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Name：Drum brake pad post-processing flexible production line

Details

1. Processing content

1. Grinding chamfering 2. Grinding length 3. Grinding inner arc 4. Drilling hole 5. Grinding outer arc 6. Grinding limit 7. Grinding width 8. Inner and outer arc cleaning and coding or laser marking 9. Other customer requirements Project increase or decrease

2. Efficiency of a single pipeline

2000-4000 tablets/class.

According to the different materials of the brake pads and the number of holes, the efficiencies are as follows:

1-6 holes: 4000 pieces/class

7-12 holes: 3000 pieces/class

12-18 holes: 2000 pieces/class

3. Process flow

The processing contents of each process are described as follows:

4. Pipeline layout

This assembly line uses materials to be conveyed from right to left, and each process is linked by a conveyor belt. The input end of the feeding is the raw material of drum brake pads, and the output of the assembly line is the finished brake pads, which can be directly connected to the packaging line.

5. Introduction to the assembly line

This assembly line is composed of 5 machine tools, which adopts the most optimized scheme and the least number of machines, which can realize automatic loading and unloading. The processing contents include grinding chamfering, grinding length, grinding inner arc, drilling, grinding outer arc, grinding limit, grinding Width, inner and outer arc cleaning and coding, LOGO printing, etc. Each machine tool is connected by a conveyor belt, and the speed can be adjusted. Each machine can be adjusted individually. The total length is about 11 meters, and the size of the whole machine can also be adjusted according to customer needs. The production line overcomes the defects of traditional production equipment such as positioning, clamping, dust extraction (collecting), and machining accuracy. Due to the equipment positioning, clamping, pneumatic mode, and digital control mode for movement mode, the product has high machining accuracy and stable operation. , Dust extraction and dust collection are carried out by means of dust particle separation, which can efficiently extract dust and collect wastes, realize clean production, and the collected scraps can be reused. Each machine tool is equipped with a protective cover and a dust extraction pipe, which can extract up to 95% of the dust. The whole machine has a transparent protective cover to isolate the dust again. The whole process of this assembly line is automatic loading and unloading, which can realize one or two people to operate multiple lines, saving labor costs. The main parameters and performance of each machine tool are briefly introduced below.

5.1 Internal arc combination grinder

Product model: MK-23-DYZ

Single machine size: 2800*1400*1600mm (length X width X height)

3D display of the main structure:

Internal arc grinding structure (can be vertically lifted 150mm, can be moved back and forth 50mm, and can be rotated at an angle of 0-10 degrees)

Chamfering and edging structure (can be vertically lifted 150mm, can be moved back and forth 50mm, and can be rotated at an angle of +/- 45 degrees)

Brush dust structure (brush inner arc, press up and down adjustable)

Brake pad moving mechanism (after the brake pad is positioned and clamped on the fixed fixture, it moves with the fixture, and there is no displacement between the fixture and the brake pad during processing)

Main functions: grinding chamfering, grinding length, grinding inner arc (the processing content can be seen on the first page)

main feature:

1. This model integrates various functions of chamfering, grinding length and grinding inner arc, saving space and shortening the length of the assembly line.

2. The feeding mechanism adopts hydraulic transmission, cylinder clamping and automatic feeding. The movement of the whole machine is controlled by PLC, and the program has been built in. The length and width of the feeding mechanism can be quickly adjusted, and can be adapted to different specifications of brake pads without replacement.

3. The chamfering mechanism uses two grinding wheels driven by a motor to rotate at high speed to grind the chamfers on both sides of the brake pads at the same time, with symmetrical processing, stable grinding, low vibration and high machining accuracy. During grinding, the brake pads are clamped by the cylinder, the brake pads and the fixture are relatively stationary, and the fixture moves in parallel along the precise linear guide rail to further improve the machining accuracy. The grinding wheel adopts electroplating/sintered diamond grinding wheel, which has large cutting capacity and long grinding life. Grinding wheel adjustment adopts dovetail sliding seat, and is equipped with digital display scale, the scale resolution is 0.01mm, and the adjustment accuracy is 0.02mm.

4. The length grinding mechanism adopts two grinding wheels driven by the motor to rotate at high speed to grind the two length sides of the brake pads at the same time, with symmetrical processing, stable grinding, low vibration and high processing accuracy. During grinding, the brake pads are clamped by the cylinder, the brake pads and the fixture are relatively stationary, and the fixture moves in parallel along the precise linear guide rail to further improve the machining accuracy. The grinding wheel adopts electroplating/sintered diamond grinding wheel, which has large cutting capacity and long grinding life. Grinding wheel adjustment adopts dovetail sliding seat, and is equipped with digital display scale, the scale resolution is 0.01mm, and the adjustment accuracy is 0.02mm.

5. The internal arc grinding adopts the structure of sintered diamond grinding wheel. The inclination angle of the grinding wheel can be adjusted within the range of 0-10 degrees. The grinding wheel has a detachable structure, which is very convenient for replacement and adjustment. When grinding, the brake pads and the fixture are compressed by the cylinder, there is no relative displacement, and the grinding precision is high. The fixture slides in parallel along the precision linear guide, with large bearing capacity and high precision.

6. The internal arc grinding power mechanism is integrally fixed on the dovetail sliding table that can be raised and lowered. The height of the grinding wheel can be adjusted by loosening the locking screw.

7. Each grinding wheel has an independent dust extraction pipe, which can extract up to 90% of the dust at one time.

8. A dust brushing mechanism is added at the rear of the equipment to initially deal with the inner arc dust.

9. The equipment is equipped with a fully enclosed cover to further isolate dust, and is equipped with extraction and dust collection devices, which is more environmentally friendly.

