A brake shoe block processing integrated digital program production control system

Abstract

The application relates to the technical field of brake control and discloses a brake shoe machining integrated digital program production control system which comprises a process filing module, a clamping confirmation module, a program generation module, a hot-pressing control module and a trace correction module. The process filing module establishes the data relationship among product models, multi-cavity forming dies, forming cavities, shoe skeletons and powder batches. The clamping confirmation module judges the conditions for entering the pressing control program. The program generation module generates the pressing control program according to the output data. The hot-pressing control module controls the hydraulic hot-pressing equipment, the shoe clamping mechanism, the heating mechanism and the pressing stage switching. The trace correction module obtains the finished product detection result and corrects the next cycle production program. Through the process filing, clamping confirmation, program generation, hot-pressing control and trace correction, the product data, the forming cavity, the clamping state, the pressing stage and the finished product detection result are corresponded, and the next cycle production program is corrected.

Description

Technical Field

[0001] This invention relates to the field of braking control technology, specifically to an integrated digital program production control system for brake shoe processing. Background Technology

[0002] In the manufacturing process of brake shoes for drum brakes, the shoe frame, powder friction material, multi-cavity molding die, and hydraulic hot pressing equipment need to be used in conjunction with each other according to the product model. After pressing and curing, the powder friction material forms the brake drum contact friction layer on the outer arc surface of the shoe frame. Current production control methods typically record or call up product data, die number, molding cavity position, shoe frame, and powder batch separately. There is a lack of continuous correspondence between the pressing control program and the above data, and the correlation between finished product inspection results and the next production cycle is also incomplete, resulting in insufficient data connection between pressing program generation, hot pressing execution, and inspection correction.

[0003] Before the multi-cavity molding die enters the hydraulic hot press, the placement of the shoe skeleton, the state of the shoe clamping mechanism, the powder introduction state, and the die positioning state affect the subsequent pre-pressing, venting and compaction, final pressing and integral molding, and curing. In existing control methods, clamping confirmation, pressing stage switching, and hot pressing execution usually rely on independent signals or manual confirmation. There is a lack of a control process that integrates process data, shoe placement results, clamping status results, and powder introduction results to determine the conditions for powder pressing and clamping integral molding. There is also a lack of program control relationships for stage judgment based on prohibition commands, compaction status, pressure relief and springback, pressure drop status, venting path status, clamping and holding status, and curing status.

[0004] During the inspection of brake shoe blocks after molding, defects can typically reflect the end molding state, edge molding state, brake drum contact friction layer arc surface state, the bonding state of powder friction material and the outer arc surface of the shoe frame, and the finished product weight state. Existing production control methods lack sufficient documentation of the correspondence between detected defects, molding cavity positions, molding control areas, and production control stages. Inspection results are difficult to directly use to determine correction targets in material feeding, pre-pressing control procedures, venting and compaction control procedures, final pressing integrated molding control procedures, holding and curing procedures, and clamping inspection conditions. Therefore, establishing a brake shoe block processing production control system that can link process documentation, clamping confirmation, program generation, hot pressing control, defect attribution, and correction of the next production cycle is a problem that needs to be solved in this field. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an integrated digital program production control system for brake shoe processing, which solves the problem of insufficient correlation between product data, forming cavity position, shoe skeleton, powder batch, pressing control program, finished product inspection results, and the next cycle production program.

[0006] To address the above problems, the present invention provides the following technical solution: This invention provides an integrated digital program production control system for brake shoe processing, employing the following technical solution: A digital program production control system for brake shoe processing includes a process documentation module, a clamping confirmation module, a program generation module, a hot pressing control module, and a traceability correction module. The process documentation module is used to establish the data relationship between product model, multi-cavity molding die, molding cavity, horseshoe skeleton and powder batch; The clamping confirmation module is used to determine whether the multi-cavity molding die meets the conditions for entering the pressing control program; The program generation module is used to generate the pressing control program based on the data output by the process documentation module and the clamping confirmation module. The hot pressing control module is used to control the hydraulic hot pressing equipment, the horseshoe clamping mechanism, the heating mechanism, and the switching of the pressing stage according to the pressing control program; The traceability correction module is used to obtain the finished product inspection results and correct the next cycle of production program based on the finished product inspection results.

[0007] By adopting the above technical solution, product data, mold cavity positions, shoe frame, powder batches, pressing procedures, hot pressing execution, and inspection and correction in brake shoe processing are integrated into a single control process. The process documentation module forms the production data foundation, the clamping confirmation module confirms the shoe placement, clamping, and powder loading status, the program generation module generates the corresponding pressing control program based on the confirmation results, the hot pressing control module executes the pressing stage switching according to the pressing control program, and the traceability and correction module uses the finished product inspection results to correct the next production cycle.

[0008] The process of integrally pressing powder friction material onto the outer arc surface of the horseshoe frame to form the brake drum contact friction layer can be controlled according to the forming cavity position and production cycle, and a corresponding data relationship can be formed between powder loading, clamping, pressing, curing, testing and program correction.

[0009] Furthermore, the process documentation module includes a product data unit, a mold identification unit, a cavity location documentation unit, and a partition setting unit: The product data unit is used to store process data corresponding to different product models; The mold identification unit is used to identify the mold number of the multi-cavity molding mold and read the number of cavities, the arrangement of cavities, and the position data of cavities corresponding to the multi-cavity molding mold. The cavity location registration unit is used to establish a cavity location address for each of the molded cavities; The partition setting unit is used to divide each of the molding cavities into multiple molding control areas according to the process data. The molding control areas include the horseshoe bonding molding area, the brake drum contact arc surface molding area, the end compensation area, the edge molding area, and the exhaust end area.

[0010] By adopting the above technical solution, each molding cavity in the multi-cavity molding mold forms a data object capable of recording product model, mold number, cavity position, horseshoe skeleton, and powder batch. The division of the molding control area allows the compaction state, venting state, bonding state, arc surface state, and subsequent defect attribution to specific areas, avoiding mixed processing of states of different cavities and different areas within the same mold.

[0011] Furthermore, the clamping confirmation module includes a horseshoe identification unit, a clamping acquisition unit, a powder filling confirmation unit, and a qualification determination unit: The horseshoe identification unit is used to determine whether the horseshoe skeleton is placed in the corresponding molding cavity, and to determine whether the horseshoe skeleton number corresponds to the cavity address, thereby generating a horseshoe placement result. The clamping acquisition unit is used to acquire the position data of the horseshoe clamping mechanism, the clamping completion signal, the horseshoe outer arc surface posture signal and the mold positioning signal, and generate the clamping status result. The powder loading confirmation unit is used to collect the powder batch, feeding amount, powder loading completion status and powder spreading confirmation status, and generate powder import results; The qualification determination unit is used to comprehensively determine whether the process data, the horseshoe placement result, the clamping state result, and the powder introduction result meet the powder pressing and clamping integrated molding conditions, and generate a clamping confirmation result.

[0012] By adopting the above technical solution, the identification of the shoe skeleton, the shoe clamping state, and the powder introduction state are used as data conditions before entering the pressing control program. The powder friction material needs to be directly pressed into shape on the outer arc surface of the shoe skeleton. Therefore, the position of the shoe skeleton, the orientation of the outer arc surface, the clamping state, and the powder coverage state will affect the subsequent pre-pressing, venting compaction, and final pressing integral molding.

[0013] The clamping confirmation module completes the above-mentioned status confirmation before the pressing control program is executed, so that the generation and execution of the pressing control program have the corresponding data prerequisites.

[0014] Furthermore, the judgment logic of the qualification determination unit is as follows: When the process data, the horseshoe placement result, the clamping state result, and the powder introduction result all meet the preset requirements, the corresponding molding cavity position is marked as an allowable pre-compression state, and an allowable instruction to enter the pre-compression control program and the exhaust compaction control program is output to the program generation module. When the horseshoe skeleton is not clamped, the powder loading status is incomplete, the mold positioning signal is not in place, or the process data is not called, a prohibition command is output to prevent entry into the final pressing integrated molding control program.

[0015] By adopting the above technical solution, the qualification determination unit establishes a pre-judgment relationship between pre-pressing and final pressing. The permitted pre-pressing state corresponds to the pre-conditions for initial powder spreading and degassing compaction, while the prohibition command corresponds to the interlocking conditions of the final pressing integrated molding stage. The judgment logic associates the final pressing integrated molding control program with the process data, shoe clamping, mold positioning, and powder introduction status.

[0016] Furthermore, the pressing control program includes the pre-pressing control program, the exhaust compaction control program, and the final pressing integral molding control program; The program generation module includes a feeding correction unit, a pre-compression generation unit, an exhaust generation unit, and a final pressure generation unit: The feeding correction unit is used to correct the feeding amount based on the product model, the powder batch, the cavity address, and historical defect data. The pre-pressure generation unit is used to generate the pre-pressure control program when the permission instruction is received. The pre-pressure control program is used to control the hydraulic hot pressing equipment to perform pressing and initial holding according to a preset pre-pressure displacement. The preset pre-pressure displacement is determined according to the process data. The exhaust generation unit is used to generate the exhaust compaction control program, which includes pressurization, holding, depressurization and exhaust, and re-pressurization actions. The final pressure generation unit is used to generate the final pressure integral molding control program.

[0017] By adopting the above technical solution, the pressing control program is generated in stages according to powder pre-pressing, degassing compaction, and final pressing integrated molding. The feeding correction unit uses the product model, the powder batch, the cavity address, and historical defect data to correct the feeding amount, so that the feeding amount is associated with the powder state, cavity position, and historical detection conditions.

[0018] The pre-pressing generation unit controls the initial distribution of powder friction material along the outer arc surface of the horseshoe skeleton. The exhaust generation unit processes the gas in the powder by pressurizing, holding, depressurizing and exhausting, and re-pressurizing. The final press generation unit generates a final press integral molding control program for forming the contact friction layer of the brake drum.

[0019] Furthermore, the hot pressing control module includes a hot pressing execution unit, a stage interlock unit, and a compaction calculation unit: The hot pressing actuator is used to output control commands to the hydraulic hot pressing equipment; The stage interlock unit is used to restrict the switching of the pressing stage. When the prohibition command is received, the stage interlock unit prohibits the hot pressing execution unit from entering the final pressing integral molding stage. The compaction calculation unit is used to calculate the compaction state of the forming cavity and the forming control area based on the pressure data and pressure head displacement data of the hydraulic hot pressing equipment.

