JP2008064190A - Low-noise brake disk, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a low-noise brake disk capable of easily and reliably reducing squeak at the braking without degrading the productivity or without any adverse effect on the designability, and its manufacturing method. <P>SOLUTION: A low-noise brake disk 20 comprises a fitting part 11 to a vehicle body, a sliding part 12 with a brake pad, and an arm part 13 for connecting the fitting part 11 to the sliding part 12. A noise reduction unit 21 for reducing the noise by adjusting the weight is formed on at least one of the sliding part 12 and the arm part 13 of the brake disk 20. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a low-noise brake disc that can effectively prevent noise such as brake squeal during braking and a method for manufacturing the same.

  Generally, as a brake disc of a motorcycle, it has an attachment part to a vehicle body, a sliding part with a brake pad, and an arm part that connects the attaching part and the sliding part, and between the attaching part and the sliding part. A pattern hole for reducing weight and a plurality of small holes for heat dissipation and weight reduction formed on the sliding part are widely used.

  By the way, in the brake disc for motorcycles, since the brake disc is exposed to the outside, not only the braking performance but also the design has been sufficiently studied at the time of designing. Regarding the design, the shape of the pattern hole and the shape and arrangement of the small holes formed in the sliding part are important design matters. The designed brake disc is mass-produced through various performance tests. However, as a result of the braking test in the actual vehicle, the design may be changed due to the occurrence of brake squeal.

  The mechanism of the occurrence of brake squeal has not yet been elucidated, but if brake squeal is confirmed on the designed brake disc, the brake pad configuration, the design of the pattern hole, the brake disc plate, It is known that the brake noise can be adjusted by changing the thickness.

  On the other hand, in the case of brake discs for automobiles, the natural frequency of the brake disc is measured with respect to the total number of manufactured brake discs, and the measured natural frequency does not fall within the allowable range that can prevent or reduce brake noise. For example, a configuration in which an outer peripheral portion of a mounting portion of a brake disc to a vehicle body is cut to adjust a natural frequency of the brake disc to prevent brake noise is proposed (for example, Patent Document 1). reference.).

JP 2005-30471 A

  By the way, in order to prevent brake squeal during braking, when changing the configuration of the material and shape of the brake pad, it is necessary to change the configuration other than the brake disc. If the manufacturer is different, there is a problem that it takes time to change the design. Also, when changing the design of the pattern hole or changing the thickness of the brake disc, the design can be changed only by the manufacturer of the brake disc, but when changing the design of the pattern hole, Since the design of the entire brake disc changes, there is a problem that it takes time to adjust the brake disc manufacturer and the motorcycle manufacturer, and when adjusting the thickness of the brake disc, From the request, there is a problem that the adjustment range is greatly restricted and the brake squeal cannot be resolved.

  On the other hand, Patent Document 1 requires a work for measuring the natural frequency and a work for adjusting the natural frequency, which increases the number of brake disk manufacturing processes and requires time for measurement and cutting. Since it is necessary to perform these processes every time, there is a problem that productivity decreases.

  An object of the present invention is to provide a low-noise brake disc that can easily and reliably reduce squeal during braking and a method for manufacturing the same without reducing productivity or greatly affecting design. is there.

  The present applicant conducted various tests on the cause of the occurrence of brake squeal during braking, and as a result of vibration analysis, found that the brake squeal occurred due to resonance between the brake disc and the vehicle body. The idea that brake noise can be prevented without significantly changing the design of the brake disc by changing the natural weight of the brake disc and shifting the natural frequency of the brake disc from the resonance frequency with the vehicle body. The present invention has been completed.

  A low noise brake disc according to the present invention is a brake disc having a mounting portion to a vehicle body, a sliding portion with a brake pad, and an arm portion connecting the mounting portion and the sliding portion. The noise reduction part which reduces noise by weight adjustment is formed in at least one of the sliding part and arm part.

