Brake Pad Backplate Adhesive Verification by Gray-Level Imaging
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Solution Overview
Problem
Existing methods for manufacturing braking elements, such as brake pads, fail to reliably verify the presence and adequate concentration of adhesive on metallic supports, leading to potential accidental detachments during use.
Innovation Solution
A method and plant that uses a video camera and electronic processing unit to detect the gray level of adhesive on metallic supports, comparing it to threshold values to ensure the adhesive is present and applied in the correct amount, with a robot discarding defective elements and ensuring reliable attachment of friction material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive is applied by spraying to the metallic support, then the adhesive application process is simple and fast, but the concentration of adhesive in the applied layer becomes variable and unreliable
Solution Approach 1:
The patent replaces mechanical/adhesive application methods with an optical detection system (video camera) to verify adhesive presence and concentration. This substitution allows for non-contact, high-speed verification that maintains production speed while ensuring precise adhesive concentration control through optical measurement rather than mechanical application control.
Solution Approach 2:
The patent implements a feedback mechanism where the video camera continuously monitors the adhesive layer on metallic supports, compares the monitored values with preset thresholds, and triggers alerts or rejections when adhesive concentration falls outside acceptable ranges. This closed-loop feedback system ensures consistent adhesive concentration while maintaining high production throughput.
2Extent of automation
If adhesive layer presence is verified using a video camera, then the verification process is fast and automated, but the system cannot verify the amount (concentration) of adhesive deposited
Solution Approach 1:
The patent enhances the basic optical detection by implementing image processing algorithms that analyze gray level variations in the video camera footage. This substitution of simple presence detection with sophisticated image analysis enables automated verification of both adhesive presence and concentration, achieving precise measurement through optical means without mechanical intervention.
Solution Approach 2:
The patent utilizes changes in optical parameters (gray level values) of the adhesive layer under video camera illumination to infer adhesive concentration. By analyzing variations in reflected light intensity and gray level distributions across the adhesive layer, the system translates optical parameter changes into quantitative concentration information, enabling precise measurement through non-contact optical analysis.
3Productivity
If the adhesive layer is not correctly applied to the metallic surface, then the manufacturing process continues without interruption, but the block of friction material may be subject to accidental detachments in use
Solution Approach 1:
The patent implements preliminary verification of adhesive application quality before the friction material bonding step. The video camera system inspects adhesive layers on metallic supports prior to friction material application, identifying and flagging defective substrates in advance. This preliminary action prevents defective bonding attempts, ensuring that only properly adhesive-coated components proceed to the next manufacturing step, thereby maintaining both production continuity and product reliability.
Solution Approach 2:
The patent implements a feedback control system where defective metallic supports with insufficient or improperly applied adhesive are automatically identified and rejected by the robot manipulator. This feedback mechanism ensures that only components meeting adhesive application specifications proceed to friction material bonding, preventing future detachment issues while maintaining high production throughput through automated quality control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures the reliable attachment of friction material by verifying the presence and concentration of adhesive, preventing accidental detachments and enhancing the reliability of braking elements.
Implementation Method 1
detecting by means of a video camera a gray level of a plurality of points of at least a first portion of a predetermined width of a first face of the metallic element
Data Source
AI summary
Method and plant for manufacturing braking elements such as vehicle brake pads. The plant can comprise a first station that applies an adhesive to a first face of a metallic element; a second station that applies to the first face of the metallic element a block of friction material; a checking station that verifies the presence of the adhesive by detecting the gray level of a plurality of points of at least one zone of the first face; and a processing unit that compares the gray level detected for each point with a first threshold value, counts the number of points that have a gray level that satisfies a relationship (which is a function of the threshold value,) and compares such a value with a second threshold value to discard those metallic elements for which the percentage calculated does not correspond to the second threshold value.