Brake assembly body structure and manufacturing method of brake clamp hanging bracket

Abstract

The invention discloses a brake assembly body structure and a brake clamp hanging bracket manufacturing method. The method comprises the steps that tolerance parameters and stress bearing limiting parameters in the mounting height direction are determined according to a digital model; according to the brake assembly body structure in the digital model, the stress direction and the structural shape of the brake clamp hanging bracket are determined; according to the relation between the brake clamp hanging bracket and the air cylinder and the relation between the brake clamp hanging bracket and the brake disc, space structure size limiting parameters of the brake clamp hanging bracket are determined; establishing a three-dimensional model of the brake clamp hanging bracket structure according to the space structure size limiting parameter, the stress bearing limiting parameter, the stress direction of the brake clamp hanging bracket, the structural shape of the brake clamp hanging bracket and the tolerance parameter; and according to the three-dimensional model of the brake clamp hanging bracket structure and the composite material laying layer design rule, generating a laying layer design scheme of the brake clamp hanging bracket structure. The fatigue resistance and the corrosion resistance of the brake clamp are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of rail transit vehicles and brake systems thereof, and in particular to a brake assembly structure and a method for manufacturing a brake clamp hanger. Background Art

[0002] With the rapid development of the rail transit industry, the demand for rail transit vehicles is gradually increasing. For this reason, the rail transit industry is constantly innovating in technology to make rail trains lighter, so that rail trains can achieve lower energy consumption, faster running speed, higher carrying capacity, stronger protection, longer life cycle and convenient maintenance.

[0003] At present, carbon fiber materials, as a new type of light, high-strength and high-rigidity material, are widely used in the lightweighting of rail trains. The brake caliper unit is an important component of the disc brake device, which consists of three parts: a follower device, a brake caliper and a brake cylinder. As a key component of the braking system, the brake caliper unit plays a vital role in the safety of train operation. In addition, since a single brake caliper unit is heavy, a group of trains need to be equipped with multiple groups of brake caliper units. Therefore, achieving the lightweighting of the brake caliper plays a vital role in the lightweighting process of the entire train. In order to meet the needs of compactness and lightweighting, the present invention provides a composite lightweight design scheme for key components of the brake caliper unit to improve the fatigue resistance and corrosion resistance of the brake caliper unit.

[0004] This section is intended to provide a background or context to the embodiments of the invention recited in the claims. No admission is made that the description herein is prior art by inclusion in this section. Summary of the invention

[0005] The embodiment of the present invention provides a brake assembly structure for improving the fatigue resistance and corrosion resistance of a brake caliper. The brake assembly structure includes: a brake disc, a cylinder, two brake pad holders, two brake levers, two brake lever bolts and a brake caliper hanger;

[0006] The brake caliper hanger comprises: an upper plate, a lower plate, and an I-beam disposed between the upper plate and the lower plate;

[0007] The upper plate is provided with a fixed spindle sleeve; the upper plate is provided with a first lever fulcrum hole and a second lever fulcrum hole; the lower plate is provided with a third lever fulcrum hole and a fourth lever fulcrum hole; the first lever fulcrum hole and the third lever fulcrum hole are provided in the same vertical direction, and the second lever fulcrum hole and the fourth lever fulcrum hole are provided in the same vertical direction; the brake caliper hanger is made of carbon fiber composite material;

[0008] The brake lever comprises: two parallel plates and a connecting rod connected between the two parallel plates, each parallel plate is provided with a first end ring, a second end ring and an intermediate ring; the first end ring is sleeved on the vertical rod of the brake pad holder, the intermediate ring is sleeved on the brake lever bolt, and the second end ring is sleeved on both ends of the connecting piece connected to the cylinder respectively;

[0009] One of the brake lever bolts passes through the first lever fulcrum hole and the third lever fulcrum hole of the brake caliper hanger, and the other brake lever bolt passes through the second lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger; the brake pad support is used to clamp the brake disc.

[0010] Furthermore, the spindle hole of the fixed spindle sleeve is sleeved on a rigid shaft; the first lever fulcrum hole and the third lever fulcrum hole are sleeved on one of the brake lever bolts of the brake assembly structure, and the second lever fulcrum hole and the fourth lever fulcrum hole are sleeved on another brake lever bolt of the brake assembly structure.

[0011] The embodiment of the present invention further provides a method for manufacturing a brake caliper hanger, which is used to improve the fatigue resistance and corrosion resistance of the brake caliper. The method comprises:

[0012] Acquire a digital model of a brake assembly structure; wherein the brake assembly structure includes: the brake disc, the brake caliper hanger and the cylinder;

[0013] Determine the tolerance parameter in the mounting height direction and the stress bearing limit parameter of the brake caliper according to the digital model;

[0014] Determining the force direction and structural shape of the brake caliper hanger according to the brake assembly structure in the digital model;

[0015] Determining the space structure size limitation parameters of the brake caliper hanger according to the relationship between the brake caliper hanger, the cylinder and the brake disc;

[0016] Establishing a three-dimensional model of the brake caliper hanger structure according to the spatial structure size limitation parameter, the stress bearing limitation parameter, the force direction of the brake caliper hanger, the structural shape of the brake caliper hanger and the tolerance parameter;

[0017] A layup design scheme for the brake caliper hanger structure is generated according to the three-dimensional model of the brake caliper hanger structure and the composite material layup design rules.

[0018] Further, determining the tolerance parameter in the mounting height direction and the stress bearing limit parameter of the brake caliper according to the digital model includes:

[0019] Determine the tolerance parameters in the mounting height direction;

[0020] The stress bearing limit parameter is determined according to the brake friction coefficient.

[0021] Further, according to the brake assembly structure in the digital model, the force direction and structural shape of the brake caliper hanger are determined, including:

[0022] Determining the positional relationship between the brake caliper hanger and the cylinder and the brake disc according to the structural distribution characteristics of the cylinder and the brake disc in the brake assembly structure;

[0023] A mechanical analysis is performed on the brake caliper hanger to determine the composite material layup direction and stress direction; wherein the stress direction includes an impact stress direction and a tensile stress direction; the impact stress direction is along the radius of the fixed spindle sleeve; the tensile stress direction is the normal direction of the friction force of the contact surface between the brake caliper and the brake disc.

[0024] Furthermore, the determining of the space structure dimension limitation parameters of the brake caliper hanger according to the relationship between the brake caliper hanger, the cylinder and the brake disc comprises:

[0025] Determining the distance between the lower surface of the brake caliper hanger and the cylinder according to the positional relationship of the brake caliper hanger in the brake assembly structure;

[0026] Determining the spindle hole radius of the fixed spindle sleeve according to the positional relationship between the fixed spindle sleeve and the brake caliper;

[0027] According to the positional relationship between the I-beam-like protruding portion of the brake caliper hanger and the brake disc, the size restriction parameters of the I-beam-like are determined.

