Method for treating high roughness of brake steel back surface

Abstract

This invention relates to a method for treating the high surface roughness of brake steel backing surfaces, belonging to the field of brake steel backing surface treatment technology. The method includes the following steps: Step 1: The brake steel backing to be processed is placed on a loading platform and processed by a conveyor belt. Step 2: In an HRT polishing assembly, the surface roughness and deburring processes of the steel backing are completed sequentially through a conventional belt sander, a forward planetary gear, a reverse planetary gear, and an HRT belt sander. Step 3: In a cleaning and rust-preventing assembly, processing residues and saponification liquid on the surface of the brake steel backing are removed by a coarse cleaning sprayer, followed by the removal of cleaning liquid and metal residue by an air cutter I. Step 4: Rust-preventing liquid is sprayed through a rust-preventing sprayer, followed by double air cutting. Step 5: The surface-treated brake steel backing is placed in a storage bin for later storage. By treating the bonding surface between the brake steel backing and the friction material, a roughness process is avoided, resulting in more stable quality and a high-roughness mating surface.

Description

Technical Field

[0001] This invention relates to the field of brake steel back surface treatment technology, and specifically to a method for treating the high roughness of the brake steel back surface. Background Technology

[0002] With increasingly stringent requirements for braking safety, the shear force of brake pads has become one of the key factors in evaluating brake pad performance. To achieve higher shear force, the adhesion between the friction material and the brake backing needs to be stronger, which requires a higher surface roughness on the bonding surface between the brake backing and the friction material. Analysis of experimental data indicates that this roughness requirement is Ra≥2.0 or Rz≥30.

[0003] Traditional methods for improving the surface roughness of brake steel backing mainly employ shot blasting and sandblasting. While these processes can meet the surface roughness requirements of brake steel backing, they also have many drawbacks:

[0004] 1. Shot blasting and sandblasting processes can alter the product's shape, dimensions, and flatness, and the changes are highly unpredictable and difficult to control, resulting in poor product quality stability.

[0005] 2. It is necessary to improve the control of stamping and reduce stamping tolerances to ensure the quality of the final product. This will increase the quality cost of the stamping process by 1.5 to 2 times compared to the past.

[0006] 3. Both shot blasting and sandblasting processes operate in extremely harsh environments, generating significant dust and noise. Summary of the Invention

[0007] This invention primarily addresses the shortcomings of existing technologies by providing a method for treating the high surface roughness of brake steel backing surfaces. This method offers advantages such as convenient operation, good operational stability, and high efficiency. It solves the problem of excessive dust and noise caused by increasing the surface roughness of brake steel backing surfaces. By treating the bonding surface between the brake steel backing and the friction material, a roughness process is avoided, resulting in more stable quality and the effect of a high-roughness mating surface.

[0008] The above-mentioned technical problems of the present invention are mainly solved by the following technical solutions:

[0009] A surface treatment device for brake steel backing includes a conveyor belt, a loading platform at the front end of the conveyor belt, an HRT polishing component above the front part of the conveyor belt, a cleaning and rust prevention component above the rear part of the conveyor belt, and a material box at the rear end of the conveyor belt.

[0010] The HRT polishing assembly includes a conventional belt sander, with an HRT belt sander located behind it. A forward planetary gear and a reverse planetary gear are sequentially arranged between the conventional belt sander and the HRT belt sander.

[0011] The cleaning and rust prevention components include a coarse washing sprayer, a rust prevention sprayer at the rear end of the coarse washing sprayer, a pair of air cutters III at the rear end of the rust prevention sprayer, and an air cutter I between the rust prevention sprayer and the coarse washing sprayer.

[0012] A method for treating high surface roughness of brake steel backing includes the following steps:

[0013] Step 1: The brake steel backing to be processed is placed on the loading platform manually or mechanically by a robotic arm, and then processed by a conveyor belt.

[0014] Step 2: The steel back surface roughness and deburring process is completed in sequence through a regular belt sander, forward planetary gears, reverse planetary gears and HRT belt sander in the HRT polishing assembly.

