WO2024054168A1

WO2024054168A1 - Full automation cold - warm press pre-grinding lining press station

Info

Publication number: WO2024054168A1
Application number: PCT/TR2022/050969
Authority: WO
Inventors: Bulent KARACA
Original assignee: Walden Mekatronik San Tic. A.S.
Priority date: 2022-09-09
Filing date: 2022-09-09
Publication date: 2024-03-14

Abstract

The invention relates to the full automation of the cold-warm press and pre- grinding production line where the lining production is provided. The subject of the invention is especially related to the cold-warm press station (A), which is in a closed structure without the need for human intervention during the operation of the press machine (5), the dosing machine (4), and the grinding machine (8) and performs the related operations automatically.

Description

FULL AUTOMATION COLD - WARM PRESS PRE-GRINDING LINING PRESS STATION

Technical Field

The invention relates to the full automation of the cold-warm press and pregrinding production line where the lining production is provided. The subject of the invention is especially related to the cold-warm press station, which is in a closed structure without the need for human intervention during the operation of the press machine, the dosing machine, and the grinding machine and performs the related operations automatically.

Prior Art

The production of linings is achieved by the cold-warm press or hot press method in the present day. The main difference between the two presses that are achieved whereas the lining mix is given in the course of the press, in the hot press at a temperature of 150-200, in the cold press at room temperature, and in the warm press at a temperature the range of 50-60. While the reaction of the resin in the mix at high temperatures, mix recycling is not possible in the hot presses, whereas recycling is possible in cold and warm press systems.

In the state of the art, the operator manually pours the lining mix into the press mold with the cold and warm pressing press, and equalizes the amount in the molds. Then, the metal sheet the operator takes from the container is placed on the press molds. Finally, the lining coming out of the press is transported to the grinding machine with the assistance of the operator. After the grinding process, the lining is transferred to the conveyor belt. All the mentioned steps depend on the operator and require manpower. In addition, while the dust that comes out grinding can be used as consumable recycling, but it becomes inert.

Depends on the existing manpower in the current technique; in other words, the disadvantages of manual press systems can be listed as follows;

• Material and time losses during loading,

• Product quality issues,

• Poor traceability,

• Loss of energy, • Environmental and work environment pollution,

• Difficulties in providing Occupational Health and Safety precautions,

• Difficulty implementing lean manufacturing processes,

• Chronic mistakes in mold change processes,

• Slow progress of mold systems,

• Ineffective use of capacity.

The existence of the above-mentioned problems in the existing technique and the inadequacy of the existing solutions made it necessary to improve in the relevant technical field.

Object of the Invention

The subject of the invention owing to the fully automated structure of the cold and the warm press station the lining production process can be completed without manpower, thus standardizing the product and increasing its quality. The main purpose of the invention is to provide an increase in production efficiency and to avert work accidents, without any necessity of outside intervention after the process is started due to the dosing, press and grinding machines being completely closed structures. The consumable dust that comes out with the pre-grinding in the cold-warm press station can be recycled and become suitable for reuse. Concurrently, with the assistance of automatic dosing in the cold-warm press station, the lining mix can be filled into the lining molds automatically and the amount of the lining mixture in the lining molds can be adjusted equally with the weighing system. Again, since manpower is eliminated with the automatic sheet feeding in the cold and warm press station, it is providing the opportunity to change the mold quickly and it has been created with a belt system suitable for continuous operation. Occupational health and safety measures can be easily integrated since the need for manpower in the process steps is reducing and in addition to this, a sustainable new generation system has been developed that provides less emission to the environment. Software and other new support elements are designed for the necessity of the cold- warm press station. Detailed Description of the Invention

The figures of the fully automated cold-warm press station created to achieve the objectives of the invention are as follows;

Figure 1 General View of the Fully Automated Cold - Cold and Warm Press Press Station

Figure - 2 Perspective View of Fully Automated Cold - Cold and Warm Press Press Station

Figure - 3 Grinding Unit Detail View

The elements in the figures above are numbered as follows and these numbers will be used in the remainder of the description:

A. Cold - warm press station

1. magazine

2. loading arm

3. carrying handle

4. dosing machine

5. press machine

6. Pattern

7. transfer arm

8. Grinding machine

9. grinding belt

10. tape motor

11. transfer motor

12. feed piston

13. pneumatic piston

The fully automated cold-warm press station (A) shown in Figure - 1 consists of four main components; these are the magazine (1), the dosing machine (4), the press machine (5), and the grinding machine (8). One of the innovations of the cold-warm press station (A) which is the subject of the invention is that the dosing machine (4), the pressing machine (5), and the grinding machine (8) are in a closed structure that does not allow interventions during operation. The magazine (1) can be located outside or partly inside the closed structure. The cold-warm press station (A) which is the subject of the invention can produce the linings of both passenger cars and commercial vehicles. In the cold-warm press station (A), which is the subject of the invention, the lining production process begins with the operator putting a lining sheet in the part of the magazine (1) that is outside of the related closed structure. The dosing machine which is located on the press machine begins to work after the sheet is placed in the magazine. It automatically pours the lining mix inside the molds (6) formed on the press machine with the operation of the dosing machine. The dosing machine (4) pours the lining mix into the molds (6) according to the automatically adjusted volumetric gauge and ensures that the lining mixes in the molds (6) are equalized. In the meantime, it is aligned to the side of the sheet metal press machine (5), which comes to the loading arm (2) in the magazine (1) and is shown in Figure - 2. The loading arm (2) takes the sheet in the magazine (1) with the assistance of the magnet and leaves it to the conveyor.

When the sheet, which is carried by the conveyor to the side of the press, is at the level of the press, the carrying arm (3), which is located on the press, takes the transported sheet metal with the assistance of magnets and moves towards the press machine (5), bringing the sheet over the molds (6) and leaving the sheet on the molds (6). After the sheet metal is located on the molds (6), the press machine (5) compresses the molds (6) by applying hydraulic pressure, and the linings are obtained. The obtained linings are taken out of the molds (6) with the assistance of the press machine (5). After completing the lining pressing work in the pressing machine (5), the transfer arm (7) located in the grinding machine (8), due to the sensor inside the pressing machine (5), takes action to take the lining pressed in the pressing machine (5).

The transfer arm (7) is driven by the transfer motor (11) and moves towards the linings over the press machine (5). The transfer arm (7) moves towards the surface of the lining, in a downward direction, and contacts the lining. When the sensor is activated by contacting the lining with the assistance of the magnetic structure in the transfer arm (7), the electric magnet is activated and the lining adheres to the magnet in the transfer arm (7). The transfer arm (7) moves upwards together with the adhered linings and moves 20mm upwards from the surface of the pressing machine (5) and brings the linings to the grinding machine (8). The linings that come to the zero point in the grinding machine (8) move downwards towards the surface of the delivery piston (12) in the grinding machine (8). (Figure - 3) The contact of the feeding piston (12) with the lining is detected by means of sensors, and the electricity applied to the magnets on the carrying arm (7) is cut off and the linings are transferred to the delivery piston (12). When the sensors in the delivery piston (12) detect the linings, it is sending air to the pneumatic piston (13) and pushing the magnets in the pneumatic piston (13) upwards, and pulling the linings on the delivery piston (12) to the pneumatic piston (13). The linings that are pulled by the pneumatic piston (13) are left to the grinding band (9) by rotating 180. After the linings come to the grinding band (9), the grinding band (9) is driven with the assistance of the band motor (10) and it is advanced in the grinding machine (8) and the lining grinding process is applied.

The linings, whose grinding process is finished, are taken out from the cold-warm press station (A) with the assistance of the conveyor, and the lining production process ends.

Claims

CLAIMS A pre-grinding and fully automated cold-warm press station (A) where linings suitable for both passenger and commercial vehicles can be produced, is characterized in that; a. The press machine (5), which has the carrying arm (3) that carries the lining sheet owing to its magnetic structure, and the molds (6) on which the linings are compressed, and b. Transfer arm(7) with a magnetic structure that can move vertically, the contact with the brake lining is perceived by the sensors, and the aforementioned transfer arm(7), feeding piston (12) where the mentioned brake lining is transferred by cutting off the electricity applied to the magnets, grinding machine(8) with pneumatic piston(13) which moves the magnets on it vertically by sending air, pulls the mentioned brake lining and transfers them to the grinding machine(9) by making them rotate 180°; it is in a closed structure which does not allow interventions during its work. A cold-warm press station (A) proper to claim 1, and its characterized in that; the grinding machine (8), and dosing machine are in the same closed structure as the pressing machine (5) that automatically fills the mentioned lining mix into the molds (6) the amount of brake lining mix to be poured into the mentioned mold (6) is previously calculated according to its volumetric measurements. A cold-warm press station (A) proper to claim 1, and its characterized in that; it incloses a magazine (1) that has a loading arm (2) that transmits the loaded lining sheets to the pressing machine (5) and can be found inside or outside the same closed structure as the pressing machine (5) and the grinding machine (8).