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Tyres - Automatic Tyres Assembly Systems

ICAPlants has been working since a long time in industrial automation, developing specific solutions for many industrial purposes to satisfy Customers worldwide. Our tyres assembly systems can ensure a high yield and safe operation rate together with a reduction in production down time. Our mission is not only the quality and the reliability of our systems but also their proper and on time installation. 
Our systems are able to assemble and inflate wheels from 4 inches for small vehicles up to 38 inches for heavy agricultural vehicles.
All our systems are capable to process different sizes with automatic and fast change over time. An important feature is the modularity: standard and special parts are assembled togheter to best fit to your business.
ICAPlants and its subsidiaries, also operates in the pharmaceutical, glass and general industry with a highly internationalized market  and offices in China and USA.
In tyres industry, our solutions can be summarized in the following groups of activities:




Robotized Wheels Loading

ROBOTIZED WHEELS LOADING

Thanks to the tyres automatic loading machine it is possible to load automatically tyres on the cage and to pick up the empty cage with the lift truck.
The system is made of a loading cage idler, a robotized loading station and unloading cage idler.
The loading cage idler allows the loading of a serial of cages from the robotized tyres loading station and manages, through blocks, the handling in cycles. At the end of these cycles a new loaded cage is ready for the idler.
The robotized tyres loading station has a rotation system which guarantees the loading from both sides of the cages. This rotation is functional for the automotive systems.
The unloading cage idler is equipped with a block for the cages in line out so that a cage does not run on till the idler station is empty.
The system allows also a loading idler for tyres one on top of the other.
The tyres are loaded with a lift truck on the idler which handles them on the loading station. Here the robot arranges the tyres on the assembly line.


Inflating

INFLATING STATION

The inflating station enables an automatic inflating of the tyre after the assembly. The inflating is done though a bell that pushes the bead off the wheel rim border. The whole area is under pressure thanks to an air-blast.
Once the requested pressure is reached, the tyre heel is accompanied back to the wheel rim border. During this movement the tyre is inflated.
All operations are performed automatically and are subject to line controls.
The request pressure can be automatically set by the Touch-panel.
At the end of the Inflating station is located a conveyor, operated by chain transmission with gearmotor. The conveyor has at its extremity a mechanical lock in order to stop the wheels.
A system of photoelectric cells checks the filling of the conveyor in order to stop the machine when a wheel is not withdrawn.


Lubrication

LUBRICATION STATION

Lubrication of wheel rim and tyre is fundamental in order to facilitate tyre assemblage on the wheel rim.
We offer, thanks to our lubrication station, an efficient answer to a demand of completely automated system that lubricates above standards.


Fitting Machine

FITTING MACHINE

Utmost attention to the assemblage of the tyre with the wheel rim must be paid. The wheel life and consequently the whole cycle of its use depends on the right usage of the above mentioned machine.
The assemblage is effected by the Fitting machine composed of a vertical tubular structure, welded vertically in order to boost mechanical resistance against torsion or other deformations, and of a basement made of thick metal sheets, all resting on a linking basement. The whole system for the rotating head and assembly is on the vertical structure, whilst all the systems for the gripping of the wheel rim are inside the basement.
The machine allows to assemble automatically the tyre and the wheel rim through a special head of assembly, which rotates continuously 360° clockwise.
The lower part of the machine guarantees, through two selfcentering slides, the centering and gripping of the wheel rim on the platform avoiding possible rotations.
The upper part allows the assembly of the tyre on the wheel rim. It is made of a head sliding long the vertical axis that positions itself at the set level and performs the assembly by keeping the tyre locked, via an endless screw system.
The rotation speed may vary according to the bead hardness.


Automatic Wheels Unloading

AUTOMATIC WHEELS UNLOADING

At the end of the line, after the tyre assembly and inflation, an automatic system picks up the tyre.
At the end of the process the tyres are stored in containers for 4-5 positions. Therefore the unloading system is equipped with a specific cager machine for these containers. It is made of three stations connected through chains fixed on the floor with two 90 degrees followers.
Whilst the first station is furnished with empty containers (4 pieces), the second is equipped with the cager machine that turns the tyre and pushes it in the container. The loaded containers are arranged in the third station (4 pieces). An operator with a lift truck handles the containers from or on the cager machine.