[0015] Step 3: After cleaning the rust-preventing components, the rough cleaning sprayer removes the processing residue and saponification liquid from the surface of the brake steel backing. Then, the air cutter I uses air knives to blow away the cleaning liquid and large metal particles from the product surface.

[0016] Step 4: The surface of the brake steel backing is sprayed with rust-preventive liquid using a rust-preventive sprayer, and then double-cut with a pair of air cutters (III) to remove excess rust-preventive agent, solidify the rust-preventive effect, and dry the brake steel backing.

[0017] Step 5: Place the surface-treated brake steel backing into the material box for storage.

[0018] Preferably, a fine cleaning sprayer is provided between the rust-preventive sprayer and the air cutter I, and an air cutter II is provided between the fine cleaning sprayer and the rust-preventive sprayer.

[0019] Preferably, the coarse wash sprayer, fine wash sprayer, and rust prevention sprayer all adopt an upper and lower opposing spray structure, so that the spraying area covers the entire conveyor belt; the spray liquid in the coarse wash sprayer and fine wash sprayer consists of a 3% to 5% concentration of cleaning agent, which removes fine metal particles and oil stains from the surface of the brake steel backing; the spray liquid in the rust prevention sprayer consists of a 2% to 3% concentration of rust inhibitor, which mainly completes the rust prevention treatment of the steel backing, so that the steel backing achieves a water-based rust prevention effect for 1 to 3 months.

[0020] Preferably, the cleaning agent in the coarse wash sprayer consists of fatty alcohol polyoxyethylene ether and soda ash; the cleaning agent in the fine wash sprayer consists of sodium carbonate, sodium metasilicate, fatty alcohol polyoxyethylene ether and sodium dodecane sulfonate.

[0021] As a preferred option, the cleaning agent may also contain graphite oxide, titanium dioxide, styrene-ethyltrimethoxysilane, sulfur trioxide, sodium hydroxide, sodium nitrate, sodium tripolyphosphate, nonylphenol polyoxyethylene ether, or coconut oil fatty acids.

[0022] Preferably, the rust inhibitor is composed of boron oleate, EDTA-4Na and glycerol.

[0023] As a preferred option, the rust inhibitor also contains triethanolamine, lauric acid, adipic acid, sodium benzoate, sodium tetraborate, sodium carbonate, or sodium gluconate.

[0024] As a preferred option, the forward planetary gear adopts a brush disc structure with clockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to perform the grinding process of burrs on the edge of the brake steel back. Since there are blind spots in the burr grinding of the forward planetary gear, the reverse planetary gear adopts a brush disc structure with counterclockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to compensate for the blind spots in the burr grinding of the forward planetary gear on the brake steel back.

[0025] Preferably, a buffer guide plate is provided between the material box and the conveyor belt, through which the surface-treated brake steel back is guided into the material box.

[0026] As a preferred option, HRT belts used in HRT belt sanders have ceramic abrasive added to their surface compared to ordinary belts. The ceramic abrasive on HRT belts provides a rapid, even, and powerful material removal rate. The grinding operation temperature is low, avoiding overheating that can cause metal discoloration, oxidation, and stress cracking. The abrasive grains in the ceramic abrasive have a self-sharpening process, preventing dulling and load reduction.

[0027] The present invention can achieve the following effects:

[0028] This invention provides a method for treating the high surface roughness of brake steel backing surfaces. Compared with existing technologies, it has the advantages of convenient operation, good operational stability, and high efficiency. It solves the problem of excessive dust and noise caused by increasing the surface roughness of brake steel backing surfaces. By treating the bonding surface between the brake steel backing and the friction material, a roughness process is avoided, resulting in more stable quality and the effect of a high-roughness mating surface. The dimensional accuracy, flatness accuracy, and consistency of the stamped product are preserved, and the stability of key dimensions can reach a level of CPK1.67 or higher.

