FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13) A CONTROL SYSTEM FOR RUBBER PROCESSING
INNOVA RUBBERS PVT LTD
an Indian Company
of H-107, MIDC, Ambad, Nashik,
Maharashtra, India.
Inventor:
KHARE GIRISH
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE NATURE OF THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

TECHNICAL FIELD
The present disclosure in general relates to rubber processing and in particular relates to control systems for controlling processes associated with rubber processing.
BACKGROUND
Mixing of rubber components and other additives are carried out by number of machines. Generally, these machines are expected to mix all the components to meet a desired product specification. The quality of the mixed rubber components produced from these machines is dependent on mixing process parameters and on controlling of these parameters by the mixing machines. Variation in these parameters, such as time, temperature, energy, etc., during mixing affects the overall quality of the end product significantly. For. example, inhomogeneous mixing of rubber components and additives may cause improper dispersion of the additives in the end product, which may lead to reduced product life, low performance of the end product and a deprived appearance.
For the purpose of eliminating the problems associated with the mixing machine, there is need of improvement in the machine or to replace existing control mechanisms and associated parameters in rubber processing with an optimized control mechanism and/or parameters.
OBJECTS
Some of the objects of the present disclosure aimed to ameliorate one or more problems of the prior art or to at least provide a useful alternative are described herein below:
It is an object of the present disclosure to provide a control system for rubber processing.

It is another object of the present disclosure to provide a centralized control system for mixing rubber components and additives in a controlled manner.
It is yet another object of the present disclosure to provide a control system for rubber processing with precise control parameters.
It is yet another object of the present disclosure to provide a control system for rubber processing having indicators in the form of audio and visual indicators.
It is additional object of the present disclosure to provide a control system for rubber processing which offer a desired product specification.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figure, which are not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure is directed to a rubber processing system to produce a rubber compound having desirable qualities and in an efficient manner.
In accordance with an embodiment, the rubber processing system comprises a kneading assembly configured to receive one or more rubber components and at least one additive to produce kneaded rubber, a mixing assembly in controlled flow communication with the kneading assembly configured to receive the kneaded rubber from the kneading assembly in a batch-wise manner, wherein the kneaded rubber is mixed with at least one of a filler and a vulcanization agent to produce the rubber compound, a monitoring station configured to monitor each stage of processing from a remote location, and a control system configured to control an operation of at least one of the kneading assembly and the mixing assembly and provide control data to the

monitoring station over a network, wherein the control is based on at least one operational parameter and further based on a predefined number of tight passes for the rubber compound, wherein the predefined number of tight passes is derived based at least on a production schedule.
In accordance with an embodiment, the rubber processing system comprises at least one PLC (programmable logic controller) for feeding the production schedule, wherein the production schedule is derived based at least on a characteristic of the rubber compound and inputs received from one or more field input devices.
In accordance with an embodiment, the characteristic of the rubber compound comprises at least one of a compound weight, compound number, and a compound composition.
In accordance with an embodiment, the one or more field input devices comprises a temperature controller, a flow meter, an energy meter, a current meter, a weight indicator and a time controller.
In accordance with an embodiment, the rubber processing system comprises at least one of buzzer, an alarm, and one or more LED (light emitting diodes) to provide audio and visual indications of stages of rubber processing.
In accordance with an embodiment, the rubber processing system comprises at least one display device at the monitoring station to view the stages of rubber processing in an animated format.
In accordance with an embodiment, the rubber processing system is configured to generate a report of the stages of the rubber processing for future reference.
In accordance with an embodiment, the kneading assembly, the mixing assembly, the monitoring station, and the control system are configured to communicate over at least one of a wired network and a wireless network.

