FR2537229A1 - BRAKE CALIPER CASE, IN PARTICULAR PARTIALLY DISCREED DISC BRAKE, AND METHOD FOR MANUFACTURING THE SAME - Google Patents

Abstract

THE INVENTION RELATES TO A BRAKE CALIPER CASING, IN PARTIAL LINING DISC BRAKE IN PARTICULAR. THIS CASING ESSENTIALLY INCLUDES A FIRST RADIAL BRANCH 20 CONTAINING A BRAKE CYLINDER 30, A SECOND RADIAL BRANCH 36 AND A BRIDGE ELEMENT 34 CONNECTING THESE TWO BRANCHES. IT IS MADE IN TWO COMPLETELY MACHINED PARTS THEN ASSEMBLED BY WELDING 196 OF THEIR JUNCTION SURFACES 192, 194.

Description

The present invention relates to a brake caliper housing,

  particular disc brake with partial lining for a vehicle

  tomobile, this housing being constituted of at least two assembled parts

one to the other.

  German patent application DE-OS 27 10 511 discloses such a brake caliper. In this brake caliper housing, a first housing part comprises a radially extending arm, it contains a cylinder of brake, and axially and tangentially extending bridge member - a second housing portion

  In a second radial branch, which is arranged in front of the first

  first radial branch The joining surface between the two parts

  The casing extends perpendicularly to the axis of the brake cylinder.

  The two parts of the housing are held together by means of

threaded.

  This known brake caliper housing certainly already has the

  vantage inherent in a bipartition-that the cylinder bore can be arranged by proceeding from the brake disk side,

  without the opposite radial branch having to include a corresponding opening

  However, as a result of the assembly of the crankcase parts by means of

  bolts, this known housing can not be optimally

  male in terms of weight In addition, with this housing, the jaws

  brake can not be removed radially.

  The present invention therefore aims to improve the known brake caliper housing, so as to improve it for what

  is weight, bulk and simplicity of manufacture.

  According to the invention, this object is achieved by the fact that the housing parts, after complete machining, are mutually assembled

by welding.

  Thanks to the solution proposed by the invention, there are more assembly elements, such as threaded bolts, leading to an increase in weight As such assembly elements require

  space, the solution proposed by the invention is also advantageous.

  In the case of housings allowing a replacement of the linings by proceeding radially, there is no need for a bore. There is no need for a bore. no need to provide holes in the outer radial casing branch so that rigidity is not

not compromised.

  In an advantageous embodiment of the invention, starting from a casing having a first radial branch provided with a

  cylinder bore for receiving a piston, and having a second

  my radial casing branch and a bridge element connecting the branches

  the radial sump, welding is planned at the location of the

  of the bridge element to the first crankcase

  The weld can also be advantageously

  at the location of the transition from the bridge element to the second

  In both cases, it is provided, on the crankcase parts to be assembled, junction surfaces are perpendicular to the longitudinal axis of the housing In the second case

  In this case, the mutually assembled housing parts may also

  lay junction surfaces parallel to the longitudinal axis

dinal of the casing.

  Another solution according to the invention starts from a housing in which an axial cylinder bore provided in a first radial casing branch is through and closed by means of a cover, and plans to weld this cover to the radial casing branch. In an advantageous embodiment according to this solution, the cylinder bore has, at its inner end remote from the bridge member, a radial enlargement in which the lid is inserted, and the weld seam connects the peripheral surface of the cover on the surface of the inner periphery of the enlargement, this weld bead

  applying axially to the material surrounding the cylinder bore.

  One can also adopt an embodiment in which

  the cover is applied to the front face of the crankcase portion

  The cylinder and the weld bead are arranged around the periphery of this cylinder-housing part. It is then advantageous that the cover has an axially projecting outer edge and that the casing portion surrounding the cylindrical bore has an annular recess in which engages said edge of the lid, so that

  junction surfaces perpendicular to the longitudinal axis are formed

3-

  of the cylinder, which are assembled by means of a

welding gift.

  According to advantageous embodiments, the parts of

  crankcase assembled to each other are in different materials.

