Hydraulic Unit Cavity Flat Surface for Direct Drilling
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Solution Overview
Problem
The production of hydraulic units, particularly those with inclined connecting bores, is hindered by large dimensional and surface tolerances in cast blanks, leading to increased manufacturing costs and tool changes due to the need for pilot bores, which complicates the manufacturing process.
Innovation Solution
A cast iron housing design featuring an inclined flat surface within the receiving cavity allows for direct drilling of connecting bores with narrow tolerances, eliminating the need for pilot bores and reducing tool changes, with the angle of inclination between 30° and 60° optimizing the contact surface for drilling tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pilot holes are created to provide optimal contact surface for drilling tools, then manufacturing precision of connecting bores is improved, but manufacturing time and device complexity increase due to additional process steps and tool changes
Solution Approach 1:
The casting process is designed to pre-create a substantially flat surface (Anschnittfläche) in the receiving cavity before the drilling operation. This preliminary action provides the optimal contact surface for the drilling tool, eliminating the need for pilot holes and enabling direct drilling of connecting bores to tight tolerances in a single operation.
2Manufacturing precision
If multiple process steps are used to create connecting bores with tight tolerances, then manufacturing precision is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The invention merges the surface preparation function into the casting process itself. The casting blank is designed with an integrated substantially flat surface (Anschnittfläche) that serves as the contact surface for drilling, combining what would traditionally be separate operations (surface preparation and drilling) into a single machining step.
3Manufacturing precision
If the flat surface is extended further into the outer surface, then tool support and drilling precision are improved, but material removal during machining increases
Solution Approach 1:
The flat surface (Anschnittfläche) is designed with specific geometric characteristics: it extends a controlled distance (e) from the bottom of the receiving cavity and has a width (b) that provides adequate tool support. The surface is positioned at an oblique angle (α) to the insertion axis, optimized to provide just enough contact area for precise drilling while minimizing unnecessary material that would require removal during subsequent machining.
Data Source
Figure 1a~3b
AI summary
The invention relates to a hydraulic unit (1) for generating brake pressure for a hydraulic brake system, comprising a housing (2) which is made from a cast blank (2') and has at least one cavity (3) for accommodating a nozzle (5) that is connected to a fluid container (4) and can be plugged into the cavity (3) along a plug-in axis (S). In order to create an improved hydraulic unit that is optimized in particular from a manufacturing point of view, according to the invention, the cavity (3) of the cast blank (2') has at least one substantially flat surface (6), the normal vector (N) of which extends at an oblique angle of inclination (W) relative to the plug-in axis (S).