Brake Pads/Brake Linings Intelligent Friction Materials Weighing and Batching System(OE)

This system is designed for the automatic weighing of raw materials prior to mixing. It functions in a fully automated manner based on the friction material formulations stored within the PLC. Once the operator selects a saved formulation, the system automatically weighs and gathers the various weighed materials and subsequently discharges them into the connected mixers.

The entire process of the electronic weighing range is under computer control. It exhibits a high level of automation, ensuring excellent formula confidentiality, with data storage and tracking capabilities and the option to print out the data. The system components are relatively independent, allowing for a flexible layout and unrestricted gate positions. The control room is isolated from the system, providing a favorable working environment.

It is equipped with a comprehensive monitoring system that presents the entire process of ingredient monitoring. The design is closed and dust-proof.

It has a rapid batching speed, capable of fulfilling the requirements of more than 2 x 1200L mixers or 4 x 600L mixers. The batching accuracy is high, with each material’s accuracy reaching 0.2%, and the system also has a reweighing function. Even materials with poor fluidity such as fibers and steel wool can be automatically weighed.

It has a feeding error prevention function and a material level alarm reminder function. Reports can be viewed and printed, enabling traceability.

• Technical Parameters：
• Batching Bins Quantity:The number of batching bins available ranges from 20 to 50, and customization options are also provided. This allows for flexibility in accommodating different production volumes and material handling requirements, ensuring efficient batching operations.
• Batching Accuracy:The batching accuracy of this equipment is highly precise, with an error rate of ≤0.2% and a margin of ±1KG. Such accuracy is crucial in industries where precise ingredient proportions are essential, guaranteeing the quality and consistency of the final product.
• Batching Speed for 200 kgs:When dealing with a batching weight of 200 kgs, the equipment can complete the process within 4 – 6 minutes. This relatively fast batching speed enhances productivity and enables seamless integration into production lines with high throughput demands.
• Suitable Batching Materials:It is suitable for handling a variety of materials, including powdery, granular, and short fibers materials. This versatility makes it applicable in numerous industries such as food processing, pharmaceuticals, and chemical manufacturing, where different types of raw materials need to be accurately proportioned.
• Batching Weight Range:The batching weight range is within 200 kg, providing a broad scope for different batching requirements. Whether it’s a small-scale production with lighter batches or a larger operation closer to the maximum weight limit, the equipment can handle it effectively.
• Compressed Air Pressure:The compressed air pressure required for the operation of the equipment is maintained between 0.5 and 0.7 Mpa. This specific pressure range ensures proper functioning of the pneumatic components involved in the batching process, facilitating the smooth transfer and mixing of materials.
• Compressed Air Amount:The amount of compressed air consumed during the process is in the range of 0.2 to 0.4 m3 / min. Understanding this parameter is essential for planning the compressed air supply system, ensuring that there is sufficient air available to support the continuous and efficient operation of the batching equipment.

• The whole system is a comprehensive and highly integrated setup that encompasses several crucial components:
• Materials Bins Layer:The Materials Bins Layer serves as the initial storage and supply hub for the various raw materials required in the production process. These bins are designed with specific capacities and configurations to hold different types of materials, such as powders, granules, or fibers, which are essential for creating the final product. They are constructed using durable and inert materials to ensure the integrity and quality of the stored substances. The bins are also equipped with advanced inventory management systems, including level sensors that can accurately monitor the quantity of materials remaining. This allows for timely reordering and prevents production disruptions due to material shortages. Additionally, the bins are designed for easy access and loading, either manually or through automated conveyor systems, depending on the scale of the operation.
• First Weighing Mechanism:The First Weighing Mechanism is a precision instrument that plays a vital role in accurately measuring the initial amounts of the raw materials. It is engineered with high-resolution load cells and advanced digital control systems. This mechanism can precisely measure the weight of each material being dispensed from the Materials Bins Layer. The accuracy of this weighing process is crucial as it determines the consistency and quality of the final product. The First Weighing Mechanism is also integrated with a data logging and reporting system, which records the weights of each material used in each production batch. This data can be used for quality control, traceability, and process optimization purposes. It is designed to handle a wide range of weights and materials, and can be calibrated and adjusted according to the specific requirements of the production process.
• Track and Trolley with 2nd Weighing Mechanism:The Track and Trolley system, along with the 2nd Weighing Mechanism, provides a means of transporting and further processing the weighed materials. The track is a sturdy and precisely engineered structure that allows the trolley to move smoothly and accurately between different workstations. The trolley is equipped with a second weighing mechanism, which serves to double-check the weights of the materials during transportation or after any intermediate processing steps. This secondary weighing ensures that there has been no loss or gain of material during handling and helps to maintain the accuracy of the overall material balance. The trolley can also be programmed to move at specific speeds and stop at precise locations along the track, enabling it to interact with other components of the system, such as mixing machines or separating systems, in a coordinated manner.
• Mixing Machines:The Mixing Machines are at the heart of the production process, where the various raw materials are combined and homogenized. These machines are available in different types and sizes, depending on the volume and nature of the materials to be mixed. They are equipped with powerful motors and specially designed mixing blades or agitators. The mixing process is carefully controlled, with adjustable speed and time settings, to ensure that the materials are thoroughly blended without causing any degradation or alteration of their properties. The mixing machines are also designed with safety features to prevent overloading, overheating, and any potential leakage of materials. They can be operated in batch mode or continuously, depending on the production requirements. After the mixing is complete, the homogeneous mixture is ready for further processing or transfer to the next stage of the system.
• Mixes Separating System:The Mixes Separating System is responsible for dividing the final mixture into specific portions or forms, depending on the end product requirements. It can use various techniques such as sieving, filtering, or mechanical separation methods. For example, if the final product needs to have a specific particle size distribution, the Mixes Separating System can use sieves of different mesh sizes to achieve this. It is also capable of separating any unwanted impurities or by-products from the main mixture. The system is designed to operate with high efficiency and accuracy, and the separated components can be either recycled back into the production process or disposed of properly. This ensures that the final product meets the desired quality and purity standards.