Three-dimensional scale cutting and grinding integrated brake pad sample cutting machine

Abstract

The invention discloses a three-dimensional scale cutting and grinding integrated brake pad sample cutting machine. The device comprises a rotatable material table which is used for driving a brake pad sample to rotate around an axis perpendicular to a cutting plane so as to realize multi-surface cutting under single clamping; the cutting unit comprises a driving device, a cutting blade main shaft and a cutting blade, the cutting blade is arranged on the cutting blade main shaft, and the driving device drives the cutting blade main shaft to rotate so as to drive the cutting blade to rotate for cutting; the adjustable base is used for supporting the material table and can adjust the position of the material table in a three-dimensional space; the cutting unit and the adjustable base work cooperatively, and multi-angle and multi-scale cutting and grinding integrated machining of the brake pad sample under single-time clamping is achieved. Cooperative movement control of a precise lead screw transmission mechanism and an adjustable base is adopted, and a'cutting-cambered surface 'machining technical scheme is created for the first time through mechanical and electrical integration design.

Description

Technical Field

[0001] This invention relates to the field of brake pad processing technology for vehicles, and in particular to a brake pad sample cutting machine that integrates three-dimensional cutting and grinding. Background Technology

[0002] Brake pads, also known as brake linings, are the most critical safety component in a car's braking system. The quality of braking performance is determined by the brake pads, so good brake pads are the guardians of both people and cars.

[0003] Brake pads are generally composed of a steel backing, an adhesive heat insulation layer, and a friction block. The steel backing is coated to prevent rust. The coating process is monitored by an SMT-4 furnace temperature tracker to ensure quality. The heat insulation layer is made of a non-heat-conducting material for heat insulation. The friction block is composed of friction material and adhesive.

[0004] During braking, the friction pads are pressed against the brake disc or brake drum, generating friction to achieve vehicle deceleration and braking. Due to friction, the friction pads will gradually wear down; generally speaking, the lower the cost of the brake pads, the faster they wear out. Brake pads must be replaced promptly after the friction material is used up; otherwise, the brake pads will come into direct contact with the brake disc, eventually leading to loss of braking effectiveness and damage to the brake disc.

[0005] The quality and function of brake pads are of paramount importance to vehicle safety. During the production process, brake pads require sample cutting and testing to ensure product quality. Currently, brake pad sample cutting is done manually using ordinary cutting machines, requiring each brake pad sample to be cut at least twice, which is inefficient.

[0006] During the production of automotive brake pads, cutting devices are often used to cut them. However, current cutting devices cannot properly adjust their working position during the cutting process, resulting in low cutting accuracy and efficiency.

[0007] In the existing brake pad sample preparation process, traditional processing equipment has three major technical bottlenecks: First, the fixed cutting blade design requires the sample to be clamped multiple times, making it impossible to complete orthogonal cutting after fixing once; second, it lacks the continuous processing capability of "rough cutting followed by fine grinding"; and third, the fixed height of the material stage makes it impossible to adapt to the processing needs of samples of different thicknesses. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a brake pad sample cutting machine that integrates three-dimensional cutting and grinding.

[0009] The brake pad sample cutting machine of the present invention includes:

[0010] Positioning clamps for fixing brake pad samples;

[0011] A rotatable material stage, wherein the positioning fixture is fixed on the material stage, and the material stage can drive the brake pad sample to rotate around an axis perpendicular to the cutting plane, so as to achieve multi-faceted cutting in a single clamping.

[0012] A cutting unit includes a driving device, a cutting disc spindle, and a cutting disc, wherein the cutting disc is disposed on the cutting disc spindle, and the driving device drives the cutting disc spindle to rotate so as to drive the cutting disc to rotate and cut.

[0013] The cutting blade includes:

[0014] A fixed cutting blade is disposed at one end near the driving device and is fixedly connected to the cutting blade spindle.

[0015] The movable cutting blade is movably mounted on the main shaft of the cutting blade via an axial translation device, thereby achieving stepless adjustment of the distance between it and the fixed cutting blade;

[0016] An adjustable base is used to support the material stage and the position of the material stage can be adjusted in three-dimensional space to accommodate brake pad samples of different thicknesses.

[0017] The cutting unit and the adjustable base work together to achieve integrated processing of multi-angle and multi-scale cutting and grinding of the brake pad sample in a single clamping.

