JP2011225009A - Method for manufacturing brake fluid pressure control unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for machining a housing allowing acquisition of a mounting surface of control equipment made as wide and flat as possible, even in a block body of the housing manufactured by a high speed extrusion molding method of the housing in a brake fluid pressure control unit.SOLUTION: This method includes a block body formation process for forming the block body to be a base body of the housing into an almost rectangular parallelepiped by drawing or extrusion molding, a mounting hole formation process for forming a plurality of mounting holes for assembling a solenoid valve and a hole for mounting a motor on a first surface of the block body and a second surface opposed to the first surface, respectively, a mounting process for mounting the solenoid valve and the motor in the mounting holes, and a cutting process for cutting the whole surface of the first surface flat in a prescribed depth before the mounting process.

Description

The present invention relates to a method for manufacturing a brake fluid pressure control unit, and more particularly to a method for processing a metal housing such as an aluminum alloy used in the unit.

As a method of molding the block body of the housing, there is a method using a drawing or extrusion molding method, but a technique of performing a high extrusion speed at the time of molding is adopted in order to reduce manufacturing time and cost. .
When a block body is formed by such a method, as a result of performing the extrusion speed at a high speed, the billet passes through the die in a short time.

If a cylindrical body having a circular cross section is formed, the pressure applied to the billet when passing through the die is uniform in the die, and the billet shape after passing through the die reflects the shape of the die. Cheap.
However, when a block body having a substantially rectangular cross section is formed like a housing used in a brake fluid pressure control unit, the pressure on the billet to the four corners in the die when passing through the die becomes uneven (the pressure becomes weaker). Therefore, cracks, cracks, etc. are likely to occur at the four corners of the extruded shape.

Therefore, when a block body having a rectangular cross section is formed by the high speed extrusion molding method, arc shapes (R) are provided at the four corners of the die to improve the flow of molding material at the four corners inside the die when passing through the die. The problem is solved (see Patent Literature).

JP 2002-317255 A

When mounting a control device including an electronic control board on one surface of a substantially rectangular parallelepiped housing manufactured by aluminum extrusion, such as a brake fluid pressure control unit, the housing is The contact surface to the control device is required to be flat. On the other hand, recent vehicle behavior control devices have many functions, and control devices are required to have a large amount of processing capacity. It is desirable that the surface of the housing with which the contact is made is as flat and wide as possible. Therefore, when a housing manufactured by extruding the housing block body at high speed is adopted for the hydraulic pressure control unit, the flat portion is eroded by the four corners R, and a flat surface for contacting the control device cannot be secured sufficiently. Is a problem.

The present invention has been made in view of the above circumstances, and even a housing block body manufactured by a high-speed extrusion method can obtain a control device mounting surface that is as wide and flat as possible. A method for processing a housing is provided.

In order to achieve the above object of the present invention, a method for manufacturing a unit according to the present invention is a method for manufacturing a brake hydraulic pressure control unit in which a motor for operating at least a solenoid valve and a pair of hydraulic pumps is mounted on a housing. A block body forming step of forming a block body that is a base of the housing into a substantially rectangular parallelepiped by drawing or extrusion molding, and a plurality of mounting holes for assembling the solenoid valve on the first surface of the block body, A mounting hole forming step of forming holes for mounting the motor on the second surface opposite to the first surface, an mounting step of mounting the solenoid valve and the motor to the mounting hole, and before the mounting step And a cutting step of cutting the entire surface of the first surface flatly at a predetermined depth. It is a method.

According to this invention, even if the block body is manufactured by high-speed extrusion molding, it is possible to secure a large mounting area for the control device and the like, and furthermore, the surface roughness and flatness of the contact surface can be reduced. The quality can be improved and the quality can be stabilized.

