In the factory, tens of thousands of brake pads are produced from the assembly line every day, and are delivered to dealers and retailers after packaging. How is the brake pad manufactured and what equipment will be used in the manufacturing? This article will introduce you to the main process of manufacturing brake pads in the factory:
1. Raw materials mixing: basically, the brake pad is composed of steel fiber, mineral wool, graphite, wear-resistant agent, resin and other chemical substances. The friction coefficient, wear-resistant index and noise value are adjusted through the proportion distribution of these raw materials. First, we need to prepare a brake pad manufacturing process formula. According to the requirements of raw material ratio in the formula, various raw materials are introduced into the mixer to obtain fully mixed friction materials. The material quantity required for each brake pad is fixed. In order to reduce the time and labor cost, we can use an automatic weighing machine to weigh the friction material in material cups.
2. Shot blasting: in addition to friction materials, another main part of the brake pad is the back plate. We need to remove the oil stain or rust on the back plate to keep the back plate clean. The shot blasting machine can efficiently remove the stains on the back plate, and the cleaning intensity can be adjusted by the shot blasting time.
3. Gluing treatment: in order to make the backing plate and the friction material can be firmly combined and improve the shear force of the brake pad, we can apply a layer of glue on the backing plate. This process can be realized by automatic glue spraying machine or semi-automatic glue coating machine.
4. Hot press forming stage: after finishing the treatment of friction materials and steel backs, we need to use a hot press to press them with high heat to make them more closely combined. The finished product is called brake pad rough embryo. Different formulations require different pressing and exhaust times.
5. Heat treatment stage: in order to make the brake pad material more stable and more heat-resistant, it is necessary to use the oven to bake the brake pad. We put the brake pad into a specific frame, and then send it to the oven. After heating the rough brake pad for more than 6 hours according to the heat treatment process, we can further process it. This step also needs to refer to the heat treatment requirements in the formula.
6. Grinding, slotting & chamfering: the surface of the brake pad after heat treatment still has many burrs, so it needs to be polished and cut to make it smooth. At the same time, many brake pads also have the process of grooving and chamfering, which can be completed in the multi-functional grinder.
7. Spraying process: in order to avoid rusting of iron materials and achieve aesthetic effect, it is necessary to coat the brake pad surface. The automatic powder coating line can spray powder on the brake pads in an assembly line. At the same time, it is equipped with a heating channel and a cooling zone to ensure that the powder is firmly attached to each brake pad after cooling.
8. After spraying, the shim can be added on the brake pad. A riveting machine can easily solve the problem. One riveting machine is equipped with an operator, which can quickly rivet the shim on the brake pad.
9. After completing the above-mentioned series of processes, the production of brake pads is completed. In order to ensure the quality and performance of the brake pads, we also need to test them. Generally, the shear force, friction performance and other indicators can be tested by testing equipment. Only after passing the test can the brake pad be considered as qualified.
10. In order to make the brake pads have more obvious model marks and brand characteristics, we usually mark the model and brand logo on the back plate with a laser marking machine, and finally use an automatic packaging line to pack the products.
The above is the basic process of manufacturing brake pads in the factory. You can also learn more detailed steps by watching the video below:
Post time: Aug-12-2022