[0018] The method for cutting brake pad samples using the aforementioned cutting machine includes the following steps:

[0019] a) Fix the brake pad sample to a rotatable material stage using a positioning clamp, the material stage being mounted on an adjustable base whose position can be adjusted in three-dimensional space;

[0020] b) Start the cutting unit to make the cutting blade rotate around the cutting blade spindle. Adjust the position of the material stage through the adjustable base so that the cutting blade performs the first cutting process on the brake pad sample.

[0021] c) After the first cut is completed, keep the positioning fixture fixed and drive the material stage to rotate 90° around the axis perpendicular to the cutting plane to change the spatial position of the brake pad sample;

[0022] d) Restart the cutting unit to perform a second orthogonal cutting process to complete the double-sided cutting of the brake pad sample;

[0023] e) The radial feed of the material stage is precisely controlled by the adjustable base. At the same time, the axial translation device on the cutting blade spindle is used to drive the cutting blade to produce precise displacement along the axial direction, so that the cutting blade cuts the brake pad sample on the arc surface according to the preset arc trajectory, realizing multi-angle and multi-scale cutting and forming of the brake pad sample in one clamping.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. This invention employs an adjustable base structure. Driven by a motor, the lead screw rotates, and under the precise guidance of the slide groove, the rotational motion of the lead screw is converted into the linear displacement of the translational table, thus enabling the entire upper actuator to move smoothly. This innovative design effectively overcomes the limitations of traditional brake pad cutting machines where the material table is fixed and cannot be adjusted, allowing the processing platform to be flexibly adjusted at multiple angles and positions. This significantly improves the equipment's processing adaptability and production efficiency, better meeting the demands of modern production for processing flexibility.

[0026] 2. This invention adjusts the position of the cutting blade, which is furthest from the motor end, using a shaped slider until the blade is in the appropriate position. The drive screw then rotates relative to the cutting blade's main shaft. During this rotation, the screw moves the shaped slider under the guidance of the guide groove, causing the cutting blade to move accordingly. The cutting blade then cuts the brake pads until the cutting is complete, providing multi-station cutting without stopping the machine, resulting in high cutting efficiency.

[0027] 3. This invention innovatively adopts the coordinated motion control of a precision lead screw transmission mechanism and an adjustable base. Through mechatronics design, it pioneers a "cutting-arc surface" processing technology solution. Specifically, the lead screw drive system realizes the axial precise feed of the cutting blade, while the adjustable base drives the workpiece to make radial movement, so that the sample is first rough cut to form an arc surface and then finely polished.

[0028] 4. This invention features an innovative design of a liftable rotary table, which gives the equipment three-dimensional spatial adjustment capabilities and can flexibly adapt to the processing needs of brake pads of different specifications.

[0029] Instruction manual illustrations

[0030] Figure 1 This is an overall view of the cutting machine of the present invention;

[0031] Figure 2 An adjustable base for securing materials to the main body of the cutting machine;

[0032] Figure 3 For the translational movement of the cutting disc;

[0033] Figure 4 This is the main body of the cutting machine. Detailed Implementation

[0034] The present invention will be further described in detail below with reference to the accompanying drawings. For clarity, only structures related to the inventive points of the present invention are shown in the drawings.

[0035] This application includes an adjustable base and a cutting unit (including a cutting machine spindle drive component and a cutting disc translation device).

[0036] In some embodiments, the adjustable base is divided into four parts: a fixed base, a vertical axis translational stage, a horizontal axis translational stage, and a liftable rotary stage.

[0037] The fixed base has guide grooves, with threads engraved in the middle groove. The lower part of the vertical axial translational stage has a groove that mates with the fixed base. Inside the vertical axial translational stage is a lead screw parallel to the translation direction, with angular contact bearings at both ends engaging with the vertical axial translational stage. The upper part has a groove perpendicular to the lower part in the horizontal direction, with threads engraved in the middle groove. The lower part of the horizontal axial translational stage has a groove that mates with the vertical axial translational stage. Inside the horizontal axial translational stage is a lead screw parallel to the translation direction, with angular contact bearings at both ends engaging with the horizontal axial translational stage. An axial thrust bearing is installed at the top for assembly with the rotary table.

[0038] The rotary table has a base with a coaxial thrust bearing at its lower part, and a ring of worm gear teeth is installed around its perimeter. The rotary table is also used to fix the material to be cut, allowing for flexible adjustment of the working height according to the thickness of the brake pad to be processed, ensuring the consistency of the cut surface and process adaptability. This application employs a 90° rotatable dual-positioning system, using an adjustable base rotation device to ensure rotational positioning, achieving orthogonal double-sided cutting of the sample in a single clamping operation.