[0028] Further, according to the positional relationship between the protruding portion of the support body of the brake caliper hanger and the brake disc, the size limit parameter of the support body is determined, including:

[0029] The spacing between the inspection point of the I-beam structure of the brake caliper hanger and the brake disc is determined based on the radius of the brake disc, the distance between the inspection point of the I-beam structure of the brake caliper hanger and the disc axis of the fixed spindle sleeve, and the distance between the axis of the brake disc and the disc axis of the fixed spindle sleeve.

[0030] Furthermore, the brake caliper hanger manufacturing method further includes: generating a parameterized ply arrangement table according to the ply design scheme.

[0031] Furthermore, generating a layup design scheme of the brake caliper hanger structure according to the three-dimensional model of the brake caliper hanger structure and the composite material layup design rule comprises:

[0032] Determining the layup restriction conditions of each component in the brake caliper hanger according to the molding characteristics of the composite material;

[0033] According to the three-dimensional model of the brake caliper hanger structure, selecting the arrangement positions of the first lever fulcrum hole, the second lever fulcrum hole, the third lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger;

[0034] According to the composite material ply design rule, the number of continuous plies in the same direction and the proportion of the number of plies in each direction are determined.

[0035] Further, the selecting the setting positions of the first lever fulcrum hole, the second lever fulcrum hole, the third lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger according to the three-dimensional model of the brake caliper hanger structure comprises:

[0036] The centers of the first lever fulcrum hole and the second lever fulcrum hole are arranged to be located inside the extension line of the inner concave contour boundary line of the position where the upper plate is connected to the I-beam;

[0037] The centers of the third lever fulcrum hole and the fourth lever fulcrum hole are located inside the extension line of the inner concave contour boundary line of the position where the lower plate is connected to the I-beam.

[0038] A brake assembly structure and a brake caliper hanger manufacturing method provided by an embodiment of the present invention identify and analyze basic parameter information of a brake caliper hanger according to a digital model of a brake assembly structure actually applied to a train. A three-dimensional model of the brake caliper hanger structure is established according to the basic parameter information of the brake caliper hanger. A layup design scheme of the brake caliper hanger structure is generated according to the stress distribution characteristics of the brake caliper hanger and the three-dimensional model of the brake caliper hanger structure, thereby avoiding the cutting of the composite material layup of the upper plate and the lower plate of the brake caliper hanger at non-boundary locations. Combined with the composite material layup design rules, the best optimized brake caliper hanger manufacturing scheme is obtained before production and manufacturing, thereby avoiding problems such as warping or deformation during the composite material layup processing. A parameterized layup arrangement table is generated according to the composite material layup design scheme, thereby processing the brake caliper hanger. By setting the arrangement direction of the carbon fiber composite material along the principal stress direction of the brake caliper hanger structure, the mechanical properties of the brake caliper hanger under actual working conditions are improved. The brake caliper hanger of the present invention adopts carbon fiber as a composite material, which realizes the lightweight of the brake caliper hanger and makes the brake caliper hanger have the characteristics of light weight, corrosion resistance and fatigue resistance. At the same time, the brake caliper hanger is suitable for three-point hanging and four-point hanging brake calipers. Under the premise of meeting the braking requirements, the purpose of reducing weight and increasing speed of the EMU is achieved. In addition, the I-beam, upper plate and lower plate are set to equal thickness to reduce internal stress. According to the characteristics of the composite material, relevant corrections are made by completing the hollow parts of the upper plate, lower plate and I-beam structure, thereby avoiding the problem of performance and stability degradation of the composite material due to opening holes. The boundaries of the concave sides of the upper plate and the lower plate are set outside the center of the lever fulcrum hole, so that the main stress is tensile stress, avoiding the problem of performance degradation due to excessive bending moment at the lever fulcrum hole. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the prior art descriptions. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. In the drawings:

[0040] Figure 1 It is a schematic diagram of the physical structure of a brake caliper hanger in one embodiment of the present invention;

[0041] Figure 2 It is a schematic diagram of the physical structure of the brake assembly structure in an embodiment of the present invention;

[0042] Figure 3 is a schematic diagram of the physical structure of the brake lever in an embodiment of the present invention;

[0043] Figure 4 It is a schematic flow chart of a method for manufacturing a brake caliper hanger in one embodiment of the present invention;

[0044] Figure 5 It is a schematic flow chart of a method for manufacturing a brake caliper hanger in another embodiment of the present invention;

[0045] Figure 6 It is a schematic flow chart of a method for manufacturing a brake caliper hanger in another embodiment of the present invention;

[0046] Figure 7 It is a schematic diagram of the physical structure of a brake assembly structure in another embodiment of the present invention;

[0047] Figure 8 It is a schematic flow chart of a method for manufacturing a brake caliper hanger in another embodiment of the present invention;

[0048] Fig. 9 It is a schematic flow chart of a method for manufacturing a brake caliper hanger in another embodiment of the present invention;

[0049] Fig.10 It is a schematic diagram of the ply structure of the upper plate with compensatory cutting in one embodiment of the present invention;

[0050] Fig.11 A schematic diagram of the laminate structure in which the main shaft sleeve and the upper plate are integrally formed;

[0051] Fig.12 The figure is a flow chart of a method for manufacturing a brake caliper hanger in another embodiment of the present invention. DETAILED DESCRIPTION

[0052] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0053] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0054] In the present application, the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings. These terms are mainly used to better describe the present application and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation.

[0055] In addition, some of the above terms may be used to express other meanings in addition to indicating orientation or positional relationship. For example, the term "on" may also be used to express a certain dependency or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in this application can be understood according to specific circumstances.

[0056] In addition, the terms "installed", "set", "provided with", "connected", "connected", and "socketed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0057] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0058] In order to achieve lightweight brake caliper hanger, the present application provides a brake assembly structure and a brake caliper hanger thereof, the brake caliper hanger has the characteristics of light weight, corrosion resistance and fatigue resistance. At the same time, the brake caliper hanger is also suitable for three-point hanging and four-point hanging brake calipers.

[0059] like Figure 1 and Figure 2As shown, the brake caliper hanger 100 is applied to a brake assembly structure 200 .

[0060] The brake caliper hanger 100 includes: a fixed spindle sleeve 102, an upper plate 108, a lower plate 109, and an I-beam 107 disposed between the upper plate 108 and the lower plate 109. The brake caliper hanger 100 is made of a carbon fiber composite material.

[0061] The upper plate 108 is provided with a first lever fulcrum hole 103 and a second lever fulcrum hole 104. The lower plate 109 is provided with a third lever fulcrum hole 105 and a fourth lever fulcrum hole 106. The first lever fulcrum hole 103 and the third lever fulcrum hole 105 are provided in the same vertical direction, and the second lever fulcrum hole 104 and the fourth lever fulcrum hole 106 are provided in the same vertical direction.

