Friction plate processing device and control method using laser texturing technology

Abstract

This invention relates to a friction plate processing device and its control method using laser texturing technology, belonging to the field of friction plate processing technology. It includes a base, on which a laser texturing component is mounted. A fixture is positioned between the base and the laser texturing component, and an X-axis processing seat is positioned between the fixture and the base to drive the fixture's forward and backward movement. The laser texturing component includes a laser, with a laser head at its lower end, a laser measurement sensor at its front end, and a cantilever beam at its rear end. A Z-axis seat is positioned between the cantilever beam and the laser, with the Z-axis seat moving laterally on the cantilever beam and the laser moving vertically on the Z-axis seat. This device offers advantages such as high automation, high processing accuracy, strong flexible processing capability, and good operational stability. It achieves real-time focus adjustment, high-precision multi-axis linkage, and laser texturing without contact with the workpiece surface.

Description

Technical Field

[0001] This invention relates to the field of friction plate processing technology, and specifically to a friction plate processing device and its control method using laser texturing technology. Background Technology

[0002] Friction pads, as a key component of braking systems, are widely used in automobiles, construction machinery, and other fields. Their performance directly affects the operational safety of the equipment. The surface texture of the friction pads (such as grooves, pits, and grids) has a crucial impact on the coefficient of friction, thermal conductivity, wear debris removal, and noise control.

[0003] Currently, the following traditional methods are mainly used for texturing the surface of friction pads: 1. Mechanical cutting / milling: This is the most common machining method, which involves cutting the surface of the friction plate with a cutting tool.

[0004] Disadvantages: Tool wear occurs during processing, leading to a decrease in texture dimensional accuracy and requiring frequent tool changes; a large amount of dust is generated during processing, polluting the environment; for complex irregular textures (such as irregular pits), machining efficiency is low and flexibility is poor.

[0005] II. Mold Forming: Textures are formed directly in the mold during the pressing process of the friction plate.

[0006] Disadvantages: The texture structure is fixed and difficult to change once the mold is made, lacking flexibility; the mold manufacturing cycle is long and the cost is high; the texture edges are easily damaged during demolding, affecting the quality.

[0007] III. Traditional Laser Processing: Although some laser processing applications exist, existing laser processing equipment has significant shortcomings when processing friction plates.

[0008] Disadvantages: Traditional laser processing equipment is mostly fixed-focus processing or simple manual focusing. Due to the flatness error of the friction pad (especially semi-metallic or powder metallurgy friction pads) surface, or thermal deformation during processing, fixed-focus processing is prone to causing the laser focus to deviate from the material surface, resulting in inconsistent processing depth, unclear texture, or even damage to the substrate, seriously affecting product consistency and processing quality. In addition, the multi-axis linkage control precision of traditional equipment is insufficient, making it difficult to process high-precision complex three-dimensional textures. Summary of the Invention

[0009] This invention addresses the shortcomings of existing technologies by providing a friction plate processing device and its control method using laser texturing technology. This device boasts advantages such as high automation, high processing accuracy, strong flexible processing capability, and good operational stability. It achieves real-time focus adjustment, high-precision multi-axis linkage, and laser texturing processing without contact with the workpiece surface.

[0010] The above-mentioned technical problems of the present invention are mainly solved by the following technical solutions: A friction pad processing device employing laser texturing technology includes a base, on which a laser texturing processing component is mounted. A fixture is positioned between the base and the laser texturing processing component, and an X-axis processing seat is positioned between the fixture and the base to drive the fixture's forward and backward movement. The laser texturing processing component includes a laser, with a laser head at its lower end, a laser measurement sensor at its front end, and a cantilever beam at its rear end. A Z-axis seat is positioned between the cantilever beam and the laser, with the Z-axis seat moving laterally on the cantilever beam and the laser moving vertically on the Z-axis seat.

[0011] Preferably, a transverse slide is provided between the Z-axis seat and the cantilever beam, and lifting cylinders are provided at both ends of the transverse slide to drive the Z-axis seat to move up and down.

[0012] Preferably, lead screws are provided between the transverse sliding block and the cantilever beam, and between the tooling table and the X-axis machining seat, with a lead screw motor at one end of each lead screw.

