Automated Brake Pad Finishing Station With Programmable Guide
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Solution Overview
Problem
Existing brake pad finishing technologies face challenges in achieving precise geometric tolerances and flexibility to accommodate various friction layer geometries, particularly in creating complex chamfers and grooves, due to limitations in tool accuracy and adaptability.
Innovation Solution
An automated finishing station equipped with a programmable 6-axis robotic arm, adjustable guide system, and multiple rotary finishing tools, including a flat grinder and disc grinder, allows for precise control of the workhead's trajectory and tool positioning to meet diverse brake pad geometries, ensuring high accuracy and flexibility in finishing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a programmable 6-axis robotic arm with adjustable guide system is used, then flexibility to accommodate various friction layer geometries is improved, but device complexity increases
Solution Approach 1:
The patent employs a programmable 6-axis robotic arm that enables dynamic positioning and movement of the workhead along complex trajectories. This dynamic capability allows the system to adapt to various friction layer geometries including different chamfer profiles and groove configurations, resolving the contradiction between flexibility and complexity by making the system programmably adaptable rather than requiring multiple fixed configurations
Solution Approach 2:
The finishing station integrates multiple rotary finishing tools (flat grinder, disc grinder) on a single workhead that can be positioned by the robotic arm. This universal setup allows one system to perform multiple finishing operations on various brake pad geometries, accommodating diverse friction layer shapes including J-form chamfers, flat chamfers, and grooves without requiring separate dedicated equipment for each operation
2Manufacturing precision
If multiple rotary finishing tools with precise control are used, then manufacturing precision of friction layer geometry is improved, but productivity decreases
Solution Approach 1:
The robotic arm enables continuous movement of the workhead along programmed trajectories, maintaining constant engagement with the friction layer for uninterrupted finishing operations. The system eliminates idle positioning time by programming optimal paths that continuously engage the grinding tools, thereby maintaining high precision while improving productivity through uninterrupted material removal
Solution Approach 2:
The system employs preliminary programming of the robotic arm trajectories and workhead positioning before actual finishing begins. By pre-calculating and programming the optimal paths for creating chamfers, grooves, and flat surfaces, the system ensures that precision requirements are met from the start of each operation, eliminating the need for repeated adjustments and repositioning that would reduce productivity
3Manufacturing precision
If a rigid guide system is used to maintain accuracy, then manufacturing precision is improved, but adaptability to different brake pad models decreases
Solution Approach 1:
The guide system combines rigid structural elements with programmable positioning capabilities. The robotic arm moves the workhead along precisely controlled trajectories while the guide system provides rigid reference surfaces for maintaining accuracy. This dynamic combination allows the system to adapt to different brake pad models through programming while the rigid guide components ensure manufacturing precision is maintained during each 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 automated station achieves high precision and efficiency in finishing brake pads, enabling the creation of complex geometries with reduced time and costs, and allows for processing of small batches with varying models, while maintaining high stiffness and accuracy.
Implementation Method 1
The finishing operation is carried out with rotary tools, such as grinders or milling cutters, which apply an action on the friction layer
Implementation Method 2
The finishing also comprises further abrasion operations for the removal of material carried out by means of milling cutters, also disk milling cutters, or grinders
Data Source
AI summary
An automated station (1) for the finishing of brake pads (4) comprises at least one rotary finishing tool (2) for finishing a friction layer (22) of the brake pad (4), a workhead (3) to pick, retain and release the brake pad (4), a handling unit (6) to move the workhead (3) along a programmable path comprising a pass over the rotary finishing tool (2) and a guide (5) having a mouth (27) which is passed through by the workhead (3) in order to start the finishing pass along the length of the programmable route, the guide (5) contacting the workhead (3) to define, along at least one direction (A; C), the relative position between the workhead (3) and the brake pad (4) during the finishing carried out by the rotary finishing tool (2).