Method for manufacturing a wheel rim and method for manufacturing a disc brake wheel hub

Abstract

The application provides a rim manufacturing method and a disc brake hub manufacturing method, wherein the rim manufacturing method comprises the steps of manufacturing a fixing member made of a first material, forming a seat body made of a second material combined with the fixing member, and fixing a disc brake disc mounting seat comprising the fixing member and the seat body on a rim body; the disc brake hub manufacturing method comprises the steps of combining a spoke with the rim, leveling a plurality of positioning end faces, and machining mounting holes on the seat body. Since the seat body is fixed on the rim body through the fixing member, the seat body and the rim body can be made of different materials, the range of materials available for the seat body is greatly expanded, the seat body can be made of a material with relatively smaller hardness, easier machining and better machining precision, and the manufacturing of the seat body, the leveling of the positioning end faces of the seat body and the machining of the mounting holes on the seat body in the above steps are more efficient and have higher precision.

Description

Technical Field

[0001] This invention belongs to the technical field of wheel hub manufacturing methods, specifically relating to a wheel rim manufacturing method and a disc brake wheel hub manufacturing method. Background Technology

[0002] Disc brake hubs are increasingly used in two-wheeled vehicles, providing a better braking experience for users. Furthermore, the open structure of disc brake hubs helps maintain cleanliness and aesthetic appeal. One type of disc brake hub is used to mount a full-disc disc brake disc with a diameter close to that of the hub. This type of disc brake hub has multiple mounting seats on its rim, each with threaded holes. The outer edge of the full-disc disc brake disc has multiple fixing holes that match the threaded holes. Considering strength and cost, existing disc brake hubs are mostly made of iron, and the mounting seats are also made of iron blocks. The manufacturing process of the aforementioned disc brake hub generally includes the following steps: (1) manufacturing iron mounting seats through machining methods such as cutting; (2) welding multiple mounting seats to the iron rim; (3) leveling the outer end faces of multiple mounting seats through cutting; and (4) machining threaded holes on each mounting seat.

[0003] On the one hand, iron materials have high hardness, are difficult to process, and have low processing efficiency. Therefore, the manufacturing efficiency of the above-mentioned mounting base is low. Moreover, when the mounting base is cut by the cutting tool, the cutting tool is prone to problems such as tool skipping, which causes processing quality problems and further affects efficiency. It will also lead to the fact that the accuracy of the outer end face of the mounting base in the above step (3) is not ideal, which in turn leads to the disc brake disc installed on the wheel hub not being well supported and positioned, and affecting braking performance and causing obvious abnormal noise when colliding with the mounting base during braking.

[0004] On the other hand, for the convenience of production changes and due to the requirements of some manufacturers, a new type of wheel rim with a mounting base is needed to be combined with different spokes. At present, there is no manufacturing method for such a new type of wheel rim, and the same problems of difficult and inefficient processing of the mounting base will be encountered when manufacturing such a new type of wheel rim. Summary of the Invention

[0005] This invention is made to solve the above-mentioned problems, and its purpose is to provide a rim manufacturing method that can manufacture a new type of wheel rim with multiple mounting seats, and which is more convenient and efficient in manufacturing and processing, as well as a corresponding disc brake wheel hub manufacturing method. The technical solution adopted by this invention is as follows:

[0006] This invention provides a method for manufacturing a wheel rim for a disc brake hub capable of mounting a disc brake disc. The method includes the following steps: Step S1-1, manufacturing a plurality of fasteners made of a first material; Step S1-2, forming a plurality of seats made of a second material that are combined with each of the fasteners, the plurality of seats forming a plurality of disc brake disc mounting seats with corresponding fasteners; Step S1-3, fixing the plurality of disc brake disc mounting seats at a plurality of predetermined positions on the wheel rim body to form the wheel rim. The fasteners have: one or more connecting portions that engage with the seats; and one or more fixing portions that protrude from the seats and are fixed at corresponding predetermined positions on the wheel rim. The seats have: a mating portion that engages with the fixing portions and mates with the wheel rim; and a supporting and positioning portion having a positioning end face for supporting and positioning the disc brake disc.

[0007] The wheel rim manufacturing method provided by the present invention may also have the following technical features, wherein, in steps S1-3, the plurality of disc brake disc mounting seats are respectively placed at the predetermined positions on the wheel rim body, and the fixing part of the fixing member of each disc brake disc mounting seat is welded to the corresponding predetermined position, thereby forming the disc brake wheel rim.

[0008] The wheel rim manufacturing method provided by the present invention may also have the following technical features, wherein, in steps S1-3, welding is performed by a welding device, the welding device comprising: a wheel rim positioning mechanism for loading and positioning the wheel rim body; a mounting base feeding mechanism for placing the disc brake disc mounting base at the predetermined position of the wheel rim body loaded and positioned by the wheel rim positioning part; and a welding mechanism for welding the fixing part of the disc brake disc mounting base placed on the wheel rim body to the predetermined position on the wheel rim body.

[0009] The wheel rim manufacturing method provided by the present invention may also have the following technical features, wherein the fixing part is two, which are exposed from one side of the seat body and one end of the seat body respectively, and are located at the bottom of the groove and the rim respectively. The welding mechanism includes two welding guns for simultaneously welding the fixing part located at the bottom of the groove and the bottom of the groove, and the fixing part located at the rim and the rim.

[0010] The wheel rim manufacturing method provided by the present invention may also have the following technical features: the mating part of the seat has a mating notch that mates with the wheel rim flange and the bead seat; there are two fixing parts, which are exposed from the mating notch of the seat and are respectively located at the bead seat of the wheel rim; the welding mechanism includes two welding guns for simultaneously welding the two fixing parts to the bead seat.

[0011] The rim manufacturing method provided by the present invention may also have the following technical features: the first material is iron, the fastener includes one or more sheet-like parts, the fastener is manufactured by stamping in step S1-1, the second material is any one of aluminum alloy, magnesium alloy, aluminum-magnesium alloy, copper alloy, copper-zinc alloy, and industrial plastic, the seat is a column with a missing corner, and the seat is formed by casting to be combined with the fastener.

[0012] The rim manufacturing method provided by the present invention may also have the following technical features: the fixing member is integrally formed from a bent sheet, the connecting part is located in the middle of the entire fixing member, the connecting part has a central hole, and there are two fixing parts, respectively located at both ends of the fixing member. The two fixing parts are respectively fixed to the rim flange and groove bottom of the rim body at the predetermined position, or respectively fixed to the bead seat of the rim body at the predetermined position. Step S1-1 includes the following sub-steps: Step S1-1-1, punching out a shape corresponding to the central hole on the flat sheet. The corresponding through hole and the outer contour groove corresponding to the outer contour of the fastener are used to form a first semi-finished piece connected to the connecting piece; in step S1-1-2, the first semi-finished piece is subjected to a first longitudinal pressing to form a bent second semi-finished piece connected to the connecting piece; in step S1-1-3, the second semi-finished piece is subjected to a second longitudinal pressing to form a third semi-finished piece connected to the connecting piece with a bending angle consistent with the bending angle of the fastener; in step S1-1-4, the third semi-finished piece is cut from the connecting piece to obtain the fastener.

[0013] The wheel rim manufacturing method provided by the present invention may also have the following technical features: in step S1-1, a stamping device is used to perform the stamping process. The stamping device includes a matching upper die mechanism and a lower die mechanism. The upper die mechanism has a blanking upper die group, a first longitudinal pressing lower die group, a second longitudinal pressing upper die group, and a cutting upper die group. The lower die mechanism has a blanking-cooperating lower die group that cooperates with the blanking upper die group to perform the blanking, a first longitudinal pressing lower die group that cooperates with the first longitudinal pressing lower die group to perform the first longitudinal pressing, a second longitudinal pressing lower die group that cooperates with the second longitudinal pressing upper die group to perform the second longitudinal pressing, and a cutting-cooperating lower die group that cooperates with the cutting upper die group to perform the cutting. When the upper die mechanism and the lower die mechanism cooperate to perform one stamping, one blanking, one first longitudinal pressing, one second longitudinal pressing, and one cutting are completed at different positions on the sheet material.

[0014] The rim manufacturing method provided by the present invention may also have the following technical features, wherein the fixing member includes a first sheet-like member and a second sheet-like member, both U-shaped. The first sheet-like member has a first connecting portion as the connecting portion and a first fixing portion as the fixing portion, the first fixing portion being fixed to the rim body at the predetermined position. The second sheet-like member has a first connecting portion as the connecting portion and a second fixing portion as the fixing portion, the second fixing portion being fixed to the groove bottom at the predetermined position on the rim body. The second sheet-like member has an arc corresponding to the rim body. Step S1-1 includes the following sub-steps: Step S1-1-1', on the flat first... A first outer contour groove corresponding to the outer contour of the first sheet is punched out on the sheet material, thereby forming a fourth semi-finished sheet connected to the first connecting piece; in step S1-1-2', the fourth semi-finished sheet is cut from the first connecting piece to obtain the first sheet material; in step S1-1-3', a second outer contour groove corresponding to the outer contour of the second sheet material is punched out on the flat second sheet material, thereby forming a fifth semi-finished sheet connected to the second connecting piece; in step S1-1-4', the fifth semi-finished sheet is longitudinally pressed to give it the curvature; in step S1-1-5', the fifth semi-finished sheet is cut from the second connecting piece to obtain the second sheet material.

[0015] The wheel rim manufacturing method provided by the present invention may also have the following technical features, wherein, in step S1-2, the seat body is formed by die casting using a die casting device. The die casting device includes a die casting machine and a die casting mold. The die casting mold includes a fixed mold and a moving mold. One of the fixed mold and the moving mold has a plurality of first seat body grooves and a positioning groove located on one side of each of the first seat body grooves. The other of the fixed mold and the moving mold has a plurality of second seat body grooves corresponding to the first seat body grooves, for combining with the corresponding first seat body grooves to form a seat body cavity. Step S1-2 includes the following sub-steps: Step S1-2-1, ... The plurality of fasteners are arranged in a manner corresponding to the plurality of first seat slots; in step S1-2-2, the plurality of fasteners are placed into the plurality of first seat slots, and the fixing part of the fastener is embedded in the corresponding positioning slot; in step S1-2-3, the die-casting machine closes the die-casting mold and injects the second material into the plurality of seat cavities for die casting to form the seat of the disc brake mounting base; in step S1-2-4, the die-casting machine opens the die-casting mold; in step S1-2-5, the plurality of disc brake mounting bases are removed from the die-casting mold.

[0016] The wheel rim manufacturing method provided by the present invention may also have the following technical features, wherein the die-casting device further includes: a fixing component pre-positioning mechanism for arranging a plurality of fixing components in an arrangement corresponding to the plurality of first seat grooves; and a workpiece transfer mechanism for simultaneously placing the arranged plurality of fixing components into the plurality of first seat grooves of the die-casting mold, and embedding the fixing parts of the plurality of fixing components into the corresponding positioning grooves, and for removing the die-cast disc brake mounting seat from the die-casting mold.