[0013] Preferably, guide rails are provided on both sides of the lead screw, and a stop block is provided on the other side of the lead screw.

[0014] Preferably, columns are provided on both sides of the cantilever beam between it and the base.

[0015] A friction plate processing apparatus and its control method include the following operating steps: Step 1: System initialization and baseline establishment, including hardware reset and laser and laser measurement sensor calibration. Control the X-axis machining base, Z-axis base, and transverse slide to return to their respective mechanical origins or reference points; turn on the laser for preheating and power self-test; simultaneously, calibrate the laser measurement sensor to ensure its measurement reference is coaxial with the laser processing optical path or has a precise relative positional relationship, laying the foundation for subsequent height measurement and focal length control.

[0016] Step 2: Workpiece clamping and pre-processing preparation. Place the friction plate to be processed on the fixture table and fix it with a special fixture. The movement of the fixture table is driven by the lead screw on the X-axis machining seat, so that the friction plate to be processed moves into the laser processing area.

[0017] The Z-axis mechanism is controlled to bring the laser head close to the workpiece surface. The distance from the workpiece surface to the laser measurement sensor is measured non-contactly using a laser measurement sensor, thereby accurately calculating the required focal length position of the Z-axis. The lifting cylinder is then controlled to adjust the laser head to the optimal focal length.

[0018] Step 3: Input the 3D model or design pattern data of the desired texture of the friction pad into the control system. Then, path generation and trajectory planning are performed. Finally, based on the material properties of the friction pad, the laser processing parameters are set. These parameters include laser power, scanning speed, pulse frequency, and focal position. Laser power controls the output energy of the laser; scanning speed controls the movement speed along the X and Y axes, and together with laser power, determines the unit energy input; the laser pulse frequency sets the number of pulses per second; and the focal position controls the Z-axis offset for textures requiring defocusing.

[0019] The control system plans the scanning path of the laser beam on the workpiece surface based on the texture data. Since the device has three-axis motion capability, the system will calculate the linkage trajectory of the workpiece moving back and forth, the lateral sliding block moving left and right, and the laser head fine-tuning up and down. For complex three-dimensional textures, the planning needs to take into account the curvature changes of the workpiece surface to ensure that the laser optical axis is always approximately perpendicular to the surface normal of the processing point to ensure processing quality.

[0020] Step 4: Multi-axis linkage and laser processing control; A controller is used to achieve precise linkage between the movement of the workpiece table and the movement of the transverse slide; The controller sends commands to the lead screw motors of the X and Y axes in real time according to the planned trajectory to control the speed and displacement, forming a complex two-dimensional planar motion trajectory.

[0021] During the processing, the laser measurement sensor monitors the changes in the surface height of the workpiece in real time. When the surface height changes, such as when the workpiece is uneven, the control system will adjust the height of the lifting cylinder in real time according to the sensor feedback to ensure that the focus of the laser beam is always on the material surface, thus achieving constant focal length processing.

[0022] Step 5: After processing is completed, control each motion axis to return to the safe position, stop the laser output, and the operator can remove the processed friction plate from the tooling table.

[0023] Preferably, the X-axis machining base, Z-axis base, and transverse slide are controlled to return to their respective mechanical origins or reference points; the laser is turned on for preheating and power self-test; at the same time, the laser measurement sensor is calibrated to ensure that its measurement reference is coaxial with the laser processing optical path or has a precise relative positional relationship, laying the foundation for subsequent height measurement and focal length control.

[0024] As a preferred method, the control system plans the scanning path of the laser beam on the workpiece surface based on the texture data. Since the device has three-axis motion capability, the system will calculate the linkage trajectory of the workpiece moving back and forth, the lateral sliding block moving left and right, and the laser head fine-tuning up and down. For complex three-dimensional textures, the planning needs to take into account the curvature changes of the workpiece surface to ensure that the laser optical axis is always approximately perpendicular to the surface normal of the processing point, so as to ensure the processing quality.

