Brake caliper shell suitable for friction stir welding
By designing the alignment mechanism of the positioning pins and positioning holes and the fixed projection design on the brake caliper shell, the mechanical strength and alignment problems of the two-piece brake caliper shell during the locking and welding process are solved, and high-quality friction stir welding and stable clamping effects are achieved.
Patent Information
- Application Number
- CN202420248276.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Priority Date
- 2024-01-03
- Filing Date
- 2024-02-01
- Publication Date
- 2025-03-18
- Estimated Expiration
- 2034-02-01
AI Technical Summary
The existing two-piece brake caliper shell needs to be added to the processing process during the locking process, and the bolt locking structure may lead to a reduction in the locking strength under long-term use and vibration, increasing the component and assembly cost. At the same time, the traditional welding method does not have enough mechanical strength to the complex three-dimensional shape brake caliper shell, and the friction and fixtures for friction and stir welding workpieces are designed in complex, making it difficult to achieve accurate alignment and stable clamping.
A brake caliper shell suitable for friction stir welding is designed, and the alignment mechanism between the positioning pin and the positioning hole is adopted, so that the left and right shells can be accurately aligned and engaged, eliminating some processing and assembly processes, and providing a stable clamping surface through the design of fixed protrusions.
Accurate alignment and stable clamping of the left and right shells is achieved, the welding process is simplified, the welding quality and mechanical strength are improved, and the component and assembly costs are reduced.
Smart Images
Figure CN222633698U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a brake caliper housing such as a disc brake, and in particular to a brake caliper housing suitable for friction stir welding, wherein the left and right housings can be accurately positioned and butted, so as to facilitate the friction stir welding. Background Art
[0002] The brake caliper housing of the hydraulic disc brake used in general vehicles mainly includes a left housing and a right housing, which are locked and fixed to each other by bolts. Since the left housing and the right housing of this two-piece brake caliper housing can be manufactured separately, the mold design and manufacturing of the left and right housings are relatively easy compared to the brake caliper housing that is forged in one piece. However, since the left housing and the right housing of this two-piece brake caliper housing are locked to each other by bolts, the locking holes need to be processed after the left housing and the right housing are cast, which increases the processing steps. In addition, in order to ensure that the brake caliper housing can still stably maintain a predetermined locking strength under the vibration of the vehicle during long-term use, the bolt locking structure needs to be specially designed and the bolt locking must be maintained within a certain locking torque range, which inevitably increases the component and assembly costs.
[0003] In order to solve the above problems, the creator of the utility model tried to weld the left and right shells by welding. However, the traditional welding method using solder and flux only uses solder to join the workpiece surface. For the brake caliper shell with a more complex three-dimensional shape and the force of the hydraulic caliper brake disc, the mechanical strength of the traditional welding is not without doubt. On the other hand, friction stir welding (Friction Stir Welding) can provide better mechanical properties than traditional welding methods, and can weld difficult-to-weld materials or heterogeneous materials such as aluminum, magnesium, copper, titanium or steel. Therefore, it has been widely used in automobile manufacturing, aviation industry and electronics industry in recent years. However, for different welding workpieces, friction stir welding first has to face the problems of weld bead design, jig design, fixture design, etc. For plate-like workpieces with relatively simple geometric shapes and similar two-dimensional shapes, the aforementioned jig and fixture design is relatively simple, but for brake caliper housings with more complex geometric three-dimensional shapes, the design of jigs and fixtures is relatively complicated. In particular, how to make the left and right shells of the brake caliper housings with complex three-dimensional geometric shapes to be welded accurately align and dock and be firmly clamped to facilitate the friction stir welding process is a problem that needs to be overcome. Summary of the invention
[0004] In view of the above problems, the main purpose of the utility model is to provide a brake caliper housing suitable for friction stir welding, which has a special alignment mechanism so that the left and right housings can be accurately aligned and joined to facilitate the friction stir welding process.
