Brake Pump Housing Non-Cutting Forming
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Solution Overview
Problem
The existing manufacturing processes for block-shaped pump housings in vehicle brake systems are costly due to machining requirements, which include deburring, machining oversize allowances, and the need for special holding surfaces, leading to increased material consumption and dimensional tolerance issues.
Innovation Solution
A method involving an extrusion process to create a block-shaped pump housing with final dimensions on both sides without cutting, using non-cutting forming techniques like pressing with rollers or stamps, eliminating the need for machining and providing enhanced corrosion protection through anodizing or plasma coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining processes are used to produce final dimensions, then dimensional precision can be achieved, but manufacturing cost and material waste increase
Solution Approach 1:
The pump housing blank is pre-formed during the extrusion process with dimensions that are already at or very close to the final required dimensions. This preliminary action eliminates the need for subsequent machining operations to achieve dimensional precision, thereby reducing manufacturing cost and material waste while maintaining the required precision standards.
2Manufacturing precision
If machining processes are used, then dimensional tolerances can be controlled, but material consumption increases
Solution Approach 1:
The extrusion process is designed to produce the blank with final dimensions and tolerances directly, eliminating the need for material removal through machining. This preliminary formation of the final shape during extrusion prevents material consumption that would otherwise occur during machining operations.
Solution Approach 2:
The extrusion process parameters are optimized to produce the blank with the required dimensional tolerances without the need for subsequent machining. By adjusting extrusion parameters such as temperature, pressure, and die design, the blank achieves the necessary dimensional precision directly from the extrusion process.
3Manufacturing precision
If machining and deburring are performed, then surface quality can be improved, but production time and cost increase
Solution Approach 1:
The extrusion process produces the blank with surface quality that meets the final requirements, eliminating the need for subsequent machining and deburring operations. This preliminary formation of the final surface quality during extrusion significantly reduces production time while maintaining the required surface standards.
4Manufacturing precision
If special holding surfaces are provided for machining, then machining stability can be improved, but device complexity increases
Solution Approach 1:
The invention extracts or eliminates the need for special holding surfaces by producing the blank with final dimensions directly during extrusion. Since no machining is performed, the complex holding surfaces and clamping mechanisms required for machining stability become unnecessary, thereby reducing device complexity.
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 reduces material waste, eliminates the need for machining and deburring, ensures precise dimensional tolerances, and simplifies the manufacturing process, resulting in cost savings and improved stability of the pump housing.
Implementation Method 1
a blank in the form of a strand is prepared by means of an extrusion process
Implementation Method 2
Pressing, in particular pressing with at least one roller or alternatively with at least one stamp, is preferably carried out as a non-cutting forming method
Implementation Method 3
Anodizing or atmospheric protection with plasma is advantageously provided as surface protection
Implementation Method 4
atmospheric protection with plasma
Data Source
Figure 1
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Figure 5~7
AI summary
In a pump housing (24), in block form, of a vehicle brake system, having a top side (63) which is manufactured to final dimensions and a bottom side (79) which is manufactured to final dimensions, the final dimensions of the top side (63) and of the bottom side (79) are obtained by means of a non-cutting deformation process (82) starting from a blank (42).