E-Bike & Bicycle Polyurethane Tire Production Line Intelligent Upgrade
Project Overview
Jiangxi Songji Sports Technology Co., Ltd. is a specialized manufacturer of polyurethane centrifugal-molded bicycle tires, offering standard bicycle tires, wheelchair tires and lightweight solid e-bike tires. The company operated 4 traditional semi-automatic centrifugal casting lines with a designed annual capacity of approximately 7.5 million tires. As the high-end e-bike market expanded, requirements for tire wall uniformity, dimensional consistency, durability and high-volume delivery increased. The existing equipment suffered from insufficient metering precision, poor casting-centrifuge synchronization, heavy reliance on manual operation and limited production data traceability. Haifeng Automation therefore implemented a comprehensive intelligent upgrade across all 4 casting stations and supporting production lines.
Solutions Delivered
Haifeng Automation upgraded the customer’s 4 traditional semi-automatic casting stations with an intelligent centrifugal casting solution designed for high-precision polyurethane bicycle and e-bike tire production. The solution integrates full-servo closed-loop metering, dynamic casting-centrifuge synchronization, automated production processes, industrial IoT data management and predictive maintenance. More than 30 standardized process formulas for mainstream tire sizes are stored in the control system for one-click selection and rapid changeover. The system also collects 12 core process indicators for real-time monitoring, automatic alerts and full-process quality traceability, while optimized metering pumps and injection nozzles reduce energy consumption and maintenance requirements.
| Equipment | Model | Qty | Function |
|---|---|---|---|
| Intelligent Centrifugal Casting Machine | Haifeng Customized Intelligent Model | 4 sets | Provides precise polyurethane feeding and casting with full-servo closed-loop control for stable and repeatable tire molding. |
| High-Precision Metering Pump | Customized High-Precision Type | 4 sets | Controls polyurethane feeding volume with an accuracy of ±2 g and supports stable material delivery. |
| Servo Injection Nozzle System | Full-Servo Control | 4 sets | Provides precise nozzle positioning and feeding-speed control with adjustment precision of ±0.5 mm/s. |
| Casting-Centrifuge Dynamic Linkage System | Haifeng Self-Developed Linkage Control | 4 systems | Synchronizes material feeding with centrifugal rotor speed to improve tire wall thickness uniformity and forming consistency. |
| Intelligent Size-Switching System | Multi-Specification Parameter Library | 4 systems | Stores more than 30 standardized process formulas and enables one-click parameter recall and automatic calibration for different tire specifications. |
| Industrial IoT Data Management System | Intelligent Management Platform | 1 system | Collects 12 core process indicators at 50 ms intervals for real-time monitoring, traceability and abnormal-condition alerts. |
| Predictive Maintenance System | Intelligent Predictive Operation & Maintenance | 1 system | Analyzes equipment and process data to identify potential faults in advance and reduce unexpected downtime. |
| Residual Polyurethane Recovery System | Supporting Environmental Equipment | 1 set | Recovers residual polyurethane and supports compliant waste management. |
Project Results
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