Finding a solution to our clients’ needs is nothing new for Rosler, nor is combining multiple solutions into a single finishing system. Take our work with Polish brake pad manufacturer Lumag Sp. z o.o. (Lumag), for example.
When they faced the challenge of de-oiling, deburring, and surface roughening brake pad carrier plates as part of their punch press process, they turned to us for a cleaning and mass finishing solution.
The Situation
Upon its founding in 1988 by Marek Zak, Lumag specialized in the production of brake linings. As the company implemented its own brake pad manufacturing technology, their products and offerings evolved. In addition to achieving enormous technological progress and applied engineering solutions, Lumag amassed a collection of machinery in need of constant upgrades and integration.
In order to meet the continuous rise of quality and safety standards for its brake pads for drum and disk brakes for commercial vehicles as well as brake pads for passenger cars and motorcycles under the trade name Breck, Lumag needed a partner with automotive expertise who could combine multiple solutions in a single system.
De-Oiling, Deburring, and Surface Roughening
With the change of its production method for the brake pad carrier plates from casting to stamping, Lumag decided to install a new in-house manufacturing line for these products.
The new system must allow for stamped carrier plates with lengths of 8-10 in (210-250 mm) and widths of 3-5 in (90-110 mm). The work pieces also have a slit or drilled hole to allow a sensor to monitor brake pad wear after installation and must undergo de-oiling, deburring, and surface roughening during the finishing process. These steps are necessary to ensure that the delicate stampings provide optimum adhesion characteristics for the subsequent bonding of the brake pads.
Another requirement presented by the customer was to directly link the finishing equipment with the punch press while providing extremely gentle processing and the complete automation of the cleaning (de-oiling) and mass finishing stages in a continuous feed operation.
In addition to an excellent reputation in the industry, Rosler’s ability to supply the equipment for both processes and the finishing media and compounds from one single source was a bonus for Lumag.
Intelligent Media Selection Allows for Cleaning Without Drying
After the stamping process, a conveyor belt transfers the work pieces to the drum washing machine equipped with an internal transport auger. In the drum the carrier plates initially pass through an un-perforated zone into which cleaning liquid is applied by spray nozzles. This creates an immersion bath for de-oiling.
In the following perforated drum section, the cleaning liquid is drained, and in a secondary de-oiling step the work pieces are spray washed.
This cleaning zone is followed by a drip-off section, a rinse station, and another drip-off section.
Complete Rosler system with transport container
Subsequently, a conveyor belt transfers the work pieces into the mass finishing machine.
Replenishment of the cleaning liquid takes place with a Dosatron proportional dosing pump. Since the cleaning liquid and the compound for the mass finishing process have practically the same chemical characteristics—including the placement of a temporary corrosion protection—carryover of the cleaning liquid into the mass finishing machine presents no issue.
This clever trick eliminated the need for a drying stage after the cleaning process, resulting in significant savings in the overall capital expenditure as well as reducing operating costs.
For proper maintenance of the cleaning liquid the washing machine is equipped with filtration units and an oil separator.
Gentle Mass Finishing
Deburring and surface roughening of the work pieces takes place in a linear, continuous flow vibrator R 550/6600 DA with a specially adapted work piece loading system. Loading actually takes place at the rear end of the processing bowl instead of on the lateral bowl side with greatly reduced dropping heights.
Similar gentle work piece transfers were incorporated in the vibratory screening unit and the drier filled with Supervelat drying media. After drying a certain work piece quantity based on precisely measured weight, components are discharged into a transport bin.
The process water from the mass finishing machine is continuously cleaned in a fully automatic peeling centrifuge Z 1000 equipped with automatic sludge discharge.
The Rosler Way
Whatever challenges you face in surface finishing, Rosler is eager to find a better way both individually and as a whole. With more than 80 years of experience, we have the knowledge and drive to continually learn about, develop, and deliver precise solutions.
Contact us to discuss your unique challenges and how we can innovate a solution for your needs and goals.
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