Vehicle Disc Brake Gate Mark Locking Design
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Solution Overview
Problem
The existing vehicle disc brake fabrication methods, such as gravity casting, require additional working hours and increased production costs due to the need for cutting the gate mark and forming projections to lock the banjo, which complicates the assembly and increases labor costs.
Innovation Solution
A vehicle disc brake design where a locking projection on the banjo is inserted into a locking hole formed on the gate mark's worked surface, with a projecting surface preventing contact with the floor and an uneven portion indicating the assembly direction, reducing the need for extensive working hours and allowing proper assembly with reduced surface area processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gate is cut and projections are formed to lock the banjo, then the banjo can be locked securely, but the number of working man-hours increases and production costs increase
Solution Approach 1:
The gate mark is formed with a worked surface and projecting surface during the initial gravity casting process, before the banjo assembly is performed. This preliminary formation of the gate mark structure eliminates the need for subsequent cutting operations to create locking features, thereby reducing working man-hours while ensuring reliable banjo locking through the pre-formed worked surface and projecting surface
2Ease of operation
If the gate is cut to form a gate mark, then the banjo can be locked, but the number of working man-hours increases
Solution Approach 1:
The gate mark with its worked surface and projecting surface is formed during the casting process itself, before assembly operations. This preliminary action eliminates the need for time-consuming post-casting cutting and projection formation operations, thereby reducing assembly time while maintaining ease of banjo assembly through the pre-prepared locking features
3Reliability
If projections are formed by cutting after casting, then the banjo can be locked, but production costs increase
Solution Approach 1:
The formation of the gate mark with its worked surface and projecting surface is merged into the gravity casting process itself. By combining the gate mark formation with the initial casting operation, separate post-casting cutting and projection formation operations are eliminated, thereby reducing production costs while ensuring reliable banjo locking through the integrated gate mark structure
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 design ensures secure locking of the banjo with fewer working hours, reduces production costs, and protects the union and locking holes from damage, while facilitating proper assembly and balanced placement of components.
Implementation Method 1
molten metal of the base material is poured from a gate opened in a bottom wall of a cylinder bore so that the whole of a cavity is filled with the molten metal by means of gravity
Data Source
AI summary
An embodiment discloses a vehicle disc brake including a caliper body, a banjo and a banjo bolt. An acting portion of the caliper body has a cylinder bore accommodating a piston. The caliper body is formed through a gravity casting method. A gate mark is formed on the bottom wall of the cylinder bore as a result of cutting the gate after the caliper body has been cast, and the gate mark includes a worked surface and a projecting surface. A union hole communicating with a hydraulic pressure chamber and a locking hole receiving the locking projection of a banjo are opened in the worked surface. And, an uneven portion is provided between the worked surface and the projecting surface.