[0039] In some embodiments, the cutting machine spindle drive assembly consists of a motor support, a motor, and a coupling. The motor is mounted on the motor support, and the motor spindle is connected to the cutting disc spindle via the coupling.

[0040] In some embodiments, the cutting blade translation device has a blind hole of a certain diameter drilled at the end of the cutting blade spindle away from the motor, and a guide groove communicating with the blind hole is formed on the cutting blade spindle. Two cutting blades are mounted on the cutting blade spindle; the cutting blade at the end away from the motor is a translational cutting blade, and the cutting blade at the other end is fixed on the shaft to form a fixed cutting blade.

[0041] The lead screw inside the main shaft is assembled with the main shaft of the cutting machine through a sliding bearing. A shaped slider is placed on the lead screw, and the shaped slider is connected to the movable cutting blade through a guide groove on the shaft. The lead screw is connected to the coil winding through a coupling. The coil winding is set inside the electromagnet. By controlling the magnitude and direction of the current on and off the electromagnet, the lead screw is decelerated or accelerated, realizing the relative rotation between the lead screw and the main shaft of the cutting blade. This causes the shaped slider to generate axial displacement in the guide groove, and the movable cutting blade, which is fixed together with the shaped slider, also generates axial displacement, i.e., translation.

[0042] Furthermore, a brake pad grinding disc assembly is coaxially integrated between the fixed cutting disc and the motor.

[0043] This application uses a motor-driven lead screw transmission structure, which enables backlash-free continuous operation and avoids the idle transmission caused by gear meshing clearance in conventional gear transmission structures, thus preventing the sample block dimensional accuracy from exceeding tolerances. Simultaneously, the motor drive also solves the problem of unstable speed in manual operation. Therefore, the transmission structure used in this application can guarantee the high-precision requirements of multi-angle machining of the test sample block.

[0044] The operation process of this application is as follows: After the workpiece is fixed to the material table by the positioning fixture, the cutting blade performs the first cutting process; after the processing is completed, the positioning fixture remains fixed, the rotary table rotates 90° to change the spatial position, and then the second orthogonal cutting process is performed. This part of the device can produce sample products that meet various test requirements.

[0045] After initial processing, the operator needs to replace the blade with a small, precision 125mm cutting blade according to process requirements. The radial (perpendicular to the spindle) feed of the material is precisely controlled by a motor. Simultaneously, the axial precision displacement of the blade is adjusted to create a specific spatial angle between the cutting blade and the workpiece (described in detail later). This complex motion requires the operator to slowly and evenly push the feed motor, allowing the rotating cutting blade to cut the material surface along a preset arc trajectory. As the material is cut from the outside in, the dynamic cutting blade continuously advances towards the static cutting blade, achieving a one-time cutting of the brake pad's arc surface. The entire cutting process is a dynamic advancement process.

[0046] Throughout the cutting process, pay close attention to changes in chip shape and cutting sound, and adjust the feed rate and depth of cut as needed to ensure the cutting insert always travels smoothly along the predetermined arc path. When the machining is close to the end of the contour, reduce the feed rate for finishing, and use multiple micro-feeds to ensure the surface finish and dimensional accuracy of the arc transition area.

[0047] This application uses a series of mechanisms to allow the main body of the cutting machine to translate and rotate within a certain range relative to the fixed base platform, and to change the distance between the cutting blades without stopping the machine. This allows the cutting machine to change different working states without stopping the machine, avoiding the situation where traditional brake pad cutting machines need to stop the machine to switch working states during the cutting process. It can provide multi-station cutting, making brake pad cutting more efficient, thereby solving the problems mentioned in the background art.

[0048] Example:

[0049] like Figure 1 and Figure 4 As shown, base 1 is installed on the ground, and motor 2 is installed above base 1. The main body of the cutting machine consists of motor 2, cutting blade spindle 5, movable cutting blade 3, fixed cutting blade 4, and grinding blade 6. The motor spindle 2 is connected to the cutting blade spindle 5 via a coupling, and the cutting blade spindle 5 distributes the motor torque to the two cutting blades. The surface of the cutting blade spindle 5 has a keyway, allowing the movable cutting blade 3 to move relative to the cutting blade spindle 5. The fixed cutting blade 4 is fixed to the end of the cutting blade spindle near the motor, and the movable cutting blade 3 can move horizontally on the cutting blade spindle 5 via a cutting blade translation device.

