Ralson is India's largest bicycle tyre manufacturer located in Ludhiana. It produces over 1.5 million tyres and tubes per day using machinery like the splicer machine. The splicer machine joins the ends of inner tubes together using pneumatic cylinders and heat. It has cutting blades, dies to hold the tube, and heaters to fuse the ends together. The splicer is an automated machine that precisely cuts and joins inner tubes using a series of pneumatic cylinders controlled by solenoid valves and limit switches.

1. FINAL YEAR INDUSTRIAL
TRAINING
ON SPLICER MACHINE
Under the Guidance of: Submitted By:
Name: Chetan Verma Name: Kamalpreet Singh
Designation: Asst. General Manager College Roll no:1312968
Department: Mechanical Maintenance Tool Room University RollNo.:1312968

2. COMPANY INTRODUCTION
• Ralson today stands tall as India's largest company in the
field of bicycle tyre industry.
• Location: Ralson Nagar, GT Road, Ludhiana.
• Led from the front in 1974 by Mr. Pahwa Chairman-Cum-
Managing Director, under the name “Ralson Cycle Pvt. Ltd.”
• 1982: name changed to Ralson Cycle Pvt. Ltd.
• 1985: Ralson India Ltd.
• In 2003 a new plant was set up at Doraha for manufacturing
automobile tyres.

3. • Company's turnover has shot up to 500 crores in 2009.
• Presently company is producing:
1.1.25 Lac tyres & 1.50 Lac tubes per day for bicycles
2.1 lac tyre, tubes per month for automobile tyres.
• It currently has workforce of about 5000 workmen.
• Distribution network: 31 branches ,13 consignee
agents and 8000 dealers spread all over India.

4. • Ralson is the first Bicycle Tyre manufacturer in India to be
accredited with an ISO 9001:2008 Certification,.
• It provides the widest possible range of tyres & tubes ensuring
that customer aspirations are always and fully met.
• It has full fledged R&D Lab. Equipped with most
sophisticated testing equipments, duly approved by Central
Govt. of India.
• Ralson’s proactive R & D department fuels momentum for
growth by continuously developing newer sizes and designs.

5. • Ralson worldwide Export activity is also developing
very quickly.
• Ralco exports are already enjoyed in Europe, South &
Central America, South East Asia, Gulf, Middle East
& African Continent.
• Ralco auto tyres have been developed keeping in
view durability, grip & ruggedness in mind, allowing
Riders to race or ride confidently both on & off-road.

6. AWARDS AND CERTIFICATIONS
Special Export awards by
CAPEPC.
Ralson has won National Safety
Awards. MANUFACTURE OF
RUBBER & PLASTIC PRODUCTS
Best Supplier and Quality
Champion awards from OEM

7. ADDITIONAL QUALITIES OF
RALSON GROUP
• R&D Department of this company is the only one of its
kind in Tyre industry.
• It is recoganized by Department of Science and
technology, govt of India.
• The R&D lab is one of the most sophisticated and best
equipped R&D set-up in cycle tyre industry in India for
testing equipments for Raw Materials, semi-finished &
finished product testing & evaluation.

8. ORGANIZATION CHART OF THE
COMPANY
Chairman
Senior V.P.
Materials
V.P.
Marketing
V.P.
Accounting
V.P. Works V.P. Tax
G.M.
{HRD}

9. INNER TUBE SPLICER MACHINE

10. INTRODUCTION OF SPLICER
• Splicer is a machine used to join the two ends of the tube
together.
• In splicer machine the sizes of tube jointed are 26×1/2,
26×1.75, 26×2.35, 28×1.75, 24×1.75 etc.
• In RALSON (INDIA) Ltd. Industry splicer are used in
moulded tube section and butyl section.
• The movement and pressure in the machine is provided by
pneumatic system.

