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GRINDERS for DISC BRAKE PADS type RPF.10/3

DISC BRAKE PADS GRINDER TYPERPF.10/3

COMEC Srl Tel : +39. 0373. 648068

Via Milano 33/35 Fax : +39. 0373. 64943326010 Bagnolo Cremasco (CR) E-mail :[email protected] website :www.comec-grinders.com

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COMEC Srl

Via Milano 33/35 - I 26010 Bagnolo Cremasco (CR) - Italy File Pads 2001 rev1 2.doc

Tel (+) 39. 0373. 648068 Fax (+) 39. 0373. 649433 E-mail [email protected]

RPF.10GRINDERS for

DISC BRAKE PADS

GRINDERS TYPE RPF. 10

1. PURPOSE OF THE GRINDER

The grinders type RPF.10 have been designed for processing small to medium volumes of

disc brake pads with a high grindingquality that meets the specifications of the OEMs.

These grinders can be provided with one, two or three grinding stations. Each grinding

station has a grinding spindle. The operations that can be carried out depend on the number

of spindle mounted on the machine :

Types of Grinders

One-station Two-station Three-station

grinder type grinder type grinder type

Operations RPF.10/1 RPF.10/2 RPF.10/3

Slots - - - yes yes

Parallel Chamfer... - - - yes yes

Thickness yes yes yes

The radial (compound) chamfering is not carried out by these grinders.

The simplicity of these machines, their low set up times, together with the fact that they do

not need pad-specific tooling, makes them suitable for the Aftermarket Suppliers (AM).

These grinders can also be automatically connected to the presses, as part of automatic

manufacturing lines; this is a solution typical of the Original Equipment Manufacturers

(OEMs).

2. PROCESS DESCRIPTION

The process is the same one described for the RPF.6/L grinders. The pads are loaded onto

the grinder either manually (i.e. the operator loads the pads into a buffer that transfers them

automatically onto the grinder) or automatically (i.e. the pads are loaded onto the machine bya fully automatic device, e.g. a pick-and-place) and are automatically transferred onto the

feeding system.

The feeding system of the grinder is provided with pushing bars that push the pads across the

machine. During their movement, the pads rest on sliding rails and are subject to a magnetic

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RPF.10GRINDERS for

DISC BRAKE PADS

field that keeps them tightly in position, while the side guide s control their transversal

position. The pads cross the grinding area, where the grinding wheels carry out the required

operations automatically. The pads can then be unloaded from the machine in several ways

depending on the required automation level of the process.

3. FUNCTIONAL FEATURES

A. These grinders are available in three versions:

Grinder type RPF.10/1 : it is provided with one vertical spindle to grind the thickness

of the pad.

Grinder type RPF.10/2: it is provided with two spindles. The first spindle is horizontal

and is used either for pre-grinding the friction material surface(in case there is no need for grinding slots or parallel chamfers)

or for grinding one or more slots and/or the parallel chamfers.

It is also possible to mount a grinding/ cutting wheel assembly

that simultaneously cuts the slot and pregrinds the friction

material.

Grinder type RPF.10/3: it is provided with three spindles. The first spindle is normally

used for pre-grinding the friction material surface; the second

spindle is used for grinding the slot and/or the parallel

chamfers; and the third spindle is used for finishing the

thickness of the friction material.

B. These grinders can be set up to process pads for motorcycle, car or truck. When

switching from pads for motorcycle to pads for trucks or viceversa, it might be necessary

to replace some of the devices of the machine.

4. PRODUCTIVITY AND SET UP TIME

Grinder type :

Productivity (p/h) Set up time (min)

RPF.10/1 up to 1,200 4

RPF.10/2 up to 1,200 7 17

RPF.10/3 up to 1,200 10 20

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RPF.10GRINDERS for

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Productivity is indicated for an average size pad for cars, with a stock allowance of 1.5

mm. Set up includes the adjustment of the sloped chute, of the side guides, of the

vertical position of the grinding wheels and the replacement of the slotting or

chamfering wheel.