[0017] This invention provides a method for manufacturing a disc brake hub, used to manufacture a disc brake hub capable of mounting disc brake discs. The method includes the following steps: Step S1, manufacturing a rim with multiple disc brake disc mounting seats; Step S2, machining the positioning end faces of the seats of the multiple disc brake disc mounting seats so that the multiple positioning end faces are coplanar and perpendicular to the axial direction of the rim; Step S3, machining mounting holes for mounting the disc brake discs on the seats of the multiple disc brake disc mounting seats; Step S4, fixing the spokes to the rim to obtain the disc brake hub, wherein in Step S1, the rim is manufactured using the aforementioned rim manufacturing method.

[0018] This invention provides a method for manufacturing a disc brake wheel hub, which includes the following steps: Step S1', manufacturing a wheel rim having multiple disc brake disc mounting seats; Step S2', fixing the spokes to the wheel rim; Step S3', machining the positioning end faces of the seats of the multiple disc brake disc mounting seats so that the multiple positioning end faces are coplanar and perpendicular to the axial direction of the wheel rim; Step S4', machining mounting holes for mounting the disc brake discs on the seats of the multiple disc brake disc mounting seats, thereby obtaining the disc brake wheel hub, wherein, in Step S1', the wheel rim is manufactured using the above-described wheel rim manufacturing method.

[0019] The disc brake hub manufacturing method provided by the present invention may also have the following technical features, wherein the spokes are made of a third material, and the spokes have: a spoke plate portion located in the middle of the spokes; a plurality of spokes extending radially from the edge of the spoke plate portion; and a plurality of inserts respectively embedded in the outer end of each of the spokes, wherein the inserts are made of a material that can be welded to the rim body and are welded to the inner middle of the rim body.

[0020] The disc brake hub manufacturing method provided by the present invention may also have the following technical features, wherein the spokes are made of a material that can be welded to the rim body, and the spokes have: a spoke plate portion located in the middle of the spokes; and a plurality of spokes extending radially from the edge of the spoke plate portion, wherein the outer ends of the plurality of spokes are respectively welded to the inner middle of the rim body.

[0021] This invention also provides a wheel hub manufacturing method, which has the following technical features: First, a connecting part (i.e., a fixing part) is stamped; then, the connecting part is placed in a mold (i.e., a die-casting mold), the cavity of which is adapted to the shape of a threaded seat (i.e., a seat body); then, molten aluminum is injected into the mold, and after the aluminum cools and solidifies, a threaded seat is formed, which encloses the connecting part to form a mounting seat (i.e., a disc brake disc mounting seat); the mounting seat is removed from the mold, cleaned appropriately, and then welded onto the wheel rim; the wheel rim is clamped on a CNC machine tool, and a cutting plane and a threaded hole are drilled on the surface of the threaded seat; a central hole for the shaft is cut at the center of the wheel rim, which is used to assemble the bearing; the threaded hole is concentric with the central hole for the shaft of the wheel rim.

[0022] Invention Function and Effect

[0023] According to the rim manufacturing method and disc brake hub manufacturing method of the present invention, the rim manufacturing method includes the steps of manufacturing a fastener of a first material, forming a seat of a second material that is combined with the fastener, and fixing a disc brake disc mounting seat including the fastener and the seat to the rim body; the disc brake hub manufacturing method includes the steps of combining the spokes with the rim, leveling the positioning end faces of multiple disc brake disc mounting seats, and machining mounting holes on the seat. Since the seat is fixed to the rim body by the fastener, the seat and the rim body can be made of different materials, greatly expanding the range of usable materials for the seat. Materials with relatively lower hardness, easier processing, and higher processing precision can be selected to manufacture the seat, making the manufacturing of the seat, the leveling of the positioning end faces of the seat, and the machining of mounting holes on the seat more efficient and precise. This results in higher processing efficiency for the disc brake hub, better positioning accuracy of the finished disc brake hub for the disc brake disc, better braking performance, and helps alleviate the aforementioned abnormal noise problem. Attached Figure Description

[0024] Figure 1 This is a flowchart of the disc brake hub manufacturing method in Embodiment 1 of the present invention;

[0025] Figure 2 This is a flowchart of the rim manufacturing method in Embodiment 1 of the present invention;

[0026] Figure 3 This is a flowchart illustrating the manufacturing of a fastener via stamping in Embodiment 1 of the present invention;

[0027] Figure 4 This is a schematic diagram of the stamping device in Embodiment 1 of the present invention;

[0028] Figure 5 This is a schematic diagram of the structure of the iron strip sheet during the stamping process in Embodiment 1 of the present invention;

[0029] Figure 6 This is a perspective view of the finished fastener in Embodiment 1 of the present invention;

[0030] Figure 7 This is a flowchart illustrating the manufacturing of the base body by die casting in Embodiment 1 of the present invention;

[0031] Figure 8 This is a schematic diagram of the die-casting device in Embodiment 1 of the present invention;

[0032] Figure 9 This is a schematic diagram of the die-casting mold in Embodiment 1 of the present invention;

[0033] Figure 10 This is a perspective view of the finished disc brake disc mounting base in Embodiment 1 of the present invention;

[0034] Figure 11 These are perspective views of the finished disc brake disc mounting base from different angles in Embodiment 1 of the present invention;

[0035] Figure 12 This is a flowchart illustrating the process of forming a wheel rim by welding in Embodiment 1 of the present invention;

[0036] Figure 13 This is a schematic diagram of the welding device in Embodiment 1 of the present invention;

[0037] Figure 14 This is a perspective view of the finished wheel rim in Embodiment 1 of the present invention;

[0038] Figure 15 This is a perspective view of the finished disc brake hub and disc brake disc in Embodiment 1 of the present invention;

[0039] Figure 16 This is a cross-sectional view of the finished disc brake hub and disc brake disc in Embodiment 1 of the present invention;

[0040] Figure 17 yes Figure 16 Enlarged view of the area inside circle A;

[0041] Figure 18 This is a flowchart of the disc brake hub manufacturing method in Embodiment 2 of the present invention;

[0042] Figure 19 This is a perspective view of the fastener in Embodiment 4 of the present invention;

[0043] Figure 20 This is a flowchart of the manufacturing of the fastener by stamping in Embodiment 4 of the present invention;

[0044] Figure 21 This is a perspective view of the fastener in Embodiment 5 of the present invention.

[0045] Figure label:

[0046] Disc brake hub 100; rim 10; groove bottom 11; tire bead seat 12; rim 13; disc brake disc mounting base 20; seat body 21; support and positioning part 211; positioning end face 2111; mating part 212; mating notch 2121; mating surface 21211; receiving groove 2122; mounting hole 213; fastener 22; mating part 221; first sheet-like part 2211; second sheet-like part 2212; connecting part 2213; central hole 2214; hollow part 2214a; mating hole 2214b; mating notch 2215; end mating hole 2216; clearance notch 2217; fixing part 222; rim fixing part 222a; groove Bottom fixing part 222b; Bead seat fixing part 222c; First plate-shaped member 223; First joint part 2231; First clearance notch 22311; First joint notch 22312; First fixing part 2232; Second plate-shaped member 224; Middle joint notch 22411; Second joint notch 22412; Second fixing part 2242; Bending part 225; Wheel spoke 30; Wheel rim welding part 41; Groove bottom welding part 42; Bead seat welding part 43; Disc brake disc 200; Friction hole 201; Fixing hole 202; Fastening rod 300; Fastening rod cap part 301; Fastening rod transition part 302; Screw part 303; Stamping device 400; Upper die machine 410; Upper die set 411; Upper die base 412; Upper punching die assembly 413; First longitudinal pressing upper die assembly 414; Second longitudinal pressing upper die assembly 415; Cutting upper die assembly 416; Lower die mechanism 420; Lower die set 421; Lower die base 422; Lower punching die assembly 423; First longitudinal pressing lower die assembly 424; Second longitudinal pressing lower die assembly 425; Cutting lower die assembly 426; Die casting device 500; Fixed part pre-positioning mechanism 510; Vibratory feeder 511; Fixed part transfer robot 512; Pre-positioning seat 513; Workpiece transfer mechanism 520; Part placement assembly 521; Part removal assembly 522; Die casting machine 530; Die casting mold 54 0; Moving mold 542; First base groove 5421; First positioning groove 5422; Second positioning groove 5423; First sprue groove 5424; Welding device 600; Mounting base feeding mechanism 610; Vibratory plate 611; Feeding channel 612; Feeding seat 613; Feeding robot 614; Hub positioning mechanism 620; Placement platform 621; Centering column 622; Welding mechanism 630; Welding torch 631; Welding torch bracket 632; Welding torch drive assembly 633; ​​Iron strip sheet 900; Through hole 901; Outer contour groove 902; Positioning hole 903; First semi-finished piece 910; Second semi-finished piece 920; Third semi-finished piece 930; Connecting piece 950. Detailed Implementation

[0047] To make the technical means, creative features, objectives and effects of the present invention easy to understand, the following describes in detail the rim manufacturing method and disc brake hub manufacturing method of the present invention with reference to embodiments and accompanying drawings.

[0048] <Example 1>

[0049] This embodiment provides a method for manufacturing a disc brake hub, which is used to manufacture a disc brake hub capable of mounting a disc brake disc.

[0050] Figure 1 This is a flowchart of the disc brake wheel hub manufacturing method in this embodiment.

[0051] like Figure 1 As shown, the method includes the following steps:

[0052] Step S1: Manufacture a rim with multiple disc brake disc mounting seats. The disc brake disc mounting seats include fasteners for fixing to the rim and a seat body that is connected to the fasteners. The seat body has a positioning end face for supporting and positioning the disc brake disc.

[0053] Step S2: The positioning end faces of the multiple disc brake mounting seats on the wheel rim are machined to make them coplanar and perpendicular to the axial direction of the wheel rim.

[0054] Step S3: On the seat of the multiple disc brake mounting brackets on the rim, mounting holes are machined for engaging with the corresponding fastening rods to install the disc brake discs.

[0055] Step S4: Press the spokes into the inner ring of the rim and fix the spokes to the rim to obtain the disc brake hub.

[0056] The steps described above will be explained in detail below.

[0057] Step S1: Manufacture a rim with multiple disc brake disc mounting seats. The disc brake disc mounting seats include fasteners for fixing to the rim and a seat body that is connected to the fasteners. The seat body has a positioning end face for supporting and positioning the disc brake disc.

[0058] Step S1 is also a method for manufacturing the rim of a disc brake wheel hub.

[0059] Figure 2 This is a flowchart of the rim manufacturing method for the disc brake wheel hub in this embodiment.

[0060] like Figure 2 As shown, the method specifically includes the following sub-steps:

[0061] Step S1-1: Manufacture multiple fasteners made of a first material, wherein the first material is a material that can be effectively welded to the rim body using conventional welding methods.