  In particular, it is advantageous that the housing part containing the

  cylinder made of nodular cast iron, cast aluminum, cast aluminum

  The crankcase portion comprising the bridge member advantageously consists of nodular cast iron, forged steel, or die-cast aluminum.

  may be advantageously chosen in particular cases

  liers. The invention also relates to a method of manufacturing a brake caliper housing, and provides that the crankcase parts

  having undergone their complete machining are mutually assembled by

dage.

  The process according to the invention leads to substantial advantages.

  during the manufacture of the brake caliper housing

  These include a simplification of manufacture and improvement of crankcase characteristics, as already indicated.

upper.

  In advantageous developments of the method according to the invention, it is envisaged that the realization of the welded assembly is carried out by

  electron beam welding, or laser welding.

  The crankcase parts to be assembled are preferably equipped with

  perpendicular junction surfaces or, where

  parallel to the longitudinal axis of the crankcase.

  Another advantageous solution includes a method in which

  the cylinder cover is also welded into the cylinder bore.

  In this case, the cylinder bore is first expanded in its

  inner end, then the lid is inserted into this widening

  the welding is carried out on the inner face of the

  housing part comprising the cylinder.

  In another mode of implementation of the method, the cover can also be placed on the front face of the housing part forming the cy

  lindre, and the weld be executed on the perimeter of this part.

  The crankcase parts can be advantageously manufactured

with different materials.

  The different objects and features of the invention are

  will now be detailed in the description which follows, made in

  by way of non-limiting example, with reference to the appended figures which represent

  FIG. 1 shows a front end of a disc brake with

  partial forms; Figure 2 is a plan view of the brake according to Figure 1;

  FIG. 3, a section taken along the line A-A of FIG.

  1 of the disc brake with partial lining; Figure 4 is a partial sectional view taken along the line B-B of Figure 1 of the disc brake with partial linings; Fig. 5 is a front view of the partial liner disc brake housing shown in Figs. 1 to 4;

  FIG. 6 is a partially cut-away plan view of the car-

  the disc brake with partial lining according to FIG. 5; Figure 7 is a longitudinal sectional view of a housing, shown schematically, a disc brake with partial liners; Figure 8 is a plan view of the housing according to Figure 7; FIG. 9, a longitudinal sectional view of another

  embodiment of a disk brake casing with

tial;

  FIG. 10 is a partial view in section of a closed cylindrical

  by means of a lid; Figure 11, another embodiment of a cylinder with closure by a lid; FIG. 12, another embodiment of a cylinder

closed by means of a lid; -

  FIG. 13, a third embodiment of a

  lindre closed with a lid;

  FIG. 14, a fourth embodiment of a

lindre closed by a lid; and

  FIG. 15 is a sectional view of another embodiment of

  sation of a brake caliper housing.

  We will first consider Figures 1 to 6 which represent

  a complete partial disc brake in which the

  The embodiments provided by the invention are implemented.

  The partial-lined disc brake shown in FIGS. 1 to 6 is intended to be mounted in a motor vehicle. It comprises a brake support, 2, which can be bolted next to a brake disc 8, on a Rocket yoke, axle or any other component of a vehicle wheel suspension

  The brake support 2 consists of two arms

  10, 12 arranged tangentially at a distance from each other, se-

  In a configuration substantially V-shaped At their ends remote from the axis of the wheel, these arms have bores 14, 16, the bore 14 in the arm 10 is arranged in a bulge 18, directed axially, to the outer end of this arm 10 This bore receives, with the possibility of axial sliding, a guide bolt 22 arranged on a stirrup 20, as described later in detail In the bore 16 of the arm 12 of the support is fixed a guide pin 24 which extends axially and which is arranged, with possibility of axial sliding in a bore of the stirrup 20, directed axially, as it will be

also explained later.

  The caliper 20 of the brake is made substantially in the form of a clevis and has a first branch 28 directed radially, which

  form a brake cylinder 30 receiving a brake piston (not shown).

