Optimised Rubber Expansion Joints

Scorpo rubber expansion joints are designed according to TANIQ's optimisation principle and manufactured using the Scorpo Robotics automation system. As a result of this technology, rubber and reinforcement layers are integrally applied in a continuous process on the product body and flanges. The result is a rubber expansion joint with a more efficient layer construction, faster production, high consistency and lower costs.

 

 

Scorpo expansion joints meet full requirements with up to 80% faster production at lower costs

The design of the Scorpo expansion joint is similar to generally known designs, with a inner rubber liner, rubberised reinforcement layers and outer rubber layer. A distinct difference is however, that the reinforcement layers are constructed of individual cords which are integrally wound on the product body and flanges in a continuous fashion. Due to individual cord design and placement,  the product consists of the exact required amount of cords in each layer. This results in a highly efficient and consistent reinforcement construction, without any seams from overlapping plies or folding at the flanges. 

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Extended testing (burst, pressure cycling and dynamic testing up to 1 million cycles) has proven that the Scorpo expansion joints meet all the specifications and industry's requirements, using up to 75% less reinforcement material. The technology has been successfully applied for both full rubber flanges and for rotating flanges of various sizes and designs. TANIQ's technology does require a change of product designs and processes compared to conventional products, changing material (rubber, tape, reinforcement nylon-type etcetera) is however not necessary. Thereby, the impact of changing to Scorpo expansion joints and automated production has been limited.

TANIQ specialises in developing customised automation solution with software, FEA and robotic automation for reinforced rubber product manufacturers. An automation solution for expansion joints has been developed and tested for expansion joints with a nominal diameter of 100 mm up until 1200 mm and burst pressures of 48 Bar to 96 Bar. The customisation options of TANIQ's products (Software, FEA, Robotics) make it possible to tailor fit or redesigns each product to the specific needs per customer. As a result, for each expansion joint range, a custom solution can be provided. For example, for small products up until ID 300 mm or large expansion joint of 1500 mm (or possibly larger).

 
 
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Historically, the production of reinforced rubber products has been a manual process, relying heavily on skill and extensive experience. This introduces three areas of production risk. Firstly, manual material application can result in inconsistency and inaccurate placement of reinforcements as the operator varies the amount and orientation of the reinforcement-sheets. Secondly, the cords in the sheets cannot correctly be aligned with the stresses, wherefore additional reinforcement material is required. Thirdly, the tapes are not always applied with the same tension. Most important of all, production speed is limited by human capabilities and requires extensive training and product knowledge. All these risks are eliminated using TANIQ's approach.

 

Full rubber flange & Rotating flange expansion joint automation

The production times for rubber expansion joints made with Scorpo Robotics are up to 80% faster than the conventional manual (or semi-automated) production. The presented production times include all the time required from placing the mandrel up until moulding. Note that the presented production times therefore exclude the placement of moulding parts and curing/vulcanisation.

Scorpo Full rubber flange expansion joints

TANIQ has developed and tested rubber expansion joints with full rubber flanges. The basic design and specifications are presented here:

Aramid reinforcement material [KG]

Reinforcement material [KG] required for TANIQ optimised expansion joint of ID nominal diameter [mm] (Other reinforcement materials also possible)

Production time [Hours]

Production time of expansion joints using TANIQ robotic production cell (excluding mandrel preperation, molding and curing)
 

Scorpo Rotating flange expansion joints

TANIQ has developed and tested rubber expansion joints with rotating flanges. The basic design and specifications are presented here:

Aramid reinforcement material [KG]

Reinforcement material [KG] required for TANIQ optimised expansion joint of ID nominal diameter [mm] (Other reinforcement materials also possible)

Production time [Hours]

Production time of expansion joints using TANIQ robotic production cell (excluding mandrel preperation, molding and curing)