Brake Linings Automatic Pressing System
Non-Negotiable Performance Benchmarks for Brake Safety
As a core production equipment for brake components in automotive and engineering machinery industries, the Brake Linings Automatic Pressing System is critical to product qualification and market competitiveness.
It adheres strictly to three non-negotiable performance requirements, all directly linked to brake safety and service life:
- Structural stability to withstand long-term braking stress without deformation
- Consistent friction coefficient to ensure stable braking performance in varied conditions
- High dimensional precision to fit perfectly with brake substrates and avoid assembly issues
These benchmarks are achieved through precise control of pressing pressure, molding temperature, and cycle rhythm—key optimizations tailored for industrial application by Fu Chun Jiang Innov Brake Pads Machines.
Integrated Molding & Intelligent Process Regulation
The system’s reliable operation hinges on its integrated servo hydraulic drive and intelligent process control, forming its core technical edge.
Key operational features include:
- One-step molding of mixed friction materials (resin binders, reinforcing fibers, metal particles) onto brake substrates under preset pressure and temperature
- Full closed-loop control from feeding to pressure maintaining, via built-in precision sensors and PLC controllers, eliminating human-error induced density unevenness
- Dynamic pressure adjustment module that optimizes parameters based on friction material viscosity and substrate type, ensuring consistent inter-batch bonding strength
This intelligent upgrade, refined by Fu Chun Jiang Innov Brake Pads Machines, enhances adaptability to diverse production needs.
Core Components & Functional Advantages
Servo Hydraulic Drive Unit
As the power core, it comprises servo motors, high-precision hydraulic pumps, and precision control valves, outperforming conventional hydraulic presses in stability and energy efficiency.
- Energy-saving design reduces power consumption by approximately 70% through on-demand oil supply control
- Servo motor adjusts pump speed in real time, enabling slider speeds of 50-175 mm/s (fast descending) and 5-20 mm/s (slow feeding) to balance efficiency and precision
- Wear-resistant hydraulic seals and built-in oil temperature monitoring (cooling activated above 50℃) extend component service life
Intelligent Control System
- Equipped with a high-definition color touchscreen HMI for parameter input/recall, real-time process monitoring, and intuitive fault diagnosis
- Supports multi-segment parameter setting for pressing, pressure maintaining, and return strokes, with storage for hundreds of programs for different brake lining specifications
- Integrated photoelectric switches and displacement sensors achieve ±0.05 mm position repeat accuracy and 1% pressure repeat accuracy, meeting strict automotive OEM standards
Molding & Feeding Mechanisms
- 200L material warehouse with screw conveyor ensures uniform, stable material delivery; plowshare stirrer prevents agglomeration
- Conveyor speed synchronizes with pressing rhythm to avoid waste or insufficient filling
- Replaceable modular molds adapt to brake linings of different widths (up to 80 mm) and thicknesses (up to 10 mm), enabling quick product switching without overall equipment modification
Performance Highlights & Industrial Applications
Core Performance Advantages
- High production efficiency: 4-10 meters per minute for continuous rolling molding, far exceeding traditional intermittent pressing equipment
- Low noise operation (60-70 decibels) and integrated dust collection device (over 90% removal efficiency), complying with environmental standards
- Energy-saving and low-maintenance: servo hydraulic system reduces idle consumption; hardened alloy rollers minimize maintenance frequency and downtime
Industrial Application Scope
- Widely used in producing brake linings for passenger cars, commercial vehicles, and engineering machinery, supporting both disc and drum brake pad manufacturing
- Meets international standards (ISO 9001, FMVSS 121) and can be customized per OEM requirements (e.g., enhancing thermal stability for heavy-duty truck linings)
- Flexible small-batch, multi-specification production capacity caters to after-sales market demand, aiding the friction material industry’s shift from labor-intensive to precision automated production—supported by the professional design of Fu Chun Jiang Innov Brake Pads Machines.
Technical Parameters & Operational Guidelines
Typical technical specifications:
- Roller dimensions: fixed roller diameter 400 mm, movable roller diameter 460 mm
- Total power: 17.2 kW (2×7.5 kW drive motors, 1×2.2 kW mixing motor)
- Equipment dimensions: approx. 3.67×1.3×2.285 meters; weight: approx. 2.5 metric tons
Operational requirements:
- Environment: temperature -10~45℃, relative humidity 40~80%, 380V three-phase five-wire power supply
- Maintenance: regular hydraulic oil cleanliness inspection (46# anti-wear hydraulic oil recommended) and sensor accuracy calibration
- User-friendly interface allows operators to master parameter setting and daily monitoring with basic training, lowering operational thresholds
Operational Notes
- System performance may vary slightly based on material characteristics; pre-production tests are recommended to determine optimal parameters
- Roller alignment during installation is critical to avoid uneven brake lining wear
- Regular inspection of the emergency stop device is required to ensure operational safety and prevent accidents