  The branch 28 is connected with a bridge element 34 extending

  in the axial direction and in the peripheral direction and passing over the disk 8 of the brake On its other side, the bridge element 34 is connected to a second branch 36 directed radially Laterally next to the brake cylinder 30, the branch 28 is provided with an axially extending bore 38, in which is fixed the guide bolt 22 which also extends axially By its free end protruding

  out of the bore 38, the guide bolt 22 engages, as already in-

  in the bore 14 of the arm 10 of the brake support, in which it can slide axially. The diameters of the guide bolt 22 and the bore 14 are mutually harmonized so that the guide bolt 22 forms, with bore 14, a fixed bearing 6 -

  guide pin 24 fixed in the arm 10 of the brake support

  poured, by its free end, a bore 40 provided in the stirrup 20,

  on the other side of the brake cylinder 30 The guide pin 24 pre-

  Here, there is a smaller diameter than the bore 40, so that an interstitial space 42, in the shape of a circular ring, is formed between the guiding pin 24 and the bore 40, and that the guide pin 24 is

  mobile radially and tangentially in this interstitial space.

  To dampen these movements, an elastic sleeve 44, made for example

  The resilient bush 44 is substantially cylindrical in shape and has on its outer periphery an annular bulge 46 which sits in an annular groove 48 of corresponding shape, arranged in the groove 40 of the yoke 20.

  bore 40, which has the effect that the elastic sleeve 44 is now

held in the bore 40.

  With the described arrangement of guide bolt 22, guide pin 24 and associated bores, the brake caliper is axially slidable on the brake support 2 and, as already indicated, the guide bolt 22. forms with the bore 38 a fixed bearing, and the guide pin 24 forms, with the bore 40, a bearing

mobile.

  In the brake support 2 is arranged a guide corridor forming two mutually parallel contact surfaces 52, 54 separated by a circumferentially spaced gap, between which an inner brake jaw 56 is guided by its back plate 58 A guide corridor corresponding, 60, is arranged opposite, on the other side of the disk 8, in the branch 36 of the caliper 20 This guide channel, 60, also has two contact surfaces 62 and 64 between which a brake shoe 66 is arranged with its back plate 68 in the bridge element 34 of the stirrup 20, it is

  provided a through opening 70, having a shape substantially rec-

  tangible, which allows access to the brake shoes 56 and 66 The brake shoes 56, 66 can easily be inserted in

  their guide openings 50, 60 or be extracted therefrom

radial effect.

  To prevent the brake shoes 56, 66 from escaping,

  their back plates 58 and 68 have, on both sides, openings

  elongated through tails of which only one, 72, 74, is shown

  for each jaw in Fig. 2 Retaining pins 76, 78 -

  axially directed packings run through these openings 72 and 74.

  These lining retaining pins 76 and 78 take their seat in holes 80 and 82 facing each other in the caliper 20. The stop of the lug retainer pins 76 and 78 is obtained by means of FIG. 'a

  deformable element 84, barrel-shaped, which is arranged to their ex-

  inner trough and by means of which the retaining pin 76 is

  In addition, there are provided packing retainers, 86 and 88, which are substantially H-shaped and extend parallel to the jaws 56 and 66. The legs 90, 92,

  94, 96 of the packing retaining springs turned towards the disc.

  8 of the brake are longer than the branches 98, 100, 102 and 104 not facing the brake disc, and pass below the pins

  retainer, 76 and 78 The median surfaces 106 and 108 of the

  Trim retainer springs 86 and 88 apply to the upper sides of the back plates 58, 68, and the short limbs, 98,

  , 102 and 104 apply against the rear sides of

sales 58, 68.

  The guide bolt 22 has a fixing portion, and a portion of: guiding 112 The fixing portion 110 takes its seat in the bore 14 formed in the stirrup 20 to which it is welded the weld seam is made by a welding process

  electron beam, assembling the contact-mutual surfaces of the

  22 for the purpose of saving weight, there is provided in the fixing portion 110 a central recess 114

  which is closed by means of a plastic plug 116, the

  mounting portion 110 to guide portion 112

  is rounded 118 so as to avoid stress by notching.

  In the guiding portion, an annular groove 120 is provided.

  the inner end of a rubber seal 122 which, by its outer end 124 is fixed, by means of a ring 126, on a circular peripheral surface of the axial bulge 18 The guide portion 112 has a lubrication groove 128 , from 8 -

helical shape.

