1. Fully Automatic Hot Pressing Machine for Forming with Quality Requirements Met:

This set of presses fundamentally addresses the quality stability issues of the old process. Previously, one pressure was used to press about ten pieces at a time, but now each piece is pressed individually, essentially custom-fitting each piece. On this basis, efficiency has been further optimized to allow for pressing four pieces at a time. Additionally, to address the old process’s drawback of uneven heat distribution due to conduction only from the top and bottom, the new process includes heating around the mold, further enhancing product stability. The machine uses PLC (Programmable Logic Controller) to automatically control pressure and holding time for each time period and records process parameters for traceability. This set of presses fully meets the product quality requirements for the main equipment.

2. New Automatic Grinding, Feeding, Coating, and Packaging Production Line for Disc Brakes:

This production line is designed based on brake pad production lines from Japan and South Korea. The grinder uses a fully CNC automatic grinding machine. It replaces the old manual adjustment process with a system where standard parameters for products can be directly inputted into the human-machine interface to complete the changeover. The machine automatically adjusts using a servo motor based on the set parameters. Previously, the process only allowed for right-angle chamfering, which did not meet customer needs. The new process improves this by using a servo motor to drive the grinding wheel’s movement during grinding, allowing for the production of chamfers as required by associated companies.

After grinding, the old process required manual sorting of products at this workstation before placing them on the coating line. The new production line has been upgraded to automatically flip the products, align them neatly using a conveyor belt, and place them onto the coating line conveyor with a robotic arm. The coating line has also been optimized by reducing the baking tunnel distance to save energy, and it now uses high infrared heating tubes to lower accessory consumption.

The coding machine has been upgraded to address the issue of insufficient printing clarity in the original process. The latest UV pigment coding machine is now used, achieving print quality close to that of traditional printing. The new machine can increase the maximum number of printed lines from 25 to 40, with a proportional increase in the text area. It can directly convert computer graphics into coding content, enhancing informatization.

A semi-automatic case sealing and packing machine has replaced the previous fully manual packing process. Fully automatic box and case machines cannot be used here due to the market’s increasing trend towards personalized and small-batch orders. Fully automatic machines would increase setup time and thus reduce efficiency. This production line also includes a crawler-type shot blasting machine. Through structural and material improvements, the new shot blasting machine reduces steel abrasive consumption by 60%, lowers maintenance plate consumption by 70%, and reduces noise from 70 decibels to approximately 50 decibels.