Robotized Wheels Unloading

ROBOTIZED WHEELS UNLOADING



The robotized tyre unloading system speeds up the handling of the tyres inside the cage conveyor.
The system is made of a loading cage idler, a robotized tyre loading station and unloading idler of full cages.
The system is made of a loading cage idler, a robotized loading station and unloading cage idler.
The loading cage idler allows manual loading of a serial of empty cages manages, through blocks, the handling in cycles. At the end of these cycles a new loaded cage is ready for the idler.
The robotized tyres loading station has a rotation system which guarantees the loading from both sides of the cages.
The program, after the robot has finished working on one part of the cage, automatically rotates and demands the robot to load the empty side of the cage.
The unloading cage idler is equipped with a block for the cages in line out so that a cage does not run on till the idler station is empty from loaded cages not handled as yet with the lift truck.


Automatic Conveyors Systems

AUTOMATIC CONVEYORS SYSTEMS

We can furnish the production systems with auxiliary equipment for the handling and storage of wheel rims, tyres or  the assembled rim and tyre.
Through the combination of idlers, belt conveyors, robots, rotating platforms and other machines, it is possible to handle without human operation.


Rims Handling

RIMS HANDLING

Wheels are transported on a belt conveyor.
The transport is carried out on Multiflex Chains, with lateral guides made of polyzen, in order to avoid any contact between the wheel rim and any metal which could damage it. Moreover it guarantees perfect quality of tyre manipulation in accordance to the more and more restrictive specifications of assemblage.


Tyres Handling

TYRE CONVEYOR

The tyre is transported through a motorized belt conveyor with fixed speed. It has a steel structure and the height of its ends is adjustable. The vulcanised belt conveyor has a manual system for sheet tension.
The line for the transport of tyres is composed of two segments: the first in slope and inclined in relation to the central axis of the system; the second in line with the axis of the machine and reaches the lubrication station.
The two segments are completed with side boards that can be regularized in width through manual crank. In the case of TAS 800 a chain system is used instead of a belt conveyor. 


TAS 500

TYRES ASSEMBLY SYSTEM 500


TAS 500 Assembly System has been developed for the automotive market with high performances in terms of productivity, yield and quality in a wide range of product sizes.
TAS 500 assembly system is able to assemble and inflate tyres from 14 to 20 inches with a cycle time shorter than 12 seconds.

STANDARD
Automatic lubrication of tyres and rims
Manual tyres loading
Manual rims loading
Automatic tyres fitting
Automatic tyres inflating
Manual tyres unloading

OPTIONAL
Balancing
Automatic loading from cages
Robotized unloading on  cages
Tyres pressure control
Automatic control of rims and tyres dimension
Valve automatic insertion
Sorting conveyors systems


TAS 800

TYRES ASSEMBLY SYSTEM 800

TAS 800 assembly system has been designed for the strict parameters and range of models of the industrial vehicles. It enables automatic assembly and inflating of wheels which weight and sizes cause severe ergonomic issues in the manual operations.
TAS 800 assembly system is able to assemble  and inflate tyres from 19  to 22,5  inches in less than 40 seconds.

STANDARD
Automatic lubrication of tyres and rims
Automatic tyres loading
Assisted rims loading
Automatic tyres fitting
Automatic tyres inflating
Robotized unloading on cages

OPTIONAL
Automatic loading from cages
Tyres pressure control
Automatic control of rims and tyres dimension
Conveyors systems


TAS 20-38 HA

TYRES ASSEMBLY SYSTEM 20-38 HA

TAS 20-38 HA assembly system has been designed for all the model range of the heavy industrial vehicles. It ensures automatic assembly and inflating of wheels with a weight not suitable for manual processing. The automation of inflating considering the size of wheels is an innovative proposal for speed and operational safety.
TAS 20-38 HA  is able to fully assemble and inflate tyres from 20 to 38 inches in less than 120 seconds.


STANDARD
Automatic tyres and rims lubrication
Assisted tyres loading
Assisted rims loading
Semi-Automatic tyres fitting
Automatic tyres inflating
Manual unloading

OPTIONAL
Tyres pressure control
Automatic tyres fitting
Automatic tyres loading
Automatic rims loading
Automatic unloading


TAS 300

TYRES ASSEMBLY SYSTEM 300

The system has been developed in order to assembly tyres of small size for light agricultural vehicles or similar.
TAS 300 line is able to assemble and inflate tyres from 4 up to 18  inches with a cycle time shorter than 15 seconds.
The system guarantees also the assembling and inflating of slightly warped tyres.

STANDARD
Manual tyres and rims lubrication
Manual tyres loading
Manual rims loading
Automatic tyres fitting
Automatic tyres inflating
Manual tyres unloading

OPTIONAL
Automatic tyres and rims  lubrication
Robotized unloading on pallets
Tyres pressure control
Stamping system