[0062] Steps S1-2: Multiple seats made of a second material are formed and combined with each fastener. The seats and the corresponding fasteners constitute a disc brake disc mounting base. The seat has a positioning end face for supporting and positioning the disc brake disc.

[0063] Steps S1-3 involve fixing multiple disc brake mounting brackets to predetermined positions on the rim body to form the rim.

[0064] The steps described above will be explained in detail below.

[0065] Step S1-1: Manufacture multiple fasteners made of a first material, which is a material that can be effectively welded to the rim body using conventional welding methods.

[0066] In this embodiment, the rim body is made of iron, and the first material is also made of iron. The raw material for the fastener is iron strip coil. The iron strip coil is uncoiled by a corresponding uncoiling device to form a continuous iron strip sheet. Then, the iron strip sheet is flattened by a flattening device. After that, the continuous and flat iron strip sheet is fed into a stamping device, which processes multiple fasteners by stamping.

[0067] Figure 3 This is a flowchart illustrating the manufacturing of the fastener using stamping in this embodiment.

[0068] like Figure 3 As shown, step S1-1 specifically includes the following sub-steps:

[0069] Step S1-1-1: Punch through holes and outer contour grooves into a flat iron strip to form a connecting piece and the first semi-finished piece connected to it.

[0070] Step S1-1-2: The first semi-finished piece is subjected to longitudinal pressing to form a bent second semi-finished piece. The bending angle of the second semi-finished piece is greater than the bending angle of the finished product fastener.

[0071] Step S1-1-3: The second semi-finished piece is subjected to secondary longitudinal pressing to form a bent third semi-finished piece. The bending angle of the third semi-finished piece is consistent with that of the finished product fixing part.

[0072] Step S1-1-4: Cut the third semi-finished piece and the connecting piece to obtain the finished fastener.

[0073] After the above steps, the fasteners can be further polished or finished.

[0074] In this embodiment, the above steps S1-1 are performed automatically by a stamping device.

[0075] Figure 4 This is a schematic diagram of the stamping device in this embodiment. Figure 5 This is a schematic diagram of the structure of the iron strip sheet during the stamping process in this embodiment.

[0076] like Figure 4 and Figure 5 As shown, the stamping device 400 includes an upper die mechanism 410 and a lower die mechanism 420 arranged vertically, a lifting drive mechanism, a guide mechanism, and a stamping control mechanism (not shown in the figure).

[0077] The upper die mechanism 410 includes an upper die frame 411, an upper die base 412, a punching upper die assembly 413, a first longitudinal pressing upper die assembly 414, a second longitudinal pressing upper die assembly 415, and a cutting upper die assembly 416.

[0078] The upper die base 412 is installed below the upper die frame 411, and multiple springs are provided between the upper die base 412 and the upper die frame 411 to serve as a buffer. The punching upper die assembly 413, the first longitudinal pressing upper die assembly 414, the second longitudinal pressing upper die assembly 415, and the cutting upper die assembly 416 are all installed below the upper die base 412 and arranged sequentially along the length of the upper die base 412.

[0079] The lower die mechanism 420 includes a lower die holder 421, a lower die base 422, a punching-fitting lower die assembly 423, a first longitudinal pressing-fitting lower die assembly 424, a second longitudinal pressing-fitting lower die assembly 425, and a cutting-fitting lower die assembly 426.

[0080] The lower die base 422 is installed above the lower die holder 421. The punching-fitting lower die assembly 423, the first longitudinal pressing-fitting lower die assembly 424, the second longitudinal pressing-fitting lower die assembly 425, and the cutting-fitting lower die assembly 426 are all installed above the lower die base 422 and arranged sequentially along the length of the lower die base 422, and are respectively located directly below the corresponding upper die assembly. In addition, the end of the lower die base 422 near the cutting-fitting lower die assembly 426 is shaped like a truncated triangle and has two inclined guide grooves, which are used to allow the finished product fixed part formed after cutting to slide along the guide grooves to the collection point.

[0081] In this process, the upper punching die 413 and the lower punching die 423 cooperate to punch an outer contour and through hole on the iron strip sheet that correspond to the structure of the finished fastener, i.e., step S1-1-1 above. Figure 7 As shown, in this embodiment, the upper punching module 413 cooperates with the lower punching module 423 to punch a pair of rounded rectangular through holes 901, a pair of T-shaped outer contour grooves 902 with generally rounded corners, and a smaller circular positioning hole 903 at a predetermined position on the iron strip sheet 900 during a single punching.

[0082] The through hole 901 corresponds to the shape of the central hole of the finished fastener.

[0083] The outer contour groove 902 corresponds to the outer contour shape of the finished fastener. The outer contour groove 902 also has two pairs of groove portions corresponding to the mating notches on both sides of the finished fastener. The groove portions are square notches with rounded corners. In an alternative, the groove portions can be formed on the fastener without using the upper punching die 413 and the lower punching die 423. Instead, the mating notches can be machined on the fastener in a subsequent process after stamping.

[0084] The positioning hole 903 is located between a pair of through holes 901. The positioning hole 903 can be detected by a sensor to automatically and accurately position the iron strip sheet in the stamping device 400.

[0085] After punching the next set of through holes 901, outer contour grooves 902, and positioning holes 903 at the next position, the previous position of the iron strip sheet forms a connecting piece 950 located in the middle and a pair of first semi-finished pieces 910 connected to both sides of the connecting piece 950 in an axially symmetrical structure. The first semi-finished pieces 910 are flat sheets. The width of the connection between the first semi-finished pieces 910 and the connecting piece 950 is relatively small.

[0086] The first longitudinal pressing upper module 414 and the first longitudinal pressing lower module 424 cooperate to perform a longitudinal pressing on the first semi-finished sheet 910, transforming it into a bent second semi-finished sheet 920, as described in steps S1-1-2 above. Furthermore, the bending angle of the second semi-finished sheet 920 is greater than that of the finished product fixing component, avoiding problems such as cracking caused by bending the iron strip sheet too much at once. The first longitudinal pressing upper module 414 and the first longitudinal pressing lower module 424 each have a bent forming end face, and these two forming end faces are arranged facing each other. These two forming end faces have a surface shape with a bend corresponding to the finished product fixing component but with a relatively larger angle.

[0087] The second longitudinal pressing upper module 415 and the second longitudinal pressing lower module 425 cooperate to perform a second longitudinal pressing on the second semi-finished product 920, making it a bent third semi-finished product 930, i.e., the above steps S1-1-3. Furthermore, the bending angle of the third semi-finished product 930 is equal to the bending angle of the finished product fastener. The second longitudinal pressing upper module 415 and the second longitudinal pressing lower module 425 each have a bent forming end face, and these two forming end faces are arranged facing each other. These two forming end faces have a bent surface shape corresponding to the finished product fastener and with the same angle.

[0088] The upper cutting module 416 and the lower cutting module 417 cut off the connection between the third semi-finished piece 930 and the connecting piece 950 to obtain the finished fastener, i.e., the above step S1-1-4.

[0089] The lifting drive mechanism is used to drive the upper die mechanism 410 to lift as a whole, so as to cooperate with the lower die mechanism 420 to perform stamping processing on the iron strip sheet. The guide mechanism is used to guide the lifting of the upper die mechanism 410, so that it lifts and moves in the vertical direction.

[0090] In this embodiment, under the control of the stamping control mechanism, during the process of the upper die mechanism 410 pressing down once (that is, during one stamping), one punching, one longitudinal pressing, one secondary longitudinal pressing, and one cutting are completed at four different positions on the iron strip sheet. Therefore, the sheet material can be continuously fed into the stamping device.

[0091] Furthermore, the stamping control mechanism controls the upper die mechanism 410 to perform stamping at a frequency matching the predetermined conveying speed of the steel strip sheet. Alternatively, the stamping device may further include a speed detection sensor for detecting the conveying speed of the steel strip sheet input to the stamping device, and the stamping control mechanism adjusts the stamping frequency in real time based on the detected conveying speed.

[0092] Figure 6 This is a perspective view of the finished fastener in this embodiment.

[0093] like Figure 6 As shown, the finished fastener 22 (connector) is integrally formed from a bent sheet (metal sheet) of a certain thickness, and its overall shape is a chamfered L-shape when viewed from the side. The fastener 22 includes a connecting part 221 and two fixing parts 222.

[0094] The connecting portion 221 is used to engage with the seat (screw seat). The connecting portion 221 is located in the middle of the entire fastener 22. The connecting portion 221 is generally in the shape of a bent square frame. From the side, the connecting portion 221 is also in the shape of a chamfered L. The connecting portion 221 can be regarded as being composed of a U-shaped first sheet portion 2211 (the horizontal segment in the bending direction), a similarly U-shaped second sheet portion 2212 (the vertical segment in the bending direction), and two generally T-shaped connecting portions 2213 (transition segments) connecting the two sheet portions. The two ends of the connecting portions 2213 are respectively connected to the corresponding ends (U-shaped ends) of the first sheet portion 2211 and the second sheet portion 2212. The length direction of the connecting portions 2213 is inclined relative to the surface direction of the first sheet portion 2211 and the surface direction of the second sheet portion 2212. The surface direction of the first sheet portion 2211 and the surface direction of the second sheet portion 2212 are approximately perpendicular to each other. Furthermore, the second sheet-like portion 2212 has a small curvature, which is basically consistent with the curvature of the bead seat. Since the size of the fastener 22 is very small relative to the overall size of the rim, the aforementioned curvature is small, and the second sheet-like portion 2212 can also be a flat sheet.

[0095] The connecting portion 221 has a large through hole 2214 in its center. The shape of the through hole 2214 corresponds to the overall shape of the connecting portion 221, and all four corners of the through hole 2214 are rounded. The connecting portion 221 has multiple connecting notches 2215 on both sides of its bending direction. In this embodiment, the connecting notches 2215 are rounded rectangular notches, with a total of four notches 2215. Two connecting notches 2215 are distributed on each side of the connecting portion 221, and the notches on both sides are symmetrically distributed. The opening direction of the connecting notches 2215 is perpendicular to the bending direction of the fastener 22. The width of the connecting notches 2215 is greater than its depth, and all corners of the connecting notches 2215 are rounded.

[0096] Two fixing portions 222 are respectively formed at both ends of the bending direction of the connecting portion 221 (i.e., at both ends of the L-shape). The fixing portions 222 are rectangular plates extending from one end of the connecting portion 221, and the length direction of the fixing portions 222 is perpendicular to the bending direction of the connecting portion 221. The length of the fixing portions 222 is the same as the width of that end of the connecting portion 221, and the surface direction of the fixing portions 222 is consistent with the surface direction of that end of the connecting portion 221. In addition, the outer end of the fixing portions 222 is rounded.