  In this low-noise brake disc, in the original brake disc having no noise reduction portion (hereinafter referred to as the original brake disc), even if brake squeal occurs during braking, the sliding portion of the original brake disc By making a simple design change in which at least one of the arm portions is provided with a noise reduction portion that reduces noise by weight adjustment, a low noise brake disc that does not generate noise such as brake noise can be realized. In addition, noise can be reduced or completely prevented by adjusting the weight of the original brake disc by the noise reduction unit, so there is no need to make a major design change to the original brake disc, and the low noise brake disc. Can be formed easily without changing the manufacturing process of a normal brake disc. In particular, in a brake disc for a motorcycle, when a single metal plate is press-molded into the shape of the brake disc, the noise reduction part can be formed integrally, so that the productivity can be improved even when a low brake disc is used. There is no decline.

  Here, the natural frequency of the original brake disk without the noise reduction unit has a resonance frequency with the vehicle body, and the natural frequency of the brake disk with the noise reduction unit does not have a resonance frequency with the vehicle body. This is a preferred embodiment. If the natural frequency of the original brake disc does not have a resonance frequency with the vehicle body, noise such as brake noise does not occur and there is no need to provide a noise reduction part. It is preferable to prevent noise from being generated by forming a noise reduction unit only for the natural frequency and shifting the natural frequency from the resonance frequency.

  The noise reduction portion can be formed at a high amplitude portion of the original brake disc that vibrates at a resonance frequency with the vehicle body. If a noise reduction part is formed in such a high amplitude part, a brake squeal can be effectively prevented without performing significant weight adjustment by the noise reduction part. For this reason, design changes to the original brake disc can be made even lighter, and changes in design are reduced, which is preferable.

  As said noise reduction part, at least 1 sort (s) selected from the through-hole, the notch part, the counterbore part, a chamfering part, a recessed part, and a processus | protrusion can be formed. If a through hole, a notch, a counterbore, a chamfer, and a recess are formed as the noise reduction part, the weight of the original brake disk can be partially reduced to prevent or suppress the generation of noise. In addition, when the protrusions are formed, the weight of the original brake disc can be partially increased to prevent or suppress the generation of noise.

  It is also a preferred embodiment that a plurality of the noise reduction units are formed in a rotationally symmetric manner at every fixed angle. By comprising in this way, while being able to set the weight balance of a brake disc favorably, the designability can be improved.

  A manufacturing method of a low noise brake disc according to the present invention is a manufacturing method of a low noise brake disc having an attachment portion to a vehicle body, a sliding portion with a brake pad, and an arm portion connecting the attachment portion and the sliding portion. In this method, at least one of the sliding portion and the arm portion of the brake disk is integrally formed with a noise reduction portion that reduces noise by weight adjustment.

  The noise reduction part can be provided as a separate member on the brake disk or can be formed separately. However, in the present invention, the noise reduction part is integrally formed with the low noise brake disk, so the manufacturing process is increased. The low-noise brake disc can be manufactured efficiently without any trouble.

  Here, as a pre-process of the manufacturing process of the low-noise brake disc, a prototype brake disc without the noise reduction part is manufactured, and when this prototype brake disc is assembled to an actual vehicle and a braking test is performed, noise is generated. Preferably, the noise reduction part is added to the design of the original brake disk. With this configuration, it is possible to easily and efficiently manufacture a low-noise brake disc that does not generate noise such as brake noise without making a significant design change.

  As a pre-process of the manufacturing process of the low-noise brake disc, a prototype brake disc without the noise reduction part is manufactured, a brake test is performed by assembling the prototype brake disc to an actual vehicle, and when noise is generated, In a preferred embodiment, a high-amplitude part of the original brake disk based on the resonance frequency is calculated by vibration analysis, and the noise reduction unit is added to the design of the original brake disk corresponding to the high-amplitude part. is there. If a noise reduction part is formed in such a high amplitude part, a brake squeal can be effectively prevented without performing significant weight adjustment by the noise reduction part.

  Further, as the noise reduction part, at least one selected from a through hole, a notch part, a counterbore part, a chamfering part, a concave part and a protrusion is formed, and the noise reduction part is rotationally symmetric at a certain angle. Forming a plurality of the like is a preferred embodiment.