The housing has a pocket portion that communicates with a hole for mounting the motor and is formed so as to be dug in a direction perpendicular to the axis of the previous motor, and the housing is fixed when the cutting process is performed. May be performed by pressing the front flange portion of the substantially L-shaped clamp tool against the motor hole opening side wall surface of the pocket portion.

As a result, by using the pocket portion as an oil sump that the conventional brake fluid pressure control unit has as a fixing portion at the time of cutting, it is not necessary to bother to provide a hole for fixing the unit. The cost of the entire unit can be reduced.

1 is an exploded perspective view showing a configuration of a brake fluid pressure control device according to an embodiment of the present invention. FIG. These are general manufacturing process flow charts of extrusion molding. FIG. 3 is a sectional view of a housing cut. Fig. 2 illustrates a housing fixing method during cutting.

Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 4.
In addition, the manufacturing process described below, the arrangement of component parts, and the like do not limit the present invention, and can be variously modified within the scope of the present invention.
First, the structure of the brake fluid pressure control unit to which the present invention is applied will be described.
FIG. 1 is an exploded perspective view showing a configuration of a brake fluid pressure control device 10 according to the present embodiment.

The brake fluid pressure control device 10 according to the present embodiment includes a housing 30, first to fourth valve bodies 1a, 2a, 3a, and 4a, a pair of pistons 5a and 5b that pressurize brake fluid, and first to Electronic control unit (E for driving and controlling the fourth valve body 1a, 2a, 3a, 4a)
(CU) 8, a motor 7 that drives the pistons 5 a and 5 b, and a pair of accumulators 9 and 12 that reduce the brake fluid pressure.

The housing 30 is made of aluminum and is formed in a substantially rectangular parallelepiped block. The housing 30 includes a first side surface (valve surface) 30a, a second side surface (left side surface) 30b,
It has a third side surface (right side surface) 30c, a fourth side surface (motor surface) 30d, a fifth side surface (lower surface) 30e, and a sixth side surface (upper surface) 30f.

A brake fluid flow path is formed inside the housing 30. Also, the first to sixth
A plurality of mounting holes 31a to 31p communicating with the front-wheel and rear-wheel passages 11 and 21 are formed in the side surfaces 30a to 30f, respectively.

The electronic control unit (ECU) 8 includes a coil unit 8a, an ECU housing 8b,
An electronic board (PCB) 8c for driving and controlling the coil unit 8a, and the electronic board 8c
An ECU cover 8d for covering. The electronic control unit 8 is attached so as to cover the first side face 30a. A connector 8e for connecting to the electronic board 8c is provided on one side of the ECU housing 8b (for example, the third side surface 30c side of the housing 30). The electronic board 8c mainly includes a microcomputer.

The coil unit 8a contains four coils for driving the first to fourth valve bodies 1a, 2a, 3a, 4a. Each coil includes first to fourth switching valve bodies 1a, 2a, 3
It is arrange | positioned in the position corresponding to a and 4a. The first to fourth valve bodies 1a, 2a,
One side of 3a, 4a is inserted into the corresponding coil, and is driven and controlled by each coil. For example, the electronic control unit 8 controls the brake fluid pressure to the vehicle wheel cylinder (not shown) by exciting the corresponding coil.

The electronic control unit 8 performs a calculation based on, for example, a wheel rotational speed signal detected by a wheel speed sensor (not shown), and drives and controls the first to fourth valve bodies 1a, 2a, 3a, 4a. Thus, for example, anti-lock brake control can be performed.

The first to fourth valve bodies 1 a, 2 a, 3 a, 4 a are connected to the first side surface 30 a of the housing 30.
It is inserted and attached in the attachment holes 31a to 31d formed in. The first to fourth valve bodies 1a, 2a, 3a, 4a are driven and controlled by the coil unit 8a, and the front wheel passage 11 and the rear wheel passage 21 of the housing 30 are brought into a communication state and a cutoff state. Switch each one.