[0020] By adopting the above technical solution, the hot pressing control module outputs action commands to the hydraulic hot pressing equipment and controls the switching of the pressing stage according to the prohibition command and the compaction state. The compaction calculation unit maps the pressure data and the pressure head displacement data to the forming cavity position and the forming control area, so that the compaction state can be used for subsequent venting judgment, bonding judgment and arc surface judgment.

[0021] The stage interlocking unit restricts the entry of the final pressing integral molding stage according to the preconditions, so that the final pressing integral molding stage corresponds to the horseshoe clamping, powder introduction and pre-pressurization degassing state.

[0022] Furthermore, the hot-pressing control module also includes an exhaust judgment unit, a bonding judgment unit, an arc surface judgment unit, and a curing judgment unit: The exhaust judgment unit is used to determine whether the exhaust compaction stage meets the conditions for entering the final pressure integral molding stage based on the pressure relief rebound, pressure drop state and exhaust path state. The bonding judgment unit is used to judge the forming state of the powder friction material and the outer arc surface of the horseshoe skeleton based on the compaction state, clamping and holding state and curing state of the horseshoe bonding forming area; The arc surface judgment unit is used to determine whether the brake drum contact friction layer meets the conditions for entering the holding and curing stage or the demolding preparation stage based on the compaction state, pressure head displacement state, clamping and holding state and curing state of the brake drum contact arc surface forming area. The curing determination unit is used to determine whether the holding and curing stage meets the end conditions based on the temperature state, pressure state, holding time, and clamping holding state.

[0023] By adopting the above technical solution, the hot pressing control module introduces the venting state, bonding molding state, arc surface molding state, and curing state into stage switching judgments respectively. The venting judgment unit associates the final pressure integral molding stage with the pressure relief and springback, pressure release, and venting path states; the bonding judgment unit associates the bonding state of the powder friction material with the outer arc surface of the horseshoe skeleton with the compaction, clamping, and curing states.

[0024] The arc surface determination unit correlates the arc surface forming state of the brake drum contact friction layer with the pressure head displacement, clamping and holding, and curing state; the curing determination unit correlates the end conditions of the holding and curing stage with temperature, pressure, holding time, and clamping and holding state. These determinations are used to determine the pressing stage switching and demolding preparation.

[0025] Furthermore, the traceability correction module includes a demolding control unit, a finished product inspection unit, a defect attribution unit, and a program correction unit: The demolding control unit is used to control the return stroke of the hydraulic hot pressing equipment, the release of the shoe clamping mechanism, the opening of the multi-cavity forming mold, and the transfer of the formed brake shoe. The finished product inspection unit is used to inspect the formed brake shoes and generate the finished product inspection results. The finished product inspection results are bound to the cavity address and the inspection defects are output. The inspection content includes the appearance of the brake drum contact friction layer, the state of the friction layer arc surface, the state of the friction layer thickness, the end forming state, the edge forming state, the bonding state of the powder friction material with the outer arc surface of the shoe skeleton, and the finished product weight state. The defect attribution unit is used to map the detected defect to the corresponding molding cavity, the corresponding molding control area and the corresponding production control stage, and to establish a defect source record. The program correction unit is used to correct the next cycle production program based on the defect source record.

[0026] By adopting the above technical solution, the molded brake shoe blocks enter the finished product inspection after demolding and transfer. The finished product inspection results are bound to the cavity address, so that the finished product inspection results can correspond to specific molding cavities. The defect attribution unit maps the detected defects to molding cavities, molding control areas, and production control stages. The program correction unit corrects the next cycle production program based on the defect source record.

[0027] The finished product inspection results serve as the source of corrective data for the next production cycle, establishing a data correspondence between inspection, attribution, and program correction.

[0028] Furthermore, the defect attribution unit maps the detected defect to the molding control area and the production control stage according to the defect attribution table: The production control stage includes the clamping confirmation stage, powder introduction stage, powder pre-compression stage, the degassing and compaction stage, the final pressure integral molding stage, the holding and curing stage, and the demolding and transfer stage; The defect attribution table includes the correspondence between end material shortage, edge flash, abnormal arc surface forming, abnormal horseshoe bonding state, surface porosity and local looseness and the forming control area and the production control stage.

[0029] By adopting the above technical solution, the defect attribution table maps the detected defects, the forming control areas, and the production control stages. End material shortages, edge flash, abnormal arc surface forming, abnormal horseshoe bonding, surface porosity, and localized looseness are used to determine the corresponding areas and stages of the detected defects. This mapping provides data for the program correction unit to determine the correction targets.

[0030] Furthermore, the correction logic of the program correction unit is as follows: The program correction unit reads the molding control area and the production control stage from the defect source record, and determines the correction object from the material feeding amount, pre-compression control program, exhaust compaction control program, final compression integrated molding control program, holding curing program and clamping inspection conditions based on the molding control area and the production control stage. When the object of correction is the feeding amount or the clamping check condition, the program correction unit corrects the feeding amount or the clamping check condition of the next cycle corresponding to the forming cavity position. When the object of correction is the pre-pressure control program, the exhaust compaction control program, the final pressure integral molding control program, or the holding and curing program, the program correction unit corrects the corresponding control program in the next cycle production program.

[0031] By adopting the above technical solution, the program correction unit determines the objects requiring correction based on the defect source record, and limits the correction objects to the following: material feeding amount, pre-compression control program, venting and compaction control program, final compression integral molding control program, holding and curing program, and clamping inspection conditions. The material feeding amount and clamping inspection conditions correspond to cavity level adjustments, while the pre-compression control program, venting and compaction control program, final compression integral molding control program, and holding and curing program correspond to control program adjustments in the next production cycle.

[0032] This invention provides an integrated digital program production control system for brake shoe processing. It has the following advantages: 1. This invention establishes data relationships between product model, multi-cavity molding die, molding cavity, horseshoe skeleton and powder batch through process filing module, clamping confirmation module, program generation module, hot pressing control module and traceability correction module. Based on the output data, it generates a pressing control program and controls the switching of pressing stages, and corrects the next cycle production program based on the finished product inspection results.

[0033] 2. The present invention uses a qualification determination unit, a stage interlocking unit, a compaction calculation unit, an exhaust judgment unit, a bonding judgment unit, an arc surface judgment unit, and a curing judgment unit to determine the conditions for entering the final pressure integral molding stage and the conditions for ending the curing stage based on the prohibition command, compaction state, pressure relief and rebound, pressure drop state, exhaust path state, clamping and holding state, and curing state.

[0034] 3. The present invention uses a finished product inspection unit, a defect attribution unit, and a program correction unit to map the detected defects to the molding cavity position, molding control area, and production control stage. It also determines the correction object from the feeding amount, pre-pressing control program, exhaust compaction control program, final press integrated molding control program, holding curing program, and clamping inspection conditions, and corrects the corresponding control program in the next production cycle. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the integrated digital program production control system for brake shoe processing according to an embodiment of the present invention; Figure 2 This is a flowchart of the integrated digital program production control method for brake shoe processing according to an embodiment of the present invention; Figure 3 This is a flowchart illustrating the product data retrieval and cavity location documentation process according to an embodiment of the present invention. Figure 4 This is a flowchart illustrating the clamping and powder loading confirmation process according to an embodiment of the present invention. Figure 5 This is a flowchart illustrating the powder pre-compression and degassing compaction process according to an embodiment of the present invention. Figure 6 This is a flowchart illustrating the final pressure integral molding and curing process according to an embodiment of the present invention; Figure 7 This is a flowchart of the demolding detection and program correction process according to an embodiment of the present invention; Figure 8 This is a spectrum diagram of the pressure fluctuation amplitude in an embodiment of the present invention; Figure 9 This is a power spectral density diagram of the arc surface deviation according to an embodiment of the present invention. Detailed Implementation

[0036] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] The brake shoe involved in this invention is a brake shoe for a drum brake. The brake shoe includes a shoe frame and a brake drum contact friction layer formed on the outer arc surface of the shoe frame. The brake drum contact friction layer is formed by pressing and curing powdered friction material in a multi-cavity molding die. The powdered friction material is directly bonded to the outer arc surface of the shoe frame during the molding process.

[0038] The controlled object of this invention is a multi-cavity molding die containing a shoe shoe skeleton and powder friction material. After the multi-cavity molding die enters the hydraulic hot press equipment, the hydraulic hot press equipment performs pre-pressing, venting and compaction, final pressing, holding and curing, and return strokes according to the control program. The integrated digital program production control system for brake shoe processing is used to uniformly control powder introduction, shoe shoe clamping, pressing stage, curing stage, demolding and transfer, and finished product inspection and correction.

[0039] The hardware components of the integrated digital program production control system for brake shoe processing include a hydraulic hot press, a multi-cavity forming mold, a shoe clamping mechanism, a powder weighing and feeding device, detection and identification components, and a controller. The hydraulic hot press includes a frame, upper pressure plate, lower pressure plate, guide pillars, a hydraulic drive mechanism, a heating mechanism, and a press control interface. It is used to apply pressure to the multi-cavity forming mold and provide the heat required for the curing of the powder friction material.

[0040] The multi-cavity molding die has multiple brake shoe forming cavities, each for placing a shoe skeleton and receiving powdered friction material. The multi-cavity molding die maintains the position of the outer arc surface of the shoe skeleton and defines the arc shape, end shape, and edge shape of the brake drum contact friction layer. A shoe clamping mechanism maintains the shoe skeleton's posture during powder loading, pre-compression, final compression, and curing, and limits positional displacement of the shoe skeleton relative to the forming cavity.

[0041] The powder weighing and feeding device is used to feed powder friction material into the multi-cavity molding die or the corresponding molding cavity according to the feeding amount given by the controller, and to provide feedback on the powder batch, feeding amount, and powder loading completion status. The detection and identification components include pressure sensors, displacement sensors, temperature sensors, clamping position detectors, die positioning detectors, barcode scanners, weighing detectors, and finished product size detectors, used to collect data on the pressing process status, die status, horseshoe clamping status, powder feeding status, and finished product inspection status.

[0042] The controller includes a PLC, an industrial computer, a data acquisition module, a temperature control module, and a production line management terminal. It is used to receive test data, call product process data, generate pressing control programs, and control the hydraulic hot pressing equipment, the horseshoe clamping mechanism, the heating mechanism, the powder weighing and feeding device, and the test feedback process.

