A machining clamp and machining process for a brake caliper

Abstract

This application discloses a brake caliper machining fixture and machining process, relating to the field of vehicle parts manufacturing technology. The brake caliper machining fixture includes a base, a positioning support assembly, and a clamping assembly. The positioning support assembly includes a fixed positioning pin group and multiple floating support units. The fixed positioning pin group is disposed on the base, and the floating support units are distributed on the periphery of the base and can abut against the workpiece. The clamping assembly is disposed on the base and is used to clamp and fix the workpiece to the positioning support assembly. The brake caliper machining fixture and machining process of this application can improve machining efficiency.

Description

Technical Field

[0001] This application relates to the field of vehicle parts manufacturing technology, and in particular to a brake caliper machining fixture and machining process. Background Technology

[0002] Brake calipers are the core actuators of automotive disc brake systems. Typically, a brake caliper has a fixed inner brake piston pump and an outer caliper structure. The inner brake pads are fixed to the piston pump, while the outer brake pads are fixed to the outside of the caliper. The piston pushes the inner brake pads through the brake lines, and at the same time, the reaction force pulls the caliper, causing the outer brake pads to move inward. Both of them press against the brake disc, and the braking force is generated through the friction between the brake disc and the inner and outer brake pads.

[0003] In the current technology, the common processing method for brake calipers is to use a single spindle or dual spindle of a vertical or horizontal machining center for processing, and then use a high-pressure cleaning device to remove burrs. This method requires a large number of devices, and different fixtures need to be changed for different processing steps. The frequent change of fixtures during the processing affects the processing efficiency. Summary of the Invention

[0004] The purpose of this application is to provide a brake caliper machining fixture and machining process to solve the problem of frequent fixture changes required in existing caliper machining.

[0005] To achieve the above objectives, this application provides a brake caliper machining fixture, comprising: a base, a positioning support assembly, and a clamping assembly;

[0006] The positioning support assembly includes a fixed positioning pin group and multiple floating support units. The fixed positioning pin group is disposed on the base, and the floating support units are distributed on the periphery of the base and can abut against the workpiece.

[0007] The clamping assembly is disposed on the base, and the clamping assembly is used to clamp and fix the workpiece to the positioning support assembly.

[0008] In some embodiments, the fixed positioning pin group includes a first positioning pin, a second positioning pin, and a third positioning pin, wherein the first positioning pin, the second positioning pin, and the third positioning pin are distributed in a right-angled triangle, and the first positioning pin, the second positioning pin, and the third positioning pin are fixedly disposed on the base.

[0009] In some embodiments, an auxiliary positioning pin is also provided. The auxiliary positioning pin is disposed on the base and is rectangularly distributed between the first positioning pin, the second positioning pin and the third positioning pin. The auxiliary positioning pin is a telescopic structure.

[0010] In some embodiments, the plurality of floating support units are divided into two groups, and the two groups of floating support units are arranged opposite to each other on both sides of the base. Each floating support unit includes a mounting base and a telescopic cylinder. The mounting base is disposed on the base, and the telescopic cylinder is disposed on the mounting base. The telescopic cylinder is capable of contacting the workpiece.

[0011] In some embodiments, the clamping assembly includes a first clamping block, a second clamping block, and a third clamping block, wherein the first clamping block, the second clamping block, and the third clamping block are arranged in a right-angled triangle and are respectively located directly above the first positioning pin, the second positioning pin, and the third positioning pin.

[0012] In some embodiments, the clamping assembly further includes an auxiliary clamping block, which is rectangularly distributed among the first clamping block, the second clamping block, and the third clamping block.

[0013] In some embodiments, the pressing end faces of the first pressing block, the second pressing block, the third pressing block, and the auxiliary pressing block are all provided with anti-slip and wear-resistant pads.

[0014] In some embodiments, the ends of the first and second positioning pins are provided with spherical protrusions, which are capable of making point contact with the workpiece.

[0015] In some embodiments, the base is a stainless steel casting.

[0016] A brake caliper machining process, applied to the brake caliper machining fixture described in any one of the above-mentioned methods, includes the following steps:

[0017] Place the workpiece on the first positioning pin, the second positioning pin, and the third positioning pin, and move the auxiliary positioning pin upward until it abuts against the workpiece. Then extend the two sets of floating support units and abut against the two side walls of the workpiece. Then press the first pressure block, the second pressure block, the third pressure block, and the auxiliary pressure block to press the workpiece, thereby fixing the workpiece on the fixture.

