US20190203791A1 - Method and plant for manufacturing braking elements - Google Patents

Method and plant for manufacturing braking elements Download PDF

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Publication number
US20190203791A1
US20190203791A1 US16/330,053 US201716330053A US2019203791A1 US 20190203791 A1 US20190203791 A1 US 20190203791A1 US 201716330053 A US201716330053 A US 201716330053A US 2019203791 A1 US2019203791 A1 US 2019203791A1
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US
United States
Prior art keywords
metallic element
adhesive
face
threshold value
points
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/330,053
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English (en)
Inventor
Paolo Galimberti
Marco Belli
Sergio Ferrero
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ITT Italia SRL
Original Assignee
ITT Italia SRL
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ITT Italia SRL filed Critical ITT Italia SRL
Publication of US20190203791A1 publication Critical patent/US20190203791A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F16D69/0408—Attachment of linings specially adapted for plane linings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F16D2069/0425—Attachment methods or devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F16D2069/0425—Attachment methods or devices
    • F16D2069/045—Bonding
    • F16D2069/0466—Bonding chemical, e.g. using adhesives, vulcanising
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F16D2069/0425—Attachment methods or devices
    • F16D2069/0491—Tools, machines, processes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic

Definitions

  • the present disclosure relates to a method and a plant for manufacturing braking elements, in particular highly reliable brake pads.
  • brake pads of vehicles and, more generally, any other type of braking element, such as brake shoes, are formed from a metallic support upon one side of which—facing in use towards an element to be braked, for example a brake disc—a block of friction material is integrally mounted.
  • the block of friction material can be formed in situ, i.e., molded directly onto the metallic support, or else it is formed separately and then applied to the metallic support. In both cases, in order to ensure the reliable attachment of the block of friction material to the metallic support, the face or zone of the face of the latter, intended to receive the block of friction material, receives beforehand a layer of adhesive.
  • the adhesive can be applied to the face of the metallic support intended to receive the block of friction material in many ways, for example by spraying or by means of a roller.
  • the block of friction material may be subject in use to accidental detachments and, therefore, the braking element will not be reliable.
  • CA2429870 is not applicable as such in the verification of metallic supports of brake pads, or braking elements in general, especially if a liquid phase adhesive is used.
  • the adhesive layer in order to ensure an adhesion between the metallic support and the block of friction material that is suitable for avoiding any accidental detachments in use, it is not sufficient that the adhesive layer be present; it is also necessary that it be present in a suitable concentration (amount per unit area), calculated during the design stage; on the contrary, it is possible that during the application of the liquid adhesive, typically by spraying, the concentration of adhesive in the applied layer is variable.
  • the object of the present disclosure is to provide a method and a plant for manufacturing braking elements, particularly brake pads that are highly reliable in use, and that therefore makes it possible to verify in an absolutely reliable way, not only the presence of an adhesive—especially of a water-based adhesive in liquid phase—upon the metallic support prior to the step of applying the block of friction material onto the metallic support, but that also makes it possible to verify the amount of adhesive deposited, in order to ensure the necessary reliability of the braking element in use.
  • the disclosure is thus related to a method and a plant for manufacturing braking elements, in particular brake pads that are highly reliable in use, having the characteristics set out in the attached claims.
  • FIG. 1 schematically illustrates a step of the method according to the disclosure as applied to a metallic support for a vehicle brake pad
  • FIG. 2 schematically and partly by means of a block diagram illustrates further steps of the method of the disclosure and the main elements of the plant according to the disclosure.
  • FIGS. 1 and 2 indicated as a whole with 1 is a plant ( FIG. 2 ) for manufacturing a braking element 2 , known and illustrated only schematically in FIG. 2 , in particular a brake pad, comprising a metallic support that is defined by a metallic element 3 exhibiting a first face 4 , in the example illustrated substantially flat, upon which there is integrally carried by the support or metallic element 3 , in a known way, a block of friction material 5 .