[0029] This new process achieves improved production efficiency and balanced production. It can reach an efficiency of 1800-2400 pieces per hour, a 10%-30% improvement over traditional processes, meeting the batch production requirements of manufacturing plants. Furthermore, the use of conveyor belts for transfer and processing eliminates intermediate or line-side inventory, achieving balanced production. Because the HRT process is integrated into the deburring process, the overall post-processing steps are reduced. Additionally, the use of conveyor belts for transfer and processing reduces inter-process accumulation time and the establishment of line-side warehouses, reducing both product turnover and stockpiling time, as well as the input of production personnel. Therefore, it has a significant advantage in production costs compared to traditional post-processing processes. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the present invention.

[0031] Figure 2 This is a schematic diagram of the structure of the HRT polishing component of the present invention.

[0032] Figure 3 This is a schematic diagram of the cleaning and rust prevention component of the present invention.

[0033] In the diagram: 1. Loading platform; 2. HRT polishing assembly; 3. Conveyor belt; 4. Cleaning and rust prevention assembly; 5. Buffer guide plate; 6. Material box; 7. Ordinary belt sander; 8. Forward planetary gear; 9. Reverse planetary gear; 10. HRT belt sander; 11. Coarse washing sprayer; 12. Air cutter I; 13. Fine washing sprayer; 14. Air cutter II; 15. Rust prevention sprayer; 16. Air cutter III. Detailed Implementation

[0034] The technical solution of the invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings.

[0035] Example: Figure 1 , Figure 2 and Figure 3 As shown, a brake steel backing surface treatment device includes a conveyor belt 3, a loading platform 1 at the front end of the conveyor belt 3, an HRT polishing component 2 above the front of the conveyor belt 3, a cleaning and rust prevention component 4 above the rear of the conveyor belt 3, and a material box 6 at the rear end of the conveyor belt 3. A buffer guide plate 5 is provided between the material box 6 and the conveyor belt 3, through which the surface-treated brake steel backing is guided into the material box 6.

[0036] The HRT polishing assembly 2 includes a conventional belt sander 7, with an HRT belt sander 10 located behind the conventional belt sander 7. A forward planetary gear 8 and a reverse planetary gear 9 are sequentially arranged between the conventional belt sander 7 and the HRT belt sander 10. The HRT belt used on the HRT belt sander 10 has ceramic abrasive added to its surface compared to the conventional belt sander.

[0037] The cleaning and rust prevention component 4 includes a coarse wash sprayer 11, a rust prevention sprayer 15 at the rear end of the coarse wash sprayer 11, a pair of air cutters III 16 at the rear end of the rust prevention sprayer 15, and an air cutter I 12 between the rust prevention sprayer 15 and the coarse wash sprayer 11. A fine wash sprayer 13 is located between the rust prevention sprayer 15 and the air cutter I 12, and an air cutter II 14 is located between the fine wash sprayer 13 and the rust prevention sprayer 15.

[0038] The coarse wash sprayer 11, the fine wash sprayer 13, and the rust prevention sprayer 15 all adopt an upper and lower opposing spray structure, so that the spraying area covers the entire conveyor belt; the spraying liquid in the coarse wash sprayer 11 and the fine wash sprayer 13 consists of a 3% to 5% concentration of cleaning agent, which completes the removal of fine metal particles and oil stains on the surface of the brake steel back.

[0039] The cleaning agent in the coarse wash sprayer 11 consists of fatty alcohol polyoxyethylene ether and soda ash; the cleaning agent in the fine wash sprayer 13 consists of sodium carbonate, sodium metasilicate, fatty alcohol polyoxyethylene ether, and sodium dodecane sulfonate. The cleaning agent also contains graphite oxide, titanium dioxide, styrene-ethyltrimethoxysilane, sulfur trioxide, sodium hydroxide, sodium nitrate, sodium tripolyphosphate, nonylphenol polyoxyethylene ether, or coconut oil fatty acids.

[0040] The spray liquid in the rust-preventive sprayer 15 consists of a 2%–3% concentration of rust inhibitor, primarily for rust prevention of the steel backing, achieving a water-based rust-preventive effect for 1–3 months. The rust inhibitor is composed of trioleoyl boronamide, EDTA-4Na, and glycerol. Triethanolamine, lauric acid, adipic acid, sodium benzoate, sodium tetraborate, sodium carbonate, or sodium gluconate are also added to the rust inhibitor.

