RPF6L3

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GR!NDERS for D!SC BRAKE PADS type RPF.6fL.3

D!SC BRAKE PADS GR!NDER TYPE RPF.6fL.3

CONEC Srl Tel : +39. 0373. 6+8068
via Nilano 33f35 Fax : +39. 0373. 6+9+33
26010 Bagnolo Cremasco (CR) E-mail : comec@comec-grinders.com
!taly website : www.comec-grinders.com

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!NDEX

1. Purpose of the grinder
2. Dimensional range of the pads that can be processed with this grinder
3. Operations
+. Advantages
5. Process description
6. Different types of controls
7. Technical features of the grinder
8. Grinding of compound chamfers
9. Tooling requirements
10. Attached layouts
11. Additional information
12. Documentation
13. Terms of sale

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1. PURPOSE OF THE GR!NDER

The grinders type RPF.6fL have been designed for processing large volumes of disc brake pads, in excess
of 2.400 padsJhour, with a high grinding quality that meets OENs specifications for :

- Notorbikes
- Passenger cars
- Cv vehicles (Commercial vehicles)

2. D!NENS!ONAL RANGE OF THE PADS THAT CAN BE PROCESSED W!TH TH!S GR!NDER

Dimensions in (mm f inches)

Motorbikes
Passenger
cars
CV vehicles
min 30 f 1.18 +5 f 1.77
Backing plate length
max 150 f 5.90 300 f 11.81
300 f 11.81 ()
380 f 1+.96 ()
min 2 f 0.08 3 f 0.08
Backing plate thickness
max 5 f 0,20 6 f 0.2+ 10 f 0.39
min 30 f 1.18 +0 f 1.57 90 f 3.5+
Friction material length
max 100 f 3.93 210 f 8.26 260 f 10.32
Pad overall thickness min + f 0.16 10,5 f 0.+1

() Cv pads having a back-plate length up to 300 mm can be loaded and unloaded with the same devices used
for processing passenger cars disc brake pads.

Cv pads having back-plates longer than 300 mm (up to a maximum of 380 mm) must be loaded and
unloaded with specific devices.

As far as the pads turnover unit is concerned, the maximum weight of each pad must not exceed 1.5 kg

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Layout of a passenger car pad with parallel chamfers

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Layout of a passenger car pad with compound chamfers

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3. OPERAT!ONS

The operations that can be carried out in a single run, using the different optional devices available, are :

- Automatic loading of the pads Choice between different options
- Grinding of one or more slots Standard characteristic
- Grinding of diagonal slots Optional device
- Grinding of one or two parallel chamfers Standard characteristic
- Grinding of two compound chamfers by vertical interpolation () Standard with NC grinders
- Grinding of two compound chamfers by horizontal interpolation () Additional module required
- Pre-grinding of the main surface Standard characteristic
- Finish grinding of the main surface Standard characteristic
- Fourth external slots grinding station Optional device
- Fourth external parallel chamfers grinding station Optional device
- Cleaning of the pads (Demagnetising and brushing) Optional device
- Automatic unloading Optional device
- 100 thickness measuring device () Optional device
- U-Cell conveyor with a device for the automatic switching of the
pads flow from the production line to the second exit, for using
the grinder as a stand alone unit, when installed in a line, for the
selection of the no good parts" or for SPC sampling Optional device
- Bar code reader for the automatic choice of the part program
and of the batch code Optional device
- Production control program (Software) Optional device
- Software for programming the acceptance sampling of the parts
required for the SPC (N parts every N parts processes) () Optional device
- Pads turnover unit Optional device
- Tele-assistance device Standard characteristic
- Possibility of connecting the grinder to an Ethernet local net Optional devices
- Connection of the grinder in line with other machines : Optional devices
Transportation conveyors for connecting the grinder to the
next processing steps with or without buffers for the
accumulation of the pads
Pick 8 Place units for loading ( from a single raw) or
unloading (in one or two rows) scorching units
Pick 8 Place units for loading powder painting units with PLC
controlled devices for calculating the optimal distance between
the pads of each raw and the space to be left between adjacent
rows (Naximum filling factor)

() See note at Compound chamfers grinding" paragraph
() U-cell conveyor and software required for the selection of the no good pads"

+. ADvANTAGES

- High productivity, in excess of 2.+00 padsfhour
- very low set up times, included between 1 and 15 minutes
- No need of pads-specific tooling to deal with protrusion on the backing plate
- High grinding quality
- Integration in a single machine of all the finishing operations
- Friendly user operator interface
- Possibility of installing PLC controlled devices for the fully controlled setting up of the grinder to be
used when setting up the grinder from remote or for reducing change-over time to about 60 seconds
- Low maintenance
- Easy connection in line of the grinder with other units located before and after the grinder
- High level of environmental and operators safety

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The above characteristics make these machines particularly suitable for both the Original Equipment
Nanufacturers (OEMs) and for the Aftermarket Suppliers {AM).

