Piston Manufacturing Device for Disc Brake Noise Reduction
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Solution Overview
Problem
Existing piston manufacturing devices experience variations in the shape of the surface that contacts the pad, leading to unstable surface pressure and brake noise in disc brakes.
Innovation Solution
A piston manufacturing device that includes a first forming device to create an annular groove and a second forming device to form a thick section from the inner circumferential surface, with a recessed section that plastically deforms the edge of the piston to stabilize the contact surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional pressing method is used to form the piston, then the manufacturing process is simple, but the shape of the contact surface varies
Solution Approach 1:
The patent applies local quality by providing different surface conditions at different locations of the forming device. Specifically, the first forming device has a smooth pressing surface while the second forming device has a rough pressing surface. This local differentiation allows the smooth surface to produce consistent contact surface shapes while the rough surface creates the desired thick section with folded structure, thereby resolving the contradiction between manufacturing precision and device complexity.
2Reliability
If the contact surface shape varies, then the manufacturing process is simple, but the surface pressure becomes unstable
Solution Approach 1:
The patent uses local quality principle where the first forming device's smooth pressing surface specifically addresses the contact surface area to ensure shape consistency, while the second forming device's rough pressing surface addresses the thick section formation. This localized functional differentiation ensures reliable surface pressure stability without requiring the entire forming device to be complex.
3Object-affected harmful factors
If the contact surface shape varies, then the manufacturing process is simple, but brake noise occurs
Solution Approach 1:
The patent applies local quality by assigning specific surface characteristics to specific forming devices. The first forming device with smooth pressing surface ensures consistent contact surface shape, directly addressing the brake noise issue. The second forming device with rough pressing surface handles the thick section formation, maintaining overall manufacturing simplicity while eliminating the harmful effect of brake noise.
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
The solution effectively suppresses variations in the piston's contact surface area, stabilizing surface pressure and reducing brake noise, while also simplifying the manufacturing process and reducing equipment costs.
Implementation Method 1
a recessed section is formed at a portion of the second forming device that is arranged to abut the edge so that an inner circumferential side of the edge is plastically deformed toward the other end side in the axial direction of the piston
Data Source
AI summary
A piston manufacturing device includes a first forming device (42) configured to form an annular groove (61) in a piston (11), and a second forming device (52) configured to press an edge (15) of an opening (14) of the piston (11) toward other end side in an axial direction of the piston (11) and to form a thick section (65) extruded from an inner circumferential surface (12b) arranged between the edge (15) and the groove (61) toward an axial center side of the piston (11), wherein a recessed section (53) is formed at a portion of the second forming device (52) that is arranged to abut the edge (15) so that an inner circumferential side of the edge (15) is plastically deformed toward the other end side in an axial direction of the piston (11).