[0097] One of the fixing portions 222 has a relatively narrow width and serves as the rim fixing portion 222a; the other fixing portion 222 has a relatively wide width and serves as the groove bottom fixing portion 222b. Furthermore, the outer end of the rim fixing portion 222a has a small curvature, which is substantially consistent with the circumferential curvature of the rim 13. Similarly, this curvature is very small, and the outer end of the rim fixing portion 222a can also be straight.

[0098] The portion of the central hole 2214 near the rim fixing portion 222a serves as the hollow portion 2214a (a hollow and open filling groove), and the portion of the central hole 2214 near the bottom fixing portion 222b serves as the connecting hole 2214b. The dividing line between the hollow portion 2214a and the connecting hole 2214b is approximately located in the middle of the central hole 2214 in the bending direction of the fastener 22, that is, the filling groove is distributed on the transverse section and / or transition section.

[0099] By following the steps S1-1 above, the finished fastener 22 can be manufactured.

[0100] Steps S1-2: Multiple seats made of a second material are formed and combined with each fastener. The seats and the corresponding fasteners constitute a disc brake disc mounting base. The seat has a positioning end face for supporting and positioning the disc brake disc.

[0101] The second material is one that is less hard than the first material, easier to process, and easier to achieve higher processing precision. In this embodiment, the second material is an aluminum alloy. In alternative embodiments, the second material can also be other materials that meet the above conditions, such as magnesium alloys, aluminum-magnesium alloys, copper alloys, copper-zinc alloys, industrial plastics, etc.

[0102] The base body that is combined with the fastener is manufactured using a die-casting machine and corresponding die-casting molds.

[0103] Figure 7 This is a flowchart illustrating the manufacturing of the base body using die casting in this embodiment.

[0104] like Figure 7 As shown, step S1-2 specifically includes the following sub-steps:

[0105] Step S1-2-1: Arrange multiple fasteners in a configuration corresponding to the multiple seat cavities in the die-casting mold cavity.

[0106] Step S1-2-2: Simultaneously place the arranged fixing parts into the moving mold of the die-casting mold in the open mold state.

[0107] In steps S1-2-3, the die-casting machine closes the die-casting mold and injects the second material into the closed die-casting mold. After heat and pressure are maintained for a certain period of time, multiple seats that are combined with the fixing parts are formed, thereby obtaining multiple disc brake mounting seats.

[0108] In step S1-2-4, the die-casting machine opens the die-casting mold and sprays the multiple disc brake mounting seats in the opened die-casting mold for cooling.

[0109] Step S1-2-5: Remove multiple disc brake mounting brackets from the die-casting mold.

[0110] Step S1-2-6: Perform precision machining on the disc brake mounting bracket.

[0111] In this embodiment, steps S1-2-1 to S1-2-5 are performed automatically by a corresponding die-casting device.

[0112] Figure 8 This is a schematic diagram of the die-casting device in this embodiment. Figure 9 This is a schematic diagram of the die-casting mold in this embodiment.

[0113] like Figure 8 and Figure 9 As shown, the die casting apparatus 500 includes a fixed part pre-positioning mechanism 510, a workpiece transfer mechanism 520, a die casting machine 530, a die casting mold 540, and a die casting control mechanism (not shown in the figure).

[0114] The pre-positioning mechanism 510 for fixing members is used to arrange multiple fixing members 22 in an arrangement corresponding to the cavity of the die-casting mold 540 (i.e., step S1-2-1).

[0115] The workpiece transfer mechanism 520 is used to place multiple fixing parts 22 into the die-casting mold 540 in the open mold state (i.e., step S1-2-2), and to remove the disc brake mounting seat 20 formed by die casting from the die-casting mold 540 in the open mold state (i.e., step S1-2-5).

[0116] The die casting machine 530 is a horizontal die casting machine in the prior art, used to cooperate with the die casting mold 540 to die cast and form a seat (i.e., step 1-2-3), and has a spray mechanism for spray cooling the die-cast seat (i.e., step S1-2-4).

[0117] The die-casting mold 540 includes a fixed mold and a movable mold 542. The fixed mold is fixed on the die-casting machine 530, and the movable mold 542 is connected to the pushing mechanism of the die-casting machine 530. Driven by the mechanism, the movable mold 542 can move away from the fixed mold to open the mold, or move toward the fixed mold to close the mold.

[0118] The fixed mold and the moving mold 542 have a fixed mold forming groove and a moving mold forming groove on their opposing surfaces, respectively. When the mold is closed, the fixed mold forming groove and the moving mold forming groove are combined to form a mold cavity.

[0119] like Figure 9 As shown, in this embodiment, the fixed mold forming groove of the moving mold 542 includes a plurality of first base grooves 5421, a plurality of first positioning grooves 5422, a plurality of second positioning grooves 5423, and a first runner groove 5424. The fixed mold forming groove of the fixed mold includes a plurality of second base grooves and a second runner groove.

[0120] The first positioning groove 5422 is located on one side of the corresponding first seat groove 5421, and the second positioning groove 5423 is located at the bottom of the first seat groove 5421. These grooves are used to embed the outer ends of the two fixing parts 222 of the fixing member 22, thereby positioning the fixing member 22 in the corresponding first seat groove 5421, that is, positioning the fixing member 22 in the seat 21. Multiple second seat grooves of the fixed mold correspond to multiple first seat grooves 5421 and can be assembled with the corresponding first seat grooves 5421 to form a seat cavity for die casting the seat. The first seat groove 5421 is approximately a rounded rectangular groove with a block-shaped protrusion inside, and the second seat groove is approximately a corresponding rounded rectangular groove. The first gating groove 5424 can be assembled with the second gating groove to form a gating system that communicates with multiple seat cavities.

[0121] When opening the mold, multiple fasteners 22 can be placed in each of the first base grooves 5421, and the outer ends of the two fixing parts 222 of the fasteners 22 can be embedded into the corresponding first positioning grooves 5422 and second positioning grooves 5423, thereby pre-positioning the fasteners 22.

[0122] After the mold is closed, the corresponding first seat groove 5421 and second seat groove combine to form a seat cavity. The die casting machine injects molten aluminum alloy into the gating system. The molten aluminum alloy flows into each seat cavity along the gating system. Then the die casting machine maintains the predetermined temperature and pressure for a predetermined time to form multiple seats that are combined with the fixing part 22, that is, multiple disc brake mounting seats are formed. After that, the mold is opened and multiple disc brake mounting seats are taken out.

[0123] The aforementioned fixture pre-positioning mechanism 510 is used to arrange multiple fixtures 22 into an arrangement corresponding to the multiple first seat grooves 5421 of the moving mold 542. The fixture pre-positioning mechanism 510 includes a vibratory feeder 511, a fixture transfer robot 512, and a pre-positioning seat 513. The vibratory feeder 511 uses vibration to arrange the multiple disordered fixtures 22 neatly and outputs them sequentially to a predetermined position (the outer end of the material channel connected to the output end of the vibratory feeder). The fixture transfer robot 512 is used to grasp the fixtures 22 from the predetermined position and place them into a placement position on the pre-positioning seat 513 according to a predetermined path until the placement position on the pre-positioning seat 513 is full. The arrangement of the multiple placement positions on the pre-positioning seat 513 is substantially consistent with the arrangement of the multiple first seat grooves 5421 of the moving mold 542.

[0124] The aforementioned workpiece transfer mechanism 520 is used to simultaneously pick up multiple fixing parts 22 from the predetermined seat 513 filled with fixing parts 22 and place them together into multiple first seat slots 5421 of the moving mold 542 in the mold-opening state. It is also used to remove multiple disc brake disc mounting seats 20 formed after die casting from the die-casting mold 540 in the mold-opening state. In this embodiment, the workpiece transfer mechanism 520 is an industrial robotic arm, the end of which has a placement assembly 521 for simultaneously picking up multiple fixing parts 22 and a picking assembly 522 for simultaneously picking up multiple disc brake disc mounting seats 20. The placement assembly 521 and the picking assembly 522 are arranged opposite to each other, and the end joint of the industrial robotic arm can rotate 360 ​​degrees. After the industrial robotic arm places its placement assembly 521 toward the moving mold 542 and places multiple fixing parts 22 into the mold cavity of the moving mold 542, the industrial robotic arm moves outside the die-casting machine 530. While the die-casting machine 530 is performing die casting, the industrial robotic arm rotates its end joint 180 degrees, so that the part-removing assembly 522 can be rotated to face the moving mold 542 in order to remove the disc brake mounting seat formed after die casting.

[0125] The die-casting control mechanism controls the operation of the aforementioned fixture pre-positioning mechanism 510, workpiece transfer mechanism 520, and die-casting machine 530, including: after controlling the die-casting machine 530 to open the mold, controlling the workpiece transfer mechanism 520 to place the arranged fixtures into the mold; controlling the workpiece transfer mechanism 520 to move to the outside of the die-casting machine 530, and then controlling the die-casting machine 530 to close the mold and perform die casting; after the die-casting machine 530 completes die casting (i.e., after waiting for the corresponding predetermined time), controlling the die-casting machine 530 to open the mold, and then controlling the workpiece transfer mechanism 520 to remove the disc brake mounting seat from the mold; and while controlling the die-casting machine 530 to perform die casting, controlling the fixture pre-positioning mechanism 510 to arrange the multiple fixtures.

[0126] In steps S1-2-6, the die-cast seat is finished by removing impurities and grinding using appropriate processing tools or devices. The outer end of the fixing part 222 of the fixing part 22 is cut or ground to remove the thin aluminum alloy layer that is attached to the outer end of the fixing part 222 due to mold allowance or other reasons, so as to avoid the thin aluminum alloy layer affecting the subsequent welding.

[0127] Figure 10 This is a perspective view of the finished disc brake disc mounting bracket in this embodiment. Figure 11 This is a perspective view of the finished disc brake disc mounting bracket from different angles in this embodiment.

[0128] like Figure 10 and Figure 11 As shown, the finished disc brake mounting base 20 includes a base body 21 and a fastener 22. A part of the fastener 22 is integrated into the base body 21, that is, the base body 21 covers the fastener 22, thus achieving a tight bond between two metals of different materials.

[0129] The base 21 is generally cylindrical with a missing corner, and can be divided into a support and positioning part 211 and a mating part 212 along its length. The base 21 also has mounting holes 213 for fixing the disc brake disc.

[0130] The support and positioning part 211 is generally rectangular in shape, and the outer contour of its cross-section along the length of the seat body 21 is a rectangle with rounded corners. The outer end of the support and positioning part 211 has a positioning end face 2111 for supporting and positioning the edge of the disc brake disc. The positioning end face 2111 is a plane, which is perpendicular to the length direction of the seat body 21.

[0131] The support and positioning part 211 is generally rectangular in shape, and the outer contour of its cross-section along the length of the seat body 21 is a rectangle with rounded corners. The outer end of the support and positioning part 211 has a positioning end face 2111 for supporting and positioning the edge of the disc brake disc. The positioning end face 2111 is a plane, which is perpendicular to the length direction of the seat body 21.

