Brake Linings Automatic Pressing System
System Overview & Core Functions
As a critical production equipment for brake components in automotive and engineering machinery fields, the Brake Linings Automatic Pressing System is designed to ensure three key performance indicators of brake linings: structural integrity, stable friction performance, and high dimensional accuracy.
This is achieved through precise control of three core process parameters: pressing pressure, forming temperature, and rhythm of the forming cycle. Its advanced automation capability has become a decisive factor in upgrading production efficiency and ensuring product consistency for modern friction material manufacturers, including Fu Chun Jiang Brake Pads Machinery.
Forming Principle & Process Control Logic
The system adopts an integrated design of servo hydraulic drive and intelligent process control, which is the core of its stable operation.
It compresses mixed friction materials—including resin binders, reinforcing fibers, and metal particles—onto the brake substrate under preset pressure and temperature conditions, completing the one-time forming of brake linings.
Unlike traditional manual or semi-automatic pressing equipment, it realizes closed-loop control throughout the entire forming process (from material feeding to pressure maintaining) via built-in precision sensors and programmable logic controllers (PLC), effectively eliminating density unevenness caused by human operation errors.
Equipped with a dynamic pressure adjustment module, the system can automatically adjust pressure parameters according to the viscosity of the friction material and the type of substrate, ensuring consistent bonding strength across each production batch.
For example, when processing high-fiber friction materials, the system increases pressure gradually in the initial stage to prevent material stratification, then maintains stable pressure to promote resin curing and improve structural compactness.
Key Structural Components & Their Performances
Servo Hydraulic Drive Unit
As the power core of the entire system, the servo hydraulic drive unit is composed of servo motors, high-precision hydraulic pumps, and precision control valves.
Compared with conventional hydraulic presses, it has significant energy-saving advantages, reducing power consumption by about 70% through on-demand oil supply control.
The servo motor adjusts the pump speed in real time according to the pressing stage, enabling the slider to achieve fast descending speed of 50-175 mm/s and slow feeding speed of 5-20 mm/s, balancing production efficiency and forming precision.
Hydraulic seals and other key components adopt wear-resistant materials to adapt to long-term high-pressure operation; the built-in oil temperature monitoring system automatically starts cooling devices when the oil temperature exceeds 50℃, extending the service life of hydraulic components.
Intelligent Control System
The intelligent control system is equipped with a high-color touch screen human-machine interface (HMI), allowing operators to input and call production parameters, monitor real-time process data, and diagnose equipment faults 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 Brake Pads Machinery has optimized this control system for its product series, enhancing its compatibility with various friction material formulations.
Forming & Feeding Mechanisms
The feeding mechanism consists of a material warehouse (usually 200L capacity) and a screw conveyor, ensuring uniform and stable material delivery to the forming area.
A plowshare stirrer inside the material warehouse prevents material agglomeration, and the conveyor speed is synchronized with the pressing rhythm to avoid material waste or insufficient filling.
The forming mechanism adopts replaceable modular molds; by adjusting mold specifications, it can adapt to different brake lining widths (up to 80 mm) and thicknesses (up to 10 mm), eliminating the need for overall equipment modification when switching product types.
Performance Advantages & Industrial Application Scenarios
Core Performance Advantages
High production efficiency is one of its prominent advantages; for continuous rolling forming, the typical production rate reaches 4-10 meters per minute, which is much higher than that of traditional intermittent pressing equipment.
It operates with low noise, ranging from 60-70 decibels, and is equipped with integrated dust collection devices with a dust removal efficiency of over 90%, complying with modern environmental protection standards and improving workshop working conditions.
The energy-saving and low-maintenance design is another key highlight: the servo hydraulic system reduces idle energy consumption, while hardened alloy rollers and wear-resistant components minimize maintenance frequency and equipment downtime. Fu Chun Jiang Brake Pads Machinery has further optimized the mechanical structure to enhance these advantages, making the 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 the manufacturing of both disc and drum brake pads.
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 brake linings for heavy-duty trucks, or enhancing the wear resistance of linings for high-performance vehicles.
In the after-sales market, its ability to produce small-batch, multi-specification brake linings provides flexibility for manufacturers, enabling them to quickly respond to market demand for replacement parts and promoting the transformation of the friction material industry from labor-intensive to precision automated production.
Technical Specifications & Operational Requirements
Typical technical specifications of the system include: fixed roller diameter of 400 mm, movable roller diameter of 460 mm, and total power of 17.2 kW (including two 7.5 kW drive motors and one 2.2 kW mixing motor).
The machine covers an area of approximately 3.67×1.3×2.285 meters and weighs about 2.5 metric tons, suitable for standard workshop layouts.
For operational environment: it should be used in areas with a temperature range of -10~45℃ and relative humidity of 40~80%, with a 380V three-phase five-wire power supply.
Regular maintenance is essential for long-term stable operation, including checking the cleanliness of hydraulic oil (46# anti-wear hydraulic oil is recommended) and calibrating sensor accuracy.
Thanks to the user-friendly control interface, operators only need basic training to master parameter setting and daily monitoring, reducing the equipment operation threshold.
Usage Notes
System performance may vary slightly according to material characteristics and process adjustments; it is recommended to conduct pre-production tests to determine the optimal parameter combination for specific friction compounds.
Special attention should be paid to roller alignment during installation to avoid uneven wear of brake linings.
The emergency stop device should be inspected regularly to ensure operational safety.