Automated Control and Intelligent O&M Solutions for Complete Rubber Tire Production Lines

Rubber tire manufacturing lines involve numerous long processes and a high count of machines. Mixing, rubber transport, molding, and vulcanization each operate with independent control systems. Equipment status and energy consumption data are scattered across individual machine localities, making it difficult to oversee line-wide coordination at the workshop level. Injection molding equipment, which performs periodic actions, experiences energy losses during holding pressure and cooling phases; its operational adjustments rely on manual experience without data-driven support. This solution adopts a unified four-layer architecture: "Terminal Collection – Local Control – SCADA Monitoring – Cloud Platform Operations." The terminal layer uses IoT controllers to collect device data and integrate communication protocols, enabling plug-and-play platform access. It supports multi-vendor devices, converting machine data into a standardized format for platform recognition. The control layer includes PLC cabinets, MCC cabinets, VFD cabinets, and low-voltage distribution panels supplied as complete sets. Circuits are customized per process, with separated power and signal zones inside the cabinets and reserved expansion circuits for future machine additions. The monitoring layer employs a SCADA system to aggregate data from multiple PLC stations via Ethernet, Profibus-DP, RS485, and MODBUS. Dynamic graphical displays on operator stations and video walls show real-time line status, supporting tiered alarm notifications, historical data queries, trend analysis, and video verification through integration with cameras and DVRs. The platform layer is powered by a SaaS IoT cloud, offering user, mobile, and backend interfaces. It enables remote device operation, rapid fault response, and centralized monitoring of electricity usage, production capacity, and operating conditions across all machines, creating an operational view that visualizes energy consumption and traces working conditions. In multi-workshop scenarios, individual workshop monitoring systems connect to the central control center via dedicated VPN networks for unified operations, allowing local control stations and the cloud to run simultaneously with synchronized data exchange. The platform can also integrate GPS vehicle tracking and real-time video surveillance, enabling integrated scheduling for equipment, logistics, and security. The solution delivery includes end-to-end personalized consulting and rapid, cost-effective platform deployment. It covers electromechanical installation, electrical control programming, debugging, and maintenance services. This turnkey scope spans construction design, scheme optimization, cabinet supply, installation, software development, and debugging. It can be implemented concurrently with permanent magnet motor upgrades, switched reluctance motor speed regulation systems, and VFD drive retrofits.

Use Cases:Control of rubber mixing and compound conveying lines, group control of molding and vulcanizing machines, full-line automation upgrades for tire plants, equipment networking and data acquisition in injection molding workshops, real-time monitoring of workshop energy consumption and equipment status, centralized multi-workshop operations and maintenance, and upgrades to existing production line control systems.