[0018] Place the workpiece and fixture on the processing equipment, and process the workpiece mounting hole and outer end face, workpiece exhaust hole and locating pin hole, oil inlet hole, brake pad mounting groove and brake disc mounting groove, piston mounting hole and dust cover mounting groove, and sealing ring mounting groove in sequence.

[0019] High-pressure cleaning of the workpiece; after cleaning, remove the fixture and the workpiece.

[0020] Compared with the above background technology, the brake caliper processing fixture provided in this application includes a base, a positioning support assembly and a clamping assembly. The positioning support assembly includes a fixed positioning pin group and a plurality of floating support units. The fixed positioning pin group is disposed on the base, and the floating support units are distributed on the periphery of the base and can abut against the workpiece. The clamping assembly is disposed on the base and is used to clamp and fix the workpiece to the positioning support assembly.

[0021] The base serves as the bearing structure of the fixture. Both the positioning support assembly and the clamping assembly are mounted on the base. The base can be installed on the rotary table of a multi-station machining equipment and rotates between machining stations with the equipment's turntable. Fixed positioning pins are distributed in the central area of ​​the base, primarily serving as the main positioning datum for workpiece clamping and supporting the workpiece. They contact the preset datum surface of the caliper blank. Multiple floating support units are distributed around the workpiece, abutting against its sidewalls to provide auxiliary support and restrict workpiece movement. The clamping assembly clamps the workpiece from top to bottom onto the positioning support assembly, ensuring a secure fixation and stable workpiece posture during machining. This fixture, by using fixed positioning pins and multiple floating support units, achieves workpiece positioning through point-to-point contact. All machined surfaces and holes are fully exposed, without fixture obstruction or interference. During workpiece machining, there is no need to change fixtures or re-align during the process, avoiding positioning errors caused by multiple clamping operations, improving machining accuracy, reducing clamping time, and increasing production efficiency. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the brake caliper machining fixture according to an embodiment of this application;

[0024] Figure 2 This is a front view of the brake caliper machining fixture according to an embodiment of this application;

[0025] Figure 3 This is a top view of the brake caliper machining fixture according to an embodiment of this application;

[0026] Figure 4 This is a schematic diagram of the assembly of the brake caliper machining fixture and the workpiece according to an embodiment of this application.

[0027] in:

[0028] 100. Workpiece;

[0029] 1. Base; 211. First positioning pin; 212. Second positioning pin; 213. Third positioning pin; 214. Auxiliary positioning pin; 22. Floating support unit; 221. Mounting seat; 222. Telescopic cylinder; 31. First pressure block; 32. Second pressure block; 33. Third pressure block; 34. Auxiliary pressure block. Detailed Implementation

[0030] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0031] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] It should be noted that the directional terms such as "upper end," "lower end," "left side," and "right side" mentioned below are defined based on the accompanying drawings in the instruction manual.

[0033] like Figures 1 to 4 As shown, the brake caliper machining fixture provided in this application embodiment includes a base 1, a positioning support assembly, and a clamping assembly. The positioning support assembly includes a fixed positioning pin group and a plurality of floating support units 22. The fixed positioning pin group is disposed on the base 1, and the floating support units 22 are distributed on the periphery of the base 1 and can abut against the workpiece 100. The clamping assembly is disposed on the base 1 and is used to clamp and fix the workpiece 100 to the positioning support assembly.

[0034] Specifically, the base 1 serves as the bearing base of the fixture. Both the positioning support assembly and the clamping assembly are mounted on the base 1. The base 1 can be installed on the rotary table of a multi-station machining equipment and rotates between machining stations with the turntable. Fixed positioning pins are distributed in the central area of ​​the base 1. These pins primarily serve as the main positioning reference for clamping the workpiece 100 and support the workpiece 100, contacting the preset reference surface of the caliper blank. Multiple floating support units 22 are distributed around the workpiece 100, abutting against the side walls of the workpiece 100 to provide auxiliary support and restrict the movement of the workpiece 100. The clamping assembly clamps and fixes the workpiece 100 onto the positioning support assembly from top to bottom, ensuring a secure fixation of the workpiece 100 and guaranteeing the stability of the workpiece 100's posture during machining. The fixture of this application achieves the positioning of the workpiece 100 through point-to-point contact by setting a fixed positioning pin group and multiple floating support units 22. All surfaces and holes of the workpiece 100 to be machined are completely exposed without any obstruction or interference from the fixture. During the machining of the workpiece 100, there is no need to change the fixture or reposition it midway, avoiding positioning errors caused by multiple clamping, improving machining accuracy, reducing clamping time, and improving production efficiency.

