Brake Pump Piston Press Forming Piercing
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Solution Overview
Problem
The existing manufacturing methods for pistons in brake system pumps, which involve forging and cutting processes, result in increased costs and decreased productivity due to lengthy processing times and complex configurations.
Innovation Solution
A method of manufacturing pistons using press forming and a piercing process to create a hollow cylindrical piston with an inlet path communicating with a suction port, incorporating a piston spring, valve seat, and filter member, which simplifies the structure and reduces manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the piston is manufactured by forging process and inlet path is formed by cutting process, then the structural strength is improved, but manufacturing cost increases and productivity decreases due to long processing time
Solution Approach 1:
The patent combines the piston body formation and inlet path creation into a single press forming process with piercing operation, eliminating the need for separate forging and cutting processes. This integration maintains structural integrity while significantly reducing manufacturing steps and processing time, thereby improving productivity without compromising strength
Solution Approach 2:
The inlet path is formed by piercing during the press forming process itself, before final assembly. This preliminary formation of the inlet path eliminates subsequent cutting operations and reduces the number of manufacturing steps, directly addressing the productivity issue while maintaining the structural requirements
2Strength
If the piston is manufactured by forging process and inlet path is formed by cutting process, then the structural strength is improved, but manufacturing cost increases due to complex processing
Solution Approach 1:
The patent merges multiple manufacturing operations (piston forming and inlet path creation) into a single press forming process with integrated piercing. This consolidation reduces the number of manufacturing steps, lowers production complexity, and decreases manufacturing cost while maintaining the necessary structural strength of the piston
Solution Approach 2:
The patent extracts the inlet path formation from the traditional multi-step forging and cutting process, implementing it as an integrated piercing operation within press forming. This extraction simplifies the manufacturing流程, reduces complexity, and lowers costs while preserving structural integrity
3Manufacturing precision
If traditional forging and cutting processes are used, then manufacturing precision can be achieved, but processing time increases leading to decreased productivity
Solution Approach 1:
The patent combines piston body formation and inlet path creation into a single press forming operation with integrated piercing. This merging maintains manufacturing precision for both the piston geometry and inlet path positioning while dramatically reducing total processing time compared to sequential forging and cutting operations
Solution Approach 2:
The inlet path is preliminarily formed by piercing during the press forming process itself, before final assembly and other subsequent operations. This preliminary action ensures precise inlet path positioning is achieved in the main forming step, eliminating the need for separate cutting operations and reducing total processing time
Data Source
AI summary
According to the embodiment of the present disclosure, it provides a method of manufacturing a piston of a pump for brake system, the piston fabricated using a piercing process by press forming to have an inlet path communicating with a suction port through which oil is introduced.