11. MECHANISM OF SPLICER
• Splicer is a pneumatically controlled automated machine which is
used tubes with butt joint.
• It consists of four pneumatic cylinders work in series.
• The 1st cylinder extends and holds the tube tightly.
• . After that, 2nd cylinder extends which brings down the cutter
blades.
• 3rd cylinder cuts the small portion from both the ends of tube
which were hanging out of holded position.
• Then 3rd & 2nd cylinder retends & blade goes to original position.
• The 4th cylinder extends to join or meet both cut ends of tubes. It
holds them for few seconds & heat is provided which forms butt
joint at the ends a then & cylinder retends in sequence.

12. COMPONENTS OF SPLICER
• Cutter Cylinder (3rd cylinder)
• Sliding Cylinder (4th cylinder)
• Single Solenoid 5/2 Valve
• Up Down Cylinder (2nd cylinder)
• Clamping Cylinder (1st cylinder)
• Top and Bottom Die
• Fixed Slide

13. • Flow Control Valve
• Limit Switches
• Movable Slide
• Movable Cutter
• FRL Unit
• Holding Jaw
• Heaters
• Pneumatic Supply Pipes

14. • a) Cutter Cylinder – This cylinder plays a vital role as it provides
forwards movement to cutter. The maximum pressure produce by
cylinder is 10 bar. When high pressure filtered air comes from
compressor to the cylinder, it moves in horizontal direction and
provide the forward movement to cutter.
• b) Single Solenoid 5/2 Valve – A solenoid valve is an
electromechanically operated valve. The valve is controlled by an
electric current through a solenoid. Solenoid valves are the most
frequently used control elements in fluidics. Their tasks are to
shut off, release, dose, distribute or mix fluids. They are found in
many application areas. Solenoids offer fast and safe switching,
high reliability, long service life, good medium compatibility of
the materials used, low control power and compact design. These
solenoid valves supply the high pressurized air from compressor
to cylinders via flow control vales

15. • c) Movable Cutter – When cutter gets a forward movement from
cylinder then initially, it cuts the extra part on both sides of the
tube. The blades on cutter do this role tremendously. When later
work is done, cutter moves to backward as cylinder returns back
to bottom position.
• d) Up Down Cylinder – Up Down Cylinder provide up down
movement to cutter. It is placed in a vertical position at the
bottom of the splicer.
• e) Clamping Cylinder – The function of this cylinder is to put
down the arms of a splicer for pressing the ends of a tube in top
and bottom die.

16. • f) Sliding Cylinder – This cylinder is placed on the right side of
the splicer machine. The function of this cylinder is to provide
forward movement to movable slide. It is placed in a horizontal
position. The maximum pressure produce by cylinder is 10 bar
similar to previous one but the only difference is the volume of
air. The diameter of clamping cylinder is more as compared to
cutter cylinder so that’s why volume of air is more in clamping
cylinder.
• g) Fixed Slide - This slide is on the left side of the splicer and on
which the top and bottom dies are fixed. When buttons are
pressed, tube is pressed between the front and bottom dies.
• h) Movable Slide – This slide is on the right side of the splicer
and the movement of this slide is controlled by the cylinder and
on the same side, movement of cylinder is limited by limit switch
which specifies the forward and backward movement.

17. • i) Limit Switch - In this machine, limit switches are used to
control the forward and backward movement of cylinders.
• j) FRL unit – This unit has a very important role to provide
filtered air to cylinders. The purpose of the air filter is to clean
the compressed air of all impurities and any condensate it
contains.
• Function of air filters
• To remove all foreign matter and allow dry and clean air flow
without restriction to regulator and then to the lubricator
• To condensate and remove water from the air
• To arrest fine particles and all solid contaminants from air

18. • The function of the air pressure regulator is to maintain working
pressure virtually constant regardless of fluctuations of the line
pressure and air consumption. When the pressure is too low, it
results in poor efficiencies and when the pressure is too high,
energy is wasted and equipment’s performance decay faster.
• In pneumatic system, pressure fluctuations occur due to variation
in supply pressure or load pressure. It is therefore essential to
regulate the pressure to match the requirement of load regardless
of variation in supply pressure or load pressure.