[0035] In some embodiments, the fixed positioning pin group includes a first positioning pin 211, a second positioning pin 212 and a third positioning pin 213. The first positioning pin 211, the second positioning pin 212 and the third positioning pin 213 are distributed in a right-angled triangle. The first positioning pin 211, the second positioning pin 212 and the third positioning pin 213 are fixedly disposed on the base 1.

[0036] Specifically, the first positioning pin 211, the second positioning pin 212, and the third positioning pin 213 form a three-point triangular positioning layout, which can restrict the planar movement and rotational freedom of the workpiece 100 and achieve rough positioning of the blank.

[0037] In some embodiments, an auxiliary positioning pin 214 is also provided. The auxiliary positioning pin 214 is disposed on the base 1 and is rectangularly distributed between the first positioning pin 211, the second positioning pin 212 and the third positioning pin 213. The auxiliary positioning pin 214 is a telescopic structure.

[0038] Specifically, the auxiliary positioning pin 214 can be a cylinder telescopic structure.

[0039] Understandably, when workpiece 100 is placed on the first positioning pin 211, the second positioning pin 212, and the third positioning pin 213, the auxiliary positioning pin 214 extends upward until its top end abuts against workpiece 100. At this time, the auxiliary positioning pin 214 can assist in supporting workpiece 100, offsetting cutting impact during milling and drilling, suppressing cutting vibration of workpiece 100, and preventing problems such as vibration marks and dimensional deviations from occurring on workpiece 100.

[0040] In some embodiments, the plurality of floating support units 22 are divided into two groups, and the two groups of floating support units are arranged opposite to each other on both sides of the base 1. The floating support unit 22 includes a mounting base 221 and a telescopic cylinder 222. The mounting base 221 is disposed on the base 1, and the telescopic cylinder 222 is disposed on the mounting base 221. The telescopic cylinder 222 can abut against the workpiece 100.

[0041] Specifically, multiple floating support units 22 are divided into two groups, left and right, and are arranged opposite each other on both sides of the base 1. Each floating support unit 22 includes a mounting base 221 and a telescopic cylinder 222. The mounting base 221 is fixed to the side of the base 1, and the telescopic cylinder 222 is mounted on the mounting base 221. The piston rod end of the cylinder faces the workpiece 100 and can abut against the side wall of the workpiece 100 after it extends.

[0042] Understandably, by setting 22 sets of floating support units on both sides of the workpiece 100, the sidewalls of the workpiece 100 can be simultaneously pressed against from both sides, achieving lateral support for the workpiece 100, offsetting the lateral cutting forces generated during drilling and milling, and preventing the workpiece 100 from shifting or misaligning due to lateral forces. It can also adapt to minor dimensional deviations in the cast blank, automatically compensating for blank dimensional tolerances through cylinder stroke, ensuring that each workpiece 100 receives uniform and stable lateral support force, and exhibiting strong clamping compatibility.

[0043] In some embodiments, the clamping assembly includes a first clamping block 31, a second clamping block 32, and a third clamping block 33, which are arranged in a right-angled triangle and are located directly above the first positioning pin 211, the second positioning pin 212, and the third positioning pin 213, respectively.

[0044] Specifically, the first pressing block 31, the second pressing block 32, and the third pressing block 33 are also arranged in a right-angled triangle, with the pressing points corresponding to the first positioning pin 211, the second positioning pin 212, and the third positioning pin 213 below, respectively, so that the pressing points are directly opposite the bearing points of the workpiece 100.