  According to the low noise brake disc of the present invention, for example, even when a brake squeal occurs in the prototype brake disc at the prototype stage, by providing a noise reduction unit for the prototype brake disc, By adjusting the weight, it is possible to reduce or completely prevent the occurrence of noise such as brake noise. In addition, noise can be reduced or completely prevented by adjusting the weight of the brake disc by the noise reduction unit, so low noise brake discs can be easily implemented without making major design changes to the brake disc. can do.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
First, the basic brake disk of the basic design at the beginning of the design, which is the original form of the low noise brake disk, will be described.

  As shown in FIG. 1, a prototype brake disc 10 is a brake disc for a motorcycle, and includes an attachment portion 11 to a vehicle body, a sliding portion 12 with a brake pad P, an attachment portion 11 and a sliding portion 12. The arm part 13 to connect is provided.

  The attachment portion 11 and the sliding portion 12 are connected by five arm portions 13, and projecting portions 14 that project to both sides in the circumferential direction are formed in the middle portion of the arm portion 13. Five pattern holes 15 defined by the arm part 13 are formed between the attachment part 11 and the sliding part 12, and these five pattern holes 15 are for improving the design of the original brake disc 10 and reducing the weight. Is provided. The shapes and the number of the arm portions 13 and the pattern holes 15 can be appropriately set in consideration of the design of the brake disc.

  A plurality of small holes 16 formed of round holes for heat dissipation and weight reduction are formed in the sliding portion 12 in a predetermined arrangement. As the small holes 16, it is possible to form long and narrow slit-shaped small holes in addition to the round holes. The shape, number and arrangement of the small holes 16 are the design characteristics of the original brake disc 10 and the heat dissipation in the sliding portion 12. Therefore, it is set appropriately.

  A mounting hole 17 through which the end of the wheel hub is inserted is formed at the center of the mounting portion 11, and five bolt insertion holes 18 for mounting to the wheel hub are formed in the middle of the mounting portion 11 in the radial direction. ing. The number of bolt insertion holes 18 is appropriately set according to the number of bolt holes in the wheel hub.

  The original brake disc 10 is manufactured by press-molding a metal plate made of stainless steel or carbon steel having excellent wear resistance, and then heat-treating the sliding portion 12. In the present embodiment, the stainless steel plate having a thickness of 7 mm is manufactured by press molding, and the mounting portion 11, the sliding portion 12, and the arm portion 13 of the original brake disc 10 are set to have substantially the same thickness. The outer diameter of the original brake disc 10 can be appropriately set according to the configuration of the motorcycle, and in this embodiment, the outer diameter is set to 30 cm.

  In the present embodiment, the mounting portion 11 and the sliding portion 12 are arranged in the same plane. However, depending on the configuration on the vehicle body side, the mounting portion 11 and the sliding portion 12 are arranged with the thickness of the original brake disc 10. It is also possible to arrange them in parallel planes that are spaced apart in the direction. Further, in the present embodiment, the present invention is applied to a brake disc made of a single metal plate. However, the sliding portion 12 and the mounting portion 11 are divided to constitute a brake disc that supports both of them in a floating manner. The present invention can be similarly applied.

  Next, the low noise brake disc 20 according to the present invention will be described. The low noise brake disc 20 was subjected to a braking test on the original brake disc 10 having the above-described configuration. In this case, in order to reduce or completely eliminate this brake squeal, the design of the original brake disc 10 is partially changed, and at least one of the sliding portion 12 and the arm portion 13 of the original brake disc 10 is subjected to noise by adjusting the weight. The noise reduction part 21 which reduces this is formed.

  Here, a vibration analysis performed to set a suitable formation position and number of formation of the noise reduction unit 21 will be briefly described.

  The original brake disc 10 was mounted on an actual vehicle and subjected to a braking test. As a result, a brake squeal having a frequency of 1026 Hz was generated. Therefore, the natural value (natural frequency) of the original brake disk 10 was obtained by modal analysis, and the results shown in Table 1 and FIG. 2 were obtained. From this result, it can be seen that at 1026 Hz, the original brake disc 10 resonates with the vehicle body and brake noise is generated.

  Further, when the amplitude of each part of the original brake disc 10 when the original brake disc 10 is vibrated at a resonance frequency of 1026 Hz is analyzed, as shown in FIG. Eight sites 19 were formed.

