全封闭湿式多盘停车制动器设计【载重5T 满载质量10T】【说明书+CAD】
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载重5T 满载质量10T
说明书+CAD
全封闭湿式多盘停车制动器设计【载重5T
满载质量10T】【说明书+CAD】
封闭
湿式多盘
停车
制动器
设计
载重
满载
质量
10
说明书
CAD
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英文原文:Disc BrakesDisc brakes are used on the front wheels of most cars and on all four wheels on many cars. A disc rotor is attached to the wheel hub and rotates with the tire and wheel. When the driver applies the brakes, hydraulic pressure from the master cylinder is used to push friction linings against the rotor to stop it.In the disc brake rotor assembly, the rotor is usually made of cast iron. The hub may be manufactured as one piece with the rotor or in two parts. The rotor has a machined braking surface on each face. A splash shield, mounted to the steering knuckle, protects the rotor from road splash.A rotor may be solid or ventilated. Ventilated designs have cooling fins cast between the braking surfaces. This construction considerably increases the cooling area of the rotor casting. Also, when the wheel is in motion, the rotation of these fan-type fins in the rotor provides increased air circulation and more efficient cooling of the brake. Disc brakes do not fade even after rapid, hard brake applications because of the rapid cooling of the rotor.The hydraulic and friction components are housed in a caliper assembly. The caliper assembly straddles the outside diameter of the hub and rotor assembly. When the brakes are applied, the pressure of the pistons is exerted through the shoes in a clamping action on the rotor. Because equal opposed hydraulic pressures are applied to both faces of the rotor throughout application, no distortion of the rotor occurs, regardless of the severity or duration of application. There are many variations of caliper designs, but they can all be grouped into two main categories: moving and stationary caliper. The caliper is fixed in one position on the stationary design. In the moving design, the caliper moves in relation to the rotor.Most late-model cars use the moving caliper design. This design uses a single hydraulic piston and a caliper that can float or slide during application. Floating designs float or move on pins or bolts. In sliding designs, the caliper sideways on machined surfaces. Both designs work in basically the same way.In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting.In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting.Inboard refers to the side of the casting nearest the center line of the car when the caliper is mounted. A fluid inlet hole and bleeder valve hole are machined into the inboard section of the caliper and connect directly to the piston bore.The caliper cylinder bore contains a piston and seal. The seal has a rectangular cross section. It is located in a groove that is machined in the cylinder bore. The seal fits around the outside diameter of the piston and provides a hydraulic seal between the piston and the cylinder wall. The rectangular seal provides automatic adjustment of clearance between the rotor and shoe and linings following each application. When the brakes are applied, the caliper seal is deflected by the hydraulic pressure and its inside diameter rides with the piston within the limits of its retention in the cylinder groove. When hydraulic pressure is released, the seal relaxes and returns to its original rectangular shape, retracting the piston into the cylinder enough to provide proper running clearance. As brake linings wear, piston travel tends to exceed the limit of deflection of the seal; the piston therefore slides in the seal to the precise extent necessary to compensate for lining wear.The top of the piston bore is machined to accept a sealing dust boot. The piston in many calipers is steel, precision ground, and nickel chrome plated, giving it a very hard and durable surface. Some manufacturers are using a plastic piston. This is much lighter than steel and provides for a much lighter brake system. The plastic piston insulates well and prevents heat from transferring to the brake fluid. Each caliper contains two shoe and lining assemblies. They are constructed of a stamped metal shoe with the lining riveted or bonded to the shoe and are mounted in the caliper on either side of the rotor. One shoe and lining assembly is called the inboard lining because it fits nearest to the center line of the car. The other is called