Brake Boot Assembly and Air-Tightness Inspection Method
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Solution Overview
Problem
Conventional methods for assembling and inspecting waterproof and dustproof boots in hydraulic brakes are prone to damage during assembly and fail to effectively test air-tightness, making it difficult to ensure the quality of the brake assembly.
Innovation Solution
A method and apparatus that involve engaging one end of the boot with the cylinder and moving the piston to restrict the movement of the other end, allowing it to be fitted into an annular groove on the piston, while monitoring pressure changes to assess the boot's air-tightness by separating the piston from the oil seal and pressurizing the cylinder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional assembly methods using jigs are used to assemble the boot to the cylinder and piston, then the boot can be assembled, but the boot is liable to be damaged during the pushing motion
Solution Approach 1:
A taper member is introduced as an intermediary tool between the assembly jig and the boot. The taper member gradually enlarges the inner diameter of the boot during assembly, distributing the deformation force evenly and preventing sudden stress concentration that would damage the boot. This mediator allows the boot to be assembled without direct pushing forces that cause damage.
Solution Approach 2:
The inner diameter of the boot is gradually changed from its initial state to the final fitted state through the taper member. By controlling the parameter change (inner diameter enlargement) in a progressive manner rather than a sudden push, the boot material can deform smoothly without exceeding its elastic limit, thus preventing damage while achieving proper fit.
2Ease of manufacture
If conventional assembly methods are used, then the boot can be assembled, but it is difficult to inspect air tightness of the boot
Solution Approach 1:
The assembly process and air tightness inspection process are merged into a single integrated operation. After the boot is assembled using the taper member, air is immediately introduced into the closed space between the boot, piston, and cylinder to inspect for leaks. This combination eliminates the need for separate inspection steps and ensures quality control is built into the manufacturing process.
3Manufacturing precision
If the boot is assembled with minimal expanding allowance, then the assembly precision is improved, but the piston cannot be withdrawn sufficiently to fit the boot end into the annular groove
Solution Approach 1:
The boot is preliminarily fitted to the cylinder body before the piston is fully withdrawn. The taper member enlarges the boot's inner diameter in advance, allowing the boot to be positioned on the cylinder. Then the piston is withdrawn, and the boot's other end is fitted into the annular groove. This preliminary fitting action allows minimal expanding allowance to be used while still achieving proper fit at both ends.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly process, reduces damage to the boot, and allows for effective inspection of air-tightness, enhancing the quality of the brake assembly by identifying any issues during the assembly process.
Implementation Method 1
an annular boot (9) which can be expanded and contracted according to movements of a piston (8)
Implementation Method 2
by separating the piston from the oil seal and pressurizing the cylinder
Data Source
AI summary
A brake includes an annular boot which can be expanded and contracted according to movements of a piston and is assembled to an opening part of a cylinder and to an annular groove on an outer peripheral face of the piston. The boot is assembled by: engaging one end of the boot with the opening part of the cylinder in a state where the piston is contained in the cylinder; moving the piston so that at least a part of the piston is withdrawn from the cylinder and that the other end of the boot is pressed by a pressing face of the piston; and fitting the other end of the boot into the annular groove of the piston, while a movable range of the other end of the boot is restricted by an expanding allowance of the boot whose one end is engaged with the opening part of the cylinder.