[0045] Understandably, the three locating pins correspond one-to-one with the three clamping blocks, and the clamping force acts directly on the support point. This can prevent the workpiece 100 from warping due to bias pressure, ensure stable and reliable clamping force, prevent the workpiece 100 from loosening or shifting during processing, withstand large cutting loads, and is compatible with high-speed, high-feed processing equipment.

[0046] In some embodiments, the clamping assembly further includes an auxiliary clamping block 34, which is rectangularly distributed among the first clamping block 31, the second clamping block 32, and the third clamping block 33.

[0047] Understandably, the auxiliary clamping block 34 can apply additional clamping force to the workpiece 100, further suppressing local vibrations during the processing and improving the surface quality of fine features such as grooves and holes.

[0048] In some embodiments, the pressing end faces of the first pressing block 31, the second pressing block 32, the third pressing block 33 and the auxiliary pressing block 34 are all provided with anti-slip and wear-resistant pads.

[0049] Specifically, the anti-slip and wear-resistant pad can be a wear-resistant hard material with a high coefficient of friction, thereby increasing the friction between the pressure block and the surface of the workpiece 100, preventing slight slippage of the workpiece 100 during cutting, and improving clamping reliability. At the same time, the anti-slip and wear-resistant pad can also prevent the pressure block from directly contacting the blank surface of the workpiece 100, preventing pressure marks and indentations on the surface of the workpiece 100, and protecting the appearance quality of the workpiece 100.

[0050] In some embodiments, the ends of the first positioning pin 211 and the second positioning pin 212 are provided with spherical protrusions, which can make contact with the workpiece 100 points.

[0051] Specifically, the first positioning pin 211 and the second positioning pin 212 are arc-shaped supports, corresponding to the arc-shaped reference surface of the workpiece 100. In addition, the top of the third positioning pin 213 is a flat surface, corresponding to the flat reference part of the workpiece 100. The tops of the first positioning pin 211, the second positioning pin 212 and the third positioning pin 213 can perfectly fit the reference shape of the workpiece 100 blank, ensuring that the positioning reference of each blank is consistent, reducing the impact of blank casting errors on the final machining accuracy, and ensuring the dimensional consistency of batch processing.

[0052] In some embodiments, the base 1 is a stainless steel casting.

[0053] Understandably, the stainless steel casting base 1 possesses excellent structural rigidity and vibration resistance, effectively absorbing cutting vibrations during machining. It provides a stable mounting reference for positioning and clamping components, is not prone to deformation over long-term use, and maintains good fixture accuracy. Furthermore, stainless steel is resistant to corrosion from cutting fluids and cleaning solutions, making it suitable for wet machining and high-pressure cleaning environments, and ensuring a long service life.

[0054] The brake caliper machining process provided in this application embodiment, applied to any of the above-mentioned brake caliper machining fixtures, includes the following steps:

[0055] The brake caliper blank is hoisted onto the first positioning pin 211, the second positioning pin 212, and the third positioning pin 213 of the fixture to complete the rough positioning. Then, the auxiliary positioning pin 214 is controlled to extend upward and abut against the lower part of the workpiece 100 to form an auxiliary support. Then, the floating support units 22 on both sides are controlled to extend synchronously and press against the side walls of the workpiece 100. Finally, the first pressure block 31, the second pressure block 32, the third pressure block 33, and the auxiliary pressure block 34 are driven to press down synchronously to firmly press the workpiece 100 onto the fixture, thus completing the clamping.

[0056] At the first station of the multi-station machining equipment, a robot loads the fixture holding the workpiece 100 and transfers it to the second station via a rotary table. The second station, using the pre-reserved positioning of the blank as a reference, processes the mounting holes and outer end faces of the workpiece 100. After processing, the fixture and workpiece 100 are transferred to the third station via the rotary table. The third station, using the mounting holes and outer end face positioning as references, processes the vent holes, locating pin holes, and oil inlet holes. After processing, the fixture and workpiece 100 are rotated via the rotary table... Move to the fourth station. The fourth station uses the mounting hole and outer end face as the positioning reference to process the brake pad mounting groove and brake disc mounting groove. After processing, the fixture and workpiece 100 are transferred to the fifth station via the rotary table. The fifth station uses the mounting hole and outer end face as the positioning reference to process the piston mounting hole and dust cover mounting groove. After processing, the fixture and workpiece 100 are transferred to the sixth station via the rotary table. The sixth station uses the mounting hole and outer end face as the positioning reference to process the sealing ring mounting groove.