In accordance with an embodiment, the control system provides at least one of a control signal and a feedback signal to control the operation of the at least one of the kneading assembly and the mixing assembly.
In accordance with an embodiment, the rubber processing system comprises a SCADA (supervisory control and data acquisition) system configured to receive inputs from the field input devices.
In accordance with an embodiment, the mixing assembly comprises at least one pair of counter rotating rolls and a nip, wherein a gap of the nip is adjusted based at least on one of a current drawn by a motor of the mixing mill and the characteristic of the rubber compound.
In accordance with an embodiment, the system comprises a Global System for Mobile Communications unit through which the monitoring station sends SMS (short message service) to receive SMS from an operator of the rubber processing system.
BRIEF DESCRIPTION OF DRAWINGS
Figure 1 illustrates a block representation of a rubber processing system, in accordance with an aspect of the present disclosure.
Figure 2 illustrates tight passing of rubber compound from the mixing assembly of the rubber processing system of Figure 1.
DETAILED DISCRETION
A preferred embodiment of the present disclosure will now be described in detail with reference to the accompanying drawing. The preferred embodiment does not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and

processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The following description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Referring to Figures 1 and 2, a rubber processing system 100 for efficient processing of rubber is shown. The rubber processing system 100 as envisaged in the present disclosure enables uniform kneading and/or mixing of rubber components and other additives for efficient processing of rubber. With the help of the rubber processing system 100, a desired rubber compound is obtained.
As shown, the rubber processing system 100 comprises a kneading assembly 102, a mixing assembly 104, and a monitoring station 106, and a control system 108, all in communication with each other over a network, wirelessly or through wires. The kneading assembly 102 receives rubber components and a plurality of additives, which are kneaded uniformly before being processed in the mixing assembly 104. The control system 108 controls

the addition of the rubber components and the additives to the kneading assembly 104 based on one or more control signals and/or feedback signals. In an embodiment, the control system 108 may receive inputs from one or more controllers, sensors, indicators, and/or meters, for example, a temperature sensor, a temperature controller, a flow meter, an energy meter, a current meter, a weight indicator, and a time controller. All these parameter controllers/meters/sensors/indicators (collectively referred to as 'field input devices' 110) are in serial communication with each other and with the kneading assembly 102, the mixing assembly 104 and the monitoring station 106 through the control system 108 over a network (not shown). The network could be a wired network or a wireless network, as is known in the art.
In the present rubber processing system 100, a control of parameters may reach up to a high degree of precision. For example, temperature could be precisely measured up to a variance of 1°C, time period up to 1 second, and energy of up to 1 Wh (watthour). In an embodiment, the control system 108 may include a suitable controller for processing input data and controlling parameters based on an output. Since every rubber compound is having its unique characteristic, in an embodiment, a PLC (programmable logic controller) is employed as the controller for loading parameters specific to the rubber compound, for example, a rubber compound number. In an exemplary embodiment, the entry of the rubber compound number into the rubber processing system 100, for instance, can be by way of a user interface provided either at the control system 108 or at the monitoring station 106, and the entry process can be supplemented by an authentication process based on password protection, thereby avoiding any unauthorized use of the rubber processing system 100 by an unauthorized person.
In an embodiment, the monitoring station 106 can be placed remotely, away from the kneading assembly 102 and the mixing assembly 104, and is configured to generate audio/video signals based on inputs from the control

system 108 to indicate stages of rubber processing. For example, an auto running stage of the kneading machine may be indicated by a green LED (light emitting diode), waiting stage by a yellow light, and non-functional/error stage by a red light. These audio/video signals may even indicate finer stages of rubber processing, for example, by providing a continuous light/audio indicator or a flashing/repetitive buzzing indicator.
In an embodiment, the control system 108 is configured to formulate a production schedule from an operator of the rubber processing system 100 based on the inputs received from the field input device 110 and from an operator of the rubber processing system 100. In an exemplary embodiment, the production schedule may automatically define a queue for the materials to be processed, i.e., the rubber components and/additives, in the kneading assembly 102, and in this way, guides the operator to schedule loading of the kneading assembly 102 with said material. The production schedule may be loaded through the PLC and the same may be followed by the kneading assembly 102 in a subsequent batch of same characteristic. In an embodiment, the production schedule may be edited by an authorized user by changing compound number, lot number, and sequence.
Further, the kneaded rubber compound from the kneading assembly 102 is received in the mixing assembly 104, which is in flow communication with the kneading assembly 102, and a vulcanization agent is mixed to the rubber compound. The mixing mill as disclosed herein has open mill architecture. In an embodiment, the rubber compound is weighed batch-wise at a weighing station in route from the kneading assembly 102 to the mixing assembly 104. In an embodiment, a flapper valve is provided between the kneading assembly 102 and the mixing assembly 104 to provide a channel between the two. In an embodiment, one or more weight indicators provided at the weighing stations measures a weight of a batch of the rubber compound from the kneading assembly 102 and the same is transferred to the monitoring station 106 through,