[0005] In order to achieve the above-mentioned purpose, the utility model provides a brake caliper housing suitable for friction stir welding, which is characterized in that it includes: a left housing having a left joint surface; a right housing having a right joint surface, and the left joint surface and the right joint surface are fixedly connected by friction stir welding; wherein, the right joint surface protrudes with at least one locating pin, and the left joint surface has at least one locating hole, and the at least one locating pin is inserted into the at least one locating hole so that the left joint surface and the right joint surface are in contact.
[0006] By adopting the above technical solution, that is, a positioning pin and a positioning hole alignment mechanism is provided between the left joint surface and the right joint surface, the left shell and the right shell can be accurately aligned and docked without the aid of a jig, so as to facilitate the clamping of the left shell and the right shell and the subsequent friction stir welding process.
[0007] In the technical solution of the above-mentioned utility model, the right joint surface has at least one positioning hole, and the at least one positioning pin is inserted into the at least one positioning hole of the right joint surface and protrudes from the right joint surface. In other words, the right joint surface and the left joint surface are both designed with positioning holes, and the positioning pin is a separate component, which is first inserted into the positioning hole of the right joint surface and protrudes from the right joint surface (of course, it can also be first inserted into the positioning hole of the left joint surface and protrude from the left joint surface), and then inserted into the other positioning hole during alignment. In this way, the alignment mechanism of the utility model can be directly applied to the two-piece brake caliper housing mentioned in the existing and previous technologies. Through simple processing procedures and assembly, the technical features of the present invention can be provided in the existing two-piece brake caliper housing, and the positioning pin can be designed to be different from the left and right housing materials to facilitate assembly.
[0008] The right housing is integrally formed with the at least one positioning pin protruding from the right joint surface. The left housing can also be integrally formed with the at least one positioning pin protruding from the left joint surface. In this way, some processing and assembly steps can be omitted.
[0009] The left shell body includes a main body, a front extension section extending from a top edge of the main body toward the right shell body, and a rear extension section extending from the top edge of the main body toward the right shell body and spaced apart from the front extension section, the front extension section has an end face facing the right shell body, the rear extension section has an end face facing the right shell body, and the end face of the front extension section and the end face of the rear extension section jointly form the left joint surface; the right shell body includes a main body, a front extension section extending from a top edge of the main body of the right shell body toward the left shell body, and a rear extension section extending from the top edge of the main body of the right shell body toward the left shell body and spaced apart from the front extension section of the right shell body, the front extension section of the right shell body has an end face facing the left shell body, the rear extension section of the right shell body has an end face facing the left shell body, and the end face of the front extension section of the right shell body and the end face of the rear extension section of the right shell body jointly form the right joint surface. In this way, the front and rear extension sections of the left and right shells fit each other, making the alignment more accurate and stable.
[0010] The left housing has a fixing protrusion protruding in a direction away from the right housing, and the right housing has a fixing protrusion protruding in a direction away from the right housing. Thus, the fixing protrusions of the left and right housings form a structure that can be clamped by a clamp, so that the left and right housings can be firmly clamped, which is convenient for the friction stir welding process.
[0011] The left shell includes a body, the body has a top edge and a bottom edge, the fixed protrusion of the left shell has a top edge, the top edge of the fixed protrusion of the left shell is lower than the top edge of the body, and the top edge of the fixed protrusion of the left shell and the bottom edge of the body respectively form a clamping surface for clamping. In this way, the left shell has upper and lower clamping surfaces for the clamp to abut or clamp, so that the left shell can be clamped more firmly.
[0012] The right shell includes a body, the body has a top edge and a bottom edge, and the fixing protrusion of the right shell has a top edge, the top edge of the fixing protrusion of the right shell is lower than the top edge of the body, and the top edge of the fixing protrusion of the right shell and the bottom edge of the body respectively form a clamping surface for clamping. In this way, the right shell has upper and lower clamping surfaces for the clamp to abut or clamp, so that the right shell can be clamped more firmly.