[0062] Specifically, the first lever fulcrum hole 103 and the third lever fulcrum hole 105 are coaxially arranged, that is, the axis of the first lever fulcrum hole 103 and the axis of the third lever fulcrum hole 105 are in a straight line, so that the brake lever 204 can pass through the first lever fulcrum hole 103 and the third lever fulcrum hole 105. The second lever fulcrum hole 104 and the fourth lever fulcrum hole 106 are coaxially arranged, that is, the axis of the second lever fulcrum hole 104 and the axis of the fourth lever fulcrum hole 106 are in a straight line, so that the brake lever 204 can pass through the second lever fulcrum hole 104 and the fourth lever fulcrum hole 106.

[0063] In one embodiment, the first lever fulcrum hole 103 , the second lever fulcrum hole 104 , the third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 are all circular through holes for pivotally connecting with the corresponding brake levers 204 .

[0064] Specifically, the first lever fulcrum hole 103 and the second lever fulcrum hole 104 are symmetrically arranged at both ends of the upper plate 108, close to the concave side 110 of the upper plate 108. The third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 are symmetrically arranged at both ends of the lower plate 109, close to the concave side 110 of the upper plate 108. The concave side 110 of the upper plate 108 is close to the brake pad holder 201, and the other side 111 of the upper plate 108 (the side opposite to the concave side 110) is close to the cylinder 23. The concave side 110 of the lower plate 109 is close to the brake pad holder 201, and the other side 111 of the lower plate 109 is close to the cylinder 23.

[0065] Specifically, the hole centers of the first lever fulcrum hole 103 and the second lever fulcrum hole 104 are located inside the extension line of the concave contour boundary line of the position where the concave side 110 of the upper plate 108 connects with the quasi-I-beam 107. The hole centers of the third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 are located inside the extension line of the concave contour boundary line of the position where the concave side 110 of the lower plate 109 connects with the quasi-I-beam 107.

[0066] In one embodiment, the concave side 110 of the upper plate 108 is one side of the upper plate 108 in the length direction, parallel to the axial direction of the wheel axle of the EMU train (i.e., perpendicular to the forward direction of the EMU train). The width direction of the upper plate 108 is the forward direction of the EMU train. The concave side 110 of the lower plate 109 is one side of the lower plate 109 in the length direction, parallel to the axial direction of the wheel axle of the EMU train (i.e., perpendicular to the forward direction of the EMU train). The width direction of the lower plate 109 is the forward direction of the EMU train.

[0067] In one embodiment, the concave side 110 of the upper plate 108 and the concave side 110 of the lower plate 109 are both provided with transition fillets, which can be large-sized fillets to avoid stress concentration caused by the output force of the cylinder 23. The other side 111 of the upper plate 108 and the other side 111 of the lower plate 109 are both planes.

[0068] In one embodiment, the spindle hole 101 of the fixed spindle sleeve 102 is sleeved on a rigid shaft. The fixed spindle sleeve 102 is used to connect with the bogie through the rigid shaft. The fixed spindle sleeve 102 is a cylindrical structure, so that the brake caliper hanger 100 can be fixed on the bogie through the rigid shaft. The axial direction of the fixed spindle sleeve 102 is arranged along the length direction of the upper plate 108, that is, it is arranged parallel to the axial direction of the wheel axle of the EMU train.

[0069] Specifically, in actual processing, the outer ring of the fixed spindle sleeve 102 can be integrally formed with the quasi-I-beam 107, the upper plate 108 and the lower plate 109. The quasi-I-beam 107, the upper plate 108 and the lower plate 109 have equal thickness to ensure uniform stress distribution and better processability of the brake caliper hanger component.

[0070] like Figure 1 As shown, the fixed spindle sleeve 102 is subjected to longitudinal impact stress, and the four lever fulcrum holes are subjected to transverse tensile stress.

[0071] The brake caliper hanger of the present invention adopts carbon fiber as a composite material, which realizes the lightweight of the brake caliper hanger and makes the brake caliper hanger have the characteristics of light weight, corrosion resistance and fatigue resistance. At the same time, the brake caliper hanger is suitable for three-point hanging and four-point hanging brake calipers. Under the premise of meeting the braking requirements, the goal of reducing weight and increasing speed of the EMU is achieved. In addition, the I-beam, upper plate and lower plate are set to equal thickness to reduce internal stress. According to the characteristics of the composite material, relevant corrections are made by completing the hollow parts of the upper plate, lower plate and I-beam structure, thereby avoiding the problem of performance and stability degradation of the composite material due to opening holes. The boundaries of the concave sides of the upper plate and the lower plate are set outside the center of the lever fulcrum hole, so that the main stress is tensile stress, avoiding the problem of performance degradation due to excessive bending moment at the lever fulcrum hole.

[0072] like Figure 2 As shown, the brake assembly structure 200 includes a brake disc 21 , a brake caliper 22 , and a cylinder 23 .

[0073] The brake caliper 22 includes two brake pad holders 201 , two vertical rods 202 , two brake lever bolts 203 , two brake levers 204 , a suspension rod 205 and a brake caliper hanger 100 .

[0074] like Figure 3 As shown, each brake lever 204 includes two parallel plates 206 spaced apart from each other, and a connecting rod 207 connected between the two parallel plates 206. Each parallel plate 206 is provided with a first end ring 301, a second end ring 302 and an intermediate ring 303.

[0075] In one embodiment, one end of each parallel plate 206 in the brake lever 204 is connected to the cylinder 23 , and the other end is pivotally connected to the brake pad support 201 .

[0076] Specifically, two first end rings 301 are sleeved on a vertical rod 202 of a brake pad support 201 , two intermediate rings 303 are sleeved on the brake lever bolt 203 , and two second end rings 302 are respectively sleeved on both ends of a connecting piece 208 connected to the cylinder 23 .

[0077] One end of the brake lever 204 is hinged to the brake pad holder 201 through the vertical rod 202 as a rotating shaft, so that the brake pad holder 201 has a certain degree of rotational freedom. A brake pad is mounted on the brake pad holder 201, and each brake pad holder 201 includes two top connecting rings 209. The bottom of the suspension rod 205 is inserted between the two top connecting rings 209 of the brake pad holder 201 and is pivoted through the corresponding rotating shaft.

[0078] In one embodiment, the brake pad holder 201 is used to clamp the brake disc 21. The axial direction of the top connecting ring 209 is horizontal. The brake caliper 22 is installed on the bogie of the EMU train in a three-point hanging or four-point hanging manner through two suspension rods 205 connected to the upper ends of the two brake pad holders 201 and the fixed spindle sleeve 102 of the brake caliper hanger 100.