[0132] The mating part 212 is an irregularly shaped block extending from one end of the support and positioning part 211. Along the thickness direction of the seat body 21, the cross-sectional shape of one side of the mating part 212 matches that of the support and positioning part 211, while the other side has a mating notch 2121 and a receiving groove 2122. The mating notch 2121 has a mating surface 21211 facing the inside of the rim. The mating surface 21211 is approximately a bent U-shaped surface, and the bending shape of the mating surface 21211 matches the shape of the inner side of the rim flange and the bead seat portion. The receiving groove 2122 is a strip-shaped groove extending along the length direction of the seat body 21, and its opening communicates with the mating notch 2121.

[0133] In this embodiment, compared with the shape of the bead seat and the inner side of the rim body, the surface shape of the mating notch 2121 is more gentle, and the curvature of each part on the surface is relatively smaller. When the disc brake mounting seat 20 is set on the rim, there is a certain gap between the surface of the mating notch 2121 and the bead seat and the inner side of the rim.

[0134] The rim fixing portion 222a of the fastener 22 extends from the side of the mating portion 212 of the seat body 21 near the support positioning portion 211, and is located on the same side as the mating notch 2121. The surface direction of the rim fixing portion 222a is approximately perpendicular to the length direction of the seat body 21. The groove bottom fixing portion 222b extends from the outer end of the mating portion 212 of the seat body 21, and the surface direction of the groove bottom fixing portion 222b is approximately perpendicular to the thickness direction of the seat body 21.

[0135] Through the above steps S1-2, multiple disc brake mounting brackets 20 are manufactured.

[0136] As one example, the base 21 in this embodiment is a square column with a missing corner. In an alternative, the base 21 can also be a cylindrical column with a missing corner, a polygonal column with a missing corner, or a composite column with a missing corner (for example, one side is a semi-cylindrical column and the other side is a cuboid column), as long as the positioning end face 2111 has a sufficient area, the base 21 has enough space to provide the above-mentioned mounting hole 213, and the mounting hole 213 has sufficient thickness from the circumference to the outer surface of the base 21.

[0137] Steps S1-3 involve fixing multiple disc brake mounting brackets to predetermined positions on the rim body to form the rim.

[0138] Figure 12 This is a flowchart illustrating the process of forming the wheel rim by welding in this embodiment.

[0139] like Figure 12 As shown, steps S1-3 specifically include the following sub-steps:

[0140] Step S1-3-1: Place a disc brake mount onto a predetermined position on the wheel rim body.

[0141] Step S1-3-2: Welding is performed between the fixing part of the fixing member of the disc brake mounting bracket and the predetermined position of the rim body.

[0142] Step S1-3-3: Repeat steps S1-3-1 to S1-3-2 until all predetermined positions on the rim body have been welded with disc brake mounting brackets, thus obtaining the rim.

[0143] In this embodiment, the above steps are performed automatically using a corresponding welding device.

[0144] Figure 13 This is a schematic diagram of the welding device in this embodiment.

[0145] like Figure 13 As shown, the welding device 600 includes a mounting base feeding mechanism 610, a hub positioning mechanism 620, a welding mechanism 630, and a welding control mechanism (not shown in the figure).

[0146] The mounting base feeding mechanism 610 is used to place the disc brake disc mounting bases 20 sequentially at predetermined positions on the rim body (i.e., step S1-3-1). The mounting base feeding mechanism 610 includes a vibratory feeder 611, a feeding channel 612, a feeding seat 613, and a feeding robot 614. The vibratory feeder 611 arranges multiple disordered disc brake disc mounting bases 20 neatly and outputs them sequentially to the feeding channel 612, pushing the multiple disc brake disc mounting bases 20 arranged sequentially on the feeding channel 612 toward the feeding seat 613, wherein the disc brake disc mounting base 20 closest to the feeding seat 613 is pushed onto the feeding seat 613. The feeding seat 613 has a mounting groove that matches the lower part (the part with the matching notch 2121) of the disc brake disc mounting base 20. After the disc brake disc mounting base 20 is pushed onto the feeding seat 613, its lower part is embedded in the mounting groove, and its upper part is exposed, making it easy for the robot to grasp. The feeding robot 614 picks up a disc brake mounting base 20 from the feeding seat 613 and places it on the rim body at the hub positioning mechanism 620 for welding.

[0147] The wheel hub positioning mechanism 620 is used to support and position the wheel rim body to be welded. The wheel hub positioning mechanism 620 includes a liftable and rotatable platform 621 for placing the wheel rim body to be processed and driving it to move up, down, and rotate. The platform 621 has a fitting structure that matches the wheel rim body; the wheel rim body is fitted onto the platform 621 on one axial side, thereby achieving centering of the wheel rim body.

[0148] The aforementioned feeding robot 614, following a predetermined movement path, places a disc brake disc mount 20 onto the rim body of the wheel hub, which is centered on the mounting platform 621, and presses the disc brake disc mount 20 firmly onto the rim body so that the welding mechanism 630 can perform welding. After the welding of the disc brake disc mount 20 is completed, the mounting platform 621 rotates by a predetermined angle, and the feeding robot 614 repeats the above process, thereby welding multiple disc brake disc mounts 20 onto the rim body and distributing them evenly along the circumference of the rim body.

[0149] The welding mechanism 630 includes two welding torches 631, two welding torch supports 632, and a welding torch drive assembly 633. The welding torches 631 are mounted on corresponding welding torch supports 632, which allow the welding torches 631 to have a predetermined tilt angle, thus facilitating welding. In this embodiment, the axial direction of the rim body placed on the mounting platform 621 is vertical, and the welding torches 631 are approximately at a 45-degree angle to the vertical direction. The welding torch drive assembly 633 is used to drive the welding torches 631 to move along a predetermined path and perform welding. In this embodiment, after the welding torch drive assembly 633 drives one welding torch 631 to the rim flange of the rim body and the other welding torch 631 to the bottom of the groove of the rim body, it drives both welding torches 631 to simultaneously weld along two approximately parallel straight lines. Because the size of the welding area between the disc brake mount 20 and the rim 10 is very small relative to the overall size of the wheel hub, although the fixing part 222, the rim, and the bottom of the groove all have a certain curvature, the curvature is not obvious at such a small scale, and straight-line welding can ensure welding quality and strength. In an alternative solution, the welding torch drive assembly 633 can also drive two welding torches 631 to perform arc-shaped welding using the curvature of the rim and the curvature of the sidewall of the groove bottom, respectively.

[0150] The welding control mechanism controls the operation of the mounting base feeding mechanism 610, the wheel hub positioning mechanism 620, and the welding mechanism 630, including: after the mounting base feeding mechanism 610 places a disc brake disc mounting base onto the wheel rim body (i.e., after waiting for a predetermined time), controlling the welding mechanism 630 to perform one welding operation; after one welding operation is completed, controlling the welding mechanism 630 to move the welding torch 631 to a position away from the wheel rim body, and then controlling the platform 621 to rotate the wheel rim body by a predetermined angle (60 degrees in this embodiment), so that the next predetermined position on the wheel rim body faces the feeding base 613; then repeating the above control until the relevant count reaches a predetermined value, that is, completing the welding of all six disc brake disc mounting bases.

[0151] Through the above steps S1-3, the welding and fixing of multiple disc brake mounting brackets can be completed, resulting in a rim that can be used in a disc brake hub.

[0152] In addition, it is worth noting that although it is also possible to first weld multiple fasteners 22 onto the rim body, and then place the entire assembly including the rim body and multiple fasteners 22 into a mold for die casting of the seat 21 to form a rim with roughly the same structure, such a process is relatively complex and the manufacturing efficiency is not as good as the above method.

[0153] Step S2: The positioning end faces of the multiple disc brake mounting seats on the rim are machined so that the multiple positioning end faces are on the same plane perpendicular to the axial direction of the rim.

[0154] The process involves using appropriate fixtures to clamp the wheel rims to be processed onto a CNC machine tool, and then turning the positioning end faces 2111 of each disc brake mounting seat 20's body 21 to make them flatter planes, ensuring that all positioning end faces 2111 of a wheel rim are on the same plane. This process is also known as leveling.

[0155] Step S3: Machining mounting holes for mounting disc brake discs on the seats of the multiple disc brake disc mounting brackets on the rim to accommodate fastening rods.

[0156] Similarly, CNC machine tools are used to drill holes and machine internal threads on the base 21 of each disc brake disc mounting seat 20, thereby forming mounting holes on the base 21. The mounting opening of the mounting hole is located on the positioning end face 2111 of the base 21.

[0157] Figure 14 This is a perspective view of the finished wheel rim in this embodiment, showing the structure of the wheel rim after steps S1 to S3.

[0158] like Figure 14 As shown, the finished wheel rim 10A includes the wheel rim body and multiple disc brake mounting seats 20.

[0159] The rim body includes a groove bottom 11, a bead seat 12, and a rim flange 13. Along the circumference of the rim body, the groove bottom 11 has a roughly trapezoidal groove shape for easy tire installation and removal. Two bead seats 12 are formed on both sides of the groove bottom 11, with a bend between the bead seats 12 and the groove bottom 11. The bead seats 12 support the tire in the radial direction. Two rim flanges 13 are formed on both sides of the two bead seats 12, with a bend between the rim flanges 13 and their corresponding bead seats 12. The two rim flanges 13 are used to clamp the tire bead on both sides to support the tire and maintain its axial direction.

[0160] The rim body is an iron rim, which can be manufactured by existing technology, which generally includes the following steps: rolling and welding an iron strip to form an iron ring, expanding and spinning the iron ring to form the structure used for mounting the tire, and punching valve core holes on the iron ring.

[0161] Multiple disc brake mounts 20 are welded to the rim body, located on the same side of the rim body's axial direction and evenly distributed along its circumference. As described above, the rim fixing portion 222a of the fixing member 22 of each disc brake mount 20 is welded to the rim 13, forming a rim weld portion 41 (i.e., a strip-shaped weld formed by welding material, weld point one) at this location. The groove bottom fixing portion 222b of the fixing member 22 is welded to one side of the groove bottom 11, forming a groove bottom weld portion 42 (weld point two) at this location. The finished rim 10A also includes the rim weld portion 41 and the groove bottom weld portion 42.

[0162] A certain gap is left between the seat body 21 of the disc brake mount 20 and the inner side of the rim body. The length direction of the seat body 21 is consistent with the axial direction of the rim body, and the thickness direction of the seat body 21 is consistent with the radial direction of the rim body. The positioning end face 2111 of the seat body 21 is flat and perpendicular to the axial direction of the rim 10. In the axial direction of the rim body, the support and positioning part 211 of the seat body 21 is located outside the rim 10, so the positioning end face 2111 is also located outside the rim 10, thus it can be used to install disc brake discs with an outer diameter close to the diameter of the rim body. In the radial direction of the rim body, the seat body 21 does not exceed the outermost end of the rim body (the outer end of the rim flange 13), so it will not affect the installation of the tire. The positioning end faces 2111 of multiple disc brake mounts 20 are coplanar, thereby stably supporting and positioning the disc brake disc.

