Bitte decken Sie die schraffierte Fläche mit einem Bild ab. Please cover the shaded area with a picture. (24,4 x 7,6 cm) Continental SportContact 6 Workshop: Performance via Mold Technologies Pattern Layout Precision www.continental-tyres.com
Technology Overview Compound Pattern Construction Benefit Maximum Grip Maximum Control Maximum Stability Technology Black Chili Force Vectoring Aralon 350 Feature Micro Flexible Compound Atomic Force Compatibiliser Centre Responsive Rib Design Advanced Macro Block Design Adaptive High Speed Cap Ply SportContact 6 25.08.2015 Public Continental 2
Tyre Target Setting for Excellent Vehicle Dynamics Key Elements of Handling and Subjective Evaluation Criteria Vehicle Dynamics Requirements Tyre Design Percision Grip at the limit Highest Steering Precision Outstanding Stability & Grip at the Limit Pattern & Compound stiffness Contact area (Macro) Tread Compound Grip (Micro contact area & Interlocking)
Lateral Force Fy [N] Tyre Target Setting for Excellent Vehicle Dynamics Role of the Tyre in Vehicle Dynamics Lateral Force versus Slip Angle 8000 6000 Lateral Force 4000 2000. -12-10 -8-6 -4-2. 2 4 6 8 10 12-2000 Lateral Grip Steering Precision Vehicle Direction Slip Angle -4000-6000 -8000 Slip Angle α [ ] Cα = Fy α α = 0
Lateral Force Fy [N] Steering Precision Centre Responsive Rib Design Benefit Maximum control even with small steering movements 8000 6000 4000 2000 Steering Precision. -12-10 -8-6 -4-2. 2 4 6 8 10 12-2000 -4000-6000 -8000 Slip Angle α [ ] SportContact 6 Reference Tyre 5
Lateral Force Fy [N] Lateral Grip Advanced Macro Block Design at the limit 1. Large shoulder blocks 1 1 Benefit Maximum control through cornering stability at the limit 8000 6000 4000 2000 Max. Lateral Grip 2. Interlocking and coupling elements 2. -12-10 -8-6 -4-2. 2 4 6 8 10 12-2000 3. Macro structured system 3-4000 -6000-8000 Slip Angle α [ ] SportContact 6 Reference Tyre 6
Importance of Defined Pattern Layout Contact Area Defines Performance Scale 100 mm 10 mm 1 mm 0.1 mm Contact Area Pattern Positive Block Deformation Road Macro Roughness Road Micro Roughness 100% Tyre contact area 70% 60% Real contact area 5% < 1% The contact area within a tyre footprint of a postcard size is getting smaller by looking at different scales Pattern quality determines the tyre performances 7
Mold Design for Defined Pattern Layout 8
Segment Molds 1 2 3 5 4 6 7 9 8 Sipes Up to 60 different sipes in one mold Manually setting in mold manufacturing process Deciding about pattern stiffness and tyre performance Vents No flash trimming Less downtime for cleaning No drilling of vent holes after cleaning Improved tyre finish 1. Top container plate 2. Lube free sliding surface 3. Top sidewall 4. Cone ring with heat chamber 5. Segments 6. Lube free segment guide pieces 7. Bottom sidewall 8. Lube free sliding surface 9. Bottom container plate 9
Mold Manufacturing Milling and Casting Manufacturing Types Milling Casting 10
Milling Process CNC Programming Milling Vent Holes and Sipes Slots Sipes and Vent setting Quality Inspection Tyre IT-data assemble the tyre pitches to a complete mold with all segments The information is sent to CNC milling machines Direct milling of each particular segment piece Drilling of the holes for the vents Milling of the slots for sipes Manually setting of vents Manually welding of sipes Final inspection of segment geometry Assembly of the mold segments 25 August 2015 11
Casting Process CNC Programming Milling of Master Sipes Setting Cast Flexible Plaster Core Tyre IT-data are assembled to a complete mold with all particular segments The information is sent to CNC milling machines The milling of the master model includes the pattern and slots for technical sipes Quality check of geometrical spacing Manually setting of technical sipes Quality check of correct sipe setting Re-usage as often as needed: master model Flexible made out of rubber Setting of production sipes in flexible Flexible to be renewed after several usage Gips casting of plaster core segments Production sipes stays in plaster core 25 August 2015 12
Casting Process Plaster Core is put in the center of a casting shell Pouring liquid aluminium to get negative of plaster core Plaster core is destroyed Cleaning of raw casted ring Cutting of casted ring in segments Cleaning of casted segments Quality check of geometrical spacing Optimization of segment lengths Drilling holes for vents Manually vent setting Assembly of segments to complete mold Final inspection Casting Cutting in Segments Optimization of Segments Final Segments Inspection 25 August 2015 13
Casting Process CNC Programming Milling of Master Sipes Setting Cast Flexible Plaster Core Casting Cutting in Segments Optimization of Segments Final Segments Inspection 25 August 2015 14
Milling and Casting in Comparison Feature Milling Casting Sipe Design - ++ Surface Finishing ++ O Winter Tyres O ++ Summer Tyres ++ ++ Volume Sizes O ++ 15
S - Split Benefit Sipes and blocks are not cutting off at segment line Performance of each tyre pitch stays as tested during the tyre development 16
Continental Tyre Division: Investment into Premium Mold Technology Know-how & Capacity AZ is a full service premium mold (mainly PLT) and machinery company 300 employees in Germany and Czech Republic, founded in 1964 Focus on mold production for (U)UHP and Nordic Winter tyres Highest requirements regarding complexity, performance and appearance Technological synergies via in-house integration Investment supports increased internal coverage of highly complex premium molds and flexibility 25 August 2015 17
Continental Tyre Division: Contribution of AZ Mold Production and Machinery GmbH Complex High Tech Molds for Nordic Winter Tyres: High Mold Precision supports Premium Tyre Performance Decisive for UHP and Nordic Winter Tyres 25 August 2015 18
SportContact 6 25 August 2015 19