[0041] A method for treating high surface roughness of brake steel backing includes the following steps:

[0042] Step 1: The brake steel backing to be processed is placed on the loading platform 1 by manual labor or mechanical arm, and then processed by the conveyor belt 3.

[0043] Step 2: Within the HRT polishing assembly 2, the steel back surface roughness and deburring processes are completed sequentially via a conventional belt sander 7, a forward planetary gear 8, a reverse planetary gear 9, and an HRT belt sander 10. The conventional belt sander 7 uses a 20-80 grit abrasive belt to remove stamping burrs from the product. The HRT belt sander 10 uses an HRT abrasive belt to grind the roughness of the machined end face of the brake steel back.

[0044] The forward planetary gear 8 adopts a brush disc structure with clockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to perform the grinding process of burrs on the edge of the brake steel back. There will be blind spots in the burr grinding of the forward planetary gear 8. The reverse planetary gear 9 adopts a brush disc structure with counterclockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to compensate for the blind spots in the burr grinding of the forward planetary gear on the brake steel back.

[0045] Step 3: In the cleaning of the rust-preventive component 4, the rough cleaning sprayer 11 removes the processing residue and saponification liquid from the surface of the brake steel backing. Then, the air cutter I 12 uses air knives to blow away the cleaning liquid and large metal particles from the product surface. Next, the fine cleaning sprayer 13 removes the fine metal particles and oil stains from the surface of the brake steel backing. The air cutter II 14 uses air knives to blow away the cleaning liquid and remaining metal residue from the product surface.

[0046] Step 4: The surface of the brake steel backing is sprayed with rust-preventive liquid by the rust-preventive sprayer 15, and then the excess rust-preventive agent is removed by double air cutting by a pair of air cutters Ⅲ16, the rust-preventive effect is cured and the brake steel backing is dried.

[0047] Step 5: Place the surface-treated brake steel backing into material box 6 for storage.

[0048] In summary, this method for treating the high surface roughness of brake steel backing offers advantages such as convenient operation, good operational stability, and high efficiency. It solves the problems of excessive dust and noise caused by increasing the surface roughness of the brake steel backing. By treating the bonding surface between the brake steel backing and the friction material, a roughness process is avoided, resulting in more stable quality and a high-roughness mating surface.

[0049] This is a manufacturing process for the subsequent brake backplate after stamping, developed to achieve automated mass production and meet the efficiency and quality requirements of the production plant. This process encompasses deburring, chamfering, roughening, cleaning, and drying, and is completed using high-roughness surface treatment equipment and cleaning and drying equipment.

[0050] The above description is only a specific embodiment of the present invention, but the structural features of the present invention are not limited thereto. Any changes or modifications made by those skilled in the art within the scope of the present invention are covered by the patent scope of the present invention.