19. • The function of air lubricator is to add a controlled amount of
oil with air to ensure proper lubrication of internal moving
parts of pneumatic components. Lubricants are used to
• To reduce the wear of the moving parts
• Reduce the frictional losses
• Protect the equipment form corrosion
• The lubricator adds the lubricating oil in the form of fine mist
to reduce the friction and wearof moving parts of pneumatic
components such as valves, packing used in air actuators.

20. • k) Pneumatic Supply Pipes – These supply pipes provide the
filtered air to cylinders via solenoid valves from compressor.
Leakage is not allowed as it leads to pneumatic losses.
• l) Heaters – Heaters are those which provide heat to blade to
cut the tube efficiently. Such heaters are electrically winded.
• m) Top and Bottom Die – These dies have a crucial role in the
whole process as they hold the ends of tubes. To ensure proper
butting and cutting, it is inevitable to hold the two ends of
tube properly.

21. • n) Holding Jaw – It has a very keen role as it holds the blade or
knives with the clamp. Without this, blades cannot hold properly
to ensure accurate, smooth cutting of tube.
• o) Flow Control Valves - Function of a flow control valve is self –
evident from its name. A flow control valve regulates the rate of
air flow. The control action is limited to the air flow passing
through the valve when it is open, maintaining a set volume per
unit of time. These flow control valves control the amount of flow
of pressurized air.
• p) Flexure bearing : A flexure bearing is a category of flexure
which is engineered to be compliant in one or more angular
degrees of freedom. Flexure bearings serve much of the same
function as conventional bearings or hinges in applications which
require angular compliance; but, flexures require no lubrication
and exhibit very low or no friction.

22. • Flexure bearings have the advantage over most other
bearings that they are simple and thus inexpensive. They are
also often compact, lightweight, have very low friction, and are
easier to repair without specialized equipment.

23. DOUBLE ACTING CYLINDER
• Double Acting Cylinders are equipped with two working ports-
one on the piston side and the other on the rod side. To
achieve forward motion of the cylinder, compressed air is
admitted on the piston side and the rod side is connected to
exhaust. During return motion supply air admitted at the rod
side while the piston side volume is connected to the exhaust.
Force is exerted by the piston both during forward and return
motion of cylinder. Double acting cylinders are available in
diameters from few mm to around 300 mm and stroke lengths
of few mm up to 2 meters.

24. DOUBLE ACTING CYLINDER

25. END CUSHIONING IN PNEUMATIC
CYLINDERS
• The inherent capability of all air cylinders to perform rapid
reciprocating motion also supplies a disadvantage in that
considerable kinetic energy is dissipated in the form of shock
at the completion of the stoke. This can set up severe stresses
in cylinders itself or end covers, or on frame work of the
machines to which it is attached. This can be overcome by
providing cushioning to produce gradual deceleration of the
piston as it approaches the end of its stroke.

26. OPERATION OF CYLINDER
CUSHIONS

27. NEED FOR CUSHIONING
• When the pressurized air is supplied at the inlet port of the
cylinder, piston accelerates and travels inside the cylinder.
Piston has to be slowed down at the end of the stroke to
prevent excessive impact on the end caps. These shock loads
arise not only from the fluid pressure, but also from the
kinetic energy of the moving parts of the cylinder and load.
These end travel shock loads can be reduced by decelerating
the piston at the end of stroke by cushioning.
• For the prevention of shock due to stopping loads at the end
of the piston stroke, cushion devices are used.

28. 5/2 WAY SINGLE SOLENOID
VALVE, SPRING RETURN
• The cross section view of 5/2 way single solenoid in the normal
and actuated positions are shown in figure

29. • In normal position, port 1 is connected to port 2, port 4 is
connected to port 5, and port 3 is blocked. When the rated
voltage is applied to coil, the valve is actuated through an
internal pilot valve. In actuated position, port 1 is connected
to port 4 , port 2 is connected to port 3, and port 5 is blocked.
The valve returns to the normal position when the voltage to
the armature coil is removed. This type of valves is normally
used as final valve to control double acting cylinders.

