Model A: PC Brake Pads Intelligent Weighing and Pressing System(Full Automaitc/OE Quality)
As a core piece of Brake Pads Machinery, this Intelligent Brake Pads Weighing and Pressing System is designed to meet the high standards of brake pad manufacturing—supporting Car Brake Pads Machine, Truck Brake Pads Machine, and commercial vehicle brake pad production lines. It integrates human-machine collaboration, advanced automation, and precise control to boost efficiency, reduce costs, and ensure OE-qualified product quality.
1. Operator Responsibilities: Key Manual Inputs
The operator plays a critical role in initiating and monitoring the system, with clear, focused tasks that lay the foundation for automated production:
| Operator Task | Specific Actions | Importance to Production |
|---|---|---|
| 1. HMI Operation | Use the Human-Machine Interface (touch screen/control panel) to input commands, set parameters (temperature, pressure, cycle time), and monitor real-time data (production rate, component status, error warnings). | Enables full oversight of the system, allowing quick adjustments to maintain smooth, efficient operation. |
| 2. Load Friction Mixture Boxes | Handle and position friction mixture boxes (containing core raw materials for brake pads) into the system’s designated loading area, following safety protocols and sequence requirements. | Ensures the system has a steady supply of correctly specified friction mixes—critical for consistent brake pad formulation. |
| 3. Load Backing Plates | Place backing plates (structural supports for brake pads) into the system’s feeder/tray, verifying correct size/type and proper alignment. | Prevents defects from misaligned backing plates, ensuring the structural integrity of finished brake pads. |
2. System Automated Procedures: Post-Operator Workflow
After the operator completes manual tasks, the system takes over with a series of precision-driven, automated steps to deliver end-to-end production:
| Automated Step | Specific Functions | Advantages for Production |
|---|---|---|
| 1. 4-Press Operation | Control 4 synchronized presses to apply precise force, compressing friction mixes onto backing plates (calibrated to specific pressure/temperature ranges). | Ensures uniform adhesion and formation of brake pads, meeting quality and performance standards. |
| 2. 8-Cavity Molds | Each press mold has 8 cavities, enabling simultaneous production of 8 brake pads per cycle (even material distribution across all cavities). | Maximizes output per cycle, boosting overall production efficiency. |
| 3. Automatic Backing Plate Placement | Use robotic arms/conveyors to pick up loaded backing plates and position them precisely in molds. | Eliminates human error in placement, speeds up production, and ensures consistent alignment. |
| 4. Small-Box Friction Mix Loading | Extract friction mixes from small, pre-measured boxes (optimizing material management, minimizing waste) and feed them into the production process. | Maintains accurate material quantities per cycle, reducing waste and ensuring formulation consistency. |
3. Core Technical Details of the Intelligent System
The system’s performance is defined by advanced features that enhance versatility, efficiency, and quality—making it a top choice for Brake Pads Machine production lines:
| Technical Feature | Specific Specifications & Functions | Value for Brake Pads Manufacturing |
|---|---|---|
| Simultaneous Brake Pad Type Handling | Capable of processing 8 different brake pad types (e.g., passenger car, truck, high-performance) at once, with adjustable parameters (pressure, temperature, time) for each type. | Delivers exceptional versatility, adapting to diverse production needs without downtime. |
| Material & Model Compatibility | Accommodates 2 different materials (e.g., asbestos-free friction material, ceramic compound) and 4 different brake pad models (varying shapes/sizes). | Supports flexible production planning, meeting the demands of different customer orders. |
| Labor Cost Savings | Automates manual tasks (material weighing, pre-pressing, mold cleaning), saving the labor cost of 4 workers per shift. | Reduces operational costs significantly while minimizing human error. |
| High Production Efficiency | Achieves 9 cycles per hour and 2500 pieces per shift (based on formula curing time), via optimized material handling and synchronized processes. | Meets medium-to-large-scale production demands, ensuring timely order fulfillment. |
| Automated Backing Plate Positioning | Enables automatic positioning/placement of 8 backing plates per cycle, using robotic arms and precision sensors. | Ensures millimeter-level accuracy in backing plate placement, critical for brake pad safety. |
| Backing Plate Position Verification | Uses sensitive optical/proximity sensors to check backing plate alignment; halts production and alerts operators if deviations are detected. | Prevents defective products, maintaining consistent quality control. |
| Equal-Pressure Cylinders | Employs 8 individual cylinders with equal-pressure technology, delivering uniform force during pressing. | Guarantees consistent brake pad density and hardness, avoiding performance variations. |
| Automatic Weighing & Dosing | Equipped with high-precision scales (fraction-of-a-gram accuracy) to weigh and dispense materials per pre-programmed recipes. | Eliminates manual weighing errors, ensuring correct material composition for each brake pad type. |
| Automatic Pre-Pressing | Compacts materials in the tray with controlled force after dosing, improving material handling and uniformity. | Lays the groundwork for even pressing, enhancing final product quality. |
| Automatic Feeding & Flattening | Uses conveyors/robotic arms to feed pre-pressed materials; flattening devices (rollers/press plates) ensure precise thickness. | Maintains consistent brake pad dimensions and surface finish, meeting dimensional standards. |
| Automatic Mold Maintenance | Conducts automatic mold release spraying (prevents material sticking) and cleaning (high-pressure jets, brushes, solvents) post-cycle. | Extends mold lifespan, ensures a clean production environment, and reduces defect risks. |
| Automatic Finished Pad Handling | Uses robotic arms to grab finished brake pads from molds and transport them to inspection/packaging stations. | Avoids damage to finished products and maintains continuous production flow. |
| OE-Qualified Equipment Manufacturing | As a distinguished manufacturer of OE-qualified brake pad equipment, adheres to strict quality control and industry standards, trusted by global OEMs. | Ensures the system produces brake pads that meet original equipm |
