Disc Brake Caliper Casting for Integrated Hydraulic Channels
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Solution Overview
Problem
The existing disc brake caliper manufacturing process faces challenges in forming hydraulic linking channels, which requires precise drilling and can lead to poor precision, long processing times, and unstable braking due to uneven oil pressure distribution, resulting in inferior products and poor cost performance.
Innovation Solution
The hydraulic linking channel is molded integrally with the cylinder-side hydraulic channels within the bridge section during casting, eliminating the need for post-casting drilling and ensuring uniform oil pressure distribution between the inner and outer caliper sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the hydraulic linking channel is formed by drilling after casting, then the channel can be created in the bridge section, but the processing precision becomes poor and productivity decreases due to long processing time and drill warping
Solution Approach 1:
The core is prepared in advance with the hydraulic linking channel formed within it before casting. This preliminary formation of the channel structure in the core eliminates the need for post-casting drilling operations, thereby improving both precision (avoiding drill warping) and productivity (eliminating long drilling time).
Solution Approach 2:
The mechanical drilling process is replaced by forming the hydraulic linking channel directly during the casting process through the pre-prepared core. This substitution eliminates the drilling operation entirely, resolving the contradiction between precision and productivity.
2Manufacturing precision
If the hydraulic linking channel is drilled from the inner caliper section through the outer caliper section, then the channel connects both sections, but the processing length becomes long causing drill warping and poor precision
Solution Approach 1:
The core is prepared in advance with the hydraulic linking channel already formed within it. This preliminary action creates the channel structure before casting, eliminating the need for long drilling operations through the caliper body and avoiding drill warping associated with long processing lengths.
Solution Approach 2:
Instead of creating the hydraulic linking channel through a long linear drilling path from one caliper section to another, the channel is formed within the core structure in three-dimensional space before casting. This dimensional approach allows the channel to be created without requiring long drilling paths.
3Reliability
If the hydraulic linking channel is formed by drilling, then the channel can be created, but the oil pressure distribution becomes uneven leading to unstable braking and inferior products
Solution Approach 1:
The core is prepared in advance with the hydraulic linking channel formed within it, ensuring proper channel geometry and positioning before casting. This preliminary formation ensures uniform oil pressure distribution, which directly improves braking stability and product reliability.
4Ease of manufacture
If the hydraulic linking channel is drilled after casting, then the channel can be created, but the processing time becomes long deteriorating cost performance
Solution Approach 1:
The hydraulic linking channel is formed within the core before casting, eliminating the need for post-casting drilling operations. This preliminary formation significantly reduces processing time and eliminates the associated costs, thereby improving cost performance.
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 improves productivity, ensures stable braking with reduced wear on brake pads, and enhances cost performance by eliminating the need for complex machining and ensuring consistent oil pressure application.
Implementation Method 1
A core 20 is used at the time of casting-molding the inner caliper section 12, the outer caliper section 13, and the bridge section 14 to form the cylinder-side hydraulic channels 16, 17 and the hydraulic linking channel 18. The core 20 is eliminated after casting-molding.
Data Source
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AI summary
A caliper comprises a hydraulic linking channel provided in a bridge section linking hydraulic cylinders, on an inner caliper section side, and hydraulic cylinders, on an outer caliper section side, to a cylinder-side hydraulic channel disposed on the back end of each respectively. A connecting channel forming section, which corresponds to each cylinder-side hydraulic channel and the hydraulic linking channel is provided, in advance, in a core used during casting of the inner caliper section, the outer caliper section, and the bridge section, and is formed by setting in a situation to be embedded at the same time as each caliper section and the bridge section are being integrally cast.