the outboard shoe and lining assembly.As already mentioned, the caliper is free to float on its two mounting pins or bolts. Teflon sleeves in the caliper allow it to move easily on the pins. During application of the brakes, the fluid pressure behind the piston increases. Pressure is exerted equally against the bottom of the piston and the bottom of the cylinder bore. The pressure applied to the piston is transmitted to the inboard shoe and lining, forcing the lining against the inboard rotor surface. The pressure applied to the bottom of the cylinder bore forces the caliper to move on the mounting bolts toward the inboard side, or toward the air. Because the caliper is one piece, this movement causes the outboard section of the caliper to apply pressure against the back of the outboard shoe and lining assembly, forcing the lining against the outboard rotor surface. As the line pressure builds up, the shoe and lining assemblies are pressed against the rotor surfaces with increased force, bringing the car to a stop.The application and release of the brake pressure actually causes a very slight movement of the piston and caliper. Upon release of the braking effort, the piston and caliper merely relax into a released position. In the released position, the shoes do not retract very far from the rotor surfaces. 外文翻译：盘式制动器许多汽车所有四个车轮，盘式制动器是用在大多数轿车的前轮上。制动盘安装在轮毂上随着轮胎和车轮转动。当汽车制动时，液压主缸推动摩擦片使其停止转动。 在盘式制动器的转动部件中，制动盘通常是使用铸铁制造。轮毂和制动盘可制造为一体或两部分。制动盘的每个面都要加工为制动表面。一块防护板，安装在转向节上，保护制动盘不被飞溅物污染。制动盘可以是实心或有通风孔。拥有通风孔的制动盘表面之间设有散热片。这种结构大大提高了制动盘的散热面积。此外，当车轮在运动时，这些风扇型散热片在制动盘旋转时增大空气流通并提供更有效的制动冷却。盘式制动器不会受热变形，即使快速、强制制动，原因就是制动盘的快速冷却。液压和摩擦部件都安装在制动钳总成中。制动钳跨越轮毂和制动盘外径。当制动器作用时，通过活塞推动制动块在夹紧制动盘的过程中产生压力。由于在制动过程中液压压力等于应用于制动盘两侧，制动盘没有出现变形，无论过程的压力多大和持续时间。也有许多种制动钳，但他们都可以分为两大类：移动和固定卡钳。固定式卡钳是固定在一个固定的设计位置上。在移动式设计中，制动卡钳相对于制动盘移动。 大多数晚期制造的汽车使用移动式卡钳。在设计中采用一个单独的液压活塞和能够在制动过程中滑动或摆动的卡钳。在滑动设计中卡钳在导向销上移动。在摆动式设计中，卡钳在垂直表面内摆动。这两种设计的工作方式基本相同。在单活塞浮动卡钳中，单活塞卡钳大多是由一个单一的铸件构成，其中包含一个大型钻孔作为铸件的内侧部分。内侧是指卡钳安装时靠近汽车铸件的一面。制动液入口孔和排气孔的加工成的卡钳内侧部分，直接连接到活塞孔。制动钳缸包含一个活塞和密封圈。该密封圈具有矩形截面。它坐落在一个在缸体的加工孔槽。适合的密封活塞周围的外径，并提供了活塞与缸壁液压密封件。长方形的密封圈提供制动盘和制动块之间的间隙自动调整。当汽车制动时，密封圈在活塞给予的摩擦力作用下变形。当液压压力释放，密封放松，并变回其原来的长方形，回缩进入气缸的正常运行提供足够的间隙活塞。由于制动器衬片的磨损，活塞行程往往超过了密封圈地挠度限制。因此，活塞密封圈能够精确对衬片的磨损进行补偿。加工活塞的顶部孔安装一个密封防尘罩。在许多卡钳活塞是钢制造的，精密研磨，镀铬和镍，给它一个非常艰难和持久的表面。一些制造商使用的是塑料活塞。这远远比钢轻,提供一个更轻的制动系统。活塞的塑料绝缘良好，并防止传递制动液的热量。每个钳包含两个背板和摩擦衬块组件。他们粘接或铆接或压嵌在一起，并在卡钳中安装在制动盘的两侧。最接近汽车中心的制动衬块被称为内侧制动衬块。另一侧称为外侧制动衬块。正如已经提到的，浮动卡钳是在两个导向销上固定。在汽车制动时，活塞后面的液体压力增加。压力施加在活塞的底部和气缸底部。作用于活塞的压力传递到内侧制动衬块上，迫使制动盘与内侧制动块摩擦。作用于气缸孔底部的压力迫使制动卡钳向着内侧端的导向销移动。由于制动钳的移动，使外侧制动衬块与制动盘接触，迫使外侧制动衬块对制动盘摩擦。随着制动压力的积累，内外制动块反相压紧制动盘，使汽车停了下来。制动压力释放实际上会产生一个相对活塞和卡钳非常轻微的运动。在释放的工程中，活塞及制动卡钳只是进入到一个放松和释放的位置。在释放的位置，制动衬块从制动盘的表面收回。英文原文：Chinas engineers and users also stay in QianPan HouGu on the idea, and, before and after the application of the disc brake is commercial vehicle braking performance increase the optimal scheme. Because HouGu type brake on the temperature, the braking performance is very big, lead to the front axle attenuation disc brakes to bear on the part of the load, cause too much of the disc brake, brake piece of life of overload shorter. For cars in the braking process, because the role of the front, inertial load always takes all the car load 70% 80%, so the front wheel brake force to than the rear wheels. Manufacturers to cut costs, use the front disc brake, rear wheel drum brake mix of matching method. The QianPan HouGu type mixed brake, this is mainly due to the cost considerations. With the rapid development of Chinas national economy, the average consumer safety and environmental requirements of cars is increasing day by day, the miniature car industry from tiny truck started, the transition to tiny coaches, and then promoted to use tiny cars as transport, become the necessity of historical development; On the other hand, all miniature car companies already will capital and power steering mini car industry, to adapt to the different needs of consumers out mini car products, some private enterprises will also mini car into the breach of the car market as, constantly of price war, make mini car prices have no longer too high, and began to close to ordinary people.Disc brake caliper disc and main overall type two kinds, modern car on the application of the most caliper disc brake, it is the rotation of the element is brake disc, fixed element is brake caliper. And, according to the brake caliper movement way and can be divided into