GRINDERS for DISC BRAKE PADS type

RPF.10/3

DISC BRAKE PADS GRINDER TYPE

RPF.10/3

COMEC Srl Via Milano 33/35 26010 Bagnolo Cremasco (CR) Italy

Tel : +39. 0373. 648068 Fax : +39. 0373. 649433 E-mail : comec@comec-grinders.com website : www.comec-grinders.com

GRINDERS for DISC BRAKE PADS

RPF.10
RPF. 10

GRINDERS TYPE
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 grinding quality 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 grinder type RPF.10/1 Two-station grinder type RPF.10/2 Three-station grinder type RPF.10/3

Operations

Slots Parallel Chamfer ... Thickness

----yes

yes yes yes

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 by a 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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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 comec@comec-grinders.com

GRINDERS for DISC BRAKE PADS

RPF.10

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

Productivity (p/h)

Grinder type : RPF.10/1 RPF.10/2 RPF.10/3

Set up time (min)

up to 1,200 up to 1,200 up to 1,200

4 7 17 10 20

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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 comec@comec-grinders.com

GRINDERS for DISC BRAKE PADS

RPF.10

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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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 comec@comec-grinders.com

GRINDERS for DISC BRAKE PADS

RPF.10

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 this case, 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: * the pre-grinding and finish grinding wheel are universal, i.e. they are the same for all types of pads.
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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 comec@comec-grinders.com

GRINDERS for DISC BRAKE PADS

RPF.10

* 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 type RPF.10/3 (Front view, top view, side sections)

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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 comec@comec-grinders.com