[0079] Specifically, one of the brake lever bolts 203 is inserted through the first lever fulcrum hole 103 of the brake caliper hanger 100, the third lever fulcrum hole 105 of the brake caliper hanger 100, and the two middle rings 303 of the brake lever 204, so that the brake lever 204 is pivotally connected to the brake caliper hanger 100. The other brake lever bolt 203 is inserted through the second lever fulcrum hole 206 of the brake caliper hanger 100, the fourth lever fulcrum hole 106 of the brake caliper hanger 100, and the two middle rings 303 of the brake lever 204, so that the brake lever 204 is pivotally connected to the brake caliper hanger 100.

[0080] In one embodiment, the brake caliper hanger 100 and the two symmetrical brake levers 204 are respectively hingedly connected through their corresponding brake lever bolts 203 as lever support shafts, so that the brake levers 204 can rotate.

[0081] One end of each parallel plate 206 in the brake lever 204 is fastened to the connecting piece 208 of the cylinder 23 via a bolt 210 .

[0082] In one embodiment, when the EMU train brakes, the connecting piece 208 of the cylinder 23 moves outward along the axial direction of the EMU train axle, pushing the brake levers 204 on both sides, so that the brake levers 204 are away from each other at the end close to the cylinder 23. The brake lever bolt 203 serves as the rotation axis and fulcrum of the brake lever 204 and remains stationary. The two brake levers 204 approach each other at the end away from the cylinder 23. In the process of approaching each other, the brake pads of the two brake pad holders 201 are also driven to approach each other and gradually pressed against the brake disc 21. Thereby, the output force of the cylinder 23 is transmitted to the brake disc 21. The brake pads of the brake pad holder 201 and the brake disc 21 act through friction, gradually reducing the running speed of the axle of the EMU train installed on the brake disc 21, thereby achieving the braking of the EMU train.

[0083] In one embodiment, when the EMU train stops braking, the cylinder 23 drives the connecting member 208 to move inward along the axial direction of the EMU train axle through exhaust, that is, the opposite direction of the braking process. The movement of the connecting member 208 pulls the two brake levers 204, so that the two brake levers 204 are close to each other at the end close to the cylinder 23. The brake lever bolt 203 serves as the rotation axis and fulcrum of the brake lever 204 and remains stationary. The two brake levers 204 move away from each other at the end away from the cylinder 23. In the process of moving away from each other, the brake pads of the two brake pad holders 201 are also driven to move away from each other, so that the brake disc 21 is no longer clamped, so that the EMU train stops braking.

[0084] In one embodiment, during the braking process of the EMU train, the brake lever 204 transmits pressure to the two brake pad holders 201 through the vertical rod 202 .

[0085] The brake caliper hanger of the present invention adopts carbon fiber as a composite material, thereby achieving lightweight of the brake caliper hanger, and making the brake caliper hanger have the characteristics of light weight, corrosion resistance and fatigue resistance. At the same time, the brake caliper hanger is suitable for three-point hanging and four-point hanging brake calipers. On the premise of meeting the braking requirements, the goal of reducing weight and increasing speed of EMU is achieved. By completing the hollow part of the I-beam, the problem of performance degradation of the composite material layer due to opening is avoided.

[0086] The embodiment of the present invention further provides a method for manufacturing a brake caliper hanger, as described in the following embodiment.

[0087] Figure 4 FIG. 1 is a flow chart of a method for manufacturing a brake caliper hanger according to an embodiment of the present invention. Figure 4 As shown, it includes steps 401 to 406.

[0088] Step 401 : obtaining a digital model of the brake assembly structure 200 ; wherein the brake assembly structure includes: a brake disc 21 , a brake caliper hanger 100 and a cylinder 23 .

[0089] Step 402 : Determine the tolerance parameters in the mounting height direction and the stress bearing limit parameters of the brake caliper 22 according to the digital model of the brake assembly structure 200 .

[0090] Step 403: Determine the force direction and structural shape of the brake caliper hanger 100 according to the brake assembly structure 200 in the digital model.

[0091] Step 404 : Determine the space structural dimension restriction parameters of the brake caliper hanger 100 according to the relationship among the brake caliper hanger 100 , the cylinder 23 and the brake disc 21 .

[0092] Step 405: Establish a three-dimensional model of the brake caliper hanger 100 structure according to the spatial structure size limitation parameters, the stress bearing limitation parameters, the force direction of the brake caliper hanger, the structural shape of the brake caliper hanger and the tolerance parameters.

[0093] Step 406: Generate a layup design scheme for the brake caliper hanger structure according to the three-dimensional model of the brake caliper hanger 100 structure and the composite material layup design rules.

[0094] from Figure 4 It can be seen from the process shown that in the embodiment of the present invention, the basic parameter information of the brake caliper hanger is identified and analyzed based on the digital model of the brake assembly structure actually applied to the EMU train. A three-dimensional model of the brake caliper hanger structure is established based on the basic parameter information of the brake caliper hanger. A layup design scheme for the brake caliper hanger structure is generated based on the stress distribution characteristics of the brake caliper hanger and the three-dimensional model of the brake caliper hanger structure. Combined with the composite material layup design rules, the best optimized brake caliper hanger manufacturing scheme is obtained before production and manufacturing, avoiding problems such as warping or deformation during the composite material layup processing. A parameterized layup arrangement table is generated based on the composite material layup design scheme, so that the brake caliper hanger is processed, thereby improving the mechanical properties of the brake caliper hanger under actual working conditions.

[0095] like Figures 1 to 4 As shown, each step is explained in detail below.

[0096] Step 401 : obtaining a digital model of the brake assembly structure 200 ; wherein the brake assembly structure includes: a brake disc 21 , a brake caliper hanger 100 and a cylinder 23 .

[0097] Step 402 : Determine the tolerance parameters in the mounting height direction and the stress bearing limit parameters of the brake caliper 22 according to the digital model of the brake assembly structure 200 .

[0098] Since the braking method of the EMU train adopts a friction braking mechanism, the pressure and high friction coefficient between the brake caliper 22 and the brake disc 21 generate a large friction resistance, thereby achieving deceleration braking of the EMU train. Therefore, during the friction braking process, the brake caliper 22 will be subjected to a large stress. When designing the brake caliper hanger 100, it is necessary to consider the stress bearing limit during the friction braking process to ensure that the structural strength and stiffness of the brake caliper hanger 100 can meet the stress requirements during braking.

[0099] like Figure 5 As shown, step 402 includes: step 501 to step 502.

[0100] Step 501: Determine the tolerance parameter in the mounting height direction.

[0101] When designing the brake caliper hanger 100 , the tolerance parameters in the height direction need to be considered to ensure that the brake caliper hanger 100 can adapt to brake caliper structures of different heights.