[0043] See attached document Figure 1 This invention provides an integrated digital program production control system for brake shoe processing, including a process documentation module, a clamping confirmation module, a program generation module, a hot pressing control module, and a traceability correction module.

[0044] The process documentation module is used to establish data relationships between product models, multi-cavity molding dies, molding cavity positions, horseshoe frames, and powder batches. The process documentation module includes a product data unit, a mold identification unit, a cavity documentation unit, and a partition setting unit.

[0045] The product data unit is used to store the process data for different models of brake shoes. The process data includes data on the outer arc surface of the shoe frame, data on the arc surface of the brake drum contact friction layer, data on the friction layer thickness, end forming data, edge forming data, batch parameters of powder friction material, basic material feeding amount, basic pressing control program, basic heating program, and process conditions that allow for one-piece molding.

[0046] The mold identification unit is used to identify the mold number of a multi-cavity molding mold entering the production line, and to read the number of cavities, the arrangement of cavities, and the position of cavities corresponding to the multi-cavity molding mold. The mold identification unit binds the mold number to the current production cycle.

[0047] The cavity location documentation unit is used to create a cavity location address for each molding cavity. The cavity location address includes the mold number, cavity row number, cavity column number, cavity sequence number, corresponding horseshoe frame number, corresponding powder batch number, and corresponding production cycle number. The cavity location documentation unit ensures that each molding cavity within the same multi-cavity molding mold has an independent data record object.

[0048] The partitioning unit is used to divide each molding cavity into multiple molding control areas based on the process data in the product data unit. These molding control areas include the horseshoe-joint molding area, the brake drum contact arc surface molding area, the end compensation area, the edge molding area, and the exhaust end area. The partitioning unit provides a regional basis for subsequent compaction state calculations, exhaust state judgments, and molding state judgments.

[0049] The clamping confirmation module is used to determine whether a multi-cavity molding die meets the conditions for entering the pressing control program. The clamping confirmation module includes a horseshoe identification unit, a clamping acquisition unit, a powder filling confirmation unit, and a qualification determination unit.

[0050] The horseshoe identification unit determines whether the horseshoe skeleton is placed in the corresponding molding cavity and whether the horseshoe skeleton number is bound to the current cavity address. The horseshoe identification unit sends the identification result of the horseshoe skeleton to the cavity filing unit and the qualification determination unit.

[0051] The clamping acquisition unit is used to acquire the position of the shoe clamping mechanism, the clamping completion signal, the shoe outer arc surface posture signal, and the mold positioning signal. The clamping acquisition unit is used to determine whether the shoe skeleton is placed in place, whether the shoe skeleton is clamped, and whether the outer arc surface of the shoe skeleton is in the allowable pressing position, and outputs the clamping status data to the qualification determination unit.

[0052] The powder loading confirmation unit is used to collect information on powder batch, feeding quantity, powder loading completion status, and powder spreading confirmation status. It determines whether the powder friction material has been introduced into the corresponding multi-cavity molding die or the corresponding molding cavity, whether the feeding quantity has been confirmed, and whether the powder friction material is in an allowable pre-compression state. The unit then outputs the powder loading status data to the qualification determination unit.

[0053] The qualification assessment unit is used to comprehensively determine whether the current product model, multi-cavity molding die, powder friction material, horseshoe skeleton, and clamping status meet the conditions for powder-pressed clamping integrated molding. When the horseshoe skeleton is not clamped, the powder friction material is not introduced, the multi-cavity molding die is not in place, or the product process data has not been fully retrieved, the qualification assessment unit is prohibited from entering the final pressing integrated molding process.

[0054] The program generation module is used to generate a pressing control program based on the data output from the process documentation module and the clamping confirmation module. The program generation module includes a feeding correction unit, a pre-pressing generation unit, an exhaust generation unit, and a final pressing generation unit.

[0055] The feeding correction unit is used to correct the feeding amount based on the product model, powder batch, cavity address, and historical defect data. The correction basis of the feeding correction unit includes powder loose density, powder moisture content, powder flow state, the location of the molding cavity, and molding defect data corresponding to the molding cavity in the previous cycle.

[0056] The pre-compression generation unit is used to generate the pre-compression control program. This program controls the hydraulic hot pressing equipment to perform downward pressure and initial holding according to the preset pre-compression displacement, allowing the powder friction material to initially spread along the outer arc surface of the horseshoe frame and enter the horseshoe bonding forming zone, end compensation zone, and edge forming zone. The preset pre-compression displacement is determined based on the product process data.

[0057] The exhaust generation unit is used to generate the control program for the exhaust compaction stage. The control program generated by the exhaust generation unit includes pressurization, holding, depressurization, and re-compaction actions. The exhaust generation unit determines whether to continue or terminate the exhaust compaction stage based on pressure, displacement, rebound status, and exhaust status.

[0058] The final pressing unit is used to generate a final pressing integral molding control program for forming the brake drum contact friction layer on the outer arc surface of the horseshoe frame using powder friction material. The control program generated by the final pressing unit is related to the clamping state, compaction state, brake drum contact arc surface forming state, and curing state.

[0059] The hot pressing control module is used to control the hydraulic hot pressing equipment, the horseshoe clamping mechanism, the heating mechanism, and the switching of pressing stages. The hot pressing control module includes a hot pressing execution unit, a stage interlock unit, a compaction calculation unit, an venting judgment unit, a bonding judgment unit, an arc surface judgment unit, and a curing judgment unit.

[0060] The hot-pressing actuator is used to output control commands to the hydraulic hot-pressing equipment. These control commands include pressing down, pre-pressing, holding, depressurizing, re-pressing, final pressing, and return. The hot-pressing actuator controls the hydraulic hot-pressing equipment's operation according to the control program output by the program generation module.

[0061] The stage interlock unit is used to restrict the switching of the pressing stage. When the horseshoe skeleton is not clamped, the powder friction material is not introduced, the multi-cavity forming mold is not in place, or the pre-pressing state does not meet the entry conditions, the stage interlock unit prohibits the hot pressing execution unit from entering the final pressing integrated forming stage.

[0062] The compaction calculation unit is used to calculate the compaction state of different forming cavities and different forming control areas based on the pressure data and pressure head displacement data of the hydraulic hot press equipment. The compaction calculation unit is also used to determine whether the powder friction material has reached the compaction state required to proceed to the next pressing stage.

[0063] The exhaust judgment unit is used to determine whether the exhaust compaction stage meets the conditions for entering the final pressure integral molding stage based on the pressure relief rebound, pressure drop status, and exhaust path status. The judgment result of the exhaust judgment unit is sent to the stage interlock unit.

[0064] The combination judgment unit is used to determine the bonding and forming state of the powder friction material on the outer arc surface of the horseshoe frame. The combination judgment unit determines the forming state of the powder friction material and the outer arc surface of the horseshoe frame based on the compaction state, clamping and holding state, and curing state of the horseshoe bonding and forming zone.

[0065] The arc surface judgment unit is used to determine the arc surface forming state of the brake drum contact friction layer. Based on the compaction state, pressure head displacement state, clamping and holding state, and curing state of the brake drum contact arc surface forming area, the arc surface judgment unit determines whether the brake drum contact friction layer meets the conditions for entering the holding and curing or demolding preparation stage.

[0066] The curing judgment unit is used to determine whether the curing stage meets the end conditions based on the temperature state, pressure state, holding time and clamping holding state, and sends the judgment result to the stage interlock unit and the demolding control unit.

[0067] The traceability and correction module is used to feed back the finished product inspection results to the next production cycle. The traceability and correction module includes a demolding control unit, a finished product inspection unit, a defect attribution unit, and a program correction unit.

[0068] The demolding control unit controls the return stroke of the hydraulic hot press, the release of the shoe clamping mechanism, the opening of the multi-cavity molding die, and the transfer of the brake shoe. The demolding control unit executes the demolding transfer control after the curing judgment unit outputs a demolding permission signal.

[0069] The finished product inspection unit is used to inspect the molded brake shoes and bind the inspection results to the cavity address. The inspection content of the finished product inspection unit includes the appearance of the brake drum contact friction layer, the state of the friction layer arc surface, the state of the friction layer thickness, the end forming state, the edge forming state, the shoe bonding state, and the finished product weight.

[0070] The defect attribution unit is used to map the detected defects output by the finished product inspection unit to specific molding cavities, specific molding control areas, and specific production control stages. The defect attribution unit establishes a defect source record based on the cavity address, molding control area, and pressing stage data.

[0071] The program correction unit is used to correct the production program for the next cycle based on the attribution results of the defect attribution unit. The program correction unit corrects the following: material feed rate, pre-compression program, venting and compaction program, final compression molding program, holding and curing program, and clamping inspection conditions.

[0072] Through the cooperation of hardware components and logic modules, the integrated digital program production control system for brake shoe processing incorporates powder introduction, shoe clamping, powder pre-pressing, venting and compaction, final pressing and molding, holding and curing, demolding detection and program correction into the same digital program production control process, enabling the powder friction material to be integrally pressed on the outer arc surface of the shoe skeleton to form the brake drum contact friction layer.

[0073] See attached document Figure 2 This invention provides an integrated digital program production control method for brake shoe processing, comprising the following steps: S100, the process documentation module reads the product model, powder batch, horseshoe skeleton batch and mold number, calls the corresponding product process data, establishes the cavity address of the multi-cavity forming mold, and establishes the data fields corresponding to the horseshoe skeleton number, powder batch and production cycle number in the cavity address; S200, the clamping confirmation module collects and judges the placement status of the horseshoe skeleton, the clamping status of the horseshoe, the mold positioning status, the powder introduction status, and the material feeding confirmation status, and determines whether the multi-cavity forming mold meets the powder pressing and clamping integrated forming conditions based on the judgment results. S300: The program generation module generates a powder pre-pressing program and an exhaust compaction program based on the product process data, cavity address and clamping confirmation results. The hot pressing control module controls the hydraulic hot pressing equipment to perform pre-pressing, holding, depressurization and exhaust and re-pressing actions, so that the powder friction material is initially spread along the outer arc surface of the horseshoe skeleton and the gas in the pressing process is discharged. After the S400 hot pressing control module meets the stage switching conditions in the clamping state, powder introduction state, pre-pressing state and venting state, it controls the hydraulic hot pressing equipment to execute the final pressing integrated molding program and the holding curing program, so that the powder friction material forms a brake drum contact friction layer on the outer arc surface of the horseshoe skeleton. The S500 traceability correction module controls the return stroke of the hydraulic hot pressing equipment, the release of the shoe clamping mechanism, the opening of the multi-cavity forming mold, and the transfer of the brake shoe. It also binds the finished product inspection results with the cavity address and corrects the next cycle of production program based on the forming cavity, forming control area, and production control stage corresponding to the inspection defect.