Claims

1. A method for treating high surface roughness of brake steel backing, characterized in that: The brake steel back surface treatment equipment includes a conveyor belt (3), a loading platform (1) is provided at the front end of the conveyor belt (3), an HRT polishing component (2) is provided above the front part of the conveyor belt (3), a cleaning and rust prevention component (4) is provided above the rear part of the conveyor belt (3), and a material box (6) is provided at the rear end of the conveyor belt (3). The HRT polishing assembly (2) includes a conventional belt sander (7), and an HRT belt sander (10) is provided behind the conventional belt sander (7). A forward planetary gear (8) and a reverse planetary gear (9) are arranged sequentially between the conventional belt sander (7) and the HRT belt sander (10). The HRT belt used on the HRT belt sander (10) has ceramic abrasive added to its surface compared to the conventional belt sander. The cleaning and rust prevention component (4) includes a coarse washing sprayer (11), a rust prevention sprayer (15) is provided at the rear end of the coarse washing sprayer (11), a pair of air cutters III (16) are provided at the rear end of the rust prevention sprayer (15), and an air cutter I (12) is provided between the rust prevention sprayer (15) and the coarse washing sprayer (11). The method for treating the high surface roughness of brake steel backing includes the following steps: Step 1: The brake steel backing to be processed is placed on the loading platform (1) by manual labor or mechanical arm, and processed by the conveyor belt (3); Step 2: The steel back surface roughness and deburring process is completed in the HRT polishing assembly (2) by passing through the ordinary belt sander (7), forward planetary gear (8), reverse planetary gear (9) and HRT belt sander (10) in sequence; Step 3: In cleaning the rust-proof components (4), the processing residue and saponification liquid on the surface of the brake steel back are removed by the coarse cleaning sprayer (11), and then the cleaning liquid and large metal residue on the product surface are blown off by the air cutter I (12) using the air knife. Step 4: The surface of the brake steel back is sprayed with rust-preventive liquid by a rust-preventive sprayer (15), and then the excess rust-preventive agent of the product is removed by a pair of air cutters III (16) to solidify the rust-preventive effect and dry the brake steel back. Step 5: Place the surface-treated brake steel back into the material box (6) for storage.

2. The method for treating high surface roughness of brake steel backing surface according to claim 1, characterized in that: A fine cleaning sprayer (13) is provided between the rust-preventing sprayer (15) and the air cutter I (12), and an air cutter II (14) is provided between the fine cleaning sprayer (13) and the rust-preventing sprayer (15).

3. The method for treating high surface roughness of brake steel backing surface according to claim 2, characterized in that: The coarse wash sprayer (11), fine wash sprayer (13) and rust prevention sprayer (15) all adopt an upper and lower spray structure, so that the spray area covers the entire conveyor belt; the spray liquid in the coarse wash sprayer (11) and fine wash sprayer (13) consists of a 3% to 5% concentration of cleaning agent, which completes the removal of fine metal particles and oil stains on the surface of the brake steel back; the spray liquid in the rust prevention sprayer (15) consists of a 2% to 3% concentration of rust inhibitor, which mainly completes the rust prevention treatment of the steel back, so that the steel back achieves a water-based rust prevention effect of 1 to 3 months.

4. The method for treating high surface roughness of brake steel backing surface according to claim 3, characterized in that: The cleaning agent in the coarse wash sprayer (11) is composed of fatty alcohol polyoxyethylene ether and soda ash; the cleaning agent in the fine wash sprayer (13) is composed of sodium carbonate, sodium metasilicate, fatty alcohol polyoxyethylene ether and sodium dodecane sulfonate.

5. The method for treating high surface roughness of brake steel backing surface according to claim 4, characterized in that: The cleaning agent also contains graphite oxide, titanium dioxide, styrene-ethyltrimethoxysilane, sulfur trioxide, sodium hydroxide, sodium nitrate, sodium tripolyphosphate, nonylphenol polyoxyethylene ether, or coconut oil fatty acids.

6. The method for treating high surface roughness of brake steel backing surface according to claim 3, characterized in that: The rust inhibitor is composed of boron oleate, EDTA-4Na and glycerol.

7. The method for treating high surface roughness of brake steel backing surface according to claim 6, characterized in that: The rust inhibitor also contains triethanolamine, lauric acid, adipic acid, sodium benzoate, sodium tetraborate, sodium carbonate, or sodium gluconate.

8. The method for treating high surface roughness of brake steel backing surface according to claim 1, characterized in that: The forward planetary gear (8) adopts a brush disc structure with clockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to perform the grinding process of burrs on the edge of the brake steel back. There will be blind spots in the burr grinding of the forward planetary gear (8). The reverse planetary gear (9) adopts a brush disc structure with counterclockwise revolution and rotation, consisting of 3 sets of rotating grinding discs and a revolution shaft, to compensate for the blind spots in the burr grinding of the forward planetary gear on the brake steel back.

9. The method for treating high surface roughness of brake steel backing surface according to claim 1, characterized in that: A buffer guide plate (5) is provided between the material box (6) and the conveyor belt (3) to guide the surface-treated brake steel back into the material box (6).

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