5. PROCESS DESCR!PT!ON

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, provided with pushing bars, push the pads across the machine. During their movement,
the pads rest on sliding rails and are subject to a magnetic field that keeps them tightly in position, while the
side guides control their transversal position.

The pads, in a continuous sequence, cross :
- the checking area where a set of sensors check the correct orientation of the pads, the excess of thickness
and counts the pads entering in the grinding area.
- the grinding area, where the grinding wheels carry out the required operations automatically,
- the cleaning area, where the demagnetiser, the brushing unit and the air nozzles clean the pads
- the checking area, where is possible to install an automatic device for checking the thickness of each pad
- the unloading area, where the pads are picked up by an automatic device and transferred to an exit
conveyor
- the turnover unit, where the pads are rotated upside down with the backing plate on their top

6. D!FFERENT TYPES OF CONTROLS

With regard to the vertical positioning of the grinding spindles, these grinders can be provided with different
types of controls :

Grinder type Different types of controls for the vertical positions of the grinding wheel

RPF.6fL.3 - N Nicrometric manual positioning of the grinding spindles
RPF.6fL.3 - X Numerical Control automatic positioning with part programs data base stored inside the
memory of the Operator !nterface

7. TECHN!CAL FEATURES OF THE GR!NDER

The different features of the grinder can be divided in three groups :

A. GR!ND!NG UN!T W!TH THREE GR!ND!NG STAT!ONS

Station 1 : !nterchangeable horizontal spindle with an 11 kW spindle motor (max 15 kW as an option)
Grinding of slots andJor parallel chamfers
OR
Grinding of compound chamfers with vertical interpolation ( NC only)
OR
Pre-grinding of the main surface of the pad
OR
Grinding of sloping main surfaces of the pad

Station 2 : !nterchangeable horizontal spindle with an 11 kW spindle motor (max 15 kW as an option)
Grinding of slots andJor parallel chamfers
OR
Grinding of compound chamfers with vertical interpolation ( NC only)
OR
Pre-grinding of the main surface of the pad

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OR
Grinding of sloping main surfaces of the pad

Station 3 : !nterchangeable vertical 7,5 kW electro-spindle
Finish-grinding of the main surface of the pads {When not sloping)

B. PADS FEED!NG SYSTEN EQU!PPED W!TH

- Two double transporting chains with upper and lower hardened steel guides and separate tensioning
systems
- Set of interchangeable pushers and pusher supports driven by the two chains
- variable speed gear motor equipped with a mechanical torque control system for driving the feeding
chains
- Permanent magnetic chuck with magnetizing f demagnetising functions
- Set of interchangeable tungsten carbide sliding rails with a single self-centring adjustment control
- Set of interchangeable side rails to centre the slots and the chamfers with a single self-centring
adjustment control
The side guides are equipped with a padsfside guides anti-collision system to prevent from damaging
the side guides mechanism with wrong manual adjustments of the sliding rails and of the side guides,
or when pads are not loaded correctly.

C. AUTONAT!C LOAD!NG UN!TS

For any type of machine :

1. Sloped chute with adjustable side and sliding guides (2,+00 padsfhour)
maximum length of the pad of 300 mm
2. Double conveyor including a loading area, an accumulating area able to store up to a maximum of 30
pads, a selection area and a mechanical pick and place (2,+00 padsfhour)

Only for Numerical Controlled grinders RPF.6JL3 - X

3. Double conveyor including a loading area, an accumulating area able to store up to a maximum of 30
pads, a selection area and a mechanical pick and place (2.+00 padsfhour)
This device is equipped (on the grinders RPF.6fL.3 - X) with two NC axes to control automatically
the vertical position of the frame of the Pick 8 Place unit and the horizontal position of the end of
stroke sensors.
Adding two optional slow electronic servo-motors it is possible to position automatically also the side
guides of the above described two double conveyors.

