CASE STUDY
Brake Disc Efficiency Breakthrough: A Case Study
OBJECTIVE
The objective was to develop a grinding solution capable of handling multiple brake disc configurations for commercial motorcycles, with the adaptability for future production needs. The challenge lay in creating a system that could maintain the necessary production strength and performance while incorporating a fully automated cycle. The specific target was to achieve a grinding cycle time of 30 seconds per disc, setting a high bar for both efficiency and flexibility in the manufacturing process.
SOLUTION
To tackle the pressing need for a flexible and efficient grinding process for various brake disc configurations, the solution implemented involved engineering a bespoke Vertical Double Disc Grinding Machine. This machine was not only tailored to the current requirements but also built with the foresight for easy reconfiguration in response to future demands or design updates for the brake discs. The customization extended to incorporating an automatic load, unload, dry, and stack system aimed at streamlining the production flow and maximizing output.
The comprehensive design of the system brought together state-of-the-art grinding technology with the necessary safety features and a custom program tailored to optimize cycle times. This approach holistically addressed the client’s demand for a sub-30-second grinding cycle while ensuring the machine’s adaptability for subsequent modifications. As a result of this strategic engineering solution, the company was poised to enhance production rates to unprecedented levels, demonstrating the value of a solution that harmonizes flexibility with efficiency.
The comprehensive design of the system brought together state-of-the-art grinding technology with the necessary safety features and a custom program tailored to optimize cycle times. This approach holistically addressed the client’s demand for a sub-30-second grinding cycle while ensuring the machine’s adaptability for subsequent modifications. As a result of this strategic engineering solution, the company was poised to enhance production rates to unprecedented levels, demonstrating the value of a solution that harmonizes flexibility with efficiency.
Key Results
The custom-engineered Vertical Double Disc Grinding Machine delivered a transformative impact on the client’s production capabilities. Key results included meeting the ambitious target of a 30-second grinding cycle, which significantly accelerated production times and increased the output rate to the highest in the company’s history. The integration of advanced safety features and optimization programs further streamlined the manufacturing process, achieving an ideal balance of speed, safety, and adaptability in production.
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