Method for producing a caliper of a disc brake
By aligning the unsealed opening on the brake caliper base closer to the dip tank, and combining cutting elements and anti-loosening agents, the problem of paint intrusion into blind holes was solved, achieving a low-cost and efficient coating and screwing process.
Patent Information
- Application Number
- CN202480040144.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-06-21
- Filing Date
- 2024-05-31
- Publication Date
- 2026-01-13
AI Technical Summary
In the prior art, during the painting process, the blind holes of the brake caliper of the disc brake are easily penetrated by the paint, which leads to an increase in tightening torque, making it difficult to fully screw in the screws, and the use of masking materials increases costs.
The brake caliper base is oriented closer to the immersion tank with an unclosed opening. Air is used to cover the blind hole to prevent paint from entering. The screws of the cutting element are used to scrape off any paint residue in the blind hole. The screwing torque and angle are controlled. Anti-loosening agent is used to improve the load-bearing capacity of the screw joint.
It reduces paint deposition in blind holes, lowers tightening torque requirements, eliminates the need for masking materials, simplifies the production process, and improves the reliability and efficiency of screw driving.
Smart Images
Figure CN121336059A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The invention relates to a method for manufacturing a brake caliper of a disc brake, in particular of a commercial vehicle disc brake, wherein the brake caliper is provided for this purpose with a cover. BACKGROUND
[0002] For the use of brake calipers of disc brakes, these are often provided with dip-coating coating for corrosion protection. Coating is a process in the field of subcontracting which is very cost-intensive. In addition to the large series of pieces required for economical operation, it is also important to reduce the size of the work steps for the preliminary and final processing in addition to the actual coating process.
[0003] The brake caliper has blind holes for fastening the cover, in which blind holes the coating should be applied as little as possible, since it would hinder the installation of the cover and would have to be removed immediately after the coating. So far, the blind holes have often been closed with a cover, in particular a silicone plug or another plug, before the coating process, in order to prevent the dip-coating liquid from possibly penetrating into the blind holes. However, this results in additional costs during the production of the brake caliper due to the use of the cover.
[0004] Coating deposits inside the blind hole are particularly disadvantageous when the blind hole has an internal thread and when the cover is to be connected to the brake caliper by screwing after the coating process in a (semi-) automated process. It has been noticed that the coating deposits increase the required screwing torque. As a result, the screw can no longer be screwed completely into the blind hole. SUMMARY
[0005] It is the task of the invention to largely reduce the aforementioned disadvantages in a method of the type mentioned at the outset.
[0006] The invention solves the task in a first aspect in that the method comprises the following steps: providing or manufacturing a base body, which has a number of blind holes with a base and an opposite, unsealed opening for fastening a cover at the base body; orienting the base body towards the dip tank in such a way that the unsealed openings are arranged closer to the dip tank than the base of the blind holes; and immersing the thus oriented base body in the dip tank to apply a dip-coating coating.
[0007] The present application is based on the insight that, in order to apply an immersion coating, in particular of a cathode, the part to be coated is immersed in a coating liquid. The substrate can be immersed in the bath once or several times and / or successively in several baths with different liquids, such as a pretreatment cleaning liquid, a primer, a paint, etc. Since the holes present in the caliper are blind holes, the coating liquid does not or only to a small extent penetrate into the blind holes when the substrate is oriented towards the bath in such a way that the unsealed openings are closer to the bath than the base of the blind holes. The reason is that there is an air accumulation inside the blind holes. According to the present application, in other words, air is used as a mask. It is thus not necessary to use a mask which generates further costs.
[0008] If the term "air" is used in the foregoing and hereinafter, this is to be understood in connection with the present application that the air can be replaced by other gases or mixtures suitable for immersion coating.
[0009] In a preferred embodiment of the method according to the present application, the method further comprises providing or manufacturing a number of screws, wherein the screws each have a cutting element; and screwing the screws into the blind holes, wherein the blind holes are preferably threaded holes. The coating residues in the holes are each scraped off by the cutting elements of the screws. The cutting elements can be configured as, for example, a scraping groove, a cutting groove or as thread-forming / thread- forming. These cutting elements will thus lead to a reduction of the jamming caused by the paint residues inside the blind holes during screwing in or to a reduction of the required torque increase caused by the paint residues when screwing in.
[0010] In a preferred embodiment of the method according to the present application, only the unthreaded section adjacent to the surface in which the blind hole is machined is coated during the immersion coating, and, if necessary, five or fewer flights inside the blind hole are coated. This reduces the torque expenditure required when screwing in next or the risk of a torque increase or even the risk of the screw jamming during the screwing-in process.
[0011] In a preferred embodiment of the method according to the present application, the depth of the blind hole exceeds the length of the screw by a predetermined length amount, so that a non-active zone is formed in the screwed-in state, which is closed by the screw inside the blind hole, respectively. The material separated by the screw inside the blind hole, respectively, is thus accumulated in the space or non-active zone below the maximum screwing-in depth of the blind hole. An additional process step in which the material accumulated inside the blind hole due to the screw is removed can thus be avoided.