[0025] Preferably, the laser processing parameters include laser power, scanning speed, pulse frequency, and focal position; laser power controls the output energy of the laser; scanning speed controls the movement speed of the X and Y axes, and together with laser power, determines the unit energy input; the laser pulse frequency sets the number of pulses per second; and the focal position controls the Z-axis offset for textures that require defocusing processing.

[0026] The present invention can achieve the following effects: This invention provides a friction pad processing device and its control method using laser texturing technology. Compared with existing technologies, it has the advantages of high automation, high processing accuracy, strong flexible processing capability, and good operational stability. It achieves real-time focus adjustment, high-precision multi-axis linkage, and laser texturing processing without contact with the workpiece surface. It has the following significant beneficial effects: I. Achieving constant focal length machining significantly improves processing quality and consistency. A laser measurement sensor is integrated into the front end of the laser. During processing, the sensor monitors changes in the workpiece surface height in real time without contact. When unevenness exists on the friction plate surface or the processing position changes, the control system adjusts the height of the laser head in real time based on the sensor feedback data. This closed-loop control ensures that the laser beam focus is always accurately on the material surface, avoiding defocusing caused by workpiece surface undulations, thus guaranteeing uniform texture depth and clear edges, and significantly improving the consistency and yield of the processed products.

[0027] Second, non-contact processing eliminates tool wear and dust pollution. Using laser texturing technology instead of traditional mechanical cutting constitutes non-contact processing. This completely eliminates problems such as tool wear and chipping, reducing consumable costs and maintenance frequency. Furthermore, the fumes generated during laser processing can be treated by a dedicated dust removal system, making it more environmentally friendly and cleaner than the large amounts of dust produced by mechanical cutting, thus improving the production environment.

[0028] Third, it boasts high flexibility, adapting to the processing needs of complex textures. The device features X, Y, and Z-axis linkage capability, coupled with precision lead screw transmission between the tooling table and the transverse slide, enabling it to plan complex two-dimensional and three-dimensional motion trajectories based on the input 3D model or design pattern. This method can flexibly process various complex textures (such as biomimetic textures, meshes, special grooves, etc.), requiring only modification of the control program to switch processing styles without changing molds. This significantly improves production flexibility and response speed, meeting the market demand for personalized, high-performance textures on friction pads.

[0029] IV. High degree of automation and precise positioning. The device adopts a transmission structure of lead screw and guide rail, and is limited by stop block (9) to ensure high-precision positioning of each motion axis. The control method covers the entire process of automation from system initialization, automatic focusing, path planning to processing end reset, reducing manual intervention and improving production efficiency and processing accuracy.

[0030] V. Stable and Reliable Structure. The device adopts a gantry / cantilever structure consisting of a base, columns, and cantilever beams, which has good overall rigidity and strong seismic resistance, providing a stable mechanical foundation for high-precision laser processing. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the present invention.

[0032] Figure 2 This is a schematic diagram of the structure of the laser texture processing component of the present invention.

[0033] In the diagram: 1. Column; 2. Laser texture processing component; 3. Tooling table; 4. X-axis machining seat; 5. Lead screw; 6. Guide rail; 7. Lead screw motor; 8. Base; 9. Stop block; 10. Cantilever beam; 11. Z-axis seat; 12. Lifting cylinder; 13. Transverse slide; 14. Laser head; 15. Laser measurement sensor; 16. Laser. 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 and Figure 2 As shown, a friction pad processing device using laser texture technology includes a base 8, a laser texture processing component 2 mounted on the base 8, a tooling table 3 between the base 8 and the laser texture processing component 2, and an X-axis processing seat 4 between the tooling table 3 and the base 8 for driving the tooling table 3 to move back and forth. The laser texture processing component 2 includes a laser 16, a laser head 14 at the lower end of the laser 16, a laser measurement sensor 15 at the front end of the laser 16, and a cantilever beam 10 at the rear end of the laser 16. Columns 1 are mounted on both sides of the cantilever beam 10 and the base 8. A Z-axis seat 11 is located between the cantilever beam 10 and the laser 16. The Z-axis seat 11 moves laterally on the cantilever beam 10, and the laser 16 moves vertically on the Z-axis seat 11. A transverse slide 13 is located between the Z-axis seat 11 and the cantilever beam 10, and lifting cylinders 12 at both ends of the transverse slide 13 for driving the Z-axis seat 11 to move up and down. A lead screw 5 is provided between the transverse slide 13 and the cantilever beam 10, and between the tooling table 3 and the X-axis machining seat 4. A lead screw motor 7 is provided at one end of the lead screw 5. Guide rails 6 are provided on both sides of the lead screw 5, and a stop block 9 is provided on the side of the other end of the lead screw 5.

