Brake Caliper Interior Machining Through Bridge Access Openings
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Solution Overview
Problem
One-piece brake calipers present challenges in machining support surfaces due to limited access and precision issues, as existing methods require complex movement sequences that introduce bearing play, affecting machining precision.
Innovation Solution
A method where a tool is guided into the brake caliper cavity through an opening other than the assembly opening, allowing for high-precision machining by using a tool holder with a rotary drive and a workpiece holder that moves in multiple axes, eliminating additional movement options and bearing play.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece brake caliper design is used, then assembly and fitting problems are eliminated, but access to certain areas for machining support surfaces is limited
Solution Approach 1:
The caliper is divided into two separate caliper sections (first caliper section and second caliper section) that are connected via a bridge section. This segmentation allows machining tools to access the rear end of the brake lever through openings in the bridge section, while maintaining structural integrity through the connection between sections.
2Ease of operation
If complex movement sequences are used for machining, then support surfaces can be accessed, but bearing play increases and machining precision deteriorates
Solution Approach 1:
By segmenting the caliper into separate sections connected by a bridge, the invention creates direct access paths through the bridge section to the rear end of the brake lever. This eliminates the need for complex L-shaped tool holder movements and multiple motion sequences, allowing straightforward tool access without introducing bearing play.
3Manufacturing precision
If working openings are added for machining, then support surfaces can be machined, but the openings serve no function during brake operation
Solution Approach 1:
The bridge section serving as both a structural connector and a machining access pathway is a multi-functional element. The openings in the bridge section that facilitate tool access to the rear end of the brake lever also serve as functional features in the assembled brake system, eliminating the need for separate non-functional working openings.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for machining the interior of a brake caliper (1) of a disc brake, on which are formed: - a first saddle portion to the one side of the brake disc of the disc brake, - a second saddle portion to the other side of the brake disc, and - a bridge section connecting the saddle portions and providing a free space for at least a part of the brake disc. At least one of the saddle portions is provided with a hollow space (7) for receiving a brake application device, wherein said hollow space comprises a mounting opening (4) towards the free space and extends in the opposite direction until a saddle rear wall (18). At least one support surface for the forces acting during the brake application is formed on the inner side of the saddle rear wall. The machining of the support surface (20) is carried out from the direction of the free space and, for this purpose, a tool (55) is brought from outside of the brake caliper (1) into the hollow space. In order to provide a method for machining the interior of a brake caliper of a disc brake, which allows a high-precision machining of the support surfaces inside the brake caliper even in the case of the narrow space conditions which are typical for the machining of a single-piece brake caliper, the tool (55) is guided into the cavity through another opening (25) than the mounting opening (4).