Monoblock Brake Caliper Sand Core Hydraulic Line Integration
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Solution Overview
Problem
Conventional brake caliper designs face issues with brake hydraulic line damage from external structures, inadequate hydraulic pressure transmission due to large line diameters, and limited directional fixing of brake hoses, leading to poor responsiveness and potential caliper movement during handling.
Innovation Solution
A method for manufacturing a monoblock brake caliper where brake hydraulic lines are press-inserted into a sand core before casting, allowing for thin hydraulic line formation inside the caliper and an omnidirectional brake hose fixing device with grooved bolts for secure, directional-free fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake hydraulic lines are placed inside the brake caliper, then protection from external damage is improved, but the diameter of the hydraulic line becomes difficult to reduce, worsening hydraulic pressure transmission characteristics
Solution Approach 1:
The hydraulic lines are inserted into the sand core before the casting process begins. This preliminary action allows the lines to be positioned precisely within the caliper body cavity before the metal is poured, enabling thin-walled lines (3-5mm thickness) to be formed accurately without being damaged during subsequent manufacturing steps.
Solution Approach 2:
The sand core serves as an intermediary structure that holds the hydraulic lines in place during the casting process. The sand core provides a protective matrix that maintains the precise positioning and dimensional accuracy of the thin hydraulic lines while the caliper body is being formed around them.
2Ease of manufacture
If conventional casting process is used, then manufacturing simplicity is maintained, but the thickness of brake hydraulic lines cannot be reduced to 3-5 millimeters, worsening brake responsiveness
Solution Approach 1:
The hydraulic lines are pre-positioned within the sand core structure before casting. This preliminary placement enables the formation of thin-walled hydraulic lines (3-5mm thickness) that would be difficult to achieve with conventional post-casting methods, while still using the straightforward casting process to form the caliper body.
Solution Approach 2:
The sand core provides localized support and dimensional control specifically at the hydraulic line positions, allowing thin-walled lines to be formed with precise thickness control (3-5mm) only where needed, while the rest of the caliper body is formed by the general casting process.
3Device complexity
If brake hose fixing device is configured for specific direction only, then manufacturing complexity is reduced, but the brake caliper may move during handling, worsening reliability
Solution Approach 1:
The brake hose fixing device is designed with omnidirectional grooves that can accommodate brake hoses approaching from any direction. This universal fixing capability allows the same device structure to secure the brake hose regardless of the caliper's orientation or handling position, preventing unintended movement while maintaining relatively simple device geometry.
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 ensures uniform and quick hydraulic pressure transmission to pistons, enhances braking responsiveness, and allows for neat cutting of unnecessary hydraulic line parts while enabling the brake hose to be fixed in any direction, reducing the risk of caliper movement.
Implementation Method 1
brake hydraulic lines in the form of a pipe are press-inserted into a sand core
Implementation Method 2
a casting process for molding the caliper body is carried out
Data Source
AI summary
A method for manufacturing a monoblock brake caliper in which brake hydraulic lines, which are pipes, are provided inside a caliper body and a brake hose fixing device is provided on the outside the caliper body, and a plurality of cylinders are cast by sand casting. Prior to the casting process for forming the caliper body, the brake hydraulic lines are pressed into a sand cast, and then the caliper body is formed by the casting process. The brake hose fixing device comprises: a brake hose fixing omnidirectional bolt which fixes by rotating into a thread on the caliper body; the brake hose seated on the brake hose fixing omnidirectional bolt; and a fixing nut which fixes the brake hose fixing omnidirectional bolt and brake hose by rotating same from the center thereof.