[0163] Step S4: Press the spokes into the inner ring of the rim and fix the spokes to the rim to obtain the disc brake hub.

[0164] In this embodiment, the wheel spoke includes a spoke body and multiple inserts. The spoke body is integrally cast from a third material and includes a central spoke plate portion and multiple spokes extending radially outward from the edge of the spoke plate portion. An insert is embedded at the outer end of each spoke. The insert is made of iron, with one end protruding outside the outer end of the spoke, for welding to the iron rim body.

[0165] In step S4, the spokes are press-fitted into the inner ring of the finished wheel rim 10A using a corresponding press-fit welding device, and the exposed portions of the inserts at the ends of each spoke are welded to the center of the groove bottom of the wheel rim body. The structure of the spokes, the spoke manufacturing method, and the structure of the corresponding press-fit welding device are all existing technologies, and therefore will not be described in detail.

[0166] Figure 15 This is a perspective view of the finished disc brake hub and disc brake disc in this embodiment. Figure 16 This is a cross-sectional view of the finished disc brake hub and disc brake disc in this embodiment. Figure 17 yes Figure 16 A magnified view of the area inside circle A.

[0167] like Figures 15 to 17As shown, the finished disc brake hub 100 includes the aforementioned disc brake hub 10A and spokes 30.

[0168] The spokes 30 are fixed to the inner ring of the rim 10 and serve to support the finished rim 10A. The spokes 30 include a central spoke plate portion and multiple spokes extending radially outward from the edge of the spoke plate portion. The outer end of each spoke is fixed to the inner center of the groove bottom 11 of the rim body, providing support for the rim 10 and thus forming an integral hub. Iron inserts are pre-embedded at the outer ends of each spoke of the spokes 30, and are welded to the inner center of the groove bottom 11 via the inserts. The specific structure of the spokes 30 is prior art and will not be described further.

[0169] The disc brake disc 200 is annular in shape, with an outer diameter close to that of the finished wheel rim 10A. The inner ring of the disc brake disc 200 has multiple friction holes 201, which are clamped by the corresponding brake unit to achieve braking. The friction holes 201 increase friction during clamping. The outer ring of the disc brake disc 200 has six fixing holes 202 for mounting on the respective disc brake mounting seats 20 of the finished wheel rim 10A via corresponding fastening rods.

[0170] like Figure 17 As shown, after drilling, the seat 21 further has a mounting hole 213 (threaded hole) for engaging with a corresponding fastening rod to fix the edge of the disc brake disc 200 onto the seat 21. The mounting hole 213 is a threaded countersunk hole extending along the length of the seat 21. One end of the mounting hole 213 is a mounting opening located at the positioning end face 2111, and the other end of the mounting hole 213 is a through opening located on one side of the extending direction of the receiving groove 2122 and communicating with the receiving groove 2122. The groove width of the receiving groove 2122 is greater than the diameter of the tail of the threaded rod.

[0171] Along the axial direction of the mounting hole 213, the mounting hole 213 includes a first hole portion, a second hole portion, and a third hole portion connected in sequence. The first hole portion is a shallow tapered hole, with its larger diameter end serving as the mounting opening. The second hole portion is a circular hole, with its diameter essentially the same as the smaller diameter end of the first hole portion, and its depth greater than that of the first hole portion. The third hole portion is a threaded circular hole with threads on its inner surface. The depth of the third hole portion is much greater than that of the second hole portion, and one end of the third hole portion is a through opening.

[0172] The fastening rod that matches the mounting hole 213 is a screw rod with a nut.

[0173] Along the length of the base 21, the mounting hole 213 passes through the cutout portion 2214a of the fastener 22. That is, by providing the cutout portion 2214a, the structure of the fastener 22 avoids the position (punched position) of the mounting hole 213 on the base 21, and the structure of the fastener 22 forms a three-sided enclosure around the lower part of the mounting hole 213.

[0174] The face of the rim fixing part 222a of the fastener 22 is in contact with the outer end of the rim 13 in the axial direction of the rim 10, and welding is performed between the outer end face of the rim fixing part 222a and the outer end of the rim 13 to form a strip-shaped rim welding part 41 (welding point 1).

[0175] The surface direction of the groove bottom fixing part 222b is perpendicular to the radial direction of the rim 10. Therefore, the outer end face of the groove bottom fixing part 222b is perpendicular to the axial direction of the rim 10. The inner side of the groove bottom 11 is inclined relative to the outer end face of the groove bottom fixing part 222b. Therefore, one side of the outer end face of the groove bottom fixing part 222b contacts one inner side of the groove bottom 11. The other side of the outer end face of the groove bottom fixing part 222b forms a gap with the inner side of the groove bottom 11. The outer end face of the groove bottom fixing part 222b and the inner side of the groove bottom 11 are welded together using this gap to form a strip-shaped groove bottom welded part 42 (welding point two).

[0176] The mounting hole 213 on the base 21 passes through the cutout on the fastener 22, so punching will not affect the shape of the fastener 22 or the bonding strength between the fastener 22 and the base 21. When installing the disc brake disc 200, the screw portion of the fastening rod 300 can also pass through the cutout on the fastener 22, and the outer end of the screw can be accommodated in the receiving groove of the base 21, so a longer screw can be used.

[0177] By following the steps above, a disc brake hub 100 that can be fitted with a disc brake disc can be obtained.

[0178] Functions and effects of Example 1

[0179] According to the rim manufacturing method and disc brake hub manufacturing method provided in this embodiment, the rim manufacturing method includes the steps of manufacturing a fastener of a first material, forming a seat of a second material that is combined with the fastener, and fixing a disc brake disc mounting seat including the fastener and the seat to the rim body; the disc brake hub manufacturing method includes the steps of combining the spokes with the rim, leveling the positioning end faces of multiple disc brake disc mounting seats, and machining mounting holes on the seat. Since the seat is fixed to the rim body by the fastener, the seat and the rim body can be made of different materials, greatly expanding the range of usable materials for the seat. Materials with lower hardness, easier processing, and higher processing precision can be selected to manufacture the seat, making the manufacturing of the seat, the leveling of the positioning end faces of the seat, and the machining of mounting holes on the seat more efficient and precise. This results in higher processing efficiency for the disc brake hub, better positioning accuracy of the finished disc brake hub for the disc brake disc, better braking performance, and helps alleviate the aforementioned abnormal noise problem.

[0180] In this embodiment, the seat body is made of aluminum alloy, while the fixing parts and rims are made of iron. Therefore, the seat body has a lower hardness than iron, making it easier to process and achieve the desired machining accuracy. This results in higher precision on the positioning end face of the seat body, which helps avoid or alleviate the aforementioned abnormal noise problem. Furthermore, die casting allows for efficient manufacturing of the aluminum alloy seat body, and also results in a more aesthetically pleasing appearance.

[0181] Furthermore, the disc brake disc is also made of iron, and the hardness of the seat material is less than that of the disc brake disc. Therefore, during braking, especially during emergency braking, the support and positioning part of the seat can maintain better and more stable contact with the disc brake disc. The relatively soft seat material can play a certain buffering role, which can effectively avoid the above-mentioned abnormal noise problem, improve the user experience, and avoid driving safety problems caused by the tension and irritability of the user due to abnormal noise.

[0182] Furthermore, the process of forming iron fasteners through stamping is mature, reliable, and highly efficient. In particular, the structure of the stamping device in the embodiment allows for the completion of one-time cutting, one-time longitudinal pressing, one-time secondary longitudinal pressing, and one-time cutting at different locations on the iron strip sheet in a single stamping operation. Continuous iron strip sheets can be continuously fed to the stamping device, which then continuously stamps and produces fasteners, resulting in very high processing efficiency.

[0183] Furthermore, the seat body, which is integrated with the fasteners, is formed by die casting, and the die casting mold has multiple seat body cavities, thus enabling efficient manufacturing of the seat body. In particular, in this embodiment, multiple fasteners are automatically arranged by a robotic arm and corresponding pre-positioned fasteners, and then the arranged fasteners are placed into the die casting mold at once by an industrial robotic arm. The manufactured disc brake mounting seats are also removed at once by an industrial robotic arm. Therefore, not only is the manufacturing efficiency of the seat body higher, but a fully automated die casting process can also be realized, avoiding workers' contact with the high-temperature die casting machine and mold, and improving production safety.

[0184] Furthermore, by using a welding device to place the disc brake disc mounting bracket onto the rim of the wheel hub body and perform welding, automated welding can be achieved, saving manpower and increasing production efficiency. In addition, the welding device in this embodiment centers the wheel hub body to be processed through its wheel hub positioning mechanism, and then, in conjunction with a rotary table and a robotic arm, places the disc brake disc mounting bracket, resulting in higher positional accuracy between the disc brake disc mounting bracket and the wheel hub body. Furthermore, because the welding area is relatively small, simultaneous linear welding using two welding torches simplifies automation control and increases welding efficiency while ensuring welding strength.

[0185] Furthermore, CNC machine tools are used to level the positioning end faces of multiple disc brake disc mounting seats on the wheel rim and to machine mounting holes on the seat body. CNC machine tools have high machining accuracy and stable machining quality, thus enabling the positioning end faces and mounting holes to have higher precision.

[0186] Furthermore, since the fastener has a hollowed-out portion, the fastener will not be touched at all when the punching and tapping device is processing the mounting hole. This avoids the punching process affecting the shape of the fastener or the bonding strength between the fastener and the seat. When installing the fastening rod, the fastening rod can also pass through the hollowed-out portion, thus avoiding the limitation on the size of the fastening rod. A longer fastening rod can be used to ensure the firmness of the disc brake disc installation.

[0187] <Example 2>

[0188] This embodiment provides a method for manufacturing a disc brake hub. In this embodiment, the same symbols are assigned to the same constituent elements as in Embodiment 1, and the corresponding descriptions are omitted.

[0189] Compared with Embodiment 1, the difference lies in the fact that the process steps of the disc brake hub manufacturing method in this embodiment are different from those in Embodiment 1.

[0190] Figure 18 This is a flowchart of the disc brake wheel hub manufacturing method in this embodiment.

[0191] like Figure 18 As shown, the disc brake wheel hub manufacturing method of this embodiment includes the following steps:

[0192] Step S1': Manufacture a rim with multiple disc brake mounts.

[0193] Step S2': Press the spokes into the inner ring of the rim and fix the spokes to the rim.

[0194] Step S3': The positioning end faces of the multiple disc brake mounting seats of the wheel rim are machined so that the multiple positioning end faces are coplanar and perpendicular to the axial direction of the wheel rim.