[0050] like Figure 3 As shown, the cutting disc spindle has an inner hole, or blind hole, at the end furthest from the motor (a keyway serves as a guide groove communicating with this blind hole). A lead screw 15 is placed inside the hole. The part of the lead screw 15 furthest from the hole that connects to the cutting disc spindle 5 is in contact with a sliding bearing. A shaped slider 16 is placed on the lead screw 15. The shaped slider is fixed to the cutting disc through the keyway on the cutting disc spindle 5. The movement of the shaped slider 16 on the lead screw 15 drives the cutting disc 3 to translate on the cutting disc spindle 5. The end of the cutting disc spindle 5 furthest from the motor is assembled with the lead screw 15 by a rolling bearing. The end of the lead screw 15 furthest from the motor is connected to a coil 13 via a coupling 14. An electromagnet 12 is externally located. By controlling the magnitude and direction of the current, the lead screw is decelerated or accelerated, realizing the relative movement between the lead screw 15 and the cutting disc spindle 5, thereby causing the cutting disc 3 to translate on the cutting disc spindle 5.

[0051] like Figure 2 As shown, the base 7 is fixed on the ground, and the vertical axis translational stage 8 is installed on the base 7. The two are assembled through a sliding groove. The vertical axis translational stage 8 and the base 7 are connected by a lead screw, which is driven by a motor, thereby realizing the lateral movement of the transverse platform 8 on the base 7.

[0052] The horizontal axial translational stage 9 is assembled via a sliding groove, similar to the one above. The installation angles of both are perpendicular to the horizontal plane of the "base 7 - vertical axial translational stage 8". A lead screw, driven by a motor, also connects the horizontal axial translational stage 9 and the vertical axial translational stage 8, thus enabling the longitudinal movement of the horizontal axial translational stage 9 on the vertical axial translational stage 8.

[0053] A height-adjustable rotary table 11 is mounted on a horizontal axial translation platform, with an axial thrust bearing connecting them. This allows the rotary table to rotate and adjust vertically in the horizontal plane. The base on which the axial thrust bearing is mounted has a ring of teeth 10 around its perimeter, and a power motor is installed around it. The output shaft of the power motor and the base on which the axial thrust bearing is mounted form a worm gear transmission, which drives the horizontal rotation of the rotary table and simultaneously fixes the block on the rotary table 11.

[0054] This embodiment features a height-adjustable rotary table mechanism in its mechanical structure, enabling precise adjustment of the working height of the block. This integrated system, through its purely mechanical design, avoids the cumulative errors caused by multiple clamping operations.

[0055] The operation process of this embodiment:

[0056] (1) After turning on the machine, first use the horizontal axis translation table, the vertical axis translation table, and the height-adjustable rotary table to find a suitable processing position. Then turn on the spindle motor. After the motor speed stabilizes, fix the sample on the material table, adjust the position of the cutting blade auxiliary positioning block according to the size requirement of a certain width of the sample block, and tighten the bolts.

[0057] (2) By controlling the current intensity and direction of the electromagnet and the coil winding, the lead screw is subjected to forces in different directions, thereby achieving the effect of deceleration or acceleration of the lead screw. As a result, the lead screw and the motor spindle generate relative motion, causing the irregularly shaped slider on the lead screw to drive the movable cutting blade to move left and right on the cutting blade spindle, changing the cutting distance between the two cutting blades, adjusting the distance between the two cutting blades to reach the sample width, and the cutting blade starts cutting.

[0058] (3) The sample is pushed in twice for cutting. First, the left and right sides of the sample are cut. Then, the rotating table is adjusted to rotate the material 90 degrees and the front and back ends of the sample are cut. Finally, a rectangular block sample is cut out.

[0059] (4) Rotate the rotary platform to reset the machining mechanism to the initial position. After completing the initial machining, the operator replaces the cutting blade with a small, precision 125mm blade according to the process requirements, and at the same time adjusts the vertical axis translation table to move the workpiece away from the blade for easy operation.

[0060] (5) The arc surface of the brake pad is an arc segment with a radius of 139mm and a central angle of 120°. You can first make an arc segment template with a radius of 139mm and a central angle of 120° using a metal plate, and mark a point every 16.5 degrees, for a total of 13 segments, each segment being about 22.3mm. Then trace the outline onto the workpiece.

[0061] Adjust the vertical axis translation stage to position the workpiece below the blade. Before cutting, be sure to use a clamp to secure the workpiece and prevent wobbling. The radial feed of the material is precisely controlled by an adjustable base driven by a motor. Simultaneously, the translation device is adjusted synchronously to create precise axial displacement of the blade. During cutting, a linear approximation method is used to cut short straight lines along the outer edge of the arc. Finally, the material is placed on a grinding disc for grinding, ultimately forming a complete brake pad.

