Intelligent Brake Pads(PC/CV) Weighing and Pressing System(Full Auto/Semi-Auto/OE)
As a core part of Brake Pads Machinery, the Intelligent Brake Pads Weighing and Pressing System is a highly sophisticated, integrated industrial solution designed to optimize brake pads production. It combines multiple essential components to ensure precision, efficiency, and consistency—making it ideal for both Car Brake Pads Machine and Truck Brake Pads Machine production lines.
1. Product Overview & Core Components
This system integrates four key functional modules and supporting accessories, forming a seamless production chain for brake pads. Its core components work in synergy to meet strict manufacturing standards:
- High-Precision Weighing System: Equipped with ultra-sensitive load cells and intelligent calibration algorithms, it accurately measures single-layer or double-layer friction mixes—critical for maintaining consistent material composition in brake pads.
- Flexible Heating Curing Press Units: Ranging from 1 to 6 units, these are built with heavy-duty, heat-resistant alloys. They feature advanced temperature control (maintaining accuracy within a fraction of a degree) and precise pressure regulation, ensuring optimal physical and chemical properties of finished brake pads.
- Automatic Manipulators on Travelling Rack: Constructed from high-strength, lightweight materials (e.g., carbon fiber composites, aluminum alloys), these multi-axis manipulators with custom grippers handle material trays, finished brake pads, and mold cleaning with exceptional dexterity.
- Supporting Accessories: Include variable-speed anti-slip conveyors for material transport, safety interlocks, emergency stop systems, quality inspection sensors, and data loggers—all enhancing functionality, safety, and process optimization.
2. Four Core Functional Modules (Design Concept)
The system is divided into 4 specialized, integral blocks. Below is a detailed breakdown of each module’s role, design, and functionality:
| Functional Module | Key Components | Core Functions | Adaptability & Advantages |
| Sect 1: Weighing Machines | 1. First layer mix weighing machine2. Under layer mix weighing machine3. Feeder | – Accurately weighs top/bottom layer friction mixes using ultra-sensitive load cells.- Transfers weighed materials to the feeder (anti-contamination, controlled flow). | – Adapts to single-layer formulas (uses one machine based on composition).- Ensures precise material ratios for consistent brake pad performance. |
| Sect 2: Feeder Trolley (Manipulators) | 1. Heavy-duty frame2. Smooth-movement wheels3. Mechanical arms/suction devices4. Flattening rollers/press plates5. Pre-pressing mechanism | – Retrieves friction material trays gently via mechanical arms/suction.- Flattens mixes (uniform thickness/density) and pre-presses them (enhances stability for hot pressing). | – Withstands continuous operation; no jolts/vibrations to disrupt materials.- Prepares mixes for efficient hot pressing in subsequent steps. |
| Sect 3: Automatic Manipulators on Travelling Rack | 1. Lightweight alloy/composite frame2. Multi-axis robotic arms3. Custom grippers (for trays/brake pads)4. High-pressure air jets + specialized brushes | – Grabs material trays, transports to press units, and discharges mixes evenly.- Seizes finished brake pads (without damage) post-pressing.- Cleans molds (removes residual material) to maintain quality. | – Fast, precise movement; adjustable grippers fit different tray/brake pad sizes.- Reduces manual labor and ensures consistent handling across production cycles. |
| Sect 4: Press Machines | 1. 1-6 press units (variable quantity)2. Mold cavities (custom-machined)3. Precision pressure/temperature controls | – Applies optimal force and temperature for hot pressing (based on brake pad formula).- Mold cavities match specific brake pad models (e.g., car/truck). | – Quantity adjusts to pressing time: fewer units for short cycles, more for long cycles.- Tonnage and mold design tailored to Brake Pads Machine requirements (meets automotive industry standards). |
3. Critical Production Procedures
The system manages a full sequence of key steps in brake pads manufacturing, ensuring end-to-end automation and quality control:
- Weighing Friction Mixes: Uses the high-precision weighing system to measure single-layer or double-layer mixes. Even tiny deviations are avoided, as material composition directly impacts brake pad performance.
- Flattening/Pre-Pressing: The feeder trolley flattens mixes to uniform thickness and pre-presses them slightly. This step stabilizes materials for transport and optimizes the hot pressing process.
- Transporting Material Trays: Automated conveyors or robotic arms move trays between workstations (e.g., weighing → pressing) without spillage, ensuring a seamless production flow.
- Feeding Mixes to Press Units: Sophisticated mechanisms (augers, pneumatic feeders) transfer mixes from trays to press cavities, controlling speed/volume for consistent filling.
- Optional: Automatic Backing Plate Placement: Robotic arms place backing plates in press units with high accuracy—aligning perfectly with friction mixes to enhance brake pad integrity (a valuable add-on for efficiency).
- Grabbing Finished Brake Pads: Post-pressing, manipulators gently lift finished products (avoiding scratches/deformation) and transport them to inspection or packaging stations.
- Mold Cleaning: High-pressure air jets and brushes remove residual material from molds, ensuring each new batch of brake pads meets the same quality standards.
4. Application Scope
This system is a versatile addition to Brake Pads Machinery lines:
- Car Brake Pads Machine: Adapts to smaller brake pad sizes and faster production cycles, ensuring precision for passenger vehicle brake pads.
- Truck Brake Pads Machine: Handles larger, heavier brake pads with adjusted press tonnage and mold cavities, meeting the durability demands of commercial vehicles.
- General Brake Pads Machine: Compatible with diverse formulas and production scales, making it a flexible solution for brake pads manufacturers.