[0102] Specifically, by measuring the tolerance parameters in the mounting height direction, the tolerance parameters include: the installation height tolerance of the brake disc 21, the vertical adjustment range of the brake caliper 22, the overall height tolerance of the brake assembly structure 200 and the vertical position tolerance of the mounting point.

[0103] In one embodiment, the overall height tolerance of the brake assembly structure 200 refers to the installation tolerance of the entire brake assembly structure including the brake disc 21 , the brake caliper 22 and the cylinder 23 in the vertical direction. This parameter is related to the stability and long-term reliability of the brake assembly structure 200 .

[0104] In one embodiment, the vertical position tolerance of the mounting point refers to the position tolerance of the mounting point of the EMU train vehicle or the steering shaft in the vertical direction, and this parameter affects the installation and corresponding adjustment of the brake assembly structure 200.

[0105] Step 502: Determine a stress bearing limit parameter according to the brake friction coefficient.

[0106] Specifically, in the stress bearing limit, according to the brake friction coefficient and the relationship between the brake friction coefficient and the braking torque, the brake clamp 22 should withstand a total bearing capacity of 110 kN during the braking process. Since both sides of the brake disc 21 can be clamped, the single-sided clamp needs to withstand a pressure of at least 55 kN.

[0107] Step 403: Determine the force direction and structural shape of the brake caliper hanger 100 according to the brake assembly structure 200 in the digital model.

[0108] like Figure 6 and Figure 7 As shown, step 403 includes steps 601 to 602.

[0109] Step 601 : Determine the positional relationship between the brake caliper hanger 100 and the cylinder 23 and the brake disc 21 according to the structural distribution characteristics of the cylinder 23 and the brake disc 21 in the brake assembly structure 200 .

[0110] Specifically, Figure 7 As shown, according to the positional relationship between the cylinder 23 and the brake disc 21 in the brake assembly structure 200, it is determined that the brake caliper hanger 100 should be set at the middle position between the two, so that the brake caliper hanger 100 serves as the active part of the cylinder 23, and the brake caliper hanger 100 serves as the driven part of the brake caliper 22 and the brake disc 21.

[0111] Since the brake caliper hanger 100 needs to leave a large space for the brake disc 21 and the cylinder 23, and the brake disc 21 is a circular structure, the main space limitation for the brake caliper hanger 100 is the radius width of the plane where the center of the brake disc 21 is located, while the upper and lower boundaries of the brake caliper hanger 100 structure are less restricted.

[0112] In one embodiment, the brake caliper hanger 100 is designed as a C-beam structure so that the brake caliper hanger 100 leaves a larger space for the brake disc 21 and the cylinder 23 .

[0113] In one embodiment, the upper and lower layers of the brake caliper hanger 100 are symmetrically processed, and the main structure of the layers is simplified. In order to adapt to the structural characteristics of the composite material, the structure of the brake caliper hanger 100 is modified, and the vertical support structure of the entire brake caliper hanger 100 is completed, thereby avoiding the problem of performance degradation of the brake caliper hanger 100 due to opening of the composite material layer, ensuring the uniformity of stress distribution and good processability of the brake caliper hanger 100.

[0114] Step 602: Perform mechanical analysis on the brake caliper hanger 100 to determine the composite material layup direction and stress direction; wherein the stress direction includes the impact stress direction and the tensile stress direction; the impact stress direction is along the radius direction of the fixed spindle sleeve 102; the tensile stress direction is the normal direction of the friction force of the contact surface between the brake caliper 22 and the brake disc 21.

[0115] Specifically, according to the relationship between the carbon fiber ply direction and stress distribution, it is determined that the main bearing direction of the carbon fiber composite material should be the maximum stress direction of the brake caliper hanger 100 structure, that is, the carbon fiber arrangement direction is arranged along the maximum stress direction.

[0116] like Figure 1 As shown, a mechanical analysis is performed on the brake caliper hanger 100 .

[0117] In one embodiment, the length direction along the I-beam 107 is defined as the 0° direction of the composite material ply, and the direction parallel to the plane of the upper plate 108 is defined as the 90° direction of the composite material ply.

[0118] In one embodiment, during the operation of the train, the fixed spindle sleeve 102 of the brake caliper hanger 100 is subjected to impact stress due to the bumps of the train. At this time, the arrangement direction of the carbon fiber should be along the radius direction of the fixed spindle sleeve 102, that is, the length direction of the I-beam 107. During the braking process of the train, the brake disc 21 is clamped by the brake caliper 22 to brake. At this time, the stress direction is perpendicular to the normal direction of the surface of the brake disc 21, and the stress is transmitted to the fulcrum hole position of the brake caliper hanger 100 through the brake lever 204. At this time, the fulcrum hole is subjected to tensile stress. Although the stress direction has changed by 180°, the line of action of the stress has not changed. Therefore, the maximum stress direction is still the normal direction of the friction contact surface between the brake caliper 22 and the brake disc 21, that is, the direction parallel to the plane of the upper plate 108.

[0119] Step 404 : Determine the space structural dimension restriction parameters of the brake caliper hanger 100 according to the relationship among the brake caliper hanger 100 , the cylinder 23 and the brake disc 21 .

[0120] like Figure 8 As shown, step 404 includes steps 801 to 803.

[0121] Step 801 : According to the positional relationship restriction of the brake caliper hanger 100 in the brake assembly structure 200 , determine the distance between the lower surface of the brake caliper hanger 100 and the cylinder 23 .

[0122] Specifically, according to the positional relationship between the brake caliper hanger 100 and the cylinder 23 , it is determined that the distance between the lower surface of the brake caliper hanger 100 and the cylinder 23 is greater than 15 mm to avoid collision between the brake caliper hanger 100 and the cylinder 23 .

[0123] In one embodiment, the brake caliper hanger 100 structure needs to satisfy the requirement that there is a gap greater than 5 mm between the components in the brake assembly structure after installation, so as to avoid the brake caliper hanger 100 from shaking due to the vibration of the vehicle body during the operation of the EMU train, causing the brake caliper hanger 100 to collide with its adjacent components, thereby causing damage to the components.

[0124] Step 802 : Determine the radius of the spindle hole 101 of the fixed spindle sleeve 102 according to the positional relationship between the fixed spindle sleeve 102 and the brake caliper 22 .

[0125] Specifically, according to the positional relationship between the opening of the fixed spindle sleeve 102 and the brake caliper 22 , the radius of the spindle hole 101 of the fixed spindle sleeve 102 is determined to be less than 38 mm to avoid collision between the opening of the fixed spindle sleeve 102 and the brake caliper 22 .