[0036] A control method for a friction plate processing device includes the following operating steps: Step 1: System initialization and benchmark establishment, hardware reset and calibration of laser 16 and laser measurement sensor 15.

[0037] Step 2: Workpiece clamping and pre-processing preparation. Place the friction plate to be processed on the fixture table 3 and fix it with a special fixture. The movement of the fixture table 3 is driven by the lead screw 5 on the X-axis machining seat 4, so that the friction plate to be processed moves into the laser processing area.

[0038] The Z-axis mechanism is controlled to bring the laser head 14 close to the workpiece surface. The distance from the workpiece surface to the laser measuring sensor 15 is measured non-contactly using the laser measuring sensor 15, thereby accurately calculating the required focal length position of the Z-axis. The lifting cylinder 12 is then controlled to adjust the laser head 14 to the optimal focal length.

[0039] The third step is to input the 3D model or design pattern data of the required texture of the friction plate into the control system, followed by path generation and trajectory planning, and then set the laser processing parameters according to the material characteristics of the friction plate.

[0040] Step 4: Multi-axis linkage and laser processing control; A controller is used to achieve precise linkage between the movement of the workpiece stage 3 and the movement of the transverse slide 13; The controller sends commands to the lead screw motors 7 of the X and Y axes in real time according to the planned trajectory to control the speed and displacement, forming a complex two-dimensional planar motion trajectory.

[0041] During the processing, the laser measurement sensor 15 monitors the changes in the surface height of the workpiece in real time. When the surface height changes, such as when the workpiece is uneven, the control system will adjust the height of the lifting cylinder in real time according to the sensor feedback to ensure that the focus of the laser beam is always on the material surface, thus achieving constant focal length processing.

[0042] Step 5: After processing is completed, control each motion axis to return to the safe position, stop the laser 16 output, and the operator can remove the processed friction plate from the tooling table.

[0043] In summary, the friction plate processing device and its control method using laser texturing technology have the advantages of high automation, high processing accuracy, strong flexible processing capability, and good operational stability. It achieves real-time focus adjustment, high-precision multi-axis linkage, and laser texturing processing without contact with the workpiece surface.

[0044] High degree of automation: Through a three-axis linkage device, the complex texture of the friction plate surface is automatically processed without the need for manual adjustment.

[0045] High machining accuracy: The use of ball screw and guide rail transmission ensures the accuracy of mechanical movement.

[0046] By introducing a laser measurement sensor for real-time height feedback, the problem of defocusing caused by uneven workpiece surface was solved, enabling constant focal length processing and ensuring texture consistency and processing quality.

[0047] Strong flexible processing capability: It supports 3D model input and path planning, and can adapt to the processing of friction pads with different shapes and textures. It can also adapt to different material properties by adjusting parameters (power, frequency, speed).

[0048] Good operational stability: It is equipped with a stop block and an initialization and reset process to ensure safe operation of the equipment.

[0049] 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 friction pad processing device using laser texturing technology, characterized in that: The system includes a base (8), on which a laser texture processing component (2) is provided. A tooling table (3) is provided between the base (8) and the laser texture processing component (2). An X-axis processing seat (4) for driving the tooling table (3) to move back and forth is provided between the tooling table (3) and the base (8). The laser texture processing component (2) includes a laser (16), with a laser head (14) at the lower end of the laser (16). A laser measurement sensor (15) is provided at the front end of the laser (16). A cantilever beam (10) is provided at the rear end of the laser (16). A Z-axis seat (11) is provided between the cantilever beam (10) and the laser (16). The Z-axis seat (11) moves horizontally left and right on the cantilever beam (10), and the laser (16) moves vertically up and down on the Z-axis seat (11).