  Therefore, as shown in FIG. 4, a low noise brake disc 20 </ b> A in which a noise reduction portion 21 </ b> A including a notch extending radially from the pattern hole 15 toward the outer periphery of the sliding portion 12 is formed corresponding to the high amplitude portion 19. As shown in FIG. 5, a low noise brake disc 20B in which noise reduction portions 21B each having a notch extending radially from the pattern hole 15 to the outer peripheral side of the sliding portion 12 are formed at regular intervals in the circumferential direction; As shown in Table 1, FIG. 2 shows the natural values (natural frequencies) obtained by modal analysis for the low noise brake disc 20C in which the noise reduction portion 21C composed of a through hole is formed in the middle of the arm portion 13. The results shown were obtained.

  From Table 1 and FIG. 2, it can be seen that the three low noise brake disks 20A, 20B, and 20C do not have a resonance frequency of 1026 Hz with the vehicle body, so that the brake squeal is eliminated. In addition, since the eigenvalue closest to the resonance frequency with the vehicle body in the low noise brake disc 20A is a farther frequency compared to the other low noise brake discs 20B and 20C, the low noise brake disc 20A corresponds to the high amplitude portion 19. Thus, it can be seen that if the noise reduction unit 21 is formed, brake noise can be effectively prevented. However, it can be seen that even when the arm portion 13 has a relatively small amplitude when vibrated at the resonance frequency, such as the low noise brake disc 20C, the noise reduction portion 21 can be formed to prevent the brake squeal.

  From the above, as long as the noise reduction part 21 is in a range that does not significantly change the design of the original brake disk 10, an arbitrary number of noise reduction parts 21 can be provided at any position of at least one of the sliding part 12 and the arm part 13. , Noise such as brake noise can be reduced. Moreover, if it forms in rotational symmetry for every fixed angle, the design property will become high, and if it forms in the high amplitude site | part 19, even if it is the noise reduction part 21 of a comparatively small dimension, a brake squeal can be prevented effectively.

  Moreover, as the noise reduction part 21, as long as the weight of the original brake disk 10 can be partially adjusted, at least one selected from a through hole, a notch part, a counterbore part, a chamfering part, a concave part, and a protrusion is used. A seed can be formed. In addition, it is possible to partially adjust the weight by attaching another member to the original brake disc 10, but since it can be formed simultaneously with the press molding of the low noise brake disc 20, from the through hole, the notch portion and the protrusion More preferably, at least one selected is formed. In order to minimize the influence on the design of the original brake disc 10, the size of the noise reduction unit 21 is preferably set to the minimum size within a range in which brake noise can be prevented.

  As another specific example in which the formation position and the number of the noise reduction portions 21 are changed, as in the low noise brake disc 20D shown in FIG. Forming the noise reduction part 21D consisting of a notch in the five protrusions 14 that increase in amplitude when vibrated, each of the ten protrusions 14 like a low noise brake disc 20E shown in FIG. The noise reduction part 21E consisting of a long hole extending in the circumferential direction is formed on the left side, and the noise reduction part 21F consisting of a long hole extending in the radial direction on the five arm parts 13 as in the low noise brake disc 20F shown in FIG. , And protrudes toward the pattern hole 15 in the sliding portion 12 corresponding to the high amplitude portion 19 as in the low noise brake disc 20G shown in FIG. Forming the noise reduction part 21G formed from the origin, like the low noise brake disk 20H shown in FIG. 11, the noise reduction part 21H consisting of a notch is formed on the outer peripheral part of the sliding part 12 corresponding to the high amplitude part 19. Forming, like the low noise brake disk 20J shown in FIG. 12, while forming a through-hole in the middle part of the arm part 13, and forming a counterbore part in the lip | edge part of a through-hole, this is made into a noise reduction part The noise reduction part which consists of a chamfering part which chamfered the corner | angular part in part or all the circumferences of the opening edge of a part or all pattern hole 15 can be formed. The noise reduction unit 21 may be provided in any combination.