[0074] The following provides further explanation of the data processing method, status judgment method, stage switching method, and program correction method in steps S100 to S500.

[0075] See attached document Figure 3 In step S100, the process documentation module uses product model, powder batch, horseshoe skeleton batch and mold number as input data to establish the data correspondence between product, mold, cavity position, horseshoe skeleton and powder batch.

[0076] S101, the process documentation module reads the product model from the production task, and the product data unit calls the product process data set according to the product model.

[0077] The product process data set includes data on the outer arc surface of the horseshoe frame, data on the arc surface of the brake drum contact friction layer, data on the friction layer thickness, data on end forming, data on edge forming, batch control data for powder friction material, basic material feeding amount, basic pressing control program, basic heating program, allowable range of pre-pressing, allowable range of venting, allowable range of final pressing, allowable range of bonding forming, allowable range of arc surface forming, allowable range of curing, and allowable range of demolding.

[0078] The outer arc surface data of the horseshoe skeleton is used to determine the support position and clamping reference of the horseshoe skeleton within the forming cavity. The arc surface data of the brake drum contact friction layer is used to determine the working arc surface formed after the powder friction material is pressed. The friction layer thickness data is used to determine the forming thickness of the powder friction material on the outer arc surface of the horseshoe skeleton. The end forming data and edge forming data are used to determine the forming range of the two ends and the two side edges of the brake drum contact friction layer. The allowable ranges for pre-pressure, venting, final pressure, bonding forming, arc surface forming, curing, and demolding are used for subsequent qualification judgment, stage interlocking, final pressure control, forming state judgment, curing retention judgment, and demolding control.

[0079] S102. The mold identification unit reads the mold number of the multi-cavity molding mold entering the production line, and reads the number of cavities, the arrangement of cavities, and the position data of cavities of the multi-cavity molding mold according to the mold number.

[0080] The mold number is used to distinguish different multi-cavity molding molds. The number of cavities is used to determine the number of brake shoes that can be pressed simultaneously within the current multi-cavity molding mold. The cavity arrangement is used to determine the layout of each molding cavity within the multi-cavity molding mold. The cavity position data is used to indicate the positional relationship of each molding cavity relative to the edge, center area, guide components, and clamping components of the multi-cavity molding mold.

[0081] S103, the cavity location filing unit establishes a cavity location address for each molding cavity in a multi-cavity molding mold based on the mold number and cavity arrangement.

[0082] Cavity addresses are used to treat each molding cavity as an independent data record object. One cavity address corresponds to a brake shoe molding position in a multi-cavity molding die and is bound to the shoe skeleton number, powder batch, and production cycle number in subsequent steps.

[0083] No. The cavity address of each molding cavity is established according to the following formula: ; in, For the first The cavity address of each molding cavity; The cavity position number; Number the mold; For the first The cavity numbering of each molding cavity; For the first The cavity position column number of each molding cavity; For the first The cavity number of each molding cavity; For the first The horseshoe skeleton number corresponding to each molded cavity; This is a powder batch; Number the production cycle.

[0084] The cavity position number and cavity position column number are used to determine the first The specific location of each molding cavity in a multi-cavity molding die. The cavity number is used to uniquely identify the first cavity in the production record. One molding cavity position. The horseshoe skeleton number is used to place the [missing information - likely a specific type of cavity]. The horseshoe skeleton in each molded cavity is bound to the cavity address. The powder batch is used to import the first... The powder friction material for each molding cavity is bound to the cavity address. The production cycle number is used to distinguish the production records of the same multi-cavity molding die in different pressing batches.

[0085] S104. The partition setting unit divides each molding cavity into multiple molding control areas based on the product process data set and cavity address.

[0086] No. The set of molding control areas for each molding cavity is established according to the following formula: ; in, For the first A collection of molding control areas for each molding cavity; For the first The horseshoe bonding molding area of ​​each molding cavity; For the first The brake drum contact arc surface forming area of ​​each forming cavity; For the first End compensation area of ​​each molding cavity; For the first The edge forming area of ​​each forming cavity; For the first The exhaust end area of ​​each molded cavity.

[0087] Horseshoe joint forming area This corresponds to the contact area between the powder friction material and the outer arc surface of the brake shoe frame. Brake drum contact arc surface forming area. This corresponds to the working arc surface area where the powder friction material contacts the inner wall of the brake drum after molding. End compensation area. This corresponds to the two ends of the brake drum contact friction layer along the arc length direction. Edge forming area. This corresponds to the two edge regions along the width direction of the brake drum contact friction layer. (Exhaust end area) This corresponds to the end area where gas is discharged during the pre-compression and exhaust compaction processes.

[0088] S105 The process documentation module writes the product process data set, cavity address, and molding control area set into the production record and establishes the correspondence between the production record and the current production cycle.

[0089] Production records are established according to the following formula: ; in, For the first Production records for each molding cavity; A collection of product process data; For the first The cavity address of each molding cavity; For the first A set of molding control areas for each molding cavity.

[0090] Production Records This module is used to write product data, cavity addresses, and molding control areas into the same data object. The clamping confirmation module is based on production records. Determine if the horseshoe frame is placed in the corresponding molding cavity. The program generation module generates the module based on production records. The corresponding material feeding, pre-compression control, venting and compaction control, and final compression molding control programs are invoked. The hot pressing control module uses production records... Record number The pressing and forming status of each forming cavity. The traceability and correction module uses production records. The finished product test results are mapped to specific molding cavities.

[0091] Product model identification, mold number identification, and production record writing can all be achieved through barcode identification, QR code identification, RFID tag reading, manual input, or production task order retrieval. The relevant identification and writing methods are well-known technologies in this field and will not be elaborated here.

[0092] See attached document Figure 4 In step S200, the clamping confirmation module judges the placement of the horseshoe skeleton, clamping position, mold positioning, powder introduction, and feeding quantity status based on the cavity address and production record formed in step S100, and generates a control result on whether to allow entry into the powder pressing clamping integrated molding process.

[0093] S201, the horseshoe identification unit reads the target horseshoe skeleton number according to the cavity address and collects the actual horseshoe skeleton number placed in the current forming cavity.

[0094] The horseshoe identification unit will be the first The cavity address corresponding to each molding cavity. As a data source, from cavity location address Read the target horseshoe skeleton number The horseshoe identification unit obtains the actual horseshoe skeleton number through barcode scanning, label reading, manual confirmation input, or workstation identification.

[0095] The horseshoe identification unit numbers the target horseshoe skeleton. The shoe placement result is generated by comparing the shoe skeleton number with the actual shoe skeleton number and combining the shoe skeleton positioning signal and the shoe outer arc surface orientation signal. The shoe placement result includes the shoe skeleton number matching result, the shoe skeleton positioning result, and the shoe outer arc surface orientation result.

[0096] The result of consistent shoe skeleton numbering is used to indicate the target shoe skeleton numbering. Check if the shoe skeleton number matches the actual shoe skeleton number. The shoe skeleton positioning result indicates whether the shoe skeleton has entered the positioning surface, support surface, or limiting surface of the molding cavity. The shoe outer arc surface orientation result indicates whether the outer arc surface of the shoe skeleton faces the powder friction material molding space.

[0097] When the results of the matching of the shoe skeleton number, the shoe skeleton being in place, and the orientation of the shoe's outer arc surface all meet the preset requirements, the shoe identification unit will write the shoe skeleton number into the first... Production records corresponding to each molding cavity If any result does not meet the preset requirements, the horseshoe identification unit outputs a horseshoe placement abnormality signal and sends the signal to the qualification determination unit.

[0098] S202, The clamping acquisition unit acquires the position of the horseshoe clamping mechanism, the clamping completion signal, the horseshoe outer arc surface posture signal, and the mold positioning signal, and forms the clamping status result.

[0099] The clamping acquisition unit reads clamping position data from the horseshoe clamping mechanism. This data includes the position of the pressure block, the guide rod position, the stroke of the clamping cylinder, the stroke of the clamping hydraulic cylinder, or the arrival signal of the spring clamping element. The clamping acquisition unit also reads whether the multi-cavity forming mold has entered the working position of the hydraulic hot press from the mold arrival detection element.

[0100] The horseshoe outer arc surface attitude signal is used to indicate whether the horseshoe skeleton remains in the allowable pressing position after clamping. The horseshoe outer arc surface attitude signal is formed by limit contact signal, positioning block contact signal, stroke detection signal, or clamp closing position detection signal.

[0101] The clamping status results include clamping mechanism position results, clamping completion results, horseshoe outer arc surface posture results, and mold positioning results. The clamping mechanism position result indicates whether the clamping block, guide rod, cylinder, hydraulic cylinder, or spring clamping component has reached the set clamping position. The clamping completion result indicates whether the horseshoe clamping mechanism has output a clamping completion signal. The horseshoe outer arc surface posture result indicates whether the horseshoe skeleton's outer arc surface remains in the position corresponding to the forming space of the friction layer in contact with the brake drum. The mold positioning result indicates whether the multi-cavity forming mold has entered the pressing position of the hydraulic hot press equipment.

[0102] When the clamping mechanism position result, clamping completion result, horseshoe outer arc surface posture result, and mold positioning result all meet the preset requirements, the clamping acquisition unit will write the clamping status data into the production record. If any result does not meet the preset requirements, the clamping acquisition unit outputs a clamping abnormality signal and sends the clamping abnormality signal to the qualification determination unit.

[0103] S203. The powder loading confirmation unit collects the powder batch, feeding amount, powder loading completion status and powder spreading confirmation status, and generates powder import results.

[0104] The powder filling confirmation unit is based on the first Cavity address of each molding cavity Read powder batch The actual feed rate is collected from the powder weighing and feeding device. The powder loading confirmation unit compares the actual feed rate with the target feed rate for the current production cycle and writes the comparison result into the production record. .