[0126] In one embodiment, during the assembly of the brake caliper, the fixed spindle sleeve 102 and the brake caliper 22 are compared in size, and a distance of 3 mm is reserved to avoid interference. Therefore, the radius of the spindle hole 101 of the fixed spindle sleeve 102 is designed to be 35 mm.

[0127] Step 803 : Determine the size restriction parameters of the quasi-I-beam 107 according to the positional relationship between the protruding portion of the quasi-I-beam 107 of the brake caliper hanger 100 and the brake disc 21 .

[0128] When step 803 is specifically implemented: according to the radius of the brake disc 21, the distance between the inspection point of the I-beam structure of the brake caliper hanger 100 and the brake disc 21, the distance between the inspection point of the I-beam 107 and the disc axis of the fixed spindle sleeve 102, and the distance between the axis of the brake disc 21 and the disc axis of the fixed spindle sleeve 102, the distance between the axis of the brake disc 21 and the disc axis of the fixed spindle sleeve 102 is determined.

[0129] Specifically, Figure 7 As shown, the distance a between the center of the brake disc 21 and the axis of the fixed spindle sleeve 102, the radius r of the brake disc 21 and the distance h between the inspection point of the I-beam 107 and the axis of the fixed spindle sleeve 102 are measured.

[0130] It is measured that the center of the brake disc 21 is located a=20 mm below the axis of the fixed spindle sleeve 102, the radius of the brake disc 21 is r=320 mm, and the inspection point of the I-beam 107 is inclined toward the brake disc 21 by a distance h=201.25 mm.

[0131] The size limit of the I-beam 107 of the brake caliper hanger 100 is calculated according to the formula to avoid the convex portion of the I-beam 107 from colliding with the brake disc 21 .

[0132]

[0133] Among them, d is the maximum allowable spacing of the I-beam-like position, r is the radius of the brake disc, h is the distance between the inspection point of the I-beam-like and the axis of the fixed spindle sleeve 102, and a is the distance between the center of the brake disc and the axis of the fixed spindle sleeve 102.

[0134] The allowable outer convex dimension of the I-beam 107 is calculated by the formula to be approximately d=59.78 mm, which is rounded down to 59 mm. According to the dimension restriction parameter, the dimension design scheme of the brake caliper hanger 100 is determined.

[0135] Step 405: Establish a three-dimensional model of the brake caliper hanger 100 structure according to the spatial structure size limitation parameters, the stress bearing limitation parameters, the force direction of the brake caliper hanger, the structural shape of the brake caliper hanger and the tolerance parameters.

[0136] Specifically, according to parameter information such as spatial structure size limitation parameters, stress bearing limitation parameters, force direction of the brake caliper hanger, structural shape and tolerance parameters of the brake caliper hanger, a three-dimensional model of the brake caliper hanger 100 structure is constructed through CAD software.

[0137] Step 406: Generate a layup design scheme for the brake caliper hanger structure according to the three-dimensional model of the brake caliper hanger structure and the composite material layup design rule.

[0138] like Fig. 9 As shown, step 406 also includes: steps 901 to 903.

[0139] Step 901: Determine the layup restriction conditions of each component in the brake caliper hanger 100 according to the molding characteristics of the composite material.

[0140] Specifically, after determining the force direction and structural shape of the brake caliper hanger 100, the layup restriction conditions of the fixed spindle sleeve 102, the I-beam 107, the upper plate 108 and the lower plate 109 of the brake caliper hanger 100 are determined according to the molding characteristics of the carbon fiber composite material.

[0141] During the composite material molding process, cutting of the plies at non-boundaries should be avoided to ensure the structural integrity of the brake caliper hanger 100 and enhance the strength of the hanger structure.

[0142] Specifically, when designing the ply boundaries of the upper plate 108 and the lower plate 109, the ply should be prevented from being cut off at non-boundary locations. Fig.10 and Fig.11 The ply structure diagram shown in the figure performs ply boundary design on the upper plate 108. And according to the molding characteristics of the composite material, the original hollowed-out upper plate 108 and lower plate 109 are filled and corrected accordingly.

[0143] like Figure 1 As shown, the outer cylinder of the fixed main shaft sleeve 102, the upper plate 108, the I-beam 107 and the lower plate 109 are formed in an integrated manner, which can realize the continuous laying of carbon fiber composite materials and avoid the fiber cutting operation of the above components at the connected positions.

[0144] Specifically, by setting the width of the fixed spindle sleeve 102 to be the same as the width of the I-beam 107 , continuous placement of carbon fibers from the fixed spindle sleeve 102 to the I-beam 107 can be achieved, thereby avoiding generation of a difference region where fibers are cut.

[0145] In one embodiment, the connection position between the quasi-I beam 107 and the upper plate 108 and the lower plate 109 cannot be located at the edge of the plate. The quasi-I beam 107, the upper plate 108 and the lower plate 109 are designed to have equal thickness to reduce internal stress.

[0146] Furthermore, according to the thickness distribution characteristics of the fixed spindle sleeve 102 and the upper plate 108 , the arrangement parameters of the carbon fiber composite material of the fixed spindle sleeve 102 are set.

[0147] like Fig.10 and Fig.11 As shown, in order to avoid affecting the uniform distribution of equal thickness plies of the I-beam 107 and the upper plate 108 due to the insertion of the fixed spindle sleeve 102 into the upper plate 108, the plies of the upper plate 108 need to be compensated to avoid generating too thick plies.

[0148] Specifically, Fig.11 The top view of the fixed spindle sleeve 102 is a rectangular structure, which is in the same layer position as the upper plate 108. The boundary contour line of the fixed spindle sleeve 102 is set as a layer boundary of the upper surface of the upper plate 108 to avoid generating an overly thick layer.

[0149] Specifically, the ply thickness of the fixed spindle sleeve 102 is set to be the upper semicircle thickness h of the fixed spindle sleeve 102 .

[0150] In one embodiment, the upper semicircle diameter of the fixed spindle sleeve 102 is 70 mm, and the diameter of the spindle hole 101 is 55 mm. By calculation, it can be obtained that the upper semicircle thickness of the fixed spindle sleeve 102 is 7.5 mm.

[0151] Since the precision requirement for the spindle hole 101 of the brake caliper hanger 100 is high, it is necessary to ensure the surface precision and structural integrity of the connection between the fixed spindle sleeve 102 and the upper plate 108. By setting up reference surfaces from both the inner and outer rings of the sleeve, the precision and interface performance of the structure can be improved.

[0152] Specifically, the inner ring of the fixed spindle sleeve 102 is set to use the rigid shaft as the reference mold, and the carbon fiber composite material is arranged in a layer arrangement around the shaft, which can improve the surface accuracy of the spindle hole 101. The outer ring of the fixed spindle sleeve 102 is formed integrally with the I-beam 107, the upper plate 108 and the lower plate 109, and the composite material layer angle of the outer ring is the same as the composite material layer angle of the upper plate. The number of layers of the outer ring and the inner ring of the fixed spindle sleeve 102 is set to 1:1, and the layer thickness is h / 2.