  As can be seen in particular in Figures 6 and 9, the brake cylinder 30 has a through cylindrical bore 130 closed by means of a cover 132 This cylinder cover sits in a widening 134 of the cylindrical bore and is applied against a shoulder 136 formed between the actual bore 130 of the

  cylinder and enlargement 134 The connection of the lid 132 to the cylinder

  30 is obtained by electron beam welding, the S-S weld connecting the surface of the periphery of the cover 132 to the inner surface

  enlargement 134, so that there is a weld seam

circular route 138.

  Other embodiments of the connection assembling a decylinder cover to the housing are visible in FIGS. 10 and 11

  In the embodiment according to FIG. 10, the bore 142 of the

  For this purpose, the lid 140 of the cylinder pre-

  a relief 144 penetrating inside the bore 142 of the cy-

  lindre A peripheral recess 146 is thus formed between this recess

  lief 144 and the portion of the lid 140 of the cylinder, and this lid

  is applied, by its radially projecting edge, 148, on the sup-

  front face 150 bordering the bore 142 of the cylinder With this agency-

  the weld seam 152 follows a path perpendicular to the axis of the cylinder, between the front surface 150 and the edge 148 of the cover of the

cylinder -

  In the embodiment shown in FIG. 11, the lid 154 of the cylinder externally has a bead 156

  sitting in a peripheral recess 158 of the portion presenting the

  160 of the cylinder the front surface 162 of the portion surrounding the bore 160 is thus arranged stepwise, and the weld bead 162 follows a path perpendicular to the axis of the cylinder in the region of the frontal surface 164 of the bead 156 and of the corresponding part

of the frontal surface 166.

  The embodiment shown in FIG.

  a cylinder cover, 168, which is fully inserted into a cylinder

  The weld bead 172 here follows a parallel path.

  aligns with the axis of the cylinder bore, between the peripheral surface 9

  the cover 168 and the inner surface of the bore 170 of the cylinder.

  In order to avoid the formation of an inner crater during electron beam welding, the weld bead to be applied externally is executed not from one end to the other but to a depth less than that of the cover 168. cylinder cover 168 has a

  recess 174, to obtain a weight reduction.

  The cover 168 is forced back (to the press) into the

  The welding of the cylinder can therefore be carried out only

  In order for the cover 168 to be forced back into the

  wise of the cylinder, a rubbing strip 169 is provided on the edge,

  inner side of the cover 168.

  A third embodiment of a closed cylinder 218

  by means of a cover 2 i 6 is shown in FIG.

  The extreme king 220 is here, as is the lid 216, made in grain between the outer part of the lid 216, the one with the smaller diameter, and the corresponding outer part of the end wall 220,

  it is planned a weld 222 As it is the staggering 224 that will sup-

  carry the forces due to the pressure developed inside the cy-

  linder 218 when braking, welding here essentially

as a sealing function.

  A fourth embodiment is shown in FIG. 14. In this variant, the front wall 226 of the cylinder 228 is further closed, so that the diameter of the cover 230 is smaller between the peripheral surface of the cover 230 and the inner wall of the housing. bore receiving the lid 230, there is, again,

  a weld bead 232 The cover is forcibly mounted in the

  wise, and the depth of the weld seam is less than the depth

  occupied by the cover The relative smallness of the diameter of the

  cover 230 leads to a low load of the connection between this cover

  230 and the front wall 226.

  In FIGS. 7 and 8, there is shown diagrammatically a

  brake caliper casing 20 This casing 20 corresponds, as to the principle

  1 to 6 and 9 to 11. FIGS. 7 and 8 serve in particular to better show the subdivision of the brake caliper housing and the position of the cords.

Welding.

  The brake caliper housing 20, as also described above, has first and second radial branches 28 and 36 which are connected by means of a bridge element 34. In the embodiment shown here, the branch 28 which contains the brake cylinder 30 is a first housing part 188, while tv &

  bridge 34 and the second radial branch 36 constitute one

  part of the housing, 190 at its end facing the element

  bridge 34, the first housing part 188 has a junction surface

  perpendicular to the axis of the cylinder, and the second housing portion 190 forms, at the end that the bridge member 34 comprises facing the brake cylinder 30, a corresponding abutment junction surface 194 These junction surfaces 192 and 194 applied against each other are assembled by means of a weld bead 196 made by electron beam welding or by

laser welding.

