PC Brake Pads Intelligent Weighing and Pressing System(Full Automatic/OE)

• What does the operator do in this system:
• Ø Operate from HMI: The operator interfaces with the system through the Human-Machine Interface (HMI). This involves using the touch screen or control panel provided by the HMI to input commands, set parameters, and monitor the overall status of the system. For example, the operator can adjust the temperature settings, pressure levels, or cycle times of the various processes within the system. They can also view real-time data such as the current production rate, the status of different components (like whether a particular conveyor is running or a press is engaged), and any error or warning messages that the system might generate. This allows the operator to have full control and oversight of the entire operation and make informed decisions to ensure smooth and efficient production.
• Ø Load friction mixture box to system:The operator is responsible for loading the friction mixture box into the system. This task requires careful handling to ensure that the box is properly positioned and secured. The friction mixture box contains the specific blend of materials that will be used to create the brake pads. The operator must follow safety protocols and any specific loading procedures dictated by the system design. This might involve using lifting equipment or following a particular sequence of actions to insert the box into a designated loading area. Once loaded, the system can then access and process the friction mixture as needed for the production of brake pads.
• Ø Load backing plates to system:Similarly, the operator has to load the backing plates into the system. Backing plates are an essential component of the brake pads as they provide structural support. The operator needs to ensure that the backing plates are of the correct size and type and are placed in the appropriate location within the system. This could involve stacking them in a specific feeder or tray that is designed to supply the backing plates to the subsequent manufacturing steps. Attention to detail is crucial here as any misalignment or incorrect loading of the backing plates could lead to defective brake pads or disruptions in the production process.
• Ø Other procedures will be done by the system: After the operator has completed the loading tasks, the system takes over and executes a series of automated procedures. These include but are not limited to the following:
• Ø ★ 4 press each system:The system operates a set of presses, with a total of 4 presses being used in the production process. Each press is precisely controlled and synchronized to perform specific functions. For example, they apply the necessary force to compress the friction mixture onto the backing plates, ensuring proper adhesion and formation of the brake pads. The presses are calibrated to work within specific pressure and temperature ranges to achieve the desired quality and performance characteristics of the final product.
• Ø ★ 8 cavities each mold(press):Each of the molds used in the presses is designed with 8 cavities. This allows for the simultaneous production of multiple brake pads in a single cycle. The cavities are carefully engineered to have the correct shape and dimensions to form the brake pads accurately. The system ensures that the friction mixture is evenly distributed among the cavities and that the pressing process is uniform across all of them, resulting in consistent quality brake pads being produced in each cycle.
• Ø ★ Automatic put backing plates: The system has an automated mechanism for placing the backing plates. Once the operator has loaded the backing plates into the designated area, the system’s robotic arms or conveyor systems pick up the backing plates and position them precisely within the molds. This automation not only speeds up the production process but also reduces the potential for human error in the placement of the backing plates, which is crucial for the integrity and performance of the brake pads.
• Ø ★Friction mixes is loaded by small boxes: The friction mixture is supplied to the system in small boxes. These boxes are designed to hold a specific quantity and type of friction mixture. The system is configured to handle these boxes and extract the mixture in a controlled manner. The use of small boxes allows for better management of the friction mixture, ensuring that the correct amount is used in each production cycle and minimizing waste. The system may have sensors or mechanisms to detect when a box is empty and prompt the operator to load a new one, maintaining a continuous production flow.

• Details of Intelligent Brake Pads Weighing and Pressing System
• Capable of handling 8 different types of brake pads simultaneously.

This intelligent pressing system showcases extraordinary versatility as it is Capable of handling 8 different types of brake pads simultaneously. These 8 types could range from brake pads designed for small passenger vehicles to those intended for heavy-duty commercial trucks or even high-performance sports cars. Each type demands specific material combinations, thicknesses, and surface finishes. The system’s advanced control algorithms and adaptable tooling allow it to seamlessly switch between these diverse brake pad variants, optimizing production processes and minimizing downtime. For instance, it can adjust the pressure, temperature, and pressing time according to the unique requirements of each brake pad type, ensuring consistent quality and performance across the board.

• Accommodates 2 different materials and 4 different models.

The system is engineered to Accommodate 2 different materials and 4 different models. The two materials might include a traditional asbestos-free friction material and a more advanced ceramic-based compound. The 4 different models could represent various brake pad shapes and sizes, such as rectangular, circular, or those with unique cutouts and grooves. The equipment’s modular design and adjustable components enable it to precisely handle and process these different materials and models. It can accurately meter and mix the two materials in the right proportions for each of the 4 models, guaranteeing that the resulting brake pads possess the desired friction characteristics, durability, and thermal stability.

• Saves the labor cost of 4 workers per shift.

One of the most significant advantages of this system is that it Saves the labor cost of 4 workers per shift. In a conventional brake pad manufacturing setup, tasks like material preparation, positioning, and pressing often require a substantial amount of manual labor. However, our intelligent system automates these processes. For example, the automatic material weighing and dosing eliminate the need for workers to manually measure and dispense materials, reducing the risk of human error and ensuring precise material composition. The automatic pre-pressing, feeding, and flattening operations replace the labor-intensive manual handling of materials. Additionally, the automatic grabbing of finished brake pads and the associated transportation to the next stage of production remove the need for manual intervention. This not only cuts down on labor costs but also enhances overall production efficiency and quality control.

