Brake Linings Automatic Pressing System
System Overview & Core Functions
As a pivotal piece of equipment for manufacturing brake components in automotive and engineering machinery fields, the Brake Linings Automatic Pressing System guarantees brake linings’ structural completeness, friction performance and dimensional precision through refined control of pressure, temperature and forming cycles.
Its automation capacity is a decisive factor in boosting production efficiency and product consistency for modern friction material manufacturers, serving as a cornerstone for large-scale, high-standard brake lining production.
Operational Mechanism & Control Logic
The system integrates servo hydraulic drive with intelligent process control, compressing mixed friction materials (resins, fibers, metal particles included) onto substrates under preset pressure and temperature to form qualified brake linings.
Unlike traditional manual or semi-automatic pressing equipment, it adopts built-in sensors and PLC to realize closed-loop control throughout the forming process—from material feeding to pressure maintaining—effectively avoiding density unevenness caused by human errors.
Equipped with a dynamic pressure adjustment module, the system automatically modifies pressure parameters based on material viscosity and substrate type; Fu Chun Jiang Brake Pads Making Machines has optimized this module to ensure consistent bonding strength across all production batches.
For example, when processing high-fiber friction materials, the system gradually increases pressure in the initial stage to prevent material stratification, followed by a stable pressure maintaining period to promote resin curing and enhance structural compactness.
Key Structural Components & Their Roles
Servo Hydraulic Drive Unit
As the power core, the unit consists of servo motors, hydraulic pumps and precision valves, boasting significant energy-saving advantages compared to conventional hydraulic presses—reducing power consumption by about 70% via on-demand oil supply.
The servo motor adjusts pump speed in real time according to the pressing stage, enabling the slider to achieve fast descending speeds (50-175 mm/s) and slow feeding speeds (5-20 mm/s), balancing production efficiency and forming precision.
Hydraulic seals and other critical components adopt wear-resistant materials to withstand long-term high-pressure operation, while a built-in oil temperature monitoring system activates cooling devices automatically when temperatures exceed 50℃, extending component service life.
Intelligent Control System
Featuring a high-color touch screen HMI, the system allows operators to input/call production parameters, monitor real-time process data and diagnose equipment status intuitively.
Integrated with photoelectric switches and displacement sensors, it achieves ±0.05 mm position repeat accuracy and 1% pressure repeat accuracy, meeting strict dimensional requirements of automotive OEMs—Fu Chun Jiang Brake Pads Making Machines has further optimized this system to enhance compatibility with various friction material formulations.
Forming & Feeding Mechanisms
The feeding mechanism, composed of a 200L material warehouse and a screw conveyor, ensures uniform material delivery to the forming area; a plowshare stirrer inside the warehouse prevents material agglomeration.
Conveyor speed is synchronized with pressing rhythm to avoid material waste or insufficient filling; the forming mechanism adopts replaceable modular molds, adapting to different lining widths (up to 80 mm) and thicknesses (up to 10 mm) without complete equipment modification.
Performance Advantages & Industrial Application Scenarios
Core Performance Highlights
High production efficiency: It achieves 4-10 meters per minute for continuous rolling forming, much higher than traditional intermittent pressing equipment.
Environment-friendly operation: Running noise is controlled at 60-70 decibels, and integrated dust collection devices achieve over 90% dust removal efficiency, complying with modern environmental standards.
Energy-saving & low-maintenance: The servo hydraulic system reduces idle energy consumption, while hardened alloy rollers and wear-resistant components minimize maintenance frequency and downtime.
Industrial Application Scope
It is widely used in producing brake linings for passenger cars, commercial vehicles and engineering machinery, supporting both disc and drum brake pad manufacturing.
It meets international standards such as ISO 9001 and FMVSS 121, and can be customized according to OEM requirements—e.g., adjusting forming parameters to improve thermal stability for heavy-duty truck linings or wear resistance for high-performance vehicle linings.
In the after-sales market, its ability to produce small-batch, multi-specification linings provides flexibility for manufacturers, enabling quick responses to replacement part demands.
Technical Specifications & Operational Guidelines
Typical technical parameters: Fixed roller diameter 400 mm, movable roller diameter 460 mm, total power 17.2 kW (2×7.5 kW drive motors + 2.2 kW mixing motor).
Equipment dimensions: Approximately 3.67×1.3×2.285 meters, weight around 2.5 metric tons, suitable for standard workshop layouts.
Operational environment: Temperature -10~45℃, relative humidity 40~80%, 380V three-phase five-wire power supply.
Maintenance requirements: Regularly check hydraulic oil cleanliness (46# anti-wear hydraulic oil recommended) and calibrate sensor accuracy; operators only need basic training to master parameter setting and daily monitoring.
Note: System performance may vary slightly based on material characteristics and process adjustments; pre-production tests are recommended to determine optimal parameters. Ensure roller alignment during installation and regular inspection of emergency stop devices for operational safety.