set caliper disc brake, sliding caliper disc brake caliper disc brake and, including sliding caliper disc brake application more widely. The working principle of caliper disc brake is similar to a bicycle brake, braking process, the brake caliper will brake piece of extrusion to brake disc, along with the brake disc and lining block of the friction between the gradually will fall speed. And sliding caliper disc brake is brake caliper can be relatively brake disc axial sliding; Only in the inside of the brake disc set oil cylinders, and the outside of the brake block is in the grips attached on the body. Disc brakes in use process, also can appear fault, among them the more common wind resistance, underpowered and brake system has noise etc.Disc brake parts of fever in a narrow focus on the brake lining block, the unit and pressure than drum brakes, brake lining large block and clamp body of the piston direct contact with, so the quantity of heat of braking extremely easily to the brake fluid. So, make disc brakes easy to produce gas resistance phenomenon. But, if take corresponding measures, also can prevent air resistance happens.Miniature and affordable in our country are big car market, in recent years the domestic demand expansion drive the car market demand for miniature of the increase. Authorities say Chinas economy has entered into the platform, the moderate growth will pull the stable growth of car market. Last year, Chinese each enterprise benefits to improve, per capita disposable income increase, cause individual needs to improve the car; Countries carrying out the strategy for western development, to WeiChe market is tremendous potential demand of no doubt. From 0.9 to 1.6 L L, the price is suitable for Chinas national conditions, suitable for the current status of the development of the China is. Automobile brake clamps body stent is one of important parts, along with the car now design processing development of manufacturing technology, the brake clamps body in support of materials and processing method and so on is also in constant development, identify processing technology and clamping plan and design, attain thus to the automobile brake clamps body stents processing technology further deeper understanding.The main use of the software has Pro/e, ANSYS and CAPP. Pro/E software using 3 d entity the exact modeling, intuitive parts to reproduce the parts, accurate experience design intention, for parts of the process arrangement after help. Pro/E Mechanica module and the software ANSYS software, finite element analysis, combining do analysis processing produces in the process of the maximum displacement and the maximum stress, and the cutting tool for cutting dosages of the size of the choice to provide reliable basis. This topic use CAPP software developed including making the process route and process design, the complete process documents and improve the process of standardization and standardization. Early detection and solve. According to the retrieval, this in processing industries, and no one made the corresponding introduction. Pro/E software can be accurately to establish various large and complex models. ANSYS software in products manufacturing advance found potential problems, but its modeling ability are weak. The two tools combined, foster strengths and circumvent weaknesses, give full play to the advantages of two kinds of software research and development, is the first choice of complex mechanical structure scheme.This is also I choose the two software reasons. Previous engineering personnel with Pro/E complete three dimensions solid parts design, then use to Mechanica parts structure finite element analysis to find the place, and weak structure is improved. And Im Pro/E, ANSYS will be applied to the design process of parts, make the past only in process actual implementation, can come into the open process defect, process design stage in can andThe error after reflects the workpiece machining allowance method to calculate is, by definition, the processing, surface: its smallest machining allowance (Zbmin) are processing parts of two adjacent step freeways will limit of the difference of the minimum size; Its the biggest machining allowance (Zbmax) are processing parts of two adjacent step freeways will limit of the difference of the largest size. Inside surface processing, the minimum machining allowance is processed spares the maximum