(A) of the original brake disc is a front view, and (b) is a perspective view. Graph showing eigenvalues of original brake disc and low noise brake disc Analysis diagram showing amplitude when resonating at the resonant frequency of the original brake disc Low noise brake disc (a) is a front view and (b) is a perspective view. (A) is a front view and (b) is a perspective view of a low noise brake disc of another configuration. (A) is a front view and (b) is a perspective view of a low noise brake disc of another configuration. Front view of other configurations of low noise brake disc Front view of other configurations of low noise brake disc Front view of other configurations of low noise brake disc Front view of other configurations of low noise brake disc Front view of other configurations of low noise brake disc (A) is a front view and (b) is a perspective view of a low noise brake disc of another configuration.

Explanation of symbols

P Brake pad 10 Original brake disc 11 Mounting portion 12 Sliding portion 13 Arm portion 14 Protruding portion 15 Pattern hole 16 Small hole 17 Mounting hole 18 Bolt insertion hole 19 High amplitude portion 20 Low noise brake disc 21 Noise reduction portion 20A Low noise brake Disc 21A Noise reduction unit 20B Low noise brake disc 21B Noise reduction unit 20C Low noise brake disc 21C Noise reduction unit 20D Low noise brake disc 21D Noise reduction unit 20E Low noise brake disc 21E Noise reduction unit 20F Low noise brake disc 21F Noise reduction unit 20G Low noise brake disc 21G Noise reduction unit 20H Low noise brake disc 21H Noise reduction unit 20J Low noise brake disc 21J Noise reduction unit

Claims (10)

  A brake disc having a mounting portion to a vehicle body, a sliding portion with a brake pad, and an arm portion connecting the mounting portion and the sliding portion, and at least one of the sliding portion and the arm portion of the brake disc In addition, a low noise brake disc is characterized in that a noise reduction section for reducing noise by weight adjustment is formed.   The natural frequency of the original brake disc without the noise reduction unit has a resonance frequency with the vehicle body, and the natural frequency of the brake disc with the noise reduction unit does not have a resonance frequency with the vehicle body. Low noise brake disc.   The low noise brake disc according to claim 2, wherein the noise reduction portion is formed at a high amplitude portion of the original brake disc that vibrates at a resonance frequency with the vehicle body.   The low noise brake disc according to any one of claims 1 to 3, wherein at least one selected from a through hole, a notch, a counterbore, a chamfer, a recess, and a protrusion is formed as the noise reduction unit. .   The low noise brake disc according to any one of claims 1 to 4, wherein a plurality of the noise reduction portions are formed in a rotationally symmetric manner at every predetermined angle.   A method of manufacturing a low noise brake disc having a mounting portion to a vehicle body, a sliding portion with a brake pad, and an arm portion connecting the mounting portion and the sliding portion, the sliding portion of the brake disc, A method of manufacturing a low-noise brake disc, wherein a noise reduction portion that reduces noise by weight adjustment is integrally formed on at least one of the arm portions.   As a pre-process of the manufacturing process of the low-noise brake disc, a prototype brake disc without the noise reduction unit is manufactured, and when the prototype brake disc is assembled to an actual vehicle and a braking test is performed. The method for manufacturing a low-noise brake disk according to claim 6, wherein the noise reduction part is added to the design of the original brake disk.   As a pre-process of the manufacturing process of the low-noise brake disc, a prototype brake disc without the noise reduction part is manufactured, a brake test is performed by assembling the prototype brake disc to an actual vehicle, and when noise is generated, 7. The low noise according to claim 6, wherein a high-amplitude portion of the original brake disc with a resonance frequency of the original brake disc is calculated by vibration analysis, and the noise reduction unit is added to the design of the original brake disc corresponding to the high-amplitude portion. Brake disc manufacturing method.   The low noise brake disk according to any one of claims 6 to 8, wherein at least one selected from a through hole, a notch, a counterbore, a chamfer, a recess, and a protrusion is formed as the noise reduction unit. Manufacturing method. The method for manufacturing a low-noise brake disk according to any one of claims 6 to 9, wherein a plurality of the noise reduction portions are formed rotationally symmetrical at a predetermined angle.

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