[0105] The "Powder Loading Completed" status indicates that the powder friction material has entered the multi-cavity molding die or the corresponding molding cavity. The "Powder Spreading Confirmed" status indicates that the powder friction material has been laid within the molding cavity and covers the molding area corresponding to the outer arc surface of the horseshoe frame.

[0106] The powder introduction results include powder batch consistency results, material feeding quantity confirmation results, powder loading completion results, and powder spreading confirmation results. The powder batch consistency result indicates whether the batch of the currently introduced powder friction material matches the cavity address. Powder batches Consistent. The material feeding quantity confirmation result indicates whether the actual material feeding quantity matches the current material feeding quantity given by the program generation module. The powder loading completion result indicates whether the powder friction material has been successfully imported. The powder spreading confirmation result indicates whether the powder friction material covers the horseshoe bonding forming area, the brake drum contact arc surface forming area, the end compensation area, and the edge forming area.

[0107] When the powder batch consistency result, feeding quantity confirmation result, powder loading completion result, and powder spreading confirmation result all meet the preset requirements, the powder loading confirmation unit outputs a powder loading qualified signal to the qualification judgment unit. If any result does not meet the preset requirements, the powder loading confirmation unit outputs a powder loading abnormality signal and sends the powder loading abnormality signal to the qualification judgment unit.

[0108] S204. The qualification determination unit determines the qualification based on the product process data retrieval status, mold identification status, horseshoe placement result, clamping status result, and powder introduction result. Does each molding cavity meet the conditions for powder pressing and clamping integrated molding?

[0109] The qualification assessment unit reads production records. Product process data set Cavity location address and molding control area set Product process data set Used to confirm that the current product model has corresponding one-piece molding process data. Cavity address Used to confirm the Each molding cavity location has been documented. Molding control area set. Used to confirm the The molding cavity area has been divided.

[0110] The qualification determination unit performs the determinations according to a preset order. The preset order is: product process data retrieval status, mold identification status, cavity filing status, shoe placement result, clamping status result, and powder introduction result. If any status or result does not meet the preset requirements, the qualification determination unit stops the qualification determination of the current molding cavity and outputs a corresponding abnormal signal.

[0111] When the product process data retrieval status, mold identification status, cavity filing status, shoe placement result, clamping status result, and powder import result all meet the preset requirements, the qualification judgment unit will... The first molding cavity position is marked as allowing pre-compression, and the program generation module is allowed to call the first... The pre-compression and venting compaction procedures correspond to each molding cavity.

[0112] When any item in the product process data retrieval status, mold identification status, cavity filing status, shoe placement result, clamping status result, or powder import result fails to meet the preset requirements, the qualification judgment unit will... Each molding cavity is marked as being in a state where final pressure is prohibited.

[0113] S205. The qualification determination unit establishes an abnormal status record for the molding cavity that does not meet the one-piece molding qualification conditions, and outputs a prohibition signal for final pressure.

[0114] When the placement of the horseshoe does not meet the preset requirements, the qualification determination unit will... The first molding cavity position is recorded as an abnormal shoe placement, and a shoe inspection signal is output. When the clamping state result does not meet the preset requirements, the qualification judgment unit will... The first molding cavity position is recorded as clamping abnormal, and a clamping check signal is output. When the powder introduction result does not meet the preset requirements, the qualification judgment unit will... Each molding cavity position is recorded as having a powder filling abnormality, and a powder filling check signal is output.

[0115] When the product process data retrieval status, mold identification status, or cavity filing status does not meet the preset requirements, the qualification judgment unit prohibits entering the powder pressing clamping integrated molding process and outputs a data filing inspection signal.

[0116] The final pressure signal must not be sent to the stage interlock unit. Upon receiving the final pressure prohibition signal, the stage interlock unit will not output a final pressure integral molding control command to the hydraulic hot press equipment. The hydraulic hot press equipment will remain in a waiting, return, or stop-for-inspection state; the specific handling method will be executed according to the production line safety control procedure.

[0117] The acquisition of horseshoe frame numbers, clamping positions, powder loading status, and the waiting, return, and shutdown checks and controls of the hydraulic hot pressing equipment can be achieved through barcode recognition, QR code recognition, limit switch detection, PLC safety interlock, press enable control, or workstation alarm signals. The relevant acquisition and control methods are well-known technologies in this field and will not be elaborated here.

[0118] See attached document Figure 5 In step S300, the program generation module produces production records. Based on the allowable pre-compression result output by the qualification determination unit, the first... The feeding amount, pre-compression control program, and exhaust compaction control program corresponding to each molding cavity are executed by the hydraulic hot pressing equipment controlled by the hot pressing control module.

[0119] S301, the feeding correction unit determines the first step based on the product process data set, powder batch data, cavity address, and historical defect data. The amount of material fed into each molding cavity in the current production cycle.

[0120] The material feeding correction unit obtains information from the production record. Read product process data set Cavity location address and molding control area set The powder loose density, powder moisture content parameters, and powder flow state parameters are read from the powder weighing and inlet device.

[0121] No. The amount of material to be fed into each molding cavity is determined according to the following formula: ; in, For the first The amount of material fed into each molding cavity; For the first The basic material input amount for each molding cavity; For the first Powder batch correction amount for each molding cavity; For the first The cavity position correction amount for each molding cavity; For the first Historical defect correction amount for each molding cavity.

[0122] No. Basic material input for each molding cavity From product process data set The data for the arc surface of the brake drum contact friction layer, the thickness of the friction layer, the end forming data, and the edge forming data are determined. Basic material input quantity. Used to satisfy the first The molding volume requirements for the brake drum contact friction layer in each molding cavity.

[0123] No. Powder batch correction amount for each molding cavity Determined by the current powder batch's loose packing density, moisture content parameters, and flow state parameters. Cavity position correction amount for each molding cavity From cavity address The cavity position number, cavity position column number, and cavity position sequence number are determined. Historical defect correction amount for each molding cavity It is formed by the traceability correction module in the previous production cycle or multiple historical production cycles.

[0124] S302, the pre-compression generation unit, according to the... The pre-compression control program is generated by taking the material input amount of each molding cavity, the set of molding control areas, and the qualification judgment results.

[0125] The pre-compression generation unit from production records Read the first A collection of molding control areas for each molding cavity. and read the first from the qualification determination unit The allowable preload result for each molding cavity is determined. When the allowable preload result meets the requirements, the preload generation unit generates the corresponding preload control program.

[0126] The pre-compression control program includes pre-compression speed, preset pre-compression displacement, pre-compression holding time, and pre-compression pressure limit. The pre-compression speed controls the speed at which the indenter contacts the powder friction material. The preset pre-compression displacement limits the initial compression position of the powder friction material; it is determined based on data from the brake drum's contact friction layer arc surface, friction layer thickness, end forming data, and edge forming data. The pre-compression holding time ensures that the powder friction material is distributed along the outer arc surface of the horseshoe frame under pre-compression. The pre-compression pressure limit prevents the pre-compression stage from directly entering the final compression state.

[0127] The preload control program directs the powder friction material into the horseshoe bonding forming zone, the brake drum contact arc surface forming zone, the end compensation zone, and the edge forming zone. The horseshoe bonding forming zone is used to establish the contact state between the powder friction material and the outer arc surface of the horseshoe frame. The brake drum contact arc surface forming zone is used to establish the initial powder distribution for subsequent working arc surfaces. The end compensation zone and the edge forming zone are used to compensate for the filling state of the powder at the ends and sides of the arc cavity.

[0128] S303, the hot pressing execution unit controls the hydraulic hot pressing equipment to perform pre-pressing actions according to the pre-pressing control program, and the compaction calculation unit collects pressure data and pressure head displacement data, and calculates the compaction state of the zones.

[0129] The hot pressing actuator converts the pre-pressing control program into action commands for the hydraulic hot pressing equipment. The hydraulic hot pressing equipment performs downward pressing according to the preset pre-pressing displacement, and performs an initial holding action after pressing, so that the powder friction material is initially compressed between the outer arc surface of the horseshoe frame and the multi-cavity forming mold.

[0130] The compaction calculation unit collects pressure data and pressure head displacement data from the hydraulic hot press. The pressure data represents the compressive force exerted on the powder friction material during pre-compression, while the pressure head displacement data represents the change in the compressed position of the powder friction material during pre-compression.

[0131] The compaction calculation unit calculates based on pressure data, head displacement data, and cavity address. Molding control area set Cavity location data and mold structure data respectively form the first The compaction status of the horseshoe bonding molding area, brake drum contact arc surface molding area, end compensation area, edge molding area, and exhaust end area in each molding cavity is recorded in the production log. The compaction status is used by the exhaust generation unit to determine whether to enter the exhaust compaction process, and is also used in subsequent judgments by the judgment unit and the arc surface judgment unit to determine the forming status.

[0132] S304. The exhaust generation unit generates an exhaust compaction program based on the zone compaction status and product process data set, and the hot pressing execution unit controls the hydraulic hot pressing equipment to perform the exhaust compaction action.

[0133] Exhaust generation unit reads production records Compaction status and product process data set When the compaction state of the shoe-shaped bonding zone, end compensation zone, and edge forming zone reaches the product process data set... When the pre-pressure is within the corresponding allowable range, the exhaust generation unit generates an exhaust compaction procedure.

[0134] The venting and compaction process includes increasing pressure, holding time before venting, depressurization displacement, and repressurization pressure. Increasing pressure further compacts the powder friction material. The holding time before venting allows entrained gas in the powder friction material to move towards the venting end zone. The depressurization displacement allows the multi-cavity molding die to create a venting gap while keeping the horseshoe frame clamped. Repressurization pressure recompacts the powder friction material after venting is complete.

[0135] The hot pressing actuator controls the hydraulic hot pressing equipment to perform pressurization, holding, depressurization, and re-pressing actions according to the depressurization and compaction procedure. During the depressurization and depressurization process, the entrained gas and heated volatile gas in the powder friction material are discharged through the mold parting surface, cavity end, depressurization groove, or depressurization gap.

[0136] S305, the exhaust judgment unit determines whether the exhaust compaction process meets the conditions for entering the final pressure integral molding stage based on the pressure relief rebound, pressure drop status and exhaust path status.

[0137] The exhaust judgment unit collects data during the depressurization and repressurization processes. In the first molding cavity position The springback state, pressure drop state, and venting path state of each molding control zone are described. The springback state indicates the degree of compression recovery of the powder friction material after pressure relief. The pressure drop state indicates the pressure release during the pressure relief process. The venting path state indicates the state of the venting channel between the corresponding molding control zone and the venting end zone.

