Brake Pads Machines

Brake Pads Intelligent Weighing and Pressing System(Back Dosing-Semi Auto-Serve Old Press Machines)

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This intelligent weighing system is designed to serve press machines already purchased by brake pads factory. To meet the varied needs of different factories, regardless of their press machine models and mold layouts. With this system, manufacturers can upgrade automation smoothly with low cost, improving production capabilities and cost-efficiency.

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    In the context of the escalating demands for automated and dust-free workshops within the manufacturing industry, a multitude of brake pad manufacturing facilities are endeavoring to enhance and modernize their existing press machine workshops. However, the traditional press machines in these workshops are typically devoid of mold shifting mechanisms. Additionally, the molds possess varying cavity counts, irregular inter-cavity spacing, and are present in substantial quantities. These characteristics have collectively contributed to a sluggish pace in the implementation of automation initiatives.

    In response to such industry exigencies, our company has dedicated extensive research and development efforts to conceive and introduce an intelligent weighing and material feeding system. This innovative system has been meticulously engineered to accommodate the diverse requirements of different brake pad factories, irrespective of the specific models of their press machines and the idiosyncratic layouts of their molds. By leveraging this system, brake pad manufacturers can effectuate a seamless upgrade to their automation processes while incurring minimal financial outlays, thereby optimizing their production capabilities and cost-efficiency.

    • System Overview and Operator’s Role

    In the context of this advanced manufacturing system for brake pad production, the division of labor between the operator and the automated machinery is carefully designed to ensure efficient and high-quality output.

    • Operator’s Responsibilities
    • HMI Operation: The operator is tasked with interacting with the Human-Machine Interface (HMI). This interface serves as the control center for the operator to input crucial production parameters, initiate and monitor various processes. Through the HMI, the operator can set specific values for the weighing and dosing of materials, adjust the speed and sequence of operations, and receive real-time feedback on the system’s performance. This level of control allows for customization of the production process based on the specific requirements of each brake pad model.
    • Backing Plate Placement: Another key responsibility of the operator is the manual placement of the backing plates onto the mold. This step demands precision and care as the proper alignment and positioning of the backing plates are essential for the structural integrity and performance of the final brake pad. The operator must ensure that the backing plates are securely in place before the next stage of production commences.
    • Material Loading:The operator is also responsible for loading the friction mixture box into the system. This involves carefully handling the box to avoid any spillage or contamination of the material. The correct loading of the friction mixture is a critical starting point for the accurate weighing and dosing that follows, ensuring the right composition of the brake pad material.
    • Finished Product Retrieval: Once the brake pads have completed the production process, the operator grabs the finished products. At this stage, the operator may conduct a preliminary visual inspection to check for any visible defects or irregularities. This simple quality control measure helps to identify any potential issues early in the production cycle.
    • Automated Processes
    • Auto Material Weighing and Dosing:The system takes over the crucial task of automatically weighing and dosing the materials. Utilizing state-of-the-art sensors and precise measurement algorithms, it can accurately measure and dispense the required amount of friction material. The weighing range is adjustable, typically spanning from 40 to 400 grams, allowing for flexibility in meeting the specific needs of different brake pad formulations. The weighing tolerance is also finely tunable, ranging from ±0.5 to ±1.0 gram, ensuring a high level of accuracy in material measurement.
    • Auto Pre-Pressing in Material Tray:Within the weighing system, the machine automatically performs pre-pressing of the material in the tray. This pre-pressing stage helps to compact the material, improving its density and distribution. By evenly distributing the material, it ensures that the subsequent pressing and curing processes result in a more uniform and high-quality brake pad.
    • Auto Mold Release Spraying and Cleaning:The system offers the option of automatic mold release spraying and cleaning. This function can be fully automated by the system, or in some cases, may require the assistance of the operator. The spraying and cleaning process is vital for maintaining the integrity of the molds, ensuring that the brake pads can be easily removed after the pressing and curing process. Regular cleaning also helps to extend the lifespan of the molds and prevent any material buildup that could affect the quality of the final product.
    • Auto Material Feeding & Flattening:The system automatically feeds the material into the mold and flattens it. This process ensures that the material is evenly spread within the mold cavity, eliminating any potential voids or unevenness. The even distribution of the material is crucial for achieving consistent physical and mechanical properties across the entire brake pad.
    • System Capabilities and Specifications
    • Mold Compatibility:The system is engineered to accommodate any layout of molds. This versatility allows manufacturers to use a wide variety of mold designs, regardless of their cavity count, shape, or spacing. Whether it’s a simple or complex mold configuration, the system can precisely weigh and press the materials, enabling the production of different brake pad models without the need for significant modifications to the production line.

    X&Y-axis of the feeder moves according to molds layout, cavities and sizes

    Mold layout:2×2/3×3/3×4/4×4/2×6….

    • Production Capacity:Equipped with two press machines, the system has the capacity to produce two different models of brake pads simultaneously. This dual-press setup not only increases production efficiency but also offers greater flexibility in meeting the diverse demands of the market. Manufacturers can easily switch between different brake pad models, optimizing their production schedules and resource utilization.
    • Weighing System Configuration:The weighing system features two material bins, each with four feeders. These bins are specifically designed to handle two different materials: the underlayer mixture and the friction mixture. This segregation allows for precise control and measurement of each material, ensuring the correct formulation for the brake pads. The multiple feeders in each bin further enhance the efficiency of the weighing and dosing process, enabling a continuous and smooth production flow.
    • Manipulator Movement: The manipulators in the system are designed to travel on the back of the system. This movement pattern is carefully planned to optimize the handling of materials and finished products. The manipulators can efficiently transfer the weighed and pre-pressed materials to the molds, as well as remove the finished brake pads from the production line. Their strategic placement and movement enhance the overall productivity and automation of the manufacturing process.
    • Material Bins: There are 2 bins, enabling the weighing of 2 different materials.
    • The two material bins are a key feature of the weighing system. They are strategically placed to allow for easy access and loading of the different materials. The bins are designed with lids or covers to prevent any contamination or spillage. They are also equipped with level sensors that can monitor the amount of material remaining in the bins. This information is relayed to the system’s control panel, which can then prompt the operator to refill the bins when necessary. The ability to weigh two different materials separately is crucial for creating the precise formulations required for high-quality brake pads.
    • Weighing Range: Ranges from 40 to 400 grams (customizable).
    • The weighing range of the system is adjustable from 40 to 400 grams, and this flexibility is a significant advantage. It allows for the precise measurement of both small and relatively large amounts of materials. The system’s sensors and control mechanisms are designed to handle this wide range with high accuracy. For example, when a formulation requires a small amount of a particular additive, the system can accurately measure 40 grams or less. On the other hand, for the main components of the friction mix, it can handle up to 400 grams. The customizable nature of the weighing range means that the system can be adapted to different production requirements and material formulations.
    • Weighing Tolerance: be up to ±0.5 gram, adjustable
    • The weighing tolerance of ±0.5 gram is an extremely tight margin of error. This high level of precision is essential for maintaining the consistency and quality of the brake pads. Even a small deviation in the weight of the materials can affect the performance and durability of the final product. The system’s weighing sensors and calibration mechanisms are constantly monitored and adjusted to ensure that the measured weights are within this tolerance. This precision is what sets this production system apart and enables the production of high-quality brake pads that meet or exceed industry standards.