Brake Linings Automatic Pressing System
As a core equipment in the production of automotive and engineering machinery brake components, the brake linings automatic pressing system ensures the structural integrity, friction performance and dimensional accuracy of brake linings through precise control of pressure, temperature and forming rhythm. Its automation capability has become a key factor in improving production efficiency and product consistency in modern friction material manufacturing.
Core Working Principles
The system operates on the principle of integrating servo hydraulic drive with intelligent process control, compressing mixed friction materials (including resins, fibers and metal particles) onto substrates under preset pressure and temperature conditions to form brake linings. Unlike traditional manual or semi-automatic pressing equipment, it realizes closed-loop control of the entire forming process—from material feeding to pressure maintaining—through built-in sensors and programmable logic controllers (PLC), which effectively avoids density unevenness caused by human operation errors.
Embedded with dynamic pressure adjustment modules, the system can automatically modify pressure parameters according to the material viscosity and substrate type, ensuring that each batch of linings maintains consistent bonding strength. For instance, when processing high-fiber friction materials, the pressure is gradually increased during the initial stage to prevent material stratification, followed by a stable pressure maintaining period to promote resin curing and improve structural compactness.
Key Structural Components
Servo Hydraulic Drive Unit
The servo hydraulic drive unit, consisting of servo motors, hydraulic pumps and precision valves, is the power core of the system. It features energy-saving advantages compared to conventional hydraulic presses, reducing power consumption by approximately 70% through on-demand oil supply. The servo motor adjusts the pump speed in real time based on the pressing stage, enabling the slider to achieve fast descending speeds of 50-175 mm/s and slow feeding speeds of 5-20 mm/s, which balances production efficiency and forming precision.
Critical components such as hydraulic seals adopt wear-resistant materials to withstand long-term high-pressure operation, while the built-in oil temperature monitoring system automatically activates cooling devices when the temperature exceeds 50℃, extending the service life of hydraulic components.
Intelligent Control System
The intelligent control system, equipped with a high-color touch screen human-machine interface, allows operators to input and call production parameters, monitor real-time process data and diagnose equipment status intuitively. It supports multi-segment parameter setting for pressing, pressure maintaining and return strokes, and can store hundreds of sets of process programs for different types of brake linings, facilitating quick switching between production batches.
Integrated with photoelectric switches and displacement sensors, the system achieves position repeat accuracy within ±0.05 mm and pressure repeat accuracy within 1%, meeting the strict dimensional requirements of automotive OEMs. FU CHUN JIANG Intelligent Brake Pads Machines has optimized this control system for its product line, enhancing compatibility with various friction material formulations.
Forming and Feeding Mechanisms
The feeding mechanism, composed of a material warehouse (usually with a 200L capacity) and a screw conveyor, ensures uniform material delivery to the forming area. A plowshare stirrer inside the warehouse prevents material agglomeration, while the conveyor speed is synchronized with the pressing rhythm to avoid material waste or insufficient filling. The forming mechanism, featuring replaceable modular molds, adapts to different lining widths (up to 80 mm) and thicknesses (up to 10 mm) by adjusting mold specifications, eliminating the need for complete equipment modification when switching product types.
Performance Advantages and Industrial Applications
Core Performance Advantages
High production efficiency is one of the prominent advantages of the system, with a typical production rate of 4-10 meters per minute for continuous rolling forming, which is significantly higher than that of traditional intermittent pressing equipment. Its low noise operation—with a running noise level of 60-70 decibels—and integrated dust collection devices (achieving over 90% dust removal efficiency) align with modern environmental protection standards, reducing workshop pollution and improving working conditions.
Another key advantage lies in its energy-saving and low-maintenance design. The servo hydraulic system reduces idle energy consumption, while the hardened alloy rollers and wear-resistant components minimize maintenance frequency and downtime. FU CHUN JIANG Intelligent Brake Pads Machines has further enhanced these advantages by optimizing the mechanical structure, making its equipment suitable for long-term high-volume production.
Industrial Application Scope
The system is widely used in the production of 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 the specific requirements of OEMs—for example, adjusting forming parameters to improve the thermal stability of linings for heavy-duty trucks or enhancing the wear resistance of linings for high-performance vehicles.
In the after-sales market, the system’s ability to produce small-batch, multi-specification linings also provides flexibility for manufacturers, enabling them to quickly respond to market demand for replacement parts. Its application has greatly promoted the upgrading of the friction material industry, shifting from labor-intensive production to precision, automated manufacturing.
Technical Specifications and Operational Requirements
Typical technical specifications of the system include a fixed roller diameter of 400 mm, a movable roller diameter of 460 mm, and a total power of 17.2 kW (including two 7.5 kW drive motors and a 2.2 kW mixing motor). The machine footprint is approximately 3.67×1.3×2.285 meters, with a weight of around 2.5 metric tons, making it suitable for standard workshop layouts.
For operational requirements, the system should be used in environments with a temperature range of -10~45℃ and relative humidity of 40~80%, with a 380V three-phase five-wire power supply. Regular maintenance, such as checking hydraulic oil cleanliness (using 46# anti-wear hydraulic oil) and calibrating sensor accuracy, is essential to ensure long-term stable operation. Operators need only basic training to master parameter setting and daily monitoring, thanks to the user-friendly control interface, reducing the threshold for equipment operation.
Note: The system’s performance may vary slightly according to material characteristics and process adjustments, and it is recommended to conduct pre-production tests to determine the optimal parameter combination for specific friction compounds. Special attention should be paid to the alignment of rollers during installation to avoid uneven wear of the linings, and the emergency stop device should be inspected regularly to ensure operational safety.