for example, a PLC provided on the weighing station. Further, in another embodiment, a SCADA (supervisory control and data acquisition) system may be provided to receive inputs from the various field input devices 110 and send them to the monitoring station 106. Through the SCADA system, one may collect various operational conditions and also user inputs pertaining to the rubber compound, such as compound number, etc., into the rubber processing system 100, and accordingly control kneading and/or mixing operations in an efficient manner. In an embodiment, one or more PLCs are provided to load such operational parameters and data for the processing in the mixing assembly 104. In an embodiment, a user may specify a predefined number of tight passes that are required to be carried out to prepare the desired rubber compound. In an embodiment, the number of tight passes is derived based on the inputs received, and after carrying out a number of steady state experimentations for different lots of rubber compounds prepared.
Generally, rubber sheets or strips eventually made out of rubber processing steps should satisfy two requirements - acceptable dispersion (intensive or dispersive mixing) and high uniformity (extensive or distributive mixing). To achieve the desired results, tight pass technique has been adopted here, which is further discussed with respect to the description below.
As shown in Figure 2, the mixing assembly 104 consists of at least one rotating pair of rolls 202 and an adjustable nip gap 204. The nip gap can be adjusted automatically according to at least one characteristics of the rubber compound received, for example, the rubber compound number. As against any existing mixing mills, which require a continuous feeding of the rubber compound during operation, the present mixing assembly 104 is configured to be fed periodically. For example, at one stage of a mixing cycle, a bank 206 of rubber compound is forced to pass through the nip 204, which may have a nip gap of up to 2 mm. One such passage of rubber compound through the nip 204 is counted as one tight pass. Each rubber compound needs at least one tight pass

for acceptable dispersion and uniformity. Through tight passing of the rubber compound, the entire of each batch of rubber compound is converted into sheet form.
In an embodiment, the control system recognizes the required number of tight passes for a batch of incoming rubber into the mixing assembly 104. For the purpose, the control system monitors any variation in current drawn by a motor of the mixing assembly 104. Ideally, the motor draws a higher current during processing and tight passing of the rubber compound than what it draws when there is no rubber processing or during processing under non-tight pass conditions. Thus, a threshold value can be established so that the control system 108 can discern a non-tight pass condition from a tight pass condition. Based on the threshold value, the control system 108 establishes whether the motor is in a tight pass mode or otherwise. Accordingly, both the nip gap and the motor current read together indicate the presence or non-presence of a tight pass.
When the tight pass condition prevails beyond a predetermined time and the current drops below the threshold, the control system 108 counts it as one tight pass. In addition, the numbers of tight passes executed are compared with the required number of tight passes specified for that rubber compound number that was fed in the rubber processing system 100. Until the desired number of tight passes is executed, the flapper valve remains closed. When the number of tight passes that were required for the particular rubber compound is achieved, an audio/visual indicator may indicate the completion of the process. Similarly, the audio-visual indicator may also indicate stages of rubber processing in the mixing assembly 104. Finally, a processed rubber compound in the form of sheets 208 is available with the desired product specification.
From the monitoring station 106, the whole process can be monitored. In an embodiment, an animated visual is provided to an operator at a display device of the monitoring station 106. Further, one or more alarms in the form of audio/visuals may be provided to indicate any unwarranted situation, such as

