Bidirectional Synchronous Broaching for Steel Back Brake Pads
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Solution Overview
Problem
Current steel back brake pad manufacturing methods, such as burred, counter-bore, and network locking types, face inefficiencies in processing and shear strength, leading to inconsistent product quality and limited mass production capabilities.
Innovation Solution
A steel back two-way synchronous broaching device with an upper and lower die system, utilizing oil hydraulic and nitrogen springs for synchronized blade movement, allowing for simultaneous two-direction grooving with high precision and density, enhancing shear strength and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a burred steel back is used with proprietary CNC apparatus, then the surface is burred, but the broaching grooving is lower in density, not firm enough, easy to be fallen down, and production efficiency is low
Solution Approach 1:
The broaching device is divided into multiple independent blades (first blade, second blade, third blade, fourth blade) that can simultaneously create grooves in different directions. This segmentation allows parallel processing of multiple grooves, increasing production efficiency while maintaining high grooving density and firmness through the coordinated action of all blades.
Solution Approach 2:
The invention combines multiple broaching functions into a single integrated device that performs bidirectional synchronous broaching. The first and second blades work together to create grooves in one direction, while the third and fourth blades create grooves in the perpendicular direction, merging multiple processing operations into one simultaneous action to improve both efficiency and grooving quality.
2Strength
If counter-bore steel back is used with blind holes, then the friction material moves into the counter-bore to increase shear strength, but the counter-bore influences the appearance and flatness of the product
Solution Approach 1:
The broaching device creates localized grooves with specific geometric patterns on the steel back surface. The grooves are designed with controlled depth, width, and spacing to optimize mechanical interlocking with friction material locally, while the overall surface remains relatively flat and smooth for acceptable appearance. The grooving pattern provides enhanced shear strength at critical locations without compromising overall product flatness.
3Strength
If network locking steel back is used with welded steel mesh, then the shear strength between steel back and friction material is increased, but the shear strength is relatively low compared to burred steel back and can only be used within a specific range
Solution Approach 1:
The broaching device creates a composite surface structure on the steel back by forming interlocking grooves that work together with the friction material. The grooves create a mechanically interlocked composite structure that enhances shear strength beyond what simple mesh welding provides. This composite approach allows the steel back to be effectively used across a wider range of applications with different friction material types and performance requirements.
4Manufacturing precision
If two-way broaching grooving is processed on the same steel back for two times, then the grooving is formed, but the processing efficiency needs to be improved and height difference is produced
Solution Approach 1:
The invention merges bidirectional broaching operations into a single simultaneous processing step. The first and second blades create grooves in one direction while the third and fourth blades create grooves in the perpendicular direction, all acting on the steel back at the same time. This eliminates the need for separate processing steps, improves efficiency, and ensures uniform groove height by maintaining consistent blade positioning and synchronization throughout the operation.
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
The device achieves uniform, high-strength grooving with increased production efficiency, stability, and aesthetic appeal, suitable for mass production, while minimizing height differences and the risk of the steel back falling.
Implementation Method 1
an upper die base connectable with an oil hydraulic machine, an upper die board mounted at the lower part of the upper die base, a lower die base connectable with the oil hydraulic machine
Implementation Method 2
utilizing oil hydraulic and nitrogen springs for synchronized blade movement
Data Source
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AI summary
The invention relates to a steel back two-way synchronous drawloom and a use method thereof. The drawloom comprises an upper die base, an upper die board, a lower die base and a lower die board, and further comprises a molded upper die and a working positioning lower die, wherein the molded upper die is mounted on the upper die board, and comprises a blade sliding board, a left blade, a right blade, a left inner slider, a right inner slider, a left outer slider and a right outer slider; the working positioning lower die is mounted on the lower die board, and comprises a concave die, a product floating block and a floating spring; the lower part of the lower die board is provided with a pushing rod; the lower die base is fixed and mounted with a left and right supporting blocks corresponding to the left and right outer sliders, and the left and the right supporting blocks are passed through and mounted on the lower die board lengthwise. With the adoption of a two-way synchronous broaching gear method, a gear of a product in the invention has the advantages of high density, high strength, as well as uniform and neat arrangement; furthermore, a brake pad of the product in the invention has the advantage of high shear strength. In addition, the drawloom has high production efficiency, stable whole production process, a firm gear root, and non easy falling, as well as is adaptable to be produced in mass.