[0138] When the exhaust status of the horseshoe joint forming area, the brake drum contact arc forming area, the end compensation area, and the edge forming area are all included in the product process data set When the final pressure is within the allowable range, the exhaust judgment unit outputs the exhaust result that allows entry into the final pressure integral molding stage to the stage interlock unit.

[0139] When the exhaust status of any molding control area is not included in the product process data set When the final pressure falls within the allowable range, the exhaust judgment unit outputs the continued exhaust compaction result to the exhaust generation unit. The exhaust generation unit adjusts the exhaust compaction program based on the continued exhaust compaction result, and the hot pressing execution unit continues to control the hydraulic hot pressing equipment to perform pressurization, holding, depressurization, exhaust, and re-pressurization actions.

[0140] The control of pressing speed, pressure, displacement, mold parting surface venting, venting groove venting, and venting gap venting of hydraulic hot pressing equipment can all be achieved according to the conventional control methods of hot pressing equipment and hot pressing mold. The relevant execution methods are well-known technologies in this field and will not be described in detail here.

[0141] See attached document Figure 6 In step S400, the hot pressing control module receives the compaction and venting states formed in step S300, and combines them with the clamping and powder introduction states formed in step S200 to control the hydraulic hot pressing equipment to enter the final pressing integrated molding stage, so that the powder friction material forms a brake drum contact friction layer on the outer arc surface of the horseshoe frame.

[0142] S401, the stage interlock unit determines the first stage based on the clamping state, powder introduction state, compaction state, and venting state. Whether each molding cavity is allowed to enter the final pressure integral molding stage.

[0143] Stage interlock unit reads production records cavity address Molding control area set The system reads the compaction and venting states, and the clamping state and powder introduction results generated by the qualification determination unit.

[0144] The compaction state is used to confirm that the powder friction material has reached the initial compaction state required for final compaction after pre-compression and venting compaction. The venting state is used to confirm that the gas discharged during pre-compression and venting compaction meets the final pressure requirements.

[0145] When the clamping status results, powder introduction results, compaction status of each molding control area, and venting status are all included in the product process data set When the corresponding final pressure is within the allowable range, the stage interlock unit outputs a final pressure allow signal to the hot pressure execution unit. If any state fails to enter the corresponding final pressure allowable range, the stage interlock unit maintains the final pressure prohibition state and returns the corresponding unmet item to the program generation module.

[0146] S402. The hot pressing execution unit controls the hydraulic hot pressing equipment to perform the final pressing action according to the final pressing integral molding control program output by the final pressing generation unit.

[0147] The final pressure generation unit is based on the product process data set. , No. Feed amount per molding cavity The program controls the final pressure integral molding process by generating the compaction and degassing states.

[0148] The final pressure molding control program includes final pressure, final pressure target displacement, final pressure holding time, and final pressure temperature. Final pressure is used to press the powder friction material onto the outer arc surface of the brake shoe frame. Final pressure target displacement is used to limit the molding thickness and arc position of the brake drum contact friction layer. Final pressure holding time is used to maintain the molding state of the powder friction material under final pressure. Final pressure temperature is used to complete the curing of the powder friction material.

[0149] The hot pressing actuator outputs the final pressing action command to the hydraulic hot pressing equipment according to the final pressing integrated molding control program. The hydraulic hot pressing equipment performs the final pressing action while the horseshoe clamping mechanism holds the horseshoe in place. The powder friction material forms a brake drum contact friction layer under the combined action of the outer arc surface of the horseshoe skeleton, the inner wall of the molding cavity, and the press pressure.

[0150] During the final pressing process, the shoe clamping mechanism continues to restrict the shoe skeleton from shifting position relative to the forming cavity. The inner side of the brake drum contact friction layer contacts the outer arc surface of the shoe skeleton and forms a bonding forming area, while the outer side of the brake drum contact friction layer is defined by the multi-cavity forming mold into an arc shape that mates with the inner wall of the brake drum.

[0151] S403. The judgment unit determines the bonding state between the powder friction material and the outer arc surface of the horseshoe skeleton based on the compaction state, clamping and holding state, and curing state of the horseshoe bonding molding zone.

[0152] Combined with the judgment unit to read the first Horseshoe bonding molding area with individual molding cavities The bonding state between the powder friction material and the outer arc surface of the horseshoe skeleton is determined based on the compaction state, clamping and holding state, and curing state of the horseshoe bonding molding zone.

[0153] The clamping and holding state is used to indicate the first Whether the horseshoe clamping mechanism maintains the clamping position during the final pressing and curing process of each molding cavity. The curing state is used to indicate the curing status of the first molding cavity. The curing process of the horseshoe-shaped molding zone in each molding cavity during final pressing and holding curing.

[0154] The judgment unit combines the compaction state, clamping and holding state, and curing state of the shoe-shaped molding zone with the product process data. The allowable range of bonding and molding is compared. When the compaction state, clamping and holding state, and curing state of the horseshoe bonding and molding zone all fall within the allowable range of bonding and molding, the bonding judgment unit records the first... The horseshoe bonding molding state of each molding cavity meets the requirements. When the compaction state, clamping and holding state, or curing state of the horseshoe bonding molding area does not enter the allowable range of bonding molding, the bonding judgment unit outputs the bonding molding to be held result to the stage interlock unit, and the stage interlock unit restricts the demolding control unit from entering the demolding preparation stage.

[0155] S404. The arc surface judgment unit judges the arc surface forming state of the brake drum contact friction layer based on the compaction state, pressure head displacement state, clamping and holding state, and curing state of the brake drum contact arc surface forming area.

[0156] The arc surface judgment unit reads the first The brake drum contact arc surface forming area of ​​each forming cavity The forming state of the arc surface of the brake drum contact friction layer is determined based on the compaction state, pressure head displacement state, clamping and holding state, and curing state of the brake drum contact arc surface forming area.

[0157] The indenter displacement state is used to represent the correspondence between the actual position of the indenter and the target displacement of the final pressure during the final pressure process. The curing state is used to represent the first... The curing process of the brake drum contact arc surface molding area in each molding cavity during final pressure and holding curing.

[0158] The arc surface judgment unit integrates the compaction state, pressure head displacement state, clamping and holding state, and curing state of the brake drum contact arc surface forming area with product process data. The allowable range of arc surface forming is compared. When the compaction state, pressure head displacement state, clamping and holding state, and curing state of the brake drum contacting the arc surface forming area all fall within the allowable range of arc surface forming, the arc surface judgment unit records the first... The arc surface forming state of the brake drum contact friction layer in each forming cavity meets the requirements. When the compaction state, pressure head displacement state, clamping and holding state, or curing state of the brake drum contact arc surface forming area does not enter the allowable range of arc surface forming, the arc surface judgment unit outputs the arc surface forming to be held result to the stage interlock unit, and the stage interlock unit restricts the demolding control unit from entering the demolding preparation stage.

[0159] S405. The curing judgment unit determines whether the curing stage meets the termination conditions based on the temperature state, pressure state, holding time, and clamping holding state.

[0160] The curing judgment unit reads the first The temperature, pressure, holding time, and clamping status of each molding control area in each molding cavity are recorded, based on the product process data set. The curing allowable range is used to determine whether the curing stage meets the termination condition.

[0161] Temperature status indicates whether the temperature of the molding control zone during the curing process meets the curing requirements of the powder friction material. Pressure status indicates whether the pressing pressure is maintained within the set range during the curing process. Holding time indicates whether the curing holding time after final pressure meets the product process data set. The time requirement is specified. The clamping hold status indicates whether the horseshoe carcass remains in the allowable clamping position during the curing process.

[0162] The curing determination unit determines the horseshoe bonding molding area respectively. Contact arc-shaped area with brake drum Does the cured state enter the product process data set? The demolding allowable range is specified. When the horseshoe bonding molding state, the arc surface molding state, the curing state of the horseshoe bonding molding area, and the curing state of the brake drum contact arc surface molding area all enter the corresponding demolding allowable range, the curing judgment unit outputs a demolding preparation signal to the demolding control unit. When any state does not enter the corresponding demolding allowable range, the curing judgment unit outputs a holding curing result to the stage interlock unit, and the hot pressing execution unit continues to execute the holding curing procedure.

[0163] The establishment of final pressure control, final pressure displacement control, final pressure temperature control, and conditions for maintaining curing can be determined based on material supply data, hot pressing process tests, and product inspection data. These methods are well-known technologies in the field of hot pressing of friction materials and will not be elaborated here.

[0164] See attached document Figure 7 In step S500, the traceability correction module receives the demolding preparation signal generated in step S400, controls the brake shoe to complete the demolding transfer, and writes the finished product inspection result into the production record of the corresponding molding cavity.

[0165] S501 After receiving the demolding preparation signal, the demolding control unit reads the production record and executes the demolding process in the order of hydraulic hot pressing equipment return, shoe clamping mechanism release, multi-cavity forming mold opening and brake shoe transfer.

[0166] After receiving the demolding preparation signal output by the curing judgment unit, the demolding control unit reads the... Production records corresponding to each molding cavity and confirm production records The process already includes the shoe-fitting molding state, the arc-shaped molding state, the shoe-fitting molding zone curing state, and the brake drum contact arc-shaped molding zone curing state.

[0167] The return stroke of the hydraulic hot press is used to release the pressure of the pressure head on the multi-cavity forming mold. The release mechanism of the shoe clamping mechanism is used to release the clamping constraint on the shoe frame. The opening of the multi-cavity forming mold is used to allow the formed brake shoe to be removed from the forming cavity. The brake shoe transfer is used to send the formed brake shoe to the inspection station or turnover station.

[0168] Before releasing the shoe clamping mechanism, the demolding control unit reads the clamping and holding states and the curing states. When the clamping and holding states, the curing states of the shoe joint forming area, and the curing states of the brake drum contact arc forming area are all within the demolding allowable range, the demolding control unit outputs a clamping release command. If any state is not within the demolding allowable range, the demolding control unit remains in a waiting state and feeds back the demolding waiting result to the stage interlock unit.

[0169] S502, The finished product inspection unit performs finished product status inspection on the molded brake shoes and generates the first... The set of detection data corresponding to each molding cavity.