[0195] Step S4': Machining mounting holes for mounting the disc brake discs are made on the seat of the plurality of disc brake disc mounting seats of the rim, thereby obtaining the disc brake hub.

[0196] That is, compared with the first embodiment, the steps of S2 to S4 have been adjusted. In this embodiment, the spokes and rim are welded together first, and then the disc brake disc mounting base is further leveled and punched.

[0197] In this embodiment, the other structures and corresponding methods are the same as in Embodiment 1, so they will not be described again.

[0198] Functions and effects of Example 2

[0199] Based on the rim manufacturing method and disc brake hub manufacturing method provided in this embodiment, and building upon the effects of Embodiment 1, the positioning end faces of the multiple disc brake disc mounting seats are leveled and the mounting holes are punched after the rim and spokes are welded together first. This results in higher precision of the positioning end faces, better support and positioning of the disc brake discs, improved braking performance, and further prevention or mitigation of the aforementioned abnormal noise problem. Specifically, during the welding of the rim and spokes, the high temperature of the welding and subsequent cooling cause thermal expansion and contraction of the rim, affecting its precision and consequently the mounting seats on the rim. In this embodiment, further processing of the mounting seats is performed after the rim and spokes are welded together, effectively avoiding or reducing the impact of thermal expansion and contraction on the precision of the positioning end faces of the mounting seats.

[0200] <Example 3>

[0201] This embodiment provides a method for manufacturing a disc brake hub. In this embodiment, the same symbols are assigned to the same constituent elements as in Embodiment 1, and the corresponding descriptions are omitted.

[0202] Compared to Embodiment 1, the difference lies in that the spokes in this embodiment are iron spokes formed by welding multiple iron components together. These spokes also have a spoke plate portion and multiple spokes, and the ends of each spoke can be directly welded to the rim body.

[0203] In this embodiment, the other structures and corresponding methods are the same as in Embodiment 1, so they will not be described again.

[0204] Alternatively, the spokes in Embodiment 2 can be replaced with the spokes of this embodiment.

[0205] Functions and effects of Example 3

[0206] Based on the rim manufacturing method and disc brake hub manufacturing method provided in this embodiment, and the effects of Embodiment 1, since the spokes are made of iron, they can be directly welded to the rim, making processing more convenient. Although the iron spokes are not as aesthetically pleasing as the aluminum alloy spokes of Embodiment 1, they are stronger and cheaper, making them suitable for scenarios with corresponding needs.

[0207] <Example 4>

[0208] This embodiment provides a method for manufacturing a disc brake hub. In this embodiment, the same symbols are assigned to the same constituent elements as in Embodiment 1, and the corresponding descriptions are omitted.

[0209] The difference between this embodiment and the first embodiment is that the structure of the fastener is different.

[0210] Figure 19 This is a perspective view of the fastener in this embodiment.

[0211] like Figure 19 As shown, the overall shape of the disc brake mounting base 20 in this embodiment is the same as that in Embodiment 1, but the fixing member 22 is a separate fixing member.

[0212] Specifically, the fastener 22 in this embodiment includes a first sheet 223 and a second sheet 224 that are separated from each other and formed by processing a first sheet and a second sheet, respectively. The surface directions of the first sheet 223 and the second sheet 224 are approximately perpendicular, and the first sheet 223 and the second sheet 224 are arranged to form an L shape.

[0213] The first sheet-like component 223 is U-shaped and includes a first connecting portion 2231 and a first fixing portion 2232.

[0214] The first joint portion 2231 is also U-shaped, having one first clearance notch 22311 and two first joint notches 22312. The first clearance notch 22311 is located at one end in the length direction and the middle in the width direction of the first sheet 223. It is relatively large, with its depth and width slightly smaller than the length and width of the first joint portion 2231, respectively. Its opening direction is consistent with the length direction of the first sheet 223. The two first joint notches 22312 are smaller and symmetrically arranged on both sides of the width direction of the first joint portion 2231. Their opening direction is consistent with the width direction of the first sheet 223. The corners of both the first clearance notch 22311 and the first joint notches 22312 are rounded. The two ends of the first joint portion 2231 are roughly rectangular sheets with rounded corners.

[0215] The first connecting portion 2231 is enclosed within the connecting and mating portion 212 of the base body 21 and is located near the support and positioning portion 211. The surface direction of the first connecting portion 2231 is perpendicular to the length direction of the base body 21. The mounting hole 213 on the base body 21 passes through the first clearance notch 22311 on the first connecting portion 2231, and the depth of the first clearance notch 22311 is greater than the diameter of the mounting hole 213.

[0216] The first fixing part 2232 extends from one end of the U-shaped bottom of the first connecting part 2231. The length direction of the first fixing part 2232 is consistent with the U-shaped opening direction of the first connecting part 2231, and the length of the first fixing part 2232 is the same as the width of that end of the first connecting part 2231. The first fixing part 2232 is used as the rim fixing part 222a, and its structure is the same as that of the rim fixing part 222a in Embodiment 1.

[0217] The second piece 224 is also U-shaped, and includes a second connecting part 2241 and a second fixing part 2242.

[0218] The second connecting portion 2241 is also U-shaped, having a central connecting notch 22411 and two second connecting notches 22412. The central connecting notch 22411 serves as the hollow portion described in Embodiment 1. It is located at one end of the second sheet-like member 224 in the length direction and in the middle of its width direction. It is relatively large, with its depth and width slightly smaller than the length and width of the second connecting portion 2241, respectively. Its opening direction is consistent with the length direction of the second sheet-like member 224. The two second connecting notches 22412 are smaller and symmetrically arranged on both sides of the second connecting portion 2241 in the width direction. Their opening direction is consistent with the width direction of the second sheet-like member 224. Both corners of the central connecting notch 22411 and the second connecting notch 22412 are rounded. The two ends of the second connecting portion 2241 are approximately rectangular sheets with rounded corners.

[0219] The second joint 2241 is enclosed inside the joint mating part 212 of the seat 21 and is located next to the mating notch 2121. The surface direction of the second joint 2241 is perpendicular to the thickness direction of the seat 21.

[0220] The second fixing part 2242 extends from one end of the U-shaped bottom of the second connecting part 2241. The length direction of the second fixing part 2242 is consistent with the U-shaped opening direction of the second connecting part 2241, and the length of the second fixing part 2242 is the same as the width of that end of the second connecting part 2241. The second fixing part 2242 is used as the bottom fixing part 222b of the groove, and its structure is the same as that of the bottom fixing part 222b in Embodiment 1, that is, its width is greater than the width of the first fixing part 2232.

[0221] That is, the overall structure of the first piece 223 and the second piece 224 is very similar, but the functions of the first clearance notch 22311 and the middle joining notch 22411 are different. In addition, the structure of the first piece 223 and the second piece 224 is also very similar to the structure of the two ends of the fastener 22 along the bending direction in Embodiment 1.

[0222] Furthermore, the second piece 224 has a small curvature, which is basically consistent with the curvature of the inner side of the bead seat 12. Similarly, the second piece 224 may also be flat and without this curvature.

[0223] That is, the fastener 22 in this embodiment includes a flat first sheet 223 and a second sheet 224 with a very small curvature or also being flat.

[0224] Figure 20 This is a flowchart of the process of stamping the fastener in this embodiment.

[0225] like Figure 20 As shown, step S1-1 in this embodiment includes the following sub-steps:

[0226] Step S1-1-1': A first outer contour groove corresponding to the outer contour of the first sheet is punched out on the flat first sheet, thereby forming a fourth semi-finished sheet connected to the first connecting piece.

[0227] Step S1-1-2': Cut the fourth semi-finished piece and the first connecting piece to obtain the first piece.

[0228] Step S1-1-3': A second outer contour groove corresponding to the outer contour of the second sheet is punched out on the flat second sheet, thereby forming a fifth semi-finished sheet connected to the second connecting piece.

[0229] Step S1-1-4' involves longitudinally pressing the fifth semi-finished sheet to achieve the aforementioned curvature. This step can be omitted if the second sheet 224 is also a flat sheet.

[0230] Step S1-1-5': Cut the fifth semi-finished piece and the second connecting piece to obtain the second piece.

[0231] Understandably, the above steps S1-1-1' to S1-1-3' and steps S1-1-4' to S1-1-5' can be performed simultaneously by two stamping devices to improve processing efficiency.

[0232] It is evident that the fastener 22 in this embodiment does not require two additional longitudinal pressing processes.

[0233] In steps S1-2, the structure of the predetermined seat 513 in the die-casting apparatus 500 differs from that in Embodiment 1. It requires supporting the first sheet 223 and the second sheet 224 respectively to form the desired shape. Figure 19 The L-shaped arrangement is shown.

[0234] Since the overall shape of the disc brake mounting base 20 in this embodiment is the same as that in Embodiment 1, the subsequent steps S1-3, S2-1 to S2-3 are the same as those in Embodiment 1.

[0235] In this embodiment, the other structures and corresponding methods are the same as in Embodiment 1, so they will not be described again.

[0236] Furthermore, the fastener of this embodiment can also be used in the methods of Embodiments 2 and 3.

[0237] Functions and effects of Example 4

[0238] Based on the rim manufacturing method and disc brake hub manufacturing method provided in this embodiment, and building upon the effects of Embodiment 1, the use of a split-type fastener eliminates the need for two longitudinal pressing processes in the fastener manufacturing, making the fastener manufacturing process more convenient and faster.

[0239] Furthermore, the overall shapes of the first and second pieces are very similar, and the first clearance notch and the middle joining notch, which are basically the same in shape, are used to achieve different functions. Through such ingenious design, the processing difficulty can be further reduced and the production efficiency can be improved while meeting the functional requirements.

[0240] Furthermore, since the first and second plate-shaped parts are two independent components, the distance between them can be adjusted as needed. This allows the fastener to be used with rims of different sizes and / or seats of different sizes. In other words, the same fastener can be used when manufacturing various models of disc brake hubs. Only different fastener pre-positioned seats are needed to make the distance between the two plate-shaped parts different. Therefore, the fastener has a wider range of applications, is more convenient to operate during production changeovers, and has higher production efficiency.

[0241] <Example 5>

[0242] This embodiment provides a method for manufacturing a disc brake wheel hub. In this embodiment, the same symbols are assigned to the same constituent elements as in Embodiment 1, and the corresponding descriptions are omitted.

[0243] Compared with Embodiment 1, the difference lies in the structure of the fastener in this embodiment. The structure of the metal sheet is as follows: the metal sheet includes two vertical sidewalls and a horizontal sidewall connecting the two vertical sidewalls. A perforated groove is formed on either the vertical or horizontal sidewall. The two vertical sidewalls and one horizontal sidewall form a flat U-shaped body, with the opening of the U-shaped body facing the sidewall of the rim. The threaded seat covers the horizontal sidewall. The two vertical sidewalls abut against the outer surface of the bead seat of the rim. The portions of the two vertical sidewalls that abut against the rim are exposed outside the threaded seat. The ends of the two vertical sidewalls are welded to the outer surface of the bead seat of the rim, forming a weld joint.