limit adjacent freeways will step size poor; Its the biggest machining allowance is processing components work of two adjacent step of the difference of the minimum size limit.The assistant time and basic time coincidence method, using the workbench processing center, get the staff in the cutting process completed work, and then, for auxiliary of the area is larger, and the volume of parts and relatively small, so can use one processing DuoGe parts to make the parts, the piece processing time as little as the basis, double the nc machining center area can also arranged four parts. The rotary worktable, two workpiece in processing at the same time, the clamping workpiece, the other two rotating, processing of just install two workpiece.Selection of cutting parameter and the formulation of &fair standards. Choose the right to improve the cutting dosages, cutting efficiency and guarantee the necessary tools durability and economy, ensure machining quality, has the vital role. Reasonable choice when processing cutting dosages should first choose a as far as possible big, secondly, optimizing the back of choice a larger feeding, and the last in the cutting tool durability, process system stiffness, machine tool power under the terms of the license, the rational choice of cutting speed. &fair standards also says time is fixed in a certain technology organization established under the condition of complete unit out products (such as a parts) or a job (such as a process that must be consumed time). &fair standards is not only, also be the measure index productivity arrange production plan, the calculations of the productioncost is an important basis for new or expansion of the factory, is also (or workshop) computing devices and workers number of basis.Brake caliper disc brake the car body is the critical, brake movement is in the grips body on the final. Installed in clamp body on parts and 16 pieces. One of the more important parts: brake caliper piston, piston callipers at the stents, sealing ring, friction piece, brake caliper shaft pins, spring of and purge screw, etc. Studio, brake fluid through the clamp body JinYou mouth will be pressure to brake caliper Detroit, and by the brake friction pressure before the pistons will to block, press the brake disc, and make clamp body in the brake caliper shaft pins, driving the sliding friction, also after pressure brake disc brake, complete action. The car brake disc brake caliper body shape, structure, material complex special for QT450-10, hardness is HB143-217, machining allowance for 3 mm, form and position tolerances stricter requirements. This product is the important parts, and related to Chinas automobile brake disc importied problem. In the existing gm in machine tool is completed or processing difficult brake caliper body, especially the lumen of processing, tank must determine the process, to ensure the quality of the processing equipment. Because in general on the machine processing, so blank datum positioning to repeated use, the request to have the precise location of the datum plane, this and use machining center is a very big difference. Such as we are in the process of slot PNE480 CNC machine even with pure inside the car, to ensure that slot cavity type, detection is precision with anatomical projection and after adjustment method of projection.Were now being mass production craft ready to work, according to the auto industry high starting point, large quantities of specialization, the policy, we have identified on the domestic equipment, save funds, and choose the XK6040 CNC milling machine.外文文献翻译:中国的工程师和用户还停留在前盘后鼓的理念上，而前、后盘式制动器的应用才是商用车提高制动性能的最佳方案。由于后鼓式制动器在温度升高后，制动性能衰减很大，导致前轴上盘式制动器承受不应承担的过多负载，致使盘式制动器的过载，制动片寿命的缩短。因轿车在制动过程中，由于惯性的作用，前轮的负荷通常占汽车全部负荷的70%80%，所以前轮制动力要比后轮大。生产厂家为了节省成本，就采用了前轮盘式制动，后轮鼓式制动的混合匹配方式。采用前盘后鼓式混合制动器，这主要是出于成本上的考虑。随着我国国民经济的快速发展，普通消费者对汽车安全和环保要求日益提高，微型汽车行业从微型货车起步，过渡到微型客车，再提升到使用微型轿车作为代步工具，成为历史发展的必然；另一方面，所有微型汽车企业已将主要资金和力量转向微型轿车行业，推出适应消费者不同需求的微型轿车产品，一些民营企业也将微型轿车作为进入汽车市场的突破口，不断的价格大战，使得微型轿车价格已不再“曲高和寡”，开始贴近普通百姓。盘式制动器主要有钳盘式和全盘式两种，现代汽车上应用最多的就是钳盘式制动器，它的旋转元件是制动盘，固定元件是制动钳。而根据制动钳的运动方式又可分为定钳盘式制动器、滑动钳盘式制动器和钳盘式制动器，其中滑动钳盘式制动器应用更广。钳盘式制动器的工作原理就类似于自行车上的刹车，在制动过程中，制动钳将制动块挤压到制动盘上，随着制动盘和衬块之间的摩擦逐渐的将速度降下来。而滑动钳盘式制动器就是制动钳可以相对制动盘作轴向滑动；只在制动盘的内侧设置油缸，而外侧的制动块则附装在钳体上。盘式制动器在使用过程中，也会出现故障，其中比较常见的有气阻、制动力不足和制动时有噪声等。盘式制动器的发热部位集中在很窄的制动衬块上，其单位压力又比鼓式制动器大，制动衬块和钳体的活塞直接接触，因此制动时的热量极易传给制动液。这样，使
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