[0013] The detailed structure, features, assembly or use of the brake caliper housing suitable for friction stir welding provided by the utility model will be described in the detailed description of the implementation method later. However, those with ordinary knowledge in the field of this invention should understand that these detailed descriptions and specific embodiments listed in the implementation of the utility model are only used to illustrate the utility model, and are not used to limit the patent protection scope of the utility model. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a three-dimensional assembly diagram of a brake caliper housing provided by a preferred embodiment of the utility model;
[0015] Figure 2 is a three-dimensional exploded view of the brake caliper housing provided by the preferred embodiment of the utility model, showing that the positioning pin is protruding from the right joint surface of the right housing;
[0016] Figure 3 is another exploded perspective view of the brake caliper housing provided by the preferred embodiment of the utility model;
[0017] Figure 4 is another exploded perspective view of the brake caliper housing provided by the preferred embodiment of the utility model;
[0018] Figure 5 yes Figure 1 A cross-sectional view along section line 5-5;
[0019] Figure 6 It is a three-dimensional schematic diagram showing the state of the rotating tool head of friction stir welding performing welding along the joint surface;
[0020] Figure 7 It is a front view schematic diagram showing a state in which a rotating tool head of friction stir welding performs welding along a joint surface, wherein the left housing is removed. DETAILED DESCRIPTION
[0021] The applicant first explains that in the embodiments and drawings to be introduced below, the same reference numbers represent the same or similar elements or their structural features. Secondly, the directional descriptions such as "front, back, left, right, up, down" described in this article are only used to illustrate the technical features of the utility model with reference to the drawings, and are not used to limit the patent protection scope of the utility model.
[0022] Please read first Figures 1 to 5 As shown, a brake caliper housing 10 provided by a preferred embodiment of the utility model mainly includes a left housing 20 and a right housing 40. The left and right housings 20 and 40 have a specially designed alignment mechanism, so that the left and right housings 20 and 40 are particularly suitable for friction stir welding and fixed as a whole. The specific structural design is detailed as follows.
[0023] like Figure 3 and Figure 4 As shown, the left housing 20 includes a body 22, a front extension section 24, and a rear extension section 26. The body 22 has an inner side surface 222 facing the right housing 40, an outer side surface 224 opposite to the inner side surface 222, a top edge 226, and a bottom edge 228, wherein the center of the outer side surface 224 has a fixing protrusion 23 protruding in a direction away from the right housing 40, and the top edge 232 of the fixing protrusion 23 is lower than the top edge 226 of the body 22 of the left housing 20, thereby, the top edge 232 of the fixing protrusion 23 and the bottom edge 228 of the body 22 respectively form a clamping surface for clamping and abutting by a clamp (not shown in the figure). Secondly, the front extension section 24 extends from the front side of the top edge 226 of the main body 22 toward the right shell body 40, and the rear extension section 26 extends from the rear side of the top edge 226 of the main body 22 toward the right shell body 40 and is spaced a predetermined distance from the front extension section 24, wherein the front extension section 24 has an end surface 242 facing the right shell body 40, and the end surface 242 is recessed inwardly with two spaced positioning holes 244, and the rear extension section 26 also has an end surface 262 facing the right shell body 40, and the end surface 262 is recessed inwardly with two spaced positioning holes 264, in addition, the end surface 242 of the front extension section 24 and the end surface 262 of the rear extension section 26 are located in the same plane, and together form a left joint surface 28.