30. SYMBOL OF 5/2 SINGLE SOLENOID
SPRING RETURN VALVE

31. SPECIFICATION OF SPLICER
Butting Time 4 seconds
Splicing pressure 80 psi
Cutting blades temperature 180 Degree Celsius
Air Pressure 80±10 p.s.i
Time to cut the end of tube 5-6 seconds
Cleaning of Blade Every 2 hour
Blade Material High Speed
Die Material EN -24

32. 2D & 3D DESIGN OF TOP, BOTTOM DIE
AND HOLDING JAW OF SPLICER

33. TOP DIE OF SPLICER

34. BOTTOM DIE OF SPLICER

35. HOLDING JAW OF SPLICER

36. WORKING OF SPLICER
• The two ends of the green tube is fitted in the splicer machine
dies and start button is pressed.
• The pair of the cylinder push the arms of the splicer vertically
downwards and the green tube is pressed.
• Then the cutting blades of splicer comes forward and cut the
extra material of green tube.
• The temperature of the cutting blades of the splicer are 180
degree Celsius.
• And then the fixed slide and movable slide(pushed by sliding
cylinder) and joint the green tube, they hold the tube constant
for 4 seconds.

37. • After 4 seconds, arms move upward, release the tube ends,
cutter and movable moves to its original positions.
• The green tube is sent for further operations on a different
machines.
• After that on a green tube, a nozzle is fitted in it .A chemlok
solution is used and pasted around the end of nozzle to remain
stick to the tube permanently. Now, green tube is sent for
curing process in a tube curing press .

38. SCOPE OF SPLICER
• Scope of splicer is not so very large but is small.
• Splicer is used only in tube plant to joint the tube perfectly.
• In RALSON INDUSTRY splicer is used in moulded tube
section, butyl section to joint green tube.
• In RAISON INDUSTRY the splicer made by PRIYA
INDUSTRY and some splicer are specially ordered from
TIWAN INDUSTRY.
• Splicer machine reduces the human effort and takes 4 seconds
for joining the tube. Splicer removes extra material of tube.

39. LIMITATION OF SPLICER
• . The steam pressure of splicer should be maintained. If the
pressure of stem is increased there should be variation in the
tube jointing and if the pressure of steam should be decreased,
then there is also a variation in the tube jointing. The
pressure of steam should be properly maintained.
• The air pressure of splicer should be maintained. There
should be variation in tube jointing if there is increasing or
decreasing of air pressure is continued. The air pressure in
splicer is varies from 80 psi.
• Butting time of splicer should be maintained. If the butting
time is not maintained, then the tube should not jointed
properly. The butting time of splicer is 4 seconds.

40. • The distance between cutting blades should also be maintained.
If the distance between the cutting blades of splicer is not
maintained properly then the length of tube may be increased or
decreased and whole order will be canceled while inspection.
• The temperature of the cutting blades of the splicer should be
balanced. If the temperature of the cutting blades of the splicer is
not maintained. then the green tube will not joint and extra
material of tube should not be properly removed. The
temperature of cutting blades of splicer are 180 to 220 degree
celsius.

41. LENGTH OF GREEN TUBE JOINTED
IN SPLICER
• 28×1/2 = 2250 mm
• 26×1.75 = 1870 mm
• 24×1.75 =1660 mm
• 20×1.9 = 1360 mm
• 16×1.75 = 950 mm

42. CONCLUSION
• After the completion of study of splicer machine, we have to do
some changes in splicer machine in RALSON (INDIA)
LIMITED.
• The changes made are timer of splicer machine should remain
constant. Timer of the machine is not to be change without the
permission of the supervisor or incharge of the particular
section.
• the second changes are thickness of holding jaw should be less
for better clamping of blades.
• Moreover, the design of Top and Bottom dies should be
changed or adjust as per the thickness and width of the tube.

43. • . In butyl section, there are 8 splicer machine but four of them
are in working. But rest of four are are offline due to shortage
of workers.
• In moulded tube section four splicer are offline. Two of them
are offline due to some technical problem in it and other pair
of splicer are offline in which some paste type material is
lying on it.