[0012] In a preferred embodiment of the method according to the application, the base body is oriented before the step of screwing in such a way that the opening is further away from the immersion bath than the base. This leads to the material that is separated during the screwing-in process accumulating at the bottom of the blind hole and being enclosed in the non-active zone at the end of the screwing-in process. There, the material does not cause disturbances and the production environment is less contaminated.
[0013] In a preferred embodiment of the method according to the application, the screwing-in torque and / or the angle of rotation acting on the screw is monitored during the step of screwing in. In this way, over-tightening during the screwing-in process can be avoided and it can be confirmed whether the screw has been completely screwed in. This is possible because the amount of paint deposit in the blind hole is reduced to a tolerable extent by the previous masking with air.
[0014] In a preferred embodiment of the method according to the application, the method further comprises applying a threadlocker in solid or liquid form to the outer thread of the screw or to the inner thread of the blind hole before screwing in. In this way, the load capacity of the screw joint is increased.
[0015] In a preferred embodiment of the method according to the application, the base body is oriented before the immersion such that the axis of the blind hole has an angle of 10° or less to the perpendicular.
[0016] In a preferred embodiment of the method according to the application, the blind hole and the corresponding hole in the cover are oriented in alignment with each other so that the cover is screwed together with the base body immediately after the screw is screwed in.
[0017] According to a second aspect of the application, the application also relates to the use of a screw having a cutting element.
[0018] The application solves the task mentioned at the beginning of this text by using a screw for fastening a cover at a base body of a brake caliper of a disc brake, in particular of a commercial vehicle disc brake, wherein the screw is screwed into a blind hole, wherein, in particular, the base body is coated in a method according to one of the aforementioned preferred embodiments.
[0019] The use according to the application exploits the same advantages as the method according to the first aspect. The preferred embodiments of the first aspect are at the same time also preferred embodiments of the second aspect and vice versa, so that for the sake of avoiding repetitions reference is made to the above explanations. BRIEF DESCRIPTION OF DRAWINGS
[0020] The application is explained in more detail below with the aid of preferred embodiments with reference to the drawings. In the drawings: Figure 1 A schematic representation of an embodiment of the method according to the application is shown in a block diagram; Figure 2 screw in the first screwing position during screwing into a blind hole according to the method according to the application is shown in a cross-sectional view; Figure 3 screw in the second screwing position during screwing into a blind hole according to the method according to the application is shown in a cross-sectional view; Figure 1 screw in the second screwing position during screwing into a blind hole according to the method according to the application is shown in a cross-sectional view; Figure 4 screw in the third screwing position during screwing into a blind hole according to the method according to the application is shown in a cross-sectional view. Figure 1 screw in the third screwing position during screwing into a blind hole according to the method according to the application is shown in a cross-sectional view. DETAILED DESCRIPTION
[0021] Figure 1 One embodiment of a method for producing a coated brake caliper for a commercial vehicle disc brake is shown, which first provides or produces a base body 1 in a step 101, which has a number of blind holes 3 with a base and opposite, unobstructed openings 5 for fastening a cover 7 at the base body 1.
[0022] The base body 1 is then oriented in a step 103. In a substep 103a, the base body 1 is first oriented toward the dip tank in such a way that the unobstructed openings 5 are arranged closer to the dip tank than the base of the blind holes.
[0023] Furthermore, in a step 103b, the base body 1 is also oriented before the dip in such a way that the axes 21 of the blind holes 3 have an angle of 10° or less to the perpendicular. The step 105 comprises dipping the thus oriented base body 1 into the dip tank for applying the dip-coated coating 9.
[0024] Furthermore, for the preparation of the screwing in, a number of screws 11 are provided in a step 107, wherein the screws 11 each have a cutting element 13.
[0025] In a step 109, a liquid threadlocker 15 is applied to the outer thread of the screws 11 before the screwing in. Alternatively or additionally, the liquid threadlocker 15 can also be applied in the step 109 (not shown) to the inner thread of the blind holes 3.
[0026] The base body 1 is optionally oriented for the preparation of the screwing in in a step 111. The step 111 thus takes place before a step 113 of the screwing in.
[0027] In a substep 111a, the orientation is such that the openings 5 are further away from the dip tank than the base. In a substep 111b, the blind holes 3 and the corresponding holes 8 in the cover 7 are oriented in alignment with one another, so that the cover 7 can be screwed together with the base body immediately after the screwing in of the screws 11.
[0028] Then, in step 113, the screw 11 is screwed into the blind hole 3, wherein preferably the blind hole 3 is a threaded hole, or alternatively the thread is machined in the same work step. During step 113, the screwing torque acting onto the screw and / or the corresponding angle of rotation are preferably monitored.