[0024] like Figures 2 to 4 As shown, the right shell 40 includes a body 42, a front extension section 44, and a rear extension section 46. The body 42 has an inner side surface 422 facing the left shell 20, an outer side surface 424 opposite to the inner side surface 422, a top edge 426, and a bottom edge 428, wherein the center of the outer side surface 424 has a fixing protrusion 43 protruding in a direction away from the left shell 20, and the top edge 432 of the fixing protrusion 43 is lower than the top edge 426 of the body 42 of the right shell 40, thereby, the top edge 432 of the fixing protrusion 43 and the bottom edge 428 of the body 42 respectively form a clamping surface for clamping and abutting by a clamp (not shown in the figure). Secondly, the front extension section 44 extends from the front side of the top edge 426 of the main body 42 toward the left shell body 20, and the rear extension section 46 extends from the rear side of the top edge 426 of the main body 42 toward the left shell body 20 and is spaced a predetermined distance from the front extension section 44, wherein the front extension section 44 has an end face 442 facing the left shell body 20, and the end face 442 is recessed inwardly with two positioning holes 444 that are spaced apart and correspond to the positioning holes 244 respectively, and the rear extension section 46 also has an end face 462 facing the left shell body 20, and the end face 462 is recessed inwardly with two positioning holes 464 that are spaced apart and correspond to the positioning holes 264 respectively. In addition, the end face 442 of the front extension section 44 and the end face 462 of the rear extension section 46 are located in the same plane, and together form a right joint surface 48.
[0025] like Figure 2 , Figure 3 and Figure 5 As shown, in this embodiment, the brake caliper housing 10 further includes four positioning pins 60, which can be made of the same metal as the left housing 20 or the right housing 40 or a different material. During assembly, the positioning pins 60 are first inserted into the positioning holes 444, 464 of the right housing 40 in a manner such as a tight fit, so that part of them protrude outside the right joint surface 48. Then, when the left housing 20 and the right housing 40 need to be butted against each other for friction stir welding, the positioning pins 60 protruding from the right joint surface 48 can be directly inserted into the positioning holes 244, 264 of the left housing 20, so that the left joint surface 28 and the right joint surface 48 can be fitted and abutted against each other.
[0026] See also Figure 6 and Figure 7 , Figure 6 and Figure 7 The following is an exemplary description of a rotating shoulder tool 80 of Friction Stir Welding performing welding processing on the brake caliper housing 10 provided by the present invention. The rotating shoulder tool 80 has a shoulder 82 and a stirring rod 84 extending outward from the shoulder 82 . During the friction stir welding, the stirring rod 84 rotates and enters between the left joint surface 28 and the right joint surface 48, and continues to feed until the shoulder 82 contacts the surface of the left shell 20 and the right shell 40 near the left joint surface 28 and the right joint surface 48. At this time, the friction heat generated by the rotation of the rotating tool head 80 will make the welded metal near the shoulder 82 and the stirring rod 84 plastic. As the rotating tool head 80 rotates and moves along the joint of the left joint surface 28 and the right joint surface 48, the plastically deformed metal of the left shell 20 and the right shell near the left joint surface 28 and the right joint surface 48 can be stirred together, and after cooling, a dense weld is formed, and the left shell 20 and the right shell 40 are firmly welded together. Since friction stir welding is a conventional technology, its processing principle and various welding processes are not described in detail here.
[0027] From the above statements, it can be seen that the brake caliper housing 10 provided by the utility model is provided with a positioning mechanism of a positioning pin 60 and positioning holes 244, 264, 444, 464 between the left joint surface 28 and the right joint surface 48. Therefore, the left housing 20 and the right housing 40 can be easily and accurately aligned and docked without the aid of a jig. This is conducive to further using a clamp to clamp and fix the docked left housing 20 and right housing 40 on a friction stir welding machine for subsequent friction stir welding processes. Secondly, as mentioned above, the left shell 20 is designed with a fixing protrusion 23, and the right shell 40 is also designed with a fixing protrusion 43, especially the top edge 232 of the fixing protrusion 23 of the left shell 20 and the bottom edge 228 of the main body 22 respectively form a clamping surface, and the top edge 432 of the fixing protrusion 43 of the right shell 40 and the bottom edge 428 of the main body 42 also respectively form a clamping surface. Such a design is more conducive to stably clamping and fixing the already connected left shell 20 and right shell 40 on the friction stir welding machine, so as to facilitate the smooth progress of the subsequent friction stir welding process.