10. The equipment and the machine tool in the next process are connected by a conveyor belt.

Equipment technical parameters:

各工序加工內(nèi)容說明如下：

四.流水線布局

本流水線采用物料從右向左輸送，各工序間用輸送帶鏈接，上料輸入端是鼓式剎車片毛胚料，流水線輸出為剎車片成品，可以直接接包裝線。

五.流水線簡介

本流水線由5臺機(jī)床組成，采用最優(yōu)化的方案，最少的機(jī)臺，可以實現(xiàn)自動上下料，加工內(nèi)容包含磨倒角、磨長度、磨內(nèi)弧、鉆孔、磨外弧、磨極限、磨寬度、內(nèi)外弧清掃打碼、LOGO印制等。各機(jī)床間采用輸送帶連接，速度均可調(diào)。每臺機(jī)床均可以單獨調(diào)整。總長約11米，也可以根據(jù)客戶需要調(diào)整整機(jī)尺寸。該生產(chǎn)線克服傳統(tǒng)的生產(chǎn)設(shè)備定位、夾緊、抽（集）塵、加工精度等缺陷，由于設(shè)備定位、夾緊、采用氣動方式、運動方式采用數(shù)字化控制方式，使產(chǎn)品的加工精度高且運行穩(wěn)定，抽塵和集塵采用粉塵顆粒分離方式進(jìn)行，可高效抽塵和收集廢料，實現(xiàn)清潔化生產(chǎn)，收集的碎料還可重復(fù)利用。每臺機(jī)床均設(shè)有護(hù)罩和抽塵管，抽塵達(dá)95%，整機(jī)有透明防護(hù)罩，再次隔離灰塵。本流水線全過程自動上下料，可以實現(xiàn)一人或兩人操作多條線，節(jié)約人力成本。下面簡要介紹下各機(jī)床的主要參數(shù)和性能。

5.1內(nèi)弧組合磨床

產(chǎn)品型號：MK-23-DYZ

單機(jī)尺寸：2800*1400*1600mm（長X寬X高）

主要結(jié)構(gòu)3D展示：

內(nèi)弧磨結(jié)構(gòu)（可垂直升降150mm，可前后移動50mm，可旋轉(zhuǎn)角度0-10度）

倒角磨邊結(jié)構(gòu)（可垂直升降150mm，可前后移動50mm，可旋轉(zhuǎn)角度+/-45度）

刷灰結(jié)構(gòu)（刷內(nèi)弧，壓緊上下可調(diào)）

剎車片運動機(jī)構(gòu)（剎車片在固定夾具上定位夾緊后，隨夾具一起運動，加工中夾具與剎車片無位移）

主要功能：磨倒角，磨長度，磨內(nèi)弧（加工內(nèi)容可看第一頁圖示）

主要特點：

1.本機(jī)型集倒角、磨長度、磨內(nèi)弧多種功能為一體，節(jié)省空間，縮短流水線長度。

2.上料機(jī)構(gòu)采用液壓傳動，氣缸夾緊，自動上料，整機(jī)運動采用PLC控制，已內(nèi)置好程序。上料機(jī)構(gòu)長度寬度均可快速調(diào)整，不需更換，即可適應(yīng)不同規(guī)格剎車片。

3. 倒角機(jī)構(gòu)采用兩個由電機(jī)帶動高速旋轉(zhuǎn)的砂輪同時磨削剎車片兩邊倒角，對稱加工，磨削平穩(wěn)，振動小，加工精度高。磨削時剎車片由氣缸夾緊，剎車片與夾具相對靜止，夾具沿精密直線導(dǎo)軌平行移動，進(jìn)一步提高加工精度。砂輪采用電鍍/燒結(jié)金剛石砂輪，切削量大，磨削壽命長。砂輪調(diào)整采用燕尾滑座，并配有數(shù)顯標(biāo)尺，標(biāo)尺分辨率0.01mm,調(diào)整精度0.02mm。

4. 磨長度機(jī)構(gòu)采用兩個由電機(jī)帶動高速旋轉(zhuǎn)的砂輪同時磨削剎車片兩長度邊，對稱加工，磨削平穩(wěn)，振動小，加工精度高。磨削時剎車片由氣缸夾緊，剎車片與夾具相對靜止，夾具沿精密直線導(dǎo)軌平行移動，進(jìn)一步提高加工精度。砂輪采用電鍍/燒結(jié)金剛石砂輪，切削量大，磨削壽命長。砂輪調(diào)整采用燕尾滑座，并配有數(shù)顯標(biāo)尺，標(biāo)尺分辨率0.01mm,調(diào)整精度0.02mm。

5.內(nèi)弧磨采用燒結(jié)金剛石砂輪結(jié)構(gòu)。砂輪傾角角度可在0-10度范圍內(nèi)調(diào)整。砂輪可拆卸結(jié)構(gòu)，更換和調(diào)整十分方便。磨削時剎車片與夾具用氣缸壓緊，無相對位移，磨削精度高。夾具沿精密直線導(dǎo)軌做平行滑動，承載力大，精度高。

6.內(nèi)弧磨動力機(jī)構(gòu)整體固定于可升降的燕尾滑臺上，松開鎖緊螺絲，可以調(diào)整砂輪高度，調(diào)整高度0-100mm，以適應(yīng)不同內(nèi)弧規(guī)格剎車片。

7.每個砂輪均有獨立的抽塵管，一次抽塵達(dá)90%。

8.設(shè)備尾部新增刷灰機(jī)構(gòu)，初步處理內(nèi)弧灰塵。

9.設(shè)備增加全封閉外罩，進(jìn)一步隔離灰塵，加裝抽排、集塵裝置，更環(huán)保。

10.設(shè)備與下工序機(jī)床采用輸送帶連接。

設(shè)備技術(shù)參數(shù)：