  • the block of friction material 5 is formed in a known manner, by heating under pressure; it can be formed separately and then attached to the face 4 , or else it can be co-molded onto the metallic support 3 . In both cases, the block of friction material 5 is rendered integral with the metallic support 3 by means of a layer of adhesive 6 carried by the face 4 , in addition to any other means of attachment such as undercuts, projecting parts, etc., known and not shown for simplicity.
  • the plant 1 therefore comprises a first station 7 in order to apply the adhesive 6 onto the first face 4 of a metallic element 3 , which has been previously processed in a known way, for example by precision blanking starting from a sheet of metal, such as to be manufactured so as to constitute the metallic support 3 of the braking element 2 to be obtained.
  • the station 7 in the illustrated non-limiting example, comprises an endless belt conveyor 8 , known, upon which are arranged horizontally metallic supports 3 that, in the example illustrated, are in the form of flat plates, with the face 4 facing upwards, that is, facing the part opposite to the conveyor 8 .
  • the station 7 also comprises a nozzle 9 suitable for spraying onto the face 4 an adhesive 6 in the liquid phase, which is taken from a reservoir 10 .
  • the plant 1 also comprises at least a second station 11 , known and indicated schematically with a block in FIG. 2 , for applying onto the first face 4 of the braking element 3 a block 5 of friction material in such a way as to obtain the braking element 2 ; and, in the example illustrated, a third station 12 for curing/thermally treating the block 5 of friction material.
  • a second station 11 known and indicated schematically with a block in FIG. 2 , for applying onto the first face 4 of the braking element 3 a block 5 of friction material in such a way as to obtain the braking element 2 ; and, in the example illustrated, a third station 12 for curing/thermally treating the block 5 of friction material.
  • the plant 1 also comprises a checking station 13 for verifying the presence of the adhesive 6 on the first face 4 of the metallic element 3 after the metallic element 3 has left the first station 7 and before the metallic element 3 reaches the at least a second station 11 .
  • the checking station 13 illustrated only in schematic form, partly in FIG. 1 and partly in FIG. 2 , comprises: a video camera 14 , preferably of the digital type, designed to detect the gray level of a plurality of points 15 (illustrated only schematically and not to scale in FIG.
  • an electronic processing unit 18 which may consist of a simple computer with appropriate software and interfaced with the video camera 14 ; and at least one robot 19 , for example of an anthropomorphic type and equipped with at least four CNC axes, designed to pick up one metallic element 3 at a time from the first station 7 , namely from the conveyor 8 , after the face 4 has received the adhesive 6 , in order to present the metallic element 3 , on the side of the face 4 that has received the adhesive 6 , in front of the video camera 14 as it is schematically illustrated in FIGS. 1 and 2 .
  • the robot 19 controlled by the processing unit 18 , which, as shall be seen, is designed to recognize as faulty those metallic elements 3 that, in the station 7 , have not received sufficient adhesive 6 on the face 4 , is suitable for selectively discarding the defective metallic elements 3 , for example by allowing them to drop into a container 20 arranged beneath the robot 19 , between the robot and the video camera 14 , and to move the non-defective metallic elements 3 , i.e., those that in the station 7 have received an adequate amount of adhesive 6 on the face 4 , towards the at least a second station 11 .
  • the video camera 14 is designed to detect 256 gray levels for each and every point 15 of the portion or zone 16 that is framed by the video camera 14 .
  • the checking station 13 also comprises a mobile support 21 that holds a sample metallic element 3 b which is identical to those metallic elements 3 upon which the presence of the adhesive 6 is to be verified, but having a first face 4 that is free of adhesive 6 and/or bearing an underspecified, i.e., insufficient, amount of adhesive spread onto the face 4 , or else on selected portions of the same.
  • the mobile support 21 is designed to arrange from time to time, in front of the video camera 14 the adhesive-free, or in any case non-compliant, sample metallic element 3 b whilst the robot 19 picks up from the first station 7 a metallic element 3 in order to verify the presence of the adhesive 6 thereupon; and to subsequently remove from in front of the video camera 14 the non-compliant sample metallic element 3 b , which is free of adhesive 6 and/or bearing an insufficient amount of adhesive 6 , whilst the robot 19 places in front of the video camera 14 a metallic element 3 that has received the adhesive 6 in the station 7 in order to verify the presence of a sufficient amount of adhesive 6 .
  • the plant 1 is designed to implement a method for manufacturing a braking element 2 , in particular a brake pad that is highly reliable in use.
  • the method implemented by the plant 1 comprises:
  • the step of verifying the presence of the adhesive 6 comprises the following steps:
  • step i) the video camera 14 detects 256 gray levels for every point 15 of the at least a first zone 16 using a digital black and white image wherein each pixel corresponds to one of the points 15 of the at least a first zone 16 and wherein each pixel is reproduced according to a range of grays having 256 different tones.
  • the value 0 is attributed by the processing unit 18 to a gray level corresponding to the color black and the value 256 to a gray level corresponding to the color white.
  • the predetermined mathematical relationship which is the function of the threshold value S 1 used in step ii) is an inequality in which the gray level detected for each point 15 must be less than or equal to a first predetermined range of gray values.
  • the threshold value S 1 will correspond to any of the finite elements of a set of values between a minimum and a maximum, for example consisting of a succession of values ranging from 0 to 70 climbing discreetly by one unit at a time:
  • the second threshold value S 2 is, according to another aspect of the disclosure, a second predetermined range of percentage values within which the percentage calculated in step iii) of those points 15 that satisfy the predetermined mathematical relationship described above must be comprised. For example a range of percentage values between 70% and 90%:
  • the processing unit 18 will discard by means of the robot 19 those metallic elements 3 for which, for example, less than 70% or more than 90% of the points 15 have provided a gray level value between 0 and 70.
  • the adhesive 6 used in the step of applying an adhesive to the face 4 of a metallic element 3 which is manufactured in such a way as to constitute a metallic support 3 of the braking element 2 is an adhesive in a liquid phase, to which a pigment or a dye has been added in a predetermined concentration.
  • the step of verifying the presence of the adhesive 6 , on the first face 4 of the metallic element 3 comprises a further step consisting of setting, from time to time, the first threshold value S 1 before performing step i) by placing in front of the video camera 14 a metallic element 3 b that is identical to those upon which the presence of the adhesive 6 is to be verified, but having its first face 4 free of adhesive and/or bearing on all of the face 4 or on a discrete portion thereof an insufficient amount of adhesive 6 and detecting, within at least one first zone of the face 4 , of predetermined size and identical to zone 16 , the gray level of a plurality of points of such a first zone.
  • the gray level of the points of the face 4 should correspond to high levels, for example between 200 and 250; the video camera 14 is then calibrated by the processing unit 18 in order to provide correct gray level values that will make it possible to fall within the expected range. This makes it possible to account for variations due to lighting conditions, which may vary in the presence of dust or dirt, etc.
  • the steps from i) to iii) are performed on a plurality of portions, indicated with 16 , 22 and 23 in FIG. 1 , of a predetermined width, of the first face 4 of the metallic element, positioned discretely, i.e. spaced apart from each other, and of a different shape and size.
  • the steps iv) and v) are performed taking into account a total percentage calculated over all of the portions 16 , 22 , 23 for the points 15 of which the gray level is detected using said video camera 14 .
  • the processing unit 18 must be designed in such a way as to be suitable for: comparing the gray level detected by the video camera 14 for each point 15 with the first threshold S 1 previously stored in the same processing unit 18 and preferably calculated by the processing unit 18 based upon the reading of the gray levels of the points of the face 4 of the sample metallic element 3 b ; counting the number of points 15 in each portion or zone 16 , 22 , 23 having a gray level that satisfies the predetermined mathematical relationship (1), which is a function of the threshold value as previously indicated; calculating, based upon the total number of points 15 the gray level of which has been detected, the percentage of points that satisfy said predetermined mathematical relationship (1); and comparing the percentage calculated with the second threshold S 2 in order to instruct the robot 19 to
  • the processing unit 18 must further be designed to set from time to time the first threshold value S 1 after that the video camera 14 has detected the gray levels of the points of at least a first zone of a predetermined width of the first face 4 that is free of adhesive of the sample metallic element 3 b and/or of a plurality of fixed zones of a predetermined width of the first face 4 of the sample metallic element 3 b , one or more being adhesive free and the other zones bearing an insufficient amount of adhesive.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Image Analysis (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Valve Device For Special Equipments (AREA)
US16/330,053 2016-09-02 2017-09-01 Method and plant for manufacturing braking elements Abandoned US20190203791A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT102016000089414A IT201600089414A1 (it) 2016-09-02 2016-09-02 Metodo ed impianto per realizzare elementi frenanti
IT102016000089414 2016-09-02
PCT/IB2017/055275 WO2018042382A2 (en) 2016-09-02 2017-09-01 Method and plant for manufacturing braking elements