[0028] It should be noted that, in this embodiment, the positioning pin 60 and the left housing 20 and the right housing 40 are different components, but the present invention is not limited thereto. For example, in another embodiment of the present invention, the right housing 40 may be integrally formed with a positioning pin 60 protruding from the right joint surface 48, so that the right joint surface 48 does not need to be provided with positioning holes 444, 464, and the left joint surface 28 only needs to be provided with positioning holes 244, 264. Alternatively, in another embodiment of the present invention, the left housing 20 may be integrally formed with a positioning pin 60 protruding from the left joint surface 28, so that the left joint surface 28 does not need to be provided with positioning holes 244, 264, and the right joint surface 48 only needs to be provided with positioning holes 444, 464. Secondly, the present invention is not limited to protruding the positioning pin 60 on the right joint surface 48 and setting the positioning holes 244, 264 on the left joint surface 28. For example, the positioning pin 60 and the positioning holes 444, 464 can be set on the right joint surface 48 at the same time, and the corresponding positioning holes 244, 264 and positioning pin 60 can also be set on the left joint surface 28, so that the left joint surface 28 and the right joint surface 48 can be aligned and docked with each other. Alternatively, the positioning pin 60 is set on the left joint surface 28, and the positioning holes 444, 464 for inserting the positioning pin 60 are set on the right joint surface 48, which can also achieve the purpose of the invention of the present invention.
[0029] Finally, it must be stated again that the constituent elements disclosed in the aforementioned embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of this case. Replacements or changes to other equivalent elements should also be covered by the scope of patent protection of this case.
Claims
1. A brake caliper housing suitable for friction stir welding, characterized in that Contains: A left housing having a left joint surface; A right shell having a right joint surface, wherein the left joint surface and the right joint surface are fixedly connected by friction stir welding; The right joint surface protrudes with at least one positioning pin, the left joint surface has at least one positioning hole, and the at least one positioning pin is inserted into the at least one positioning hole, so that the left joint surface is in contact with the right joint surface.
2. The brake caliper housing suitable for friction stir welding according to claim 1, characterized in that: The right joint surface has at least one positioning hole, and the at least one positioning pin is inserted into the at least one positioning hole of the right joint surface and protrudes from the right joint surface.
3. The brake caliper housing suitable for friction stir welding according to claim 1, characterized in that: The right shell is integrally formed with at least one positioning pin protruding from the right joint surface.
4. The brake caliper housing suitable for friction stir welding according to claim 1, characterized in that: The left housing comprises a body, a front extension section extending from a top edge of the body toward the right housing, and a rear extension section extending from the top edge of the body toward the right housing and spaced apart from the front extension section, the front extension section having an end surface facing the right housing, the rear extension section having an end surface facing the right housing, the end surface of the front extension section and the end surface of the rear extension section jointly forming the left joint surface; The right shell includes a main body, a front extension section extending from a top edge of the main body of the right shell toward the left shell, and a rear extension section extending from the top edge of the main body of the right shell toward the left shell and spaced apart from the front extension section of the right shell. The front extension section of the right shell has an end surface facing the left shell, and the rear extension section of the right shell has an end surface facing the left shell. The end surface of the front extension section of the right shell and the end surface of the rear extension section of the right shell together form the right joint surface.
5. The brake caliper housing suitable for friction stir welding according to claim 1, characterized in that: The left housing has a fixing protrusion protruding in a direction away from the right housing, and the right housing has a fixing protrusion protruding in a direction away from the right housing.
6. The brake caliper housing suitable for friction stir welding according to claim 5, characterized in that: The left shell body includes a main body having a top edge and a bottom edge. The fixed protrusion of the left shell body has a top edge. The top edge of the fixed protrusion of the left shell body is lower than the top edge of the main body. The top edge of the fixed protrusion of the left shell body and the bottom edge of the main body respectively form a clamping surface that can be clamped by a clamp.
7. The brake caliper housing suitable for friction stir welding according to claim 5, characterized in that: The right shell includes a main body having a top edge and a bottom edge, and the fixed protrusion of the right shell has a top edge, the top edge of the fixed protrusion of the right shell is lower than the top edge of the main body, and the top edge of the fixed protrusion of the right shell and the bottom edge of the main body respectively form a clamping surface for clamping by a clamp.