[0244] Figure 21 This is a perspective view of the fastener in this embodiment.

[0245] like Figure 21 As shown, the fastener 22 (connector) of this embodiment is integrally formed from a bent sheet (metal sheet) and has an axisymmetric structure. Its cross-section along the axial direction of the rim 10 is U-shaped, and the opening of the U faces the bead seat 12 of the rim 10. The fastener 22 includes a connecting part 221 and two fixing parts 222.

[0246] The connecting portion 221 is located in the middle of the bending direction of the entire fastener 22. It is in the shape of a bent plate, and its axial cross-section of the rim 10 is also U-shaped. The width of the middle part of the connecting portion 221 in the bending direction is smaller than the width of the two ends. The middle part of the connecting portion 221 is generally flat and plate-shaped (i.e., a transverse sidewall) and has a rectangular central hole 2214 for use as a connecting hole. The two ends of the connecting portion 221 each have rectangular end connecting holes 2216.

[0247] Two fixing portions 222 extend from both ends of the bending direction of the connecting portion 221. The fixing portions 222 are rectangular plates, with their surface direction aligned with the surface direction of the corresponding end of the connecting portion 221, and their length being the same as the width of the corresponding end of the connecting portion 221. Both fixing portions 222 serve as bead seat fixing portions 222c. The straight ends of the fixing portions 222 on the sides corresponding to the connecting portion 221 form vertical sidewalls.

[0248] The outer end faces of the two bead seat fixing parts 222c are in contact with the inner side of the bead seat 12 of the rim 10, and the outer side of the outer end of each bead seat fixing part 222c is welded to the inner side of the bead seat 12 to form two strip-shaped bead seat welding parts 43 (welding point four).

[0249] The surface direction of the middle part of the joint 221 is perpendicular to the radial direction of the rim 10, so that the thickness direction of the seat 21 is consistent with the radial direction of the rim 10.

[0250] The aforementioned hollow portion is formed by the connecting part 221 and the two fixing parts 222 surrounding it. The lower part of the mounting hole 213 on the base 21 is located in the space surrounded by the connecting part 221 and the two fixing parts 222, and the lower part of the fastening rod 300 can also pass through this space.

[0251] Step S1-1 in this embodiment is basically the same as in Embodiment 1. The only difference is that the first longitudinal pressing upper module 414 and the first longitudinal pressing lower module 424 of the stamping device 400 give the sheet a bending structure corresponding to the above-mentioned fixing member 22, but the bending angle is greater than that of the fixing member 22; the second longitudinal pressing upper module 415 and the second longitudinal pressing lower module 425 give the sheet a bending structure corresponding to the above-mentioned fixing member 22 and with the same bending angle.

[0252] In step S2-1, the welding torch drive assembly 633 drives the two welding torches 631 to move to the positions where the two fixing parts 222 of the fixing member 22 contact the tire bead seat 12, and simultaneously drives the welding torches 631 to move in a straight line in the vertical direction to perform linear welding.

[0253] In this embodiment, the other structures and corresponding methods are the same as in Embodiment 1, so they will not be described again.

[0254] Furthermore, the fastener of this embodiment can also be used in the methods of Embodiments 2 and 3.

[0255] Functions and effects of Example 5

[0256] Based on the rim manufacturing method and disc brake hub manufacturing method provided in this embodiment, and building upon the effects of Embodiment 1, the fastener adopts the above-mentioned structure, making it easier to place and position the fastener in the die-casting mold, thereby further improving production efficiency.

[0257] The above embodiments are merely illustrative of specific implementations of the present invention, and the present invention is not limited to the scope of the description of the above embodiments. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are only for illustrating the principles of the present invention. Various changes and modifications can be made to the present invention without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing a wheel rim, used to manufacture a wheel rim in a disc brake hub capable of mounting a disc brake disc, characterized in that, Includes the following steps: Step S1-1: Manufacture multiple fasteners made of the first material; Step S1-2: Multiple seats made of a second material are formed by casting and are combined with each of the fixing components. The multiple seats and the corresponding fixing components constitute multiple disc brake mounting seats. Steps S1-3 involve fixing the plurality of disc brake mounting brackets to multiple predetermined positions on the rim body, thereby forming the rim. The fastener has the following features: One or more connecting portions, which are engaged with the seat body; and One or more fixing parts protrude from the seat body and are fixed to the corresponding predetermined positions on the rim. The seat body has: The mating part engages with the fixing part and mates with the wheel rim; and The support and positioning part has a positioning end face for supporting and positioning the disc brake disc; In steps S1-3, the plurality of disc brake mounting seats are placed at the predetermined positions on the rim body, and the fixing part of the fixing member of each disc brake mounting seat is welded to the corresponding predetermined position to form the rim. The first material is iron. The fastener includes one or more sheet-like components. In step S1-1, the fastener is manufactured by stamping. The second material is any one of aluminum alloy, magnesium alloy, aluminum-magnesium alloy, copper alloy, copper-zinc alloy, or industrial plastic. The base is a column with a missing corner. In steps S1-2, the base is formed by die casting.

2. The rim manufacturing method according to claim 1, characterized in that: in, The fastener is integrally formed from a bent sheet, and has a central hole in its center. Step S1-1 includes the following sub-steps: Step S1-1-1: Punch out through holes corresponding to the central hole and outer contour grooves corresponding to the outer contour of the fastener on a flat sheet, thereby forming the first semi-finished sheet connected to the connecting piece. Step S1-1-2: The first semi-finished sheet is subjected to longitudinal pressing to form a bent second semi-finished sheet connected to the connecting piece; Step S1-1-3: Perform secondary longitudinal pressing on the second semi-finished sheet to form a third semi-finished sheet whose bending angle on the connecting piece is consistent with the bending angle of the fastener. Step S1-1-4: Cut the third semi-finished piece and the connecting piece to obtain the fastener.

3. The rim manufacturing method according to claim 2, characterized in that: in, In step S1-1, the stamping process is performed using a stamping device. The stamping device includes a matching upper die mechanism and a lower die mechanism. The upper die mechanism includes a punching upper die assembly, a first longitudinal pressing upper die assembly, a second longitudinal pressing upper die assembly, and a cutting upper die assembly. The lower die mechanism includes a punching-cooperating lower die assembly that cooperates with the upper punching die assembly to perform the punching, a first longitudinal pressing-cooperating lower die assembly that cooperates with the first longitudinal pressing-forming upper die assembly to perform the first longitudinal pressing-forming, a second longitudinal pressing-cooperating lower die assembly that cooperates with the second longitudinal pressing-forming upper die assembly to perform the second longitudinal pressing-forming, and a cutting-cooperating lower die assembly that cooperates with the upper cutting die assembly to perform the cutting. When the upper die mechanism and the lower die mechanism cooperate to perform a stamping, they complete one punching, one first longitudinal pressing, one second longitudinal pressing, and one cutting at different positions on the sheet.

4. The rim manufacturing method according to claim 1, characterized in that: in, The fastener includes a first sheet and a second sheet, both U-shaped. The second piece has a curvature corresponding to the rim body. Step S1-1 includes the following sub-steps: Step S1-1-1': A first outer contour groove corresponding to the outer contour of the first sheet is punched out on the flat first sheet, thereby forming a fourth semi-finished sheet connected to the first connecting piece. Step S1-1-2': Cut the fourth semi-finished piece and the first connecting piece to obtain the first sheet-like part; Step S1-1-3': A second outer contour groove corresponding to the outer contour of the second sheet is punched out on the flat second sheet, thereby forming a fifth semi-finished sheet connected to the second connecting piece; Step S1-1-4': The fifth semi-finished product sheet is longitudinally pressed to give it the curvature; Step S1-1-5': Cut the fifth semi-finished piece and the second connecting piece to obtain the second sheet-like component.

5. The rim manufacturing method according to claim 1, characterized in that: in, In steps S1-2, the base body is formed by die casting using a die casting device. The die-casting apparatus includes a die-casting machine and a die-casting mold. The die-casting mold includes a fixed mold and a movable mold. One of the fixed mold and the movable mold has a plurality of first seat grooves and a positioning groove located on one side of each of the first seat grooves. The other of the fixed mold and the movable mold has a plurality of second seat grooves corresponding to the first seat grooves, for combining with the corresponding first seat grooves to form a seat cavity. Step S1-2 includes the following sub-steps: Step S1-2-1: Arrange the plurality of fasteners in a configuration corresponding to the plurality of first seat grooves; Step S1-2-2: Place the arranged plurality of fasteners into the plurality of first seat grooves, and make the fixing part of the fasteners embed into the corresponding positioning groove; Step S1-2-3: The die-casting machine closes the die-casting mold and injects the second material into the multiple seat cavities for die casting to form the seat of the disc brake mounting base; Step S1-2-4: The die-casting machine opens the die-casting mold; Step S1-2-5: Remove the plurality of disc brake mounting seats from the die-casting mold.

6. A method for manufacturing a disc brake hub, used to manufacture a disc brake hub capable of mounting a disc brake disc, characterized in that, Includes the following steps: Step S1: Manufacture a rim with multiple disc brake mounting brackets; Step S2: The positioning end faces of the seats of the plurality of disc brake mounting bases are machined so that the plurality of positioning end faces are coplanar and perpendicular to the axial direction of the wheel rim. Step S3: Machining mounting holes for mounting the disc brake discs on the base of the plurality of disc brake mounting seats; Step S4: Fix the spokes to the rim to obtain the disc brake hub. In step S1, the rim is manufactured by the rim manufacturing method as described in any one of claims 1-5.

7. The method for manufacturing a disc brake wheel hub according to claim 6, characterized in that: in, The spokes are made of a third material. The spokes have: Multiple spokes; and Multiple inserts are respectively embedded at the outer end of each of the spokes. The insert is made of a material that can be welded to the rim body and is welded to the inner middle part of the rim body.

8. The method for manufacturing a disc brake wheel hub according to claim 6, characterized in that: in, The spokes are made of a material that can be welded to the rim body. The wheel spokes have multiple spokes. The outer ends of the plurality of spokes are respectively welded to the inner middle of the rim body.

9. A method for manufacturing a disc brake hub, used to manufacture a disc brake hub capable of mounting a disc brake disc, characterized in that, Includes the following steps: Step S1': Manufacture a rim with multiple disc brake mounting brackets; Step S2': Fix the spokes to the rim; Step S3': The positioning end faces of the seats of the plurality of disc brake mounting brackets are machined so that the plurality of positioning end faces are coplanar and perpendicular to the axial direction of the wheel rim; Step S4': Mounting holes for mounting the disc brake discs are machined on the base of the plurality of disc brake mounting seats, thereby obtaining the disc brake hub. In step S1', the rim is manufactured by the rim manufacturing method as described in any one of claims 1-5.

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