und Wartung nach dem Verkauf
Erbringung von Instandhaltungs- und Modernisierungsdiensten auf der Grundlage des nationalen Servicenetzes.