2. The friction plate processing device using laser texture technology according to claim 1, characterized in that: A transverse slide (13) is provided between the Z-axis seat (11) and the cantilever beam (10), and a lifting cylinder (12) is provided at both ends of the transverse slide (13) to drive the Z-axis seat (11) to move up and down.

3. The friction plate processing device using laser texture technology according to claim 2, characterized in that: A lead screw (5) is provided between the transverse sliding block (13) and the cantilever beam (10), and between the tooling table (3) and the X-axis machining seat (4). A lead screw motor (7) is provided at one end of the lead screw (5).

4. The friction plate processing device using laser texture technology according to claim 3, characterized in that: The lead screw (5) is provided with guide rails (6) on both sides, and a stop block (9) is provided on the other side of the lead screw (5).

5. The friction plate processing device using laser texture technology according to claim 1, characterized in that: The cantilever beam (10) is provided with columns (1) on both sides and between the base (8).

6. A control method for the friction plate processing apparatus according to claim 4, characterized in that... The following steps are included: Step 1: System initialization and benchmark establishment, hardware reset and laser (16) and laser measurement sensor (15) calibration; Step 2: workpiece clamping and pre-processing preparation. Place the friction plate to be processed on the fixture table (3) and fix it with a special fixture. The movement of the fixture table (3) is driven by the lead screw (5) on the X-axis machining seat (4), so that the friction plate to be processed moves to the laser processing area. The Z-axis mechanism is controlled to bring the laser head (14) close to the workpiece surface. The distance from the workpiece surface to the laser measurement sensor (15) is measured non-contactly using the laser measurement sensor (15), thereby accurately calculating the required focal length position of the Z-axis and controlling the lifting cylinder (12) to adjust the laser head (14) to the optimal focal length. Step 3: Input the 3D model or design pattern data of the required texture of the friction pad into the control system, then generate the path and plan the trajectory, and then set the laser processing parameters according to the material characteristics of the friction pad; Step 4: Multi-axis linkage and laser processing control; The controller is used to realize the precise linkage between the movement of the workpiece stage (3) and the movement of the transverse slide (13); The controller sends instructions to the lead screw motors (7) of the X-axis and Y-axis in real time according to the planned trajectory to control the speed and displacement, forming a complex two-dimensional planar motion trajectory; During the processing, the laser measurement sensor (15) monitors the change in workpiece surface height in real time; when the surface height changes, such as when the workpiece is uneven, the control system will adjust the height of the lifting cylinder in real time according to the sensor feedback to ensure that the laser beam focus is always on the material surface and achieve constant focal length processing. Step 5: After processing is completed, control each motion axis to return to the safe position, stop the laser (16) output, and the operator can remove the processed friction plate from the tooling table.

7. The control method for the friction plate processing device according to claim 6, characterized in that: Control the X-axis machining seat (4), Z-axis seat (11) and transverse slide (13) to return to their respective mechanical origins or reference points; turn on the laser (16) for preheating and power self-test; at the same time, calibrate the laser measurement sensor (15) to ensure that its measurement reference is coaxial with the laser processing optical path or has a precise relative positional relationship, so as to lay the foundation for subsequent height measurement and focal length control.

8. The control method for the friction plate processing device according to claim 6, characterized in that: The control system plans the scanning path of the laser beam on the surface of the workpiece based on the texture data. Since the device has three-axis motion capability, the system will calculate the linkage trajectory of the workpiece moving back and forth, the horizontal sliding block moving left and right, and the laser head (15) fine-tuning up and down. For complex three-dimensional textures, the planning needs to take into account the curvature change of the workpiece surface to ensure that the laser optical axis is always approximately perpendicular to the surface normal of the processing point in order to ensure the processing quality.

9. The control method for the friction plate processing device according to claim 8, characterized in that: The laser processing parameters include laser power, scanning speed, pulse frequency and focal position; laser power is the output energy of the laser (16); scanning speed is the movement speed of the X-axis and Y-axis, which together with the laser power determine the unit energy input; the pulse frequency of the laser (16) is set to the number of pulses per second; the focal position is the offset of the Z-axis for textures that need to be defocused.

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