+. Loadingfturnover unit for transferring automatically hot pads (up to 160 ) onto the sliding rails of the
grinder from the conveyors carrying the pads out from the compression -curing units.
This type of loading unit requires a specific study of the characteristics of the compression-curing exit
area.
An anthropomorphic robot is normally required for this scope
NOTE :
The advantages of this solution, using a full PLC controlled grinder (setting up time of about 60
seconds), is the possibility of enslaving a group of presses producing different types of pads,
accumulating for example +0 pads per type on different conveyors.
The ratio between the setting up time and the production time of the grinder will be of about 1f1 and
the real full automatic production of the line will be of 1,200 padsfhour when using for example two 12
stations presses with 2+ different type of moulds working at the same time.

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D. SPEC!AL DEv!CES THAT CAN BE !NSTALLED ON ALL THE GR!NDERS

1. Pads cleaning station including : the extension of the feeding system for accommodating the
cleaning devices, a tunnel pads demagnetiser, a brushing unit and a set of air nozzles for the slots
2. Automatic unloading unit
3. Pads turnover unit with an input and an exit conveyors
+. Station 3 high speed kit for grinding at about 90 mfsec (Surface cutting speed)
5. Stations 1 and 2 high speed kit for grinding at about 80 mfsec (surface cutting speed)
6. Set of adjustable side guides kit for grinding CV disc brake pads
7. Set of adjustable side guides for grinding motorcycle disc brake pads
8. External 2 kW fourth grinding station for the single slotting of the pads
9. External + kW fourth station for grinding parallel chamfers or multiple slots
10. U-Cell conveyor with a device for the automatic switching of the pads flow from the processing line to
the second exit.
11. Software for programming the acceptance sampling of the parts required for the SPC ( N parts every
N parts processes)

E. SPEC!AL DEv!CES AvA!LABLE ONLY FOR THE GR!NDER type RPF.6fL.3 - X (NC version)

1. Grinding of compound chamfers with vertical interpolation (Standard characteristic)
2. Grinding of compound chamfers with horizontal interpolation (Optional module)
3. U-cell conveyor for the deviation of the no goods pads" from
the production line(checking instrumentation excluded) , for
using the machine installed in a processing line as a stand alone
unit and for SPC sampling (Optional module)
+. Neasuring system and software for 100 checking of the
thickness of the pads (on two adjustable trajectories) (Optional module)
5. Production control program (Software) (Optional module)
6. Software for the automatic adjustment of the distance between
the pads coming out from the grinder and to be loaded on a
scorching unit or on the powder painting unit (Standard characteristic)
and
to create small batches of pads on the conveyors going to the
scorching or powder painting unit for allowing the loading
Pick 8 Place to pick up the parts, from the conveyor, without
interference with the incoming batch of pads (Standard characteristic)
7. Bar code reader for the automatic selection of the part program
to be used for each specific pad and for loading the operator code
and the batch code (Optional module)
8. PLC controlled positioning of the sliding rails (Optional module)
9. PLC controlled positioning of the side guides (Optional module)
10. PLC controlled vertical positioning of the brushing unit (Optional module)
11. PLC controlled vertical positioning of the unloading unit (Optional module)

8. GR!ND!NG OF CONPOUND CHANFERS

The compound chamfers can be ground in two different ways, that differ for their performance and price:

A. By vertical interpolation : using the standard software available for the grinder type RPF.6fL3 that
allows to interpolate between the position of the pad along its trajectory on the feeding system and the
vertical position of the spindle in station 1 or 2

This system requires a dedicated grinding wheel for each type of pad to be ground and allows to grind
about 70 of the existing types of compound chamfers, but nearly the 100 of those required by the
aftermarket production.

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A specific program, free of cost, is available on request, for checking if a specific pad can be ground with
this method.

This is a low cost solution , particularly suitable for the aftermarket production able to produce up to
2.400 pads J hour.

B. By horizontal interpolation : using the module installed at the exit of the main frame of the standard
RPF.6fL3-X.

!n this case two separate grinding units located in opposition, using a different type of software,
interpolate between the position of the pad along its trajectory on the feeding system and their horizontal
(transversal) position, with reference to the centreline of the grinder.

This is a medium cost solution , suitable for processing OEs and aftermarket disc brake pads able to
produce up to 2,400 pads J hour.

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.
The replacement of the slotting or chamfering wheel cannot be done automatically and requires additional
setting up time when necessary.