[0153] In one embodiment, to ensure uniform stress distribution in the carbon fiber composite material, the number of layers of the inner ring and the outer ring of the fixed spindle sleeve 102 should not differ too much, and a distribution ratio of 1:1 can be adopted, but the present invention is not limited thereto. The layer thickness of the inner ring and the outer ring of the fixed spindle sleeve 102 is 3.75 mm, and is rounded and adjusted according to the thickness parameters of the carbon fiber composite material actually used.

[0154] Step 902 : According to the three-dimensional model of the brake caliper hanger 100 structure, select the setting positions of the first lever fulcrum hole 103 , the second lever fulcrum hole 104 , the third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 .

[0155] Since the upper plate 108 and the lower plate 109 of the brake caliper hanger 100 have hole structures, it is necessary to open the lever fulcrum holes in the upper plate 108 and the lower plate 109 through fiber cutting operation. After the carbon fiber composite material is cured, the carbon fiber has a certain degree of deformation, and the fiber cutting will strengthen the problem of stress distribution concentration in the hole area. Therefore, by reasonably selecting the position of the lever fulcrum hole, the stress concentration problem caused by opening the hole can be avoided.

[0156] Specifically, after the upper plate 108 and the lower plate 109 are laid, the hole punching operation is performed. Since the deformation coefficient of the upper plate 108 and the lower plate 109 in the length direction is small, the bending moment is the main factor affecting the stress concentration. Therefore, when selecting the punching position, the center of the lever fulcrum hole should be located inside the boundary of the upper plate 108 and the lower plate 109, so that the moment passing through the center of the circle is mainly concentrated inside the layer to avoid lateral deviation.

[0157] like Fig.12 As shown: step 1002 includes step 1201 and step 1202.

[0158] Step 1201: The centers of the first lever fulcrum hole 103 and the second lever fulcrum hole 104 are set to be located inside the extension line of the inner concave contour boundary line of the position where the upper plate 108 and the I-beam 107 are connected.

[0159] Specifically, the centers of the first lever fulcrum hole 103 and the second lever fulcrum hole 104 are located inside the extension line of the inner concave contour boundary line where the upper plate 108 is connected to the I-beam 107. That is, more than half of the holes are located inside the extension line of the inner concave contour boundary line, so that the moment passing through the center of the hole is inside the ply of the upper plate 108.

[0160] Step 1202 : The centers of the third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 are set to be located inside the extension line of the inner concave contour boundary line of the position where the lower plate 109 and the I-beam 107 are connected.

[0161] Specifically, the centers of the third lever fulcrum hole 105 and the fourth lever fulcrum hole 106 are located inside the extension line of the inner concave contour boundary line where the lower plate 109 is connected to the I-beam 107. That is, more than half of the holes are located inside the extension line of the inner concave contour boundary line, so that the moment passing through the center of the hole is inside the ply of the lower plate 109.

[0162] In one embodiment, the composite material ply boundaries of the upper plate 108 and the lower plate 109 are arranged to be outside the center of the lever fulcrum hole.

[0163] Step 903: According to the composite material ply design rule, determine the number of continuous plies in the same direction and the ratio of the number of plies in each direction.

[0164] Specifically, composite material layup should satisfy symmetry and balance. Composite material layup design rules include:

[0165] Rule 1: The ply laying sequence is symmetrical about the midplane.

[0166] Rule 2: Balance the laying angle θ, that is, the number of plies at the +θ angle should be the same as the number of plies at the -θ angle.

[0167] Rule 3: When laying layers at the same laying angle θ, the number of consecutive layers shall not exceed 3.

[0168] Rule 4: The number of plies at each laying angle θ shall not be less than 10% of the total number of plies.

[0169] According to the force direction of the brake caliper hanger 100 determined in step 403, the brake caliper hanger 100 has only two main force bearing directions, namely, impact stress in the 0° direction and tensile stress in the 90° direction, and has no moment bearing form. Therefore, the arrangement direction of the carbon fiber composite material is set along the above two main force bearing directions.

[0170] Specifically, the plies in the 0° direction and the 90° direction are arranged alternately according to the ply design rules. The main ply direction of the I-beam 107 is the 0° direction, and the main ply direction of the upper plate 108 and the lower plate 109 is the 90° direction. In the direction of impact stress, the number of plies in the 0° direction should account for the highest proportion of all plies in this direction. In the direction of tensile stress, the number of plies in the 90° direction accounts for the highest proportion of all plies in this direction. The maximum number of continuous plies of carbon fiber composite materials in the same direction is set to 3 layers, and the number of plies in each direction is set to be no less than 10% of the total number of plies.

[0171] In one embodiment, when laying the I-beam 107, since the I-beam 107 is only subjected to impact stress, the laying direction of the composite material is mainly in the 0° direction. After laying 3 layers in the 0° direction, a layer in the 90° direction is laid alternately to ensure better mechanical properties in the 0° direction.

[0172] In one embodiment, the ply design of half of the brake caliper hanger 100 is determined according to the structural thickness of the brake caliper hanger 100 and the thickness of a single layer, and then the ply design of the other half of the brake caliper hanger is generated by axisymmetric processing.

[0173] For example, if the composite material is 0.24 mm thick carbon fiber ply, for a brake caliper hanger 100 structure with a thickness of 21 mm, the total number of plies should be 87.5, which is rounded to 88. First, a 44-ply ply sequence is designed, and then an axisymmetric arrangement is performed to ensure the symmetry of the composite material ply sequence.

[0174] In the embodiment of the present invention, the basic parameter information of the brake caliper hanger is identified and analyzed according to the digital model of the brake assembly structure actually applied to the EMU train. According to the basic parameter information of the brake caliper hanger, a three-dimensional model of the brake caliper hanger structure is established. According to the stress distribution characteristics of the brake caliper hanger and the three-dimensional model of the brake caliper hanger structure, a layup design scheme of the brake caliper hanger structure is generated, so as to avoid the composite material layup of the upper plate and the lower plate of the brake caliper hanger being cut at the non-boundary. In combination with the composite material layup design rules, the best optimized brake caliper hanger manufacturing scheme is obtained before production and manufacturing, so as to avoid the problems such as warping or deformation during the composite material layup processing. According to the composite material layup design scheme, a parameterized layup arrangement table is generated, so as to process the brake caliper hanger. By setting the arrangement direction of the carbon fiber composite material along the principal stress direction of the brake caliper hanger structure, the mechanical properties of the brake caliper hanger under actual working conditions are improved. The brake caliper hanger of the present invention adopts carbon fiber as a composite material, realizes the lightweight of the brake caliper hanger, and makes the brake caliper hanger have the characteristics of light weight, corrosion resistance and fatigue resistance. At the same time, the brake clamp hanger is suitable for three-point hanging and four-point hanging brake clamps. Under the premise of meeting the braking requirements, the purpose of reducing the weight and increasing the speed of the EMU is achieved. In addition, the I-beam, upper plate and lower plate are set to equal thickness to reduce internal stress. According to the characteristics of composite materials, relevant corrections are made by completing the hollow parts of the upper plate, lower plate and I-beam structure to avoid the problem of performance and stability degradation of composite materials due to opening holes. The boundary of the concave side of the upper plate and the lower plate is set outside the center of the lever fulcrum hole, so that the main stress is tensile stress, avoiding the problem of performance degradation due to excessive bending moment at the lever fulcrum hole.