[0170] The finished product inspection unit inspects the brake shoes after demolding. The inspection items include the appearance of the brake drum contact friction layer, the condition of the friction layer arc surface, the condition of the friction layer thickness, the end forming condition, the edge forming condition, the shoe bonding condition, and the finished product weight.

[0171] The visual inspection data of the brake drum contact friction layer is used to record the surface porosity, spalling, cracks, localized loosening, and surface contamination. The inspection data of the friction layer's curved surface is used to record the working curved surface of the brake drum contact friction layer in relation to the product's process data set. The corresponding state between the data of the mid-arc surface. The friction layer thickness state detection data is used to record the brake drum contact friction layer thickness and the product process data set. The corresponding state between the intermediate friction layer thickness data.

[0172] End forming condition inspection data is used to record the material shortage, flash, and end shape of the brake drum contact friction layer at both ends along the arc length direction. Edge forming condition inspection data is used to record the material shortage, flash, and edge shape of the brake drum contact friction layer on both sides along the width direction. Horseshoe bonding condition inspection data is used to record the bonding condition between the powder friction material and the outer arc surface of the horseshoe frame. Finished product weight condition inspection data is used to record the weight of the formed brake shoe.

[0173] S503, the finished product inspection unit binds the inspection data with the cavity address to form the first... The finished product inspection results for each molding cavity.

[0174] Finished product testing unit reads the first Production records for each molding cavity The inspection data of the brake drum contact friction layer appearance, friction layer arc surface condition, friction layer thickness, end forming condition, edge forming condition, shoe bonding condition, and finished product weight are recorded in the production log. In the corresponding data items.

[0175] Detection data and cavity address After binding, the finished product inspection results can be mapped to specific mold number, cavity row number, cavity column number, cavity sequence number, horseshoe skeleton number, powder batch, and production cycle number.

[0176] When any brake shoe experiences an anomaly during the same production cycle, the anomaly result is not directly attributed to the entire multi-cavity molding die, but rather written into the production record of the corresponding molding cavity. .

[0177] S504, the defect attribution unit assigns the detected defects to the molding cavity, molding control area, and production control stage based on the finished product inspection results.

[0178] Defect attribution unit reads the first Production records for each molding cavity And combine the detected abnormal items with the molding control area. This corresponds to the production control stage. The production control stage includes the clamping confirmation stage, powder introduction stage, powder pre-compression stage, venting and compaction stage, final compression molding stage, holding and curing stage, and demolding and transfer stage.

[0179] No. The defect attribution results for each molded cavity are expressed by the following formula: ; in, For the first Defect attribution results for each molding cavity; For the first The cavity address of each molding cavity; For the first In the first molding cavity position One molding control area; This refers to the sequence number of the molding control area; For the first In the first molding cavity position Each production control stage; This refers to the production control stage number.

[0180] Defect attribution results This serves as a defect source record, used to document the cavity address, molding control area, and production control stage corresponding to the detected defect. The program correction unit reads the defect attribution results. And based on the defect attribution results Identify the objects to be corrected in the next production cycle.

[0181] No. In the first molding cavity position Each molding control area Used to indicate the location of the area corresponding to the detected defect. In the first molding cavity position Production control stage Used to indicate the production control stage corresponding to the detected defect.

[0182] The defect attribution unit maps detected defects to molding control areas and production control stages based on the defect attribution table. The defect attribution table includes the correspondence between end material shortages, edge flash, abnormal curved surface forming, abnormal horseshoe bonding, surface porosity, and localized looseness, and these correspond to molding control areas and production control stages. A detected defect can correspond to one molding control area and one production control stage, or it can correspond to multiple molding control areas and multiple production control stages.

[0183] The defect attribution unit assigns the defect attribution results Write to the Production records for each molding cavity And send it to the program correction unit.

[0184] S505, The program correction unit corrects the next cycle production program based on the defect attribution results.

[0185] The program correction unit reads the first Defect attribution results for each molding cavity And based on the defect attribution results cavity address Molding control area and production control stage The correction target for the next production cycle is determined. When the same inspection defect corresponds to multiple forming control areas or multiple production control stages, the program correction unit determines the corresponding correction target based on the defect attribution table.

[0186] The correction amount for the next production cycle is expressed by the following formula: ; in, For the first The correction amount for the next cycle production process of each molding cavity; For the first Correction value for the next cycle feed amount of each forming cavity; For the first Correction value for the next cycle preload procedure of each molding cavity; For the first Correction value for the next cycle exhaust compaction procedure of each forming cavity; For the first Correction value for the final pressure integral molding process of each molding cavity in the next cycle; For the first The next cycle for each molding cavity retains the curing process correction value; For the first Correction value for clamping check conditions in the next cycle of each forming cavity.

[0187] When the defect attribution result When corresponding to the end compensation zone and the powder introduction or powder pre-compression stage, the program correction unit corrects the first... Next cycle feed amount correction value for each molding cavity Or the correction value for the next cycle of preloading program. .

[0188] When the defect attribution result When corresponding to the edge forming area and the final integral forming stage, the program correction unit corrects the first... Next cycle final pressure integral molding program correction value for each molding cavity .

[0189] When the defect attribution result When corresponding to the brake drum contact arc surface forming area and the final pressure integral forming stage or the holding and curing stage, the program correction unit corrects the first... Next cycle final pressure integral molding program correction value for each molding cavity Or maintain the correction value for the curing process in the next cycle. .

[0190] When the defect attribution result When corresponding to the horseshoe bonding molding area, clamping confirmation stage, final pressing integral molding stage, or holding and curing stage, the program correction unit corrects the first... Next cycle clamping check condition correction value for each molding cavity Correction value for the final pressing integral molding process in the next cycle Or maintain the correction value for the curing process in the next cycle. .

[0191] When the defect attribution result When corresponding to the exhaust end zone and exhaust compaction stage, the program correction unit corrects the first... Next cycle exhaust compaction procedure correction value for each forming cavity .

[0192] The program correction unit will adjust the production program for the next cycle. Write to the The production records corresponding to each molding cavity are retrieved by the program generation module in the next production cycle. Finished product inspection results are used to correct the control programs for the corresponding molding cavity, molding control area, and production control stage. The correction amount for the next production cycle is... No more than the product process data set The corresponding allowable adjustment range.

[0193] Demolding and transfer control, appearance inspection, size inspection, weight inspection, and production record writing can be achieved by PLC sequential control, limit switch detection, manual inspection, visual inspection, caliper inspection, displacement sensor detection, or electronic scale detection. The relevant execution and detection methods are well-known technologies in this field and will not be elaborated here.

[0194] Specific application examples: To better understand the technical solution of this invention, the invention will be further described below in conjunction with specific application scenarios and accompanying drawings. This embodiment is constructed on a production line for processing brake shoes for drum brakes. The brake shoe includes a shoe frame and a brake drum contact friction layer formed on the outer arc surface of the shoe frame. The brake drum contact friction layer is formed by pressing and curing powdered friction material in a multi-cavity forming mold. The integrated digital program production control system for brake shoe processing runs in a production line including hydraulic hot pressing equipment, multi-cavity forming mold, shoe clamping mechanism, powder weighing and introducing device, detection and identification components, and controller. It acquires product process data, cavity addresses, clamping confirmation data, pressing process status, and finished product inspection data, and executes the next cycle production program correction.

[0195] In this specific application embodiment, the multi-cavity molding mold has 2 rows and 4 columns, totaling 8 molding cavities. The selected cavity is... One molding cavity is used as the subject of this explanation. The cavity address of each molding cavity is established according to the following formula: ; In this specific application embodiment, the mold number is MJ01, the cavity row number is 1, the cavity column number is 3, the cavity sequence number is 3, the corresponding horseshoe skeleton number is GT031, the powder batch number is FM26, and the production cycle number is 8. Substituting the values, we can express the following: ; The cavity address is used to set the first The horseshoe skeleton, powder batch, pressing process status, and finished product test results for each molding cavity are bound to the same data record object, so that subsequent clamping confirmation, program generation, hot pressing control, and traceability correction can be matched to the specific molding cavity.

[0196] During the powder introduction stage, the feeding correction unit calculates the first step based on the product process data set, powder batch data, cavity address, and historical defect data. The amount of material fed into each molding cavity. The amount of material to be fed into each molding cavity is determined according to the following formula: ; In this specific application example, the base feed amount is 126.00g, the powder batch correction amount is +1.20g, the cavity position correction amount is -0.45g, and the historical defect correction amount is +0.80g. Substitute the values ​​for calculation: ; The calculation results are in grams. Product process data set. The current allowable range for the feed amount is set to 126.50g to 128.50g. Due to the... If the amount of material fed into each forming cavity is within the allowable range of the current amount of material fed, the powder loading confirmation unit determines that the material feeding confirmation result meets the preset requirements, and the qualification determination unit allows the program generation module to call the corresponding pre-compression program and venting and compaction program.

[0197] The clamping confirmation module collects data on the placement status of the shoe frame, the clamping status of the shoe, the positioning status of the mold, the powder introduction status, and the material feeding quantity confirmation status. Once all statuses meet the preset requirements, the program generation module generates the powder pre-compression program and the venting and compaction program. The hot pressing execution unit controls the hydraulic hot pressing equipment to perform pre-compression, holding, depressurization, venting, and re-compression actions. The venting judgment unit confirms the venting status and enters it into the product process data set. After determining the final pressure allowable range, the stage interlock unit outputs a final pressure allow signal to the hot pressure execution unit.

[0198] During the final pressure molding and curing stage, the hot pressing execution unit controls the hydraulic hot pressing equipment to perform the final pressure action according to the final pressure molding control program. A judgment unit assesses the bonding molding state between the powder friction material and the outer arc surface of the horseshoe frame; an arc surface judgment unit assesses the arc surface molding state of the brake drum contact friction layer; and a curing judgment unit determines whether the curing stage meets the termination conditions based on temperature, pressure, holding time, and clamping status. Once each state enters the corresponding demolding allowable range, the demolding control unit executes the return stroke, release, mold opening, and transfer.