[0029] Figure 2 A cross section of a base body 1 of a brake caliper of a disc brake used in a method according to the application is shown. In this cross section a blind hole 3 with an opening 5 is shown. The base body has a dip coating layer 9. For fastening the cover 7 at the housing 1 a screw 11 is screwed into the blind hole 3 through a hole 8 of the cover 7. The screw 11 has a cutting element 13 and the screw is coated with a thread locker 15, wherein it is understood that alternatively or additionally the thread locker 15 can also be applied to the inner thread of the blind hole 3. A part of the blind hole 3 is provided with dip coating residues 17. The blind hole 3 has an axis 21 which is oriented for example 0 degrees to the perpendicular.
[0030] Figure 2 The beginning of the screwing process is shown, in which the cutting element 13 of the screw 11 reaches the area of the undesired dip coating residues 17 within the blind hole 3 and from this point onwards the dip coating residues 17 are scraped off with further screwing.
[0031] Figure 3 The arrangement shown in Figure 2 is shown, wherein the screw 11 is screwed further in and almost all of the dip coating residues 17 are removed from the side wall of the blind hole 3 by the cutting element 13. The scraped-off coating residues 19 accumulate and are enclosed in the area of the lower part of the blind hole 3.
[0032] The screwing process ends in Figure 4 . The screw 11 is completely screwed into the blind hole 3. All of the dip coating residues 17 are removed by the cutting element 13 and are in the form of scraped-off coating residues 19 in the area of the lower part of the blind hole 3. Thus, the base body 1 is screwed together with the cover 7. Here, I B denotes the thickness of the coated part of the base body plus the thickness of the cover, I S denotes the length of the screw (without head), and I T +I B denotes the height of the non-acting area.
[0033] List of reference signs (part of the description)
[0034] 1 base body
[0035] 3 blind hole
[0036] 5 opening of the blind hole
[0037] 7 cover
[0038] 9 dip coating layer
[0039] 11 screw
[0040] 12 non-active zone
[0041] 13 cutting element
[0042] 15 anti-loosening agent
[0043] 17 dip coating layer / dip coating residue in the blind hole
[0044] 19 paint residue that is scraped off
[0045] 21 axis of the blind hole
[0046] 101, 103, 103a, 103b, 105, 107, 109, 111, 111a, 111b, 113 method steps
[0048] I S screw length (not including head)
[0049] I B thickness of the coated portion of the base body plus thickness of the cover
[0050] I T +I B height of the non-active zone
Claims
1. A method for manufacturing brake calipers for disc brakes, particularly disc brakes for commercial vehicles, wherein, The brake caliper is therefore provided with a cover (7), wherein the method includes the following steps: - Provide or manufacture a substrate (1) having a number of blind holes (3) having a base and opposing unclosed openings (5) for fastening the cover (7) to the substrate (1). - Orient the substrate (1) toward the immersion tank, such that the unclosed opening (5) is arranged closer to the immersion tank than the base of the blind hole, and - The dip coating section (9) is applied by immersing the substrate (1) in the dip tank in this orientation.
2. The method according to claim 1, wherein, The blind hole (3) has an internal thread (4), and the method includes the following steps: - A certain number of screws (11) are provided, wherein each screw (11) has a cutting element (13), and - Screw the screw (11) into the blind hole (3), wherein the blind hole (3) is preferably a threaded hole.
3. The method according to claim 2, wherein, The depth of the blind hole (3) exceeds the length of the screw (I). S A predetermined length (I) T Thus, in the screwed-in state, a non-functional area (12) is formed within the blind hole (3) by the screw (11).
4. The method according to claim 3, wherein the method comprises the steps of: The substrate (1) is oriented such that the opening (5) is farther from the dip tank than the substrate before the screwing-in step.
5. The method according to any one of claims 2 to 4, the method comprising the steps of: Monitor the screwing torque and / or rotation angle acting on the screw during the screwing step.
6. The method according to any one of claims 2 to 5, further comprising: Before screwing in, apply a solid or liquid anti-loosening agent (15) to the external thread of the screw (11) or the internal thread of the blind hole (3).
7. The method according to any one of the preceding claims, wherein, The substrate (1) is oriented before immersion such that the axis (21) of the blind hole (3) is 10° relative to the perpendicular. Or even smaller angles.
8. The method according to any one of claims 2 to 7, wherein the method comprises: The blind hole (3) and the corresponding hole (8) in the cover (7) are aligned with each other so that the cover (7) is screwed together with the base when the screw (11) is then screwed in.
9. Screws with cutting elements are used to fasten covers to the base of the brake caliper of disc brakes, particularly disc brakes for commercial vehicles, wherein... The screw is screwed into a blind hole, wherein, in particular, the screw is configured for application in the method according to any one of the preceding claims.