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2017/055275 A-371-Of-International WO2018042382A2 (en) 2016-09-02 2017-09-01 Method and plant for manufacturing braking elements

Related Child Applications (1)

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US17/155,710 Continuation US11499598B2 (en) 2016-09-02 2021-01-22 Method and plant for manufacturing braking elements

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US20190203791A1 true US20190203791A1 (en) 2019-07-04

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US16/330,053 Abandoned US20190203791A1 (en) 2016-09-02 2017-09-01 Method and plant for manufacturing braking elements
US17/155,710 Active US11499598B2 (en) 2016-09-02 2021-01-22 Method and plant for manufacturing braking elements
US17/963,452 Active US11821484B2 (en) 2016-09-02 2022-10-11 Method and plant for manufacturing braking elements

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US17/155,710 Active US11499598B2 (en) 2016-09-02 2021-01-22 Method and plant for manufacturing braking elements
US17/963,452 Active US11821484B2 (en) 2016-09-02 2022-10-11 Method and plant for manufacturing braking elements

Country Status (8)

Country Link
US (3) US20190203791A1 (ko)
EP (1) EP3507520B1 (ko)
JP (1) JP2019526762A (ko)
KR (1) KR102448695B1 (ko)
CN (1) CN109844352B (ko)
IT (1) IT201600089414A1 (ko)
MX (1) MX2019002470A (ko)
WO (1) WO2018042382A2 (ko)

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Publication number Priority date Publication date Assignee Title
US20210190160A1 (en) * 2018-07-31 2021-06-24 Tmd Friction Services Gmbh Method for Producing Brake Linings, Method for Reducing the Drying Time of an Adhesive Layer Applied to a Lining Carrier for a Brake Lining
US11821484B2 (en) 2016-09-02 2023-11-21 Itt Italia S.R.L. Method and plant for manufacturing braking elements

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IT202200006797A1 (it) * 2022-04-06 2023-10-06 Itt Italia Srl Sistema e metodo per effettuare online test di qualita' su blocchi di materiale di attrito di elementi frenanti per veicoli, in particolare pastiglie freno

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US11821484B2 (en) 2016-09-02 2023-11-21 Itt Italia S.R.L. Method and plant for manufacturing braking elements
US20210190160A1 (en) * 2018-07-31 2021-06-24 Tmd Friction Services Gmbh Method for Producing Brake Linings, Method for Reducing the Drying Time of an Adhesive Layer Applied to a Lining Carrier for a Brake Lining
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Also Published As

Publication number Publication date
CN109844352A (zh) 2019-06-04
US11499598B2 (en) 2022-11-15
WO2018042382A3 (en) 2018-04-12
CN109844352B (zh) 2021-03-09
US11821484B2 (en) 2023-11-21
KR102448695B1 (ko) 2022-09-28
US20230167868A1 (en) 2023-06-01
JP2019526762A (ja) 2019-09-19
MX2019002470A (es) 2019-09-18
KR20190044644A (ko) 2019-04-30
WO2018042382A2 (en) 2018-03-08
IT201600089414A1 (it) 2018-03-02
EP3507520A2 (en) 2019-07-10
EP3507520B1 (en) 2020-08-05
US20210246957A1 (en) 2021-08-12

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