[0199] The finished product testing unit detected the first The brake drum contact friction layer corresponding to a molding cavity has an abnormal arc surface molding, and there is a slight material shortage in the end area. Based on the finished product inspection results and the defect attribution table, the defect attribution unit associates the arc surface molding abnormality with the brake drum contact arc surface molding area and the final pressure integral molding stage or the holding and curing stage, and the end material shortage with the end compensation area and the powder introduction stage or the powder pre-pressing stage. The program correction unit then determines the correction targets for the next production cycle. The correction amount for the next production cycle is expressed by the following formula: ; The correction values ​​for the following programs are as follows: Next cycle feed rate increase: 0.80g; Next cycle pre-compression program correction value: 0.12mm increase in pre-compression target displacement; Next cycle venting and compaction program correction value: 0; Next cycle final compression molding program correction value: 0.10MPa decrease in final pressure; Next cycle holding and curing program correction value: 20s increase in holding and curing time; Next cycle clamping check condition correction value: 0. Substitute the values ​​to express: ; This set of values ​​indicates that the program correction unit increases the material feed rate in the next cycle and increases the pre-compression target displacement to address end material shortages, and reduces the final pressure in the next cycle and extends the holding and curing time to address arc surface forming abnormalities, while maintaining the venting and compaction program and clamping inspection conditions unchanged. All correction values ​​are within the product process data set. Within the corresponding allowable adjustment range.

[0200] To verify the control effect of the present invention, a control group and an application group were set up for comparison. The control group was produced using a fixed feed rate, a fixed pre-compression program, a fixed venting and compaction program, and a fixed final compression molding program. The application group was produced using an integrated digital program production control system for brake shoe processing. Both groups of experiments were conducted using the same model of brake shoes, the same multi-cavity molding die, the same batch of powder friction material, and the same hydraulic hot pressing equipment.

[0201] See attached document Figure 8 , Figure 8 The horizontal axis represents frequency, and the vertical axis represents the group. (Appendix) Figure 8 The pressure fluctuation amplitude spectrum of the control group and the application group was displayed using a longitudinal offset method. Both the control group and the application group showed pressure fluctuation peaks near 1.80Hz, 4.62Hz, and 7.22Hz, but the peak value of the application group at the same frequency position was lower than that of the control group, indicating that the solution of the present invention can reduce pressure fluctuations in the powder pre-compression, degassing compaction, and final compression integrated molding process.

[0202] See attached document Figure 9 , Figure 9 The horizontal axis represents spatial frequency, and the vertical axis represents the power spectral density of the arc surface deviation. The control group and the application group are at 0.045 mm. -1 0.180mm -1 and 0.310mm -1 Peak values ​​of arc surface deviation were present in all vicinity, but the power spectral density of the application group at the same spatial frequency position was lower than that of the control group, indicating that the present invention can reduce the arc surface deviation of the brake drum contact friction layer and improve the consistency of arc surface forming. (See attached diagram.) Figure 8 and attached Figure 9 It can be seen that the amount of material fed and the correction amount for the next production cycle It can support cavity-level closed-loop control, thereby reducing pressure fluctuations and minimizing surface deviation.

[0203] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A digital program production control system for brake shoe processing, characterized in that, include: The process documentation module is used to establish data relationships between product models, multi-cavity molding dies, molding cavity positions, horseshoe skeletons, and powder batches. The clamping confirmation module is used to determine whether the multi-cavity molding die meets the conditions for entering the pressing control program; The program generation module is used to generate the pressing control program based on the data output by the process documentation module and the clamping confirmation module. A hot pressing control module is used to control the hydraulic hot pressing equipment, the horseshoe clamping mechanism, the heating mechanism, and the switching of pressing stages according to the pressing control program; The traceability correction module is used to obtain the finished product inspection results and correct the next cycle of production program based on the finished product inspection results.

2. The integrated digital program production control system for brake shoe processing according to claim 1, characterized in that, The process documentation module includes a product data unit, a mold identification unit, a cavity location documentation unit, and a partition setting unit. The product data unit is used to store process data corresponding to different product models; The mold identification unit is used to identify the mold number of the multi-cavity molding mold and read the number of cavities, the arrangement of cavities, and the position data of cavities corresponding to the multi-cavity molding mold. The cavity location registration unit is used to establish a cavity location address for each of the molded cavities; The partition setting unit is used to divide each of the molding cavities into multiple molding control areas according to the process data. The molding control areas include the horseshoe bonding molding area, the brake drum contact arc surface molding area, the end compensation area, the edge molding area, and the exhaust end area.

3. The integrated digital program production control system for brake shoe processing according to claim 2, characterized in that, The clamping confirmation module includes a horseshoe identification unit, a clamping acquisition unit, a powder filling confirmation unit, and a qualification determination unit. The horseshoe identification unit is used to determine whether the horseshoe skeleton is placed in the corresponding molding cavity, and to determine whether the horseshoe skeleton number corresponds to the cavity address, thereby generating a horseshoe placement result. The clamping acquisition unit is used to acquire the position data of the horseshoe clamping mechanism, the clamping completion signal, the horseshoe outer arc surface posture signal and the mold positioning signal, and generate the clamping status result. The powder loading confirmation unit is used to collect the powder batch, feeding amount, powder loading completion status and powder spreading confirmation status, and generate powder import results; The qualification determination unit is used to comprehensively determine whether the process data, the horseshoe placement result, the clamping state result, and the powder introduction result meet the powder pressing and clamping integrated molding conditions, and generate a clamping confirmation result.

4. The integrated digital program production control system for brake shoe processing according to claim 3, characterized in that, The judgment logic of the qualification determination unit is as follows: When the process data, the horseshoe placement result, the clamping state result, and the powder introduction result all meet the preset requirements, the corresponding molding cavity position is marked as an allowable pre-compression state, and an allowable instruction to enter the pre-compression control program and the exhaust compaction control program is output to the program generation module. When the horseshoe skeleton is not clamped, the powder loading status is incomplete, the mold positioning signal is not in place, or the process data is not called, a prohibition command is output to prevent entry into the final pressing integrated molding control program.

5. The integrated digital program production control system for brake shoe processing according to claim 4, characterized in that, The pressing control program includes the pre-pressing control program, the exhaust compaction control program, and the final pressing integral molding control program; The program generation module includes a feeding correction unit, a pre-compression generation unit, an exhaust generation unit, and a final pressure generation unit: The feeding correction unit is used to correct the feeding amount based on the product model, the powder batch, the cavity address, and historical defect data. The pre-pressure generation unit is used to generate the pre-pressure control program when the permission instruction is received. The pre-pressure control program is used to control the hydraulic hot pressing equipment to perform pressing and initial holding according to a preset pre-pressure displacement. The preset pre-pressure displacement is determined according to the process data. The exhaust generation unit is used to generate the exhaust compaction control program, which includes pressurization, holding, depressurization and exhaust, and re-pressurization actions. The final pressure generation unit is used to generate the final pressure integral molding control program.

6. The integrated digital program production control system for brake shoe processing according to claim 4, characterized in that, The hot pressing control module includes a hot pressing execution unit, a stage interlock unit, and a compaction calculation unit: The hot pressing actuator is used to output control commands to the hydraulic hot pressing equipment; The stage interlock unit is used to restrict the switching of the pressing stage. When the prohibition command is received, the stage interlock unit prohibits the hot pressing execution unit from entering the final pressing integral molding stage. The compaction calculation unit is used to calculate the compaction state of the forming cavity and the forming control area based on the pressure data and pressure head displacement data of the hydraulic hot pressing equipment.

7. The integrated digital program production control system for brake shoe processing according to claim 6, characterized in that, The hot pressing control module also includes an exhaust judgment unit, a bonding judgment unit, an arc surface judgment unit, and a curing judgment unit: The exhaust judgment unit is used to determine whether the exhaust compaction stage meets the conditions for entering the final pressure integral molding stage based on the pressure relief rebound, pressure drop state and exhaust path state. The bonding judgment unit is used to judge the forming state of the powder friction material and the outer arc surface of the horseshoe skeleton based on the compaction state, clamping and holding state and curing state of the horseshoe bonding forming area; The arc surface judgment unit is used to determine whether the brake drum contact friction layer meets the conditions for entering the holding and curing stage or the demolding preparation stage based on the compaction state, pressure head displacement state, clamping and holding state and curing state of the brake drum contact arc surface forming area. The curing determination unit is used to determine whether the holding and curing stage meets the end conditions based on the temperature state, pressure state, holding time, and clamping holding state.

8. The integrated digital program production control system for brake shoe processing according to claim 7, characterized in that, The traceability correction module includes a demolding control unit, a finished product inspection unit, a defect attribution unit, and a program correction unit: The demolding control unit is used to control the return stroke of the hydraulic hot pressing equipment, the release of the shoe clamping mechanism, the opening of the multi-cavity forming mold, and the transfer of the formed brake shoe. The finished product inspection unit is used to inspect the formed brake shoes and generate the finished product inspection results. The finished product inspection results are bound to the cavity address and the inspection defects are output. The inspection content includes the appearance of the brake drum contact friction layer, the state of the friction layer arc surface, the state of the friction layer thickness, the end forming state, the edge forming state, the bonding state of the powder friction material with the outer arc surface of the shoe skeleton, and the finished product weight state. The defect attribution unit is used to map the detected defect to the corresponding molding cavity, the corresponding molding control area and the corresponding production control stage, and to establish a defect source record. The program correction unit is used to correct the next cycle production program based on the defect source record.

9. The integrated digital program production control system for brake shoe processing according to claim 8, characterized in that, The defect attribution unit maps the detected defect to the molding control area and the production control stage according to the defect attribution table: The production control stage includes the clamping confirmation stage, powder introduction stage, powder pre-compression stage, the degassing and compaction stage, the final pressure integral molding stage, the holding and curing stage, and the demolding and transfer stage; The defect attribution table includes the correspondence between end material shortage, edge flash, abnormal arc surface forming, abnormal horseshoe bonding state, surface porosity and local looseness and the forming control area and the production control stage.

10. The integrated digital program production control system for brake shoe processing according to claim 9, characterized in that, The correction logic of the program correction unit is as follows: The program correction unit reads the molding control area and the production control stage from the defect source record, and determines the correction object from the material feeding amount, pre-compression control program, exhaust compaction control program, final compression integrated molding control program, holding curing program and clamping inspection conditions based on the molding control area and the production control stage. When the object of correction is the feeding amount or the clamping check condition, the program correction unit corrects the feeding amount or the clamping check condition of the next cycle corresponding to the forming cavity position. When the object of correction is the pre-pressure control program, the exhaust compaction control program, the final pressure integral molding control program, or the holding and curing program, the program correction unit corrects the corresponding control program in the next cycle production program.

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