[0175] The specific embodiments described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A brake assembly structure, characterized in that: include: brake disc, cylinder, two brake pad holders, two brake levers, two brake lever bolts and brake caliper hanger; The brake caliper hanger comprises: an upper plate, a lower plate, and an I-beam disposed between the upper plate and the lower plate; The upper plate is provided with a fixed spindle sleeve; the upper plate is provided with a first lever fulcrum hole and a second lever fulcrum hole; the lower plate is provided with a third lever fulcrum hole and a fourth lever fulcrum hole; the first lever fulcrum hole and the third lever fulcrum hole are provided in the same vertical direction, and the second lever fulcrum hole and the fourth lever fulcrum hole are provided in the same vertical direction; the brake caliper hanger is made of carbon fiber composite material; The brake lever comprises: two parallel plates and a connecting rod connected between the two parallel plates, each parallel plate is provided with a first end ring, a second end ring and an intermediate ring; the first end ring is sleeved on the vertical rod of the brake pad holder, the intermediate ring is sleeved on the brake lever bolt, and the second end ring is sleeved on both ends of the connecting piece connected to the cylinder respectively; One of the brake lever bolts passes through the first lever fulcrum hole and the third lever fulcrum hole of the brake caliper hanger, and the other brake lever bolt passes through the second lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger; the brake pad support is used to clamp the brake disc.

2. The brake assembly structure according to claim 1, characterized in that: The spindle hole of the fixed spindle sleeve is sleeved on a rigid shaft; the first lever fulcrum hole and the third lever fulcrum hole are sleeved on one brake lever bolt of the brake assembly structure, and the second lever fulcrum hole and the fourth lever fulcrum hole are sleeved on another brake lever bolt of the brake assembly structure.

3. A method for manufacturing a brake caliper hanger, characterized in that: The brake assembly structure according to claim 1 comprises: Acquire a digital model of a brake assembly structure; wherein the brake assembly structure includes: the brake disc, the brake caliper hanger and the cylinder; Determine the tolerance parameter in the mounting height direction and the stress bearing limit parameter of the brake caliper according to the digital model; Determining the force direction and structural shape of the brake caliper hanger according to the brake assembly structure in the digital model; Determining the space structure size limitation parameters of the brake caliper hanger according to the relationship between the brake caliper hanger, the cylinder and the brake disc; Establishing a three-dimensional model of the brake caliper hanger structure according to the spatial structure size limitation parameter, the stress bearing limitation parameter, the force direction of the brake caliper hanger, the structural shape of the brake caliper hanger and the tolerance parameter; A layup design scheme for the brake caliper hanger structure is generated according to the three-dimensional model of the brake caliper hanger structure and the composite material layup design rules.

4. The method according to claim 3, characterized in that Determining the tolerance parameter in the mounting height direction and the stress bearing limit parameter of the brake caliper according to the digital model includes: Determine the tolerance parameters in the mounting height direction; The stress bearing limit parameter is determined according to the brake friction coefficient.

5. The method according to claim 3, characterized in that: Determining the force direction and structural shape of the brake caliper hanger according to the brake assembly structure in the digital model includes: Determining the positional relationship between the brake caliper hanger and the cylinder and the brake disc according to the structural distribution characteristics of the cylinder and the brake disc in the brake assembly structure; A mechanical analysis is performed on the brake caliper hanger to determine the composite material layup direction and stress direction; wherein the stress direction includes an impact stress direction and a tensile stress direction; the impact stress direction is along the radius of the fixed spindle sleeve; the tensile stress direction is the normal direction of the friction force of the contact surface between the brake caliper and the brake disc.

6. The method according to claim 3, characterized in that Determining the space structure size limitation parameters of the brake caliper hanger according to the relationship between the brake caliper hanger, the cylinder and the brake disc comprises: Determining the distance between the lower surface of the brake caliper hanger and the cylinder according to the positional relationship of the brake caliper hanger in the brake assembly structure; Determining the spindle hole radius of the fixed spindle sleeve according to the positional relationship between the fixed spindle sleeve and the brake caliper; According to the positional relationship between the I-beam-like protruding portion of the brake caliper hanger and the brake disc, the size restriction parameters of the I-beam-like are determined.

7. The method according to claim 6, characterized in that Determining the size limit parameters of the support body according to the positional relationship between the outer protruding portion of the support body of the brake caliper hanger and the brake disc includes: The spacing between the inspection point of the I-beam structure of the brake caliper hanger and the brake disc is determined based on the radius of the brake disc, the distance between the inspection point of the I-beam structure of the brake caliper hanger and the disc axis of the fixed spindle sleeve, and the distance between the axis of the brake disc and the disc axis of the fixed spindle sleeve.

8. The method according to claim 3, characterized in that The method further includes: generating a parameterized ply arrangement table according to the ply design scheme.

9. The method according to claim 3, characterized in that: The step of generating a layup design scheme for the brake caliper hanger structure according to the three-dimensional model of the brake caliper hanger structure and the composite material layup design rule comprises: Determining the layup restriction conditions of each component in the brake caliper hanger according to the molding characteristics of the composite material; According to the three-dimensional model of the brake caliper hanger structure, selecting the arrangement positions of the first lever fulcrum hole, the second lever fulcrum hole, the third lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger; According to the composite material ply design rule, the number of continuous plies in the same direction and the proportion of the number of plies in each direction are determined.

10. The method according to claim 9, characterized in that The selecting, based on the three-dimensional model of the brake caliper hanger structure, the setting positions of the first lever fulcrum hole, the second lever fulcrum hole, the third lever fulcrum hole and the fourth lever fulcrum hole of the brake caliper hanger comprises: The centers of the first lever fulcrum hole and the second lever fulcrum hole are arranged to be located inside the extension line of the inner concave contour boundary line of the position where the upper plate is connected to the I-beam; The centers of the third lever fulcrum hole and the fourth lever fulcrum hole are located inside the extension line of the inner concave contour boundary line of the position where the lower plate is connected to the I-beam.

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