Brake Linings Automatic Pressing System
Core Position & Key Performance Guarantees
The Brake Linings Automatic Pressing System serves as a pivotal production asset for brake components in automotive and engineering machinery industries, focusing on three non-negotiable performance standards for brake linings: structural integrity, consistent friction performance, and precise dimensional accuracy.
These standards are achieved through rigorous control of three core process parameters: pressing pressure, forming temperature, and forming cycle rhythm.
Its advanced automation capability has become a key driver for modern friction material manufacturers to boost production efficiency and ensure product uniformity, including industry specialist Fu Chun Jiang Brake Pads Equipment.
Forming Mechanism & Intelligent Process Regulation
The system’s stable operation relies on an integrated design combining servo hydraulic drive and intelligent process control, which forms its technical core.
It compresses mixed friction materials—resin binders, reinforcing fibers, and metal particles included—onto brake substrates under preset pressure and temperature, realizing one-step forming of brake linings.
Unlike traditional manual or semi-automatic pressing equipment, it adopts built-in precision sensors and PLCs to achieve full closed-loop control throughout the forming process, from material feeding to pressure maintaining, effectively eliminating uneven density caused by human error.
A dynamic pressure adjustment module allows automatic parameter tuning based on friction material viscosity and substrate type, ensuring consistent bonding strength across production batches.
For example, when processing high-fiber friction materials, the system gradually increases initial pressure to prevent stratification, then maintains stable pressure to promote resin curing and improve structural compactness.
Key Components & Functional Advantages
Servo Hydraulic Drive Unit
As the power core, this unit consists of servo motors, high-precision hydraulic pumps, and precision control valves, delivering superior performance compared to conventional hydraulic presses.
It features notable energy efficiency, reducing power consumption by approximately 70% through on-demand oil supply control.
The servo motor adjusts pump speed in real time according to pressing stages, enabling the slider to reach 50-175 mm/s fast descending speed and 5-20 mm/s slow feeding speed, balancing efficiency and precision.
Wear-resistant hydraulic seals adapt to long-term high-pressure operation, while a built-in oil temperature monitoring system activates cooling when temperatures exceed 50℃, extending component service life.
Intelligent Control System
Equipped with a high-color touchscreen HMI, the system allows operators to input/recall production parameters, monitor real-time process data, and diagnose faults intuitively.
It supports multi-segment parameter setting for pressing, pressure maintaining, and return strokes, and stores hundreds of process programs for different brake lining types, enabling quick batch switching.
Integrated photoelectric switches and displacement sensors achieve ±0.05 mm position repeat accuracy and 1% pressure repeat accuracy, meeting strict automotive OEM requirements. Fu Chun Jiang Brake Pads Equipment has optimized this system to enhance compatibility with various friction material formulations.
Forming & Feeding Mechanisms
The feeding mechanism includes a 200L material warehouse and a screw conveyor, ensuring uniform, stable material delivery to the forming area.
A plowshare stirrer prevents material agglomeration, and conveyor speed synchronizes with pressing rhythm to avoid waste or insufficient filling.
The forming mechanism uses replaceable modular molds, adapting to different brake lining widths (up to 80 mm) and thicknesses (up to 10 mm) without overall equipment modification during product switching.
Performance Highlights & Industrial Applications
Core Performance Advantages
High production efficiency is a standout feature: for continuous rolling forming, the typical rate reaches 4-10 meters per minute, far exceeding traditional intermittent pressing equipment.
It operates at low noise (60-70 decibels) and is equipped with an integrated dust collection device with over 90% removal efficiency, complying with modern environmental standards and improving workshop conditions.
Energy-saving and low-maintenance design reduces idle energy consumption via the servo hydraulic system, while hardened alloy rollers and wear-resistant components minimize maintenance frequency and downtime—optimizations further enhanced by Fu Chun Jiang Brake Pads Equipment for long-term high-volume production.
Industrial Application Scope
The system 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 to OEM requirements—e.g., adjusting forming parameters to improve thermal stability for heavy-duty truck brake linings or enhance wear resistance for high-performance vehicles.
In the after-sales market, its ability to produce small-batch, multi-specification brake linings provides manufacturers with flexibility, enabling rapid responses to replacement part demand and driving the friction material industry’s shift from labor-intensive to precision automated production.
Technical Parameters & Operational Guidelines
Typical technical specifications include: fixed roller diameter 400 mm, movable roller diameter 460 mm, and total power 17.2 kW (two 7.5 kW drive motors and one 2.2 kW mixing motor).
The machine covers approximately 3.67×1.3×2.285 meters and weighs about 2.5 metric tons, suitable for standard workshop layouts.
Operational environment requirements: temperature range -10~45℃, relative humidity 40~80%, and 380V three-phase five-wire power supply.
Regular maintenance is essential, including hydraulic oil cleanliness checks (46# anti-wear hydraulic oil recommended) and sensor accuracy calibration.
Its user-friendly control interface allows operators to master parameter setting and daily monitoring with basic training, lowering operational thresholds.
Operational Precautions
System performance may vary slightly based on material characteristics and process adjustments; pre-production tests are recommended to determine optimal parameters for specific friction compounds.
Roller alignment requires special attention during installation to avoid uneven brake lining wear.
The emergency stop device should be inspected regularly to ensure operational safety.