[0062] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A brake pad sample cutting machine, characterized in that, include: Positioning clamps for fixing brake pad samples; A rotatable material stage, wherein the positioning fixture is fixed on the material stage, and the material stage can drive the brake pad sample to rotate around an axis perpendicular to the cutting plane, so as to achieve multi-faceted cutting in a single clamping. A cutting unit includes a driving device, a cutting disc spindle, and a cutting disc, wherein the cutting disc is disposed on the cutting disc spindle, and the driving device drives the cutting disc spindle to rotate so as to drive the cutting disc to rotate and cut. The cutting blade includes: A fixed cutting blade is disposed at one end near the driving device and is fixedly connected to the cutting blade spindle. The movable cutting blade is movably mounted on the main shaft of the cutting blade via an axial translation device, thereby achieving stepless adjustment of the distance between it and the fixed cutting blade; An adjustable base is used to support the material stage and the position of the material stage can be adjusted in three-dimensional space to accommodate brake pad samples of different thicknesses. The cutting unit and the adjustable base work together to achieve integrated processing of multi-angle and multi-scale cutting and grinding of the brake pad sample in a single clamping.

2. The brake pad sample cutting machine according to claim 1, characterized in that, The adjustable base includes: Fixed base; A vertical axis translational stage slides with the fixed base through a first groove and is driven by a first lead screw to achieve vertical displacement. The horizontal axial translational stage slides into the vertical axial translational stage via a second groove and is driven by a second lead screw to achieve horizontal displacement. A rotary table is mounted on the horizontal axial translational platform and is assembled with an axial thrust bearing to achieve horizontal rotation and height adjustment.

3. A brake pad sample cutting machine according to claim 2, characterized in that, The lower part of the rotary table is equipped with worm gear teeth, which mesh with the worm of the power motor to achieve precise horizontal rotation positioning.

4. A brake pad sample cutting machine according to claim 1, characterized in that, The axial translational device includes: The lead screw is coaxially disposed in a blind hole at the far end of the cutting disc spindle; An irregularly shaped slider is fixedly connected to the movable cutting blade, and the movable cutting blade is axially displaced by the screw thread through the guide groove on the surface of the cutting blade spindle. The electromagnetic drive assembly, including coil windings and electromagnets, drives the lead screw to rotate by controlling the magnitude and direction of the current, thereby achieving precise axial translation of the movable cutting blade.

5. A brake pad sample cutting machine according to claim 4, characterized in that, The electromagnetic drive assembly is connected to the lead screw via a coupling to achieve backlash-free transmission and avoid backlash error.

6. A brake pad sample cutting machine according to claim 1, characterized in that, The cutting unit also includes a grinding disc assembly, which is coaxially integrated with the cutting disc spindle to achieve synchronous grinding after cutting.

7. A method for cutting a brake pad sample, using the cutting machine described in any one of claims 1-6, characterized in that, Includes the following steps: a) Fix the brake pad sample to a rotatable material stage using a positioning clamp, the material stage being mounted on an adjustable base whose position can be adjusted in three-dimensional space; b) Start the cutting unit to make the cutting blade rotate around the cutting blade spindle. Adjust the position of the material stage through the adjustable base so that the cutting blade performs the first cutting process on the brake pad sample. c) After the first cut is completed, keep the positioning fixture fixed and drive the material stage to rotate 90° around the axis perpendicular to the cutting plane to change the spatial position of the brake pad sample; d) Restart the cutting unit to perform a second orthogonal cutting process to complete the double-sided cutting of the brake pad sample; e) The radial feed of the material stage is precisely controlled by the adjustable base. At the same time, the axial translation device on the cutting blade spindle is used to drive the cutting blade to produce precise displacement along the axial direction, so that the cutting blade cuts the brake pad sample on the arc surface according to the preset arc trajectory, realizing multi-angle and multi-scale cutting and forming of the brake pad sample in one clamping.

8. The method for cutting a brake pad sample according to claim 7, characterized in that, The arc surface cutting adopts a continuous processing technology of "rough cutting followed by fine grinding". That is, the initial arc surface contour is first formed by rough cutting with a cutting disc, and then the arc surface is finely ground by a coaxial integrated grinding disc assembly to improve the surface finish and dimensional accuracy.

9. A method for cutting a brake pad sample according to claim 7, characterized in that, The combined motion of radial feed and axial displacement is precisely controlled by an electric motor. A linear approximation method is used to cut short straight lines in segments along the outer side of the arc. When approaching the end of the contour, the feed rate is reduced to perform multiple micro-feeds to ensure the machining accuracy of the arc transition area.

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