[0057] After machining, workpiece 100 undergoes high-pressure cleaning to remove burrs. After cleaning, workpiece 100 is unloaded and removed from the fixture. It should be noted that in this specification, relational terms such as "first" and "second" are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0058] The above provides a detailed description of the brake caliper machining fixture and machining process provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are merely for the purpose of helping to understand the solution and core ideas of this application. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A brake caliper machining fixture, characterized in that, include: Base (1); The positioning support assembly includes a fixed positioning pin group and a plurality of floating support units (22). The fixed positioning pin group is disposed on the base (1), and the floating support units (22) are distributed on the periphery of the base (1) and can abut against the workpiece (100). A clamping assembly is disposed on the base (1) and is used to clamp and fix the workpiece (100) to the positioning support assembly.

2. The brake caliper machining fixture according to claim 1, characterized in that, The fixed positioning pin group includes a first positioning pin (211), a second positioning pin (212), and a third positioning pin (213). The first positioning pin (211), the second positioning pin (212), and the third positioning pin (213) are arranged in a right-angled triangle. The first positioning pin (211), the second positioning pin (212), and the third positioning pin (213) are fixedly disposed on the base (1).

3. The brake caliper machining fixture according to claim 2, characterized in that, An auxiliary positioning pin (214) is also provided. The auxiliary positioning pin (214) is disposed on the base (1) and is rectangularly distributed between the first positioning pin (211), the second positioning pin (212) and the third positioning pin (213). The auxiliary positioning pin (214) is a telescopic structure.

4. The brake caliper machining fixture according to claim 3, characterized in that, The multiple floating support units (22) are divided into two groups, and the two groups of floating support units are arranged opposite each other on both sides of the base (1). The floating support unit (22) includes a mounting base (221) and a telescopic cylinder (222). The mounting base (221) is arranged on the base (1), and the telescopic cylinder (222) is arranged on the mounting base (221). The telescopic cylinder (222) can abut against the workpiece (100).

5. The brake caliper machining fixture according to claim 4, characterized in that, The clamping assembly includes a first clamping block (31), a second clamping block (32), and a third clamping block (33). The first clamping block (31), the second clamping block (32), and the third clamping block (33) are arranged in a right-angled triangle and are located directly above the first positioning pin (211), the second positioning pin (212), and the third positioning pin (213), respectively.

6. The brake caliper machining fixture according to claim 5, characterized in that, The clamping assembly also includes an auxiliary clamping block (34), which is rectangularly distributed with the first clamping block (31), the second clamping block (32), and the third clamping block (33).

7. The brake caliper machining fixture according to claim 6, characterized in that, The pressing end faces of the first pressing block (31), the second pressing block (32), the third pressing block (33) and the auxiliary pressing block (34) are all provided with anti-slip and wear-resistant pads.

8. The brake caliper machining fixture according to claim 2, characterized in that, The ends of the first positioning pin (211) and the second positioning pin (212) are provided with spherical protrusions, which can make point contact with the workpiece (100).

9. The brake caliper machining fixture according to claim 1, characterized in that, The base (1) is a stainless steel casting.

10. A brake caliper machining process, applied to the brake caliper machining fixture according to any one of claims 1-9, characterized in that, Includes the following steps: Place the workpiece (100) on the first positioning pin (211), the second positioning pin (212) and the third positioning pin (213), and move the auxiliary positioning pin (214) upward until it abuts against the workpiece (100). Then extend the two sets of floating support units (22) and abut against the two side walls of the workpiece (100). Then press the first pressure block (31), the second pressure block (32), the third pressure block (33) and the auxiliary pressure block (34) against the workpiece (100) to fix the workpiece (100) on the fixture. Place the workpiece (100) together with the fixture on the processing equipment and process the mounting hole and outer end face of the workpiece (100), the exhaust hole and positioning pin hole of the workpiece (100), the oil inlet hole, the brake pad mounting groove and the brake disc mounting groove, the piston mounting hole and the dust cover mounting groove, and the sealing ring mounting groove in sequence. High-pressure cleaning of workpiece (100) is performed. After cleaning, the fixture and workpiece (100) are removed.

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