  In another embodiment, a weld seam

  198 passes between the branch 36 and the end that the bridge element 34 com-

  door opposite this branch 36 This weld bead 198 is

  The alternative is to use a weld bead 200 disposed parallel to the axis of the cylinder, as also represented by a FIG. 7 and 8 diagrammed by means of a zig-zag line.

zig-zag line in Figure 7.

  The parts of casing 188 and 190 can be in

  In particular, a material such as nodular iron, cast aluminum, forged aluminum, or die-cast aluminum is suitable for the housing portion 188, while for the housing portion 190 it is advantageous to use the nodular iron. , forged steel, cast aluminum, forged aluminum or die-cast aluminum

  The most diverse combinations of these materials are

  depending on the particular application.

  When producing the brake caliper cover the parts

  Housing parts 188 and 190 are completely machined before welding,

  that is, the housing portion 188 is provided with the bore of

  130 and grooves 202 and 204 for receiving gasket

I 11 -

  Evenness and cuffs ("soft joints") If the cylinder bore 130,

  142, 160 is embodied as a through-hole, as shown in FIG.

  shown in FIGS. 7 to 11, the contact surfaces for covering

  The cylinder part is then already machined during this step of the process. Similarly, the casing portion 190 goes through all the machining operations necessary for its complete elaboration. After the casing parts 188 and 190 have been thus completely fabricated. they are assembled by electron beam welding or by laser welding. The welding of the cylinder cover can be carried out

  performed before or after welding the crankcase branches.

  Figure 15 shows an embodiment of a brake caliper housing 234 in which the radial housing portions 236 and 238 and the spool element 240 are executed in one piece in the radially located housing portion 228. on the outside, there is provided a through recess 242 with a U-shaped cross-section through which the bore 244 of the cylinder can be arranged. In this recess 242 there is inserted a pressure plate 246 whose outside contour is adapted to at least partially at the contour of the recess The pressure plate 246 and the radial housing portion 238 are welded one to the other.

  to the other by a welding process such as electron beam,

  laser welding, or any other suitable welding process.

  design leads to a particularly simple manufacturing method.

  The final welding of the pressure plate 246 makes it possible to obtain a

  bearing surface for an external brake lining (not shown

  ted), and leads to an increase in the rigidity of the casing.

12 -

Claims (22)