9. TOOL!NG REQU!RENENTS

This grinder has been designed to minimise tooling costs, by minimising the requirement for dedicated (i.e.
pad-specific) tooling to deal with the protrusions on the backing plates. When processing either pads for
motorcycles, for cars or for trucks :

A. Grinding wheels:

1 The rough and finish grinding wheels are universal, i.e. are the same for all types of pads.
2 The slotting wheels 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.
3 For grinding chamfers, parallel or compound, single or double, symmetric or asymmetric, it is
necessary to use dedicated wheels having the required angle measured along the trajectory of the
pad on the feeding system.
Different pads with the same chamfers angle can normally be ground with the same diamond
grinding wheels, changing only the spacers.
very large pads require special diamond grinding wheels in order to accommodate the nose of the
spindle
We suggest to pre-assemble the diamond grinding wheels, the spacers and the hub off the grinder
in order to eliminate possible mounting errors and reduce start up time.
Comec can supply directly the diamond grinding wheels or, if required by the customer, only the
drawings of the wheels, of the spacers and their assembly drawing .

B. Sliding rails : no supporting jigs are required. The distance between the two rails is manually adjustable
with a single self-centring device. On request, and only for the grinder type RPF.6fL.3 - X the movement
of the side guides can be controlled automatically by the PLC

C. Side guides: the opening of the side guides is manually adjustable with a single self-centring device.
On request, and only for the grinder type RPF.6fL.3 - X the movement of the side guides can be
controlled automatically by the PLC

This minimum requirement for tooling allows to :

- avoid investments in tooling,
- save on tooling maintenance and management costs,

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- reduce set up time.

10. ATTACHED LAYOUTS

The attached layouts show the grinder with the available options and the different types of loading units that
can be used.

S-2002-10-01f01 Grinder type RPF.6JL3 with a sloped chute loading unit (Front view)
S-2002-10-01f02 Grinder type RPF.6JL3 with a sloped chute loading unit (Top view)
S-2002-10-01f03 Grinder type RPF.6JL3 with a sloped chute loading unit (Top view)

S-2002-10-03f01 Grinder type RPF.6JL3 with a Pick 8 Place loading unit (Front view)
S-2002-10-03f02 Grinder type RPF.6JL3 with a Pick 8 Place loading unit (Top view)
S-2002-10-03f03 Grinder type RPF.6JL3 with a Pick 8 Place loading unit (Top view)

11. ADD!T!ONAL !NFORNAT!ON

On request, Comec can also provide additional information on the following subjects:

A. SPC (Statistical Process Control) procedure, measuring fixtures, etc.
B. Full description of the Guarantee clauses
C. Examples of layouts showing the connection of the grinder type RPF.6fL3 to the scorching andfor to the
painting unit
D. Customized solutions

12. DOCUNENTAT!ON

Comec will supply with the grinder a complete documentation including :

A. General instruction manual
B. Operational procedures containing start-up and operating instructions, troubleshooting guide and
maintenance instructions.
C. Electrical, pneumatic and lubrication diagrams
D. PLC program commented in English language
E. List of spare parts
F. List of critical components
G. All the suppliers components manuals and information provided with the machine
H. Preventive maintenance procedures

The above documentation will be provided on paper (two copies) and, except the catalogues described at
point G", also on optical support (CD).

The above documentation, G" point excluded, will be supplied, free of charge, in the following languages :

- English
- French
- German
- !talian
- Spanish

The translation of the documentation in a language different from the above described ones, will be quoted
separately.

The PLC program, in any case, will be commented in English language only.

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The documentation will be supplied in two steps as follows :

- A temporary release : at the acceptance test in Comec, before the shipment
- A final release : 6 weeks after the commissioning of the machine at the plant of the customer

13. TERNS OF SALE

See attachment 1 of the offer

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Disc brake pads grinder type RPF.6fL3 with a double conveyor Pick 8 Place loading unit and automatic unloading system (Front view)

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Disc brake pads grinder type RPF.6fL3 with a double conveyor Pick 8 Place loading unit and automatic unloading system (Side view)

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1
1
9
5
2
7
.
5
8
3
7
8
3
S-2002-10-01f01 Grinder type RPF.6fL3 with a sloped chute loading unit (Front view)

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2
1
2
0
S-2002-10-01f01 Grinder type RPF.6fL3 with a sloped chute loading unit (Top view)

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S-2002-10-01f01 Grinder type RPF.6fL3 with a sloped chute loading unit (Side view)

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2
7
.
5
8
3
7
8
3
S-2002-10-03f01 Grinder type RPF.6fL3 with a Pick 8 Place loading unit (Front view)

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S-2002-10-03f02 Grinder type RPF.6fL3 with a Pick 8 Place loading unit (Top view)

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S-2002-10-03f03 Grinder type RPF.6fL3 with a Pick 8 Place loading unit (Side view)

RPF6L3

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