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Modular Assembly Line for
Brake Pads

Design and manufacturing of a high-efficiency custom line for the automotive sector

THE PROJECT:

For over 45 years, BONETTO AUTOMATION has been designing and manufacturing assembly and finishing lines for brake pads, serving the leading international manufacturers in the automotive industry.

The configuration described here represents one of the most comprehensive and technologically advanced solutions developed by the company: a fully automated line that integrates all primary mechanical processing, assembly, and quality control operations into a single, continuous flow.

KEY ADVANTAGES

⦁ Full integration of all processes into a single production flow
⦁ High level of automation
⦁ Minimized downtime thanks to in-line quality control
⦁ End-to-end product traceability
⦁ Continuous monitoring of process parameters
⦁ Automatic reject separation for analysis and rework
⦁ High repeatability and production cycle stability
⦁ Modular architecture designed for future scalability

LAYOUT AND OPERATING STATIONS

The line consists of several functional stations, including:

  • Load Manipulator
  • Drilling & Control Station
  • Flaming Station (pre-assembly)
  • Shim Assembly
  • Cold Pressing
  • Hot Pressing
  • Flaming Station (post-assembly)
  • Shim Riveting (x2)
  • Shim Check & Riveting Pin Control
  • Inkjet & Barcode Marking
  • Barcode Reader
  • W.I. Assembly (handled by robot)
  • Clip Assembly (handled by robot)
  • Notch Control (on double side)
  • Camera Station
  • Unload Good / Scrap
  • Label Layer Assembly & Check

QUALITY CONTROL AND TRACEABILITY

Every phase is monitored in real time.

⦁ Dimensional inspections
⦁ Machine vision systems
⦁ Process parameter monitoring
⦁ Differentiated scrap management
⦁ SCADA system for centralized supervision and data management
⦁ Integration / Interfacing with MES systemsEach brake pad is tracked throughout the entire production cycle.

MODULARITY AND LONG-TERM EVOLUTION

The modular architecture enables:

  • Future integration of new stations
  • Technological upgrades of individual modules
  • Increased automation levels
  • Adaptation to new brake pad models

BONETTO AUTOMATION also performs revamping on existing lines, improving performance, efficiency, and quality control without replacing the entire system.

PROVEN EXPERIENCE IN THE SECTOR

Over the years, BONETTO AUTOMATION has built numerous brake pad assembly lines installed at international manufacturing sites. The experience gained allows us to:

  • Optimize layout and cycle times

  • Integrate complex in-line processes

  • Ensure long-term reliability

  • Develop fully customized solutions

The combination of mechanical engineering, automation, and software integration makes BONETTO AUTOMATION a leading technological partner in the brake system industry.

Do you have a project to develop?
Contact us
sales@bonettoautomazioni.com