5. TECHNICAL FEATURES

A. GRINDING STATIONS: spindle motor power

The spindle motor power can be chosen among the following options :

Station 1 (horizontal spindle) : kW 4 or 7.5

Station 2 (horizontal spindle) : kW 4 or 7.5

Station 3 (vertical spindle) : kW 4 or 7.5

If the grinder is provided with one grinding station there is only the vertical spindle; if

the grinder is provided with two grinding spindles, there are one horizontal and one

vertical spindle.

B. CONTROLS

These grinders are provided with manual controls: the vertical positions of the grinding

wheels are set by rotating handwheels, while the position of the spindle is indicated on a

digital display.

C. MAGNETIC CHUCK

While the pads slide across the machine, they are tightly kept onto the sliding rails by

means of a magnetic chuck. There are two types of magnetic chucks :

1. Standard: the magnetic field is permanent and is always active. This type of

magnetic chuck is available only for the interchangeable chuck.

2. Demagnetizable: the magnetic field is permanent and is always active, but the

operator can switch it off by means of an electronic device. This

operation is particularly useful during the cleaning of the grinder.

This type of magnetic chuck is available only for the adjustable rails.

D. SLIDING RAILS

The pads move across the machine sliding on tungsten carbide sliding rails, so that the

possible protrusions on the backing plate can be accommodated between the rails.

There are two available types of sliding rails:

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RPF.10GRINDERS for

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1. Interchangeable: the distance between sliding rails is fixed. If it is necessary to

process a pad that has protrusions that interfere with the position of

the rails, it is necessary to replace the chuck with another one. In thiscase, each inter-changeable sliding rails system is suitable for the

processing of a family of pads (example: all the pads for cars

produced in Europe can be divided in three families and therefore

require a total of three interchangeable sliding rails). This is the

most simple and economical solution.

2. Adjustable: the distance between the sliding rails can be adjusted. This is the

most flexible solution and the most commonly supplied type of

sliding rails.

E. LOADING THE PADS ON THE GRINDER

There are several options for loading the pads onto the grinder:

1. Manual: the operator loads the pads onto a sloped chute that automatically transfers

the pads onto the machine feeding system. If the machine controls

are fully manual, the sloped chute is controlled by a pneumatic logic.

If the machine is provided with a PLC, the sloped chute is controlled

by the PLC. For processing pads for CVs and trucks, a special

sloped chute is to be used.

2 Automatic: a pick-and-place automatically loads the grinder.

F. OPTIONAL DEVICES

1. Unloading system

In the standard version, the pads fall out of the grinder after being processed. Our

automatic unloading system allows to remove the pads from the grinder maintaining

their orientation and therefore enhancing the automatic connection of the grinder to

other machines. This device normally does not need adjustments during set ups.

6. TOOLING REQUIREMENTS

These grinders have been designed to minimise tooling costs, by minimising the

requirement for dedicated (i.e. pad-specific) tooling:

A. Grinding wheels: * thepre-grinding andfinish grinding wheel are universal, i.e. they

are the same for all types of pads.

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RPF.10GRINDERS for

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* the cutting wheel(s) can be assembled on the spindle hub in

different positions, by using different spacers. When slots are

required in different positions, it will be necessary to have different

spacers, which are simple and inexpensive metal disks.

* each chamfering wheel with a given angle can be used for the

parallel chamfer of a range of pads. Different chamfer angles

require different chamfering wheels.

B. Sliding rails : they are adjustable and no tooling is required, regardless of the

protrusions on the backing plate.

This very limited requirement for tooling allows to:

- avoid investment in tooling

- save on tooling maintenance and management costs

- reduce set up time

When the production changes from pads for motorcycle to pads for trucks or viceversa, it

might be necessary to replace some of the devices of the machine.

7. ATTACHED LAYOUTS

The attached layouts show one of the available options for loading and unloading the

grinders; other options are available.

- Three-station grinder typeRPF.10/3 (Front view, top view, side sections)

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