unexpected temperature rise of the kneading assembly 102. Moreover, the rubber processing system 100 may be equipped with a GSM (Global System for Mobile Communications) unit or device (not shown) through which the monitoring station 106 may send and receive SMS (short message service) to or from the operator. The monitoring station 106 may also receive or sends alerts upon modification of processing parameters of the rubber processing system 100, at the processing site.
In accordance with an embodiment, the rubber processing system 100, at the monitoring station 106, is equipped to generate reports of detailed processes and the stages of rubber processing. The reports may prove useful for records and analysis purposes. The report may include summary reports exhibiting batch wise summary and footnote of changes made to the operating parameters during rubber processing. Further, instances of high temperature occurring during the rubber processing may also be made available.
ECONOMIC SIGNIFICANCE AND TECHNICAL ADVANCEMENT
A control system for rubber processing, as described in the present disclosure, has several technical advantages including, but not limited to, the realization of the following:
• The present rubber processing system incorporates open mill architecture.
• The mixing assembly as described herein can be fed periodically.
• The control system as described herein controls processing of the rubber based on various parameters in an efficient manner.
• The control system as described herein takes into account the number of tight passes that is required for each particular rubber compound.
Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not

the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression "at least'1 or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
In view of the wide variety of embodiments to which the principles of the present invention can be applied, it should be understood that the illustrated embodiments are exemplary only. While considerable emphasis has been placed herein on the particular features of this invention, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principle of the invention. These and other modifications in the nature of the invention or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

WE CLAIM;
1. A rubber processing system to produce a rubber compound comprising:
a kneading assembly configured to receive one or more rubber components and at least one additive to produce kneaded rubber;
a mixing assembly in controlled flow communication with the kneading assembly configured to receive the kneaded rubber from the kneading assembly in a batch-wise manner, wherein the kneaded rubber is mixed with at least one of a filler and a vulcanization agent to produce the rubber compound;
a monitoring station configured to monitor each stage of processing from a remote location; and
a control system configured to control an operation of at least one of the kneading assembly and the mixing assembly and provide control data to the monitoring station over a network, wherein the control is based on at least one operational parameter and further based on a predefined number of tight passes for the rubber compound, wherein the predefined number of tight passes is derived based at least on a production schedule.
2. The rubber processing system as claimed in claim 1, wherein the rubber processing system comprises at least one PLC (programmable logic controller) for feeding the production schedule, wherein the production schedule is derived based at least on a characteristic of the rubber compound and inputs received from one or more field input devices.
3. The rubber processing system as claimed in claim 1, wherein the characteristic of the rubber compound comprises at least one of a compound weight, compound number, and a compound composition.

4. The rubber processing system as claimed in claim 2, wherein the one or more field input devices comprises a temperature controller, a flow meter, an energy meter, a current meter, a weight indicator and a time controller.
5. The rubber processing system as claimed in claim 1 further comprising at least one of buzzer, an alarm, and one or more LED (light emitting diodes) to provide audio and visual indications of stages of rubber processing.
6. The rubber processing system as claimed in claim 1 further comprising at least one display device at the monitoring station to view the stages of rubber processing in an animated format.
7. The rubber processing system as claimed in claim 1, wherein the rubber processing system is configured to generate a report of the stages of the rubber processing for future reference.
8. The rubber processing system as claimed in claim 1, wherein the kneading assembly, the mixing assembly, the monitoring station, and the control system are configured to communicate over at least one of a wired network and a wireless network.
9. The rubber processing system as claimed in claim 1, wherein the control system provides at least one of a control signal and a feedback signal to control the operation of the at least one of the kneading assembly and the mixing assembly.
10. The rubber processing system as claimed in claim 1, wherein the rubber
processing system comprises a SCADA (supervisory control and data
acquisition) system configured to receive inputs frorn the field input devices.

11. The rubber processing system as claimed in claim 1, wherein the mixing assembly comprises at least one pair of counter rotating rolls and a nip, wherein a gap of the nip is adjusted based at least on one of a current drawn by a motor of the mixing mill and the characteristic of the rubber compound.
12. The rubber processing system as claimed in claim 1 further comprises a Global System for Mobile Communications unit through which the monitoring station sends SMS (short message service) to and receives SMS from an operator of the rubber processing system.