  1 Brake caliper cover, in particular disc brake with   partial fittings for a motor vehicle, this casing being   at least two parts joined to each other, characterized in that the housing parts (188, 190), after complete machining,   are joined together by welding -   2 Carter according to claim 1, having a first radial portion provided with a cylinder bore for receiving a piston, and having a second radial casing branch and a bridge element connecting the radial casing branches, characterized in that the weld is planned at the location of the transition from the element to   bridge (34) to the first housing branch (28), the one containing the wise of cylinder (30).   3 Carter according to claim 1, having a first radial casing branch provided with a cylinder bore for receiving a piston and having a second radial casing branch and a bridge element connecting the radial casing branches, characterized in that the welding is planned at the location of the transition of the element   bridge (34) to the second radial casing branch (36).   4 Carter according to claim 2 or 3 characterized in that   that the crankcase parts to be assembled (188, 190) have   junction faces (192, 194) perpendicular to the longitudinal axis of the housing.   Housing according to Claim 3, characterized in that the mutually assembled housing parts (188, 190)   junction surfaces parallel to the longitudinal axis tudinal of the housing.   Carter, particularly according to any one of the claims   preceding embodiments, in which an axial cylinder bore provided in a first radial casing branch is through and closed by means of a cover, characterized in that the cover (132, 140,   144) is welded to the radial casing branch (28).   Carter according to claim 6, characterized in that   the cylinder bore (130) has at its inner inner end   of the bridge element (34), a radial enlargement (134), in that the lid (130) is inserted into this enlargement (134), and in that   that the weld bead (138) connects the peripheral surface of the neck   around the inner periphery of the enlargement, this   weld-donate axially applied to the material surrounding the   wise (130) of the cylinder 8 Carter according to claim 6, characterized in that the   cover (140) is applied to the front face of the body limb.   ter (128), and in that the weld seam (152) is located on the   around the part of the casing branch forming the cylinder.   9 Carter according to claim 8, characterized in that the cover has an outer bead (156) protruding axially and in that the housing branch surrounding the cylinder bore (160)   externally has an annular recess (158) in which   securing said bead (156) of the cover so that abutment surfaces perpendicular to the longitudinal axis of the cylinder are formed, which are assembled by means of a weld seam (162).   Housing according to Claim 8, characterized in that the cover has, inwardly, a relief (144) penetrating into   the cylinder bore and adapted to it -   The housing according to claim 6, characterized in that the cover is fully inserted into the cylinder bore and that the weld bead passes parallel to the axis of the cylinder bore between the peripheral surface of the cylinder bore. lid and surface   inside the cylinder, the depth of the weld seam being less   the depth occupied by the edge of the lid.   Carter according to any one of the preceding claims   characterized in that the housing parts (188, 190) are in different subjects.   13 Carter according to claim 12, characterized in that the casing branch (28) containing the cylinder is made of nodular cast aluminum die cast aluminum, or forged aluminum.   Carter according to any one of the preceding claims   characterized in that the housing portion containing the element 14 - bridge (34) is made of nodular cast iron, forged steel, cast aluminum,   made of forged aluminum, or die-cast aluminum.   Method of manufacturing a brake caliper housing   also a floating caliper brake with partial fittings for vehicles   automobile parts, in which at least two crankcase parts constituting the crankcase are made as raw parts and   substantially completely, characterized in that the parts of the car-   ter having undergone their complete machining are mutually assembled by welding. Method according to claim 15, characterized in that the welded joint is produced by welding with electron beam.   Method according to claim 15, characterized in that   the welded joint is made by laser welding.   Method according to any one of claims 15 to   Characterized in that the housing has a first radial housing leg having a cylinder bore for receiving a piston, and has a second radial housing leg and a bridge member connecting said crankcase branches, characterized in that than   the welded joint is made at the location of the transition of the   bridge to the first crankcase, the one containing the wise of cylinder.   Method according to any one of claims 15 to   17, in which the casing has a first crankcase branch   equipped with a cylinder bore for receiving a piston and   a second radial casing branch and a bridge element connecting the radial casing branches, characterized in that the welded assembly is made at the point of transition from the bridge element to the casing.   second branch of radial casing.   A process according to any one of claims 18 or   19, characterized in that the casing branches to be assembled are   tees of joint surfaces perpendicular to the longitudinal axis of the housing.   Method according to claim 19, characterized in that: the casing branches to be assembled are provided with joint surfaces - parallel to the crankcase axis.   Process, especially according to any one of the claims   cations 15 to 21, wherein an axial cylinder bore provided in a first radial casing leg is formed as a through-hole and closed by means of a cover, characterized in that   that the cover is welded to the radial casing branch.   Method according to claim 21, characterized in that the cylinder bore is widened at its inner end, in that the cover is inserted into the enlargement, and in that the welding is effected on the inner end face of the branch of casing containing the cylinder.   Method according to claim 22, characterized in that the cover is applied to the front face of the casing branch and the cylinder, and that the welding is carried out around the circumference. of this branch.   A process according to any one of the preceding claims   characterized in that the crank springs are made of different types.   Carter according to any one of claims I to 14,   wherein the cylinder bore is closed by means of a lid,   characterized in that the cover (168) is force-fitted in the Wise cylinder (170).   27 Carter according to claim 26 characterized in that the cover (168) has a rubbing strip (169) on its edge, interior side.   Carter according to any one of claims 6 to   14, and 26, 27, characterized in that the welding performed is a welding by points.   Carter according to any one of claims 2 to 14   or 25 to 28, characterized in that the outer radial casing portion   (238) has an axially translating recess (242) into which a pressure plate (246) is inserted welded to this housing part.