• Achieves 9 cycles per hour and produces 2500 pieces per shift.(based on the curing time of each formula)

The system Achieves 9 cycles per hour and produces 2500 pieces per shift. This remarkable production rate is a result of the seamless integration and optimization of multiple subsystems. The rapid material handling mechanisms ensure a continuous supply of materials to the pressing area. The efficient pressing process, with its precisely controlled pressure and temperature, allows for quick curing and shaping of the brake pads. The automated mold release and cleaning procedures minimize the time between cycles. Each cycle is meticulously timed and synchronized, enabling the system to maintain a consistent production pace. Over the course of a shift, this high productivity results in the production of 2500 pieces, meeting the demands of medium to large-scale brake pad manufacturing operations and contributing to cost-effective production.

• Enables automatic positioning and placement of 8 backing plates.

It Enables automatic positioning and placement of 8 backing plates. The backing plates are critical components that provide structural support and stability to the brake pads. The system’s automated positioning mechanism utilizes a combination of robotic arms and advanced sensors. The robotic arms are programmed to pick up the backing plates from a designated storage area and transport them to the correct position within the production line. The sensors, which could be optical or proximity sensors, ensure that the backing plates are placed with millimeter precision. This accuracy is essential as any misalignment could affect the overall performance and safety of the brake pads.

• Utilizes sensor to check if the backing plates are correctly positioned.

The system Utilizes sensor to check if the backing plates are correctly positioned. These sensors are highly sensitive and reliable. They continuously monitor the position of the backing plates during the placement process. If the sensor detects even a slight deviation from the desired position, it immediately sends a signal to the control system. The control system then halts the production process and triggers an alarm, alerting the operators. This real-time monitoring and error detection mechanism prevent defective brake pads from being produced, ensuring that only properly assembled products move forward in the manufacturing process.

• Employs 8 individual cylinders with equal-pressure technology.

The system Employs 8 individual cylinders with equal-pressure technology. These cylinders are the workhorses of the pressing operation. Each cylinder is designed to deliver a specific amount of force, and the equal-pressure technology ensures that all 8 cylinders apply the same amount of pressure simultaneously. This is crucial for achieving uniform compression and curing of the brake pad materials. The cylinders are made of high-strength materials and are precisely calibrated to maintain consistent pressure levels throughout the pressing cycle. Any variation in pressure could lead to differences in the density and hardness of the brake pads, affecting their performance and lifespan.

• Performs automatic material weighing and dosing.

The system Performs automatic material weighing and dosing. It is equipped with highly accurate weighing scales that can measure the weight of different materials with a precision of up to a fraction of a gram. The dosing mechanisms are designed to dispense the materials in exact quantities based on the pre-programmed recipes for each type of brake pad. The system’s control software continuously monitors and adjusts the weighing and dosing processes to ensure that the correct material composition is maintained. This automated process not only saves time but also eliminates the potential for human error in material preparation, which is essential for producing high-quality brake pads.

• Conducts automatic pre-pressing within the material tray.

It Conducts automatic pre-pressing within the material tray. After the materials are weighed and dosed into the material tray, the pre-pressing mechanism activates. This mechanism applies a controlled amount of pressure to the materials, compacting them and ensuring that they are evenly distributed within the tray. The pre-pressing force is carefully calibrated based on the type of materials and the desired final density of the brake pads. This initial compression helps to improve the handling of the materials during the subsequent feeding and pressing operations and contributes to the overall uniformity and quality of the final product.

• Executes automatic material feeding and flattening.

The system Executes automatic material feeding and flattening. The material feeding mechanism uses a combination of conveyors and robotic arms to transport the pre-pressed material from the tray to the pressing area. Once in the pressing area, the flattening device, which could consist of rollers or press plates, applies a specific force to flatten the material to the required thickness. The thickness is precisely controlled by the system’s sensors and control algorithms, ensuring that each brake pad has the correct dimensions. The flattening process also helps to improve the surface finish of the brake pads, which is important for their performance and compatibility with the braking system.

• Carries out automatic mold release spraying and cleaning.

It Carries out automatic mold release spraying and cleaning. After each pressing cycle, a mold release agent is automatically sprayed onto the mold surfaces. This agent forms a thin film that prevents the brake pad material from sticking to the molds, facilitating easy removal of the finished brake pads. Subsequently, the molds are cleaned using a combination of high-pressure jets, brushes, and solvents. The high-pressure jets remove loose debris and residual material, while the brushes scrub the mold surfaces to ensure a thorough clean. The solvents are used to dissolve any remaining adhesive or contaminants. This automated mold release and cleaning process not only extends the life of the molds but also ensures that each new batch of brake pads is produced in a clean and consistent environment, reducing the risk of defects.

• Performs automatic grabbing of finished brake pads.

The system Performs automatic grabbing of finished brake pads. Robotic arms or other automated handling devices are used to pick up the finished brake pads from the molds. These devices are carefully programmed to approach the molds with the correct orientation and apply a gentle yet firm grip to the brake pads. They then transport the brake pads to the next stage of the production line, such as a quality inspection area or a packaging station. The automatic grabbing process ensures that the brake pads are handled without damage and that the production flow is continuous and efficient.

• Manufacturer of Equipment for OE-Qualified Brake Pads.

We take pride in being a distinguished Manufacturer of Equipment for OE-Qualified Brake Pads. With years of experience and a commitment to excellence, our manufacturing facility is equipped with state-of-the-art machinery and a team of highly skilled engineers. We adhere to strict quality control protocols and industry standards to ensure that every piece of equipment leaving our premises is of the highest caliber. Our reputation in the automotive sector is built on the reliability and performance of our brake pad manufacturing equipment, which has been trusted by numerous Original Equipment Manufacturers (OEMs) around the world.