The pair of pistons 5a and 5b are attached to the mounting holes 3 formed in the second and third side surfaces 30b and 30c.
1e and 31f are respectively inserted, and are movable in the center O direction of the housing 30.
Moreover, each piston 5a, 5b can pressurize brake fluid by reciprocating in the center O direction.

The motor 7 includes a motor main body 7a, a drive shaft 7b connected to the motor main body 7a and driven to rotate, and an eccentric cam 7c connected to the drive shaft 7b. The motor body 7a is attached to the fourth side surface 30d of the housing 30 (see FIG. 4B). The drive shaft 7b and the eccentric cam 7c are rotatably inserted into an attachment hole 31g formed in the fourth side surface 30d of the housing 30.

The pair of pistons 5 a and 5 b is biased toward the center O direction of the housing 30 by a spring member or the like, and the front ends thereof are in contact with the outer peripheral surface of the eccentric cam 7 c of the motor 7. Therefore, when the eccentric cam 7c of the motor 7 is rotationally driven, a so-called plunger type pump is configured in which the pair of pistons 5a and 5b reciprocate.

The pair of accumulators 9 and 12 is composed of an elastic member such as a spring and a piston or rubber. In the figure, elastic rubber members 9a and 12a for reducing the hydraulic pressure, and the elastic rubber member 9
cover portions 9b and 12b covering a and 12a. The accumulators 9 and 12 are respectively attached to attachment holes 31h and 31i formed in the fifth side surface 30e of the housing 30.

A pair of pump outlet valves 60a and 60b are provided in the pair of mounting holes 31v and 31w formed in the sixth side surface 30f of the housing 30, respectively. Further, the mounting hole 31x formed in the second side surface 30b of the housing 30 has a pump inlet valve 6 therein.
1a is provided, and a pump inlet valve 61b is provided in the mounting hole 31y formed in the third side face 30c.
As described above, in the brake fluid pressure control device 10 according to the present embodiment, constituent members necessary for vehicle brake fluid pressure control (particularly, antilock brake control), that is, the first to fourth switching valve bodies 1a, 2a, 3 a, 4 a, pistons 5 a, 5 b, electronic control unit 8, motor 7, and a pair of accumulators 9, 12 are integrally formed via a housing 30.

Next, a manufacturing process of a housing block body (referring to a block body before processing such as a valve insertion hole and a brake fluid flow path) will be described with reference to FIG. Although extrusion molding will be described here, the present invention can also be applied to an aluminum block manufactured by a pultrusion molding method.

First, in step 1 (S1), an ingot (metal) is melted and cast to produce a billet (aluminum ingot for extrusion) having a circular cross section. Thereafter, in step 2 (S2), the billet is cut at an appropriate place in the longitudinal direction. In step 3, the billet after cutting is put into a heater and heated to 400 to 500 degrees C.

Next, in step 4 (S4), an extrusion molding process is started. Specifically, a heated billet is inserted into a container, compressed directly in the die direction with a stem, and extruded through a die hole. At this time, the billet flow when passing through the die becomes more uniform in the die as it is slowly pushed out, and the cross-sectional shape of the extruded shape material after passing through the die is more likely to reflect the shape of the die. On the other hand, when extruded at high speed, the flow of billets at the four corners of the die when passing through the die becomes non-uniform, and cuts and cracks are likely to occur at the four corners of the extruded shape after passing. Therefore, when extruding at high speed, do not make the four corners of the die square, but make it an arc shape (R shape)
The billet flow at the four corners of the die is prevented from becoming uneven. Although the size of R depends on the size of the aluminum block to be formed, at least R = 2 mm is required for the aluminum block of the brake fluid pressure control unit.

Thereafter, in step 5 (S5), the both ends of the extruded shape member that has passed through the die are pulled and trimmed. Then, in step 6 (S6), the extruded shape member is cut, and step 7 (S7).
Then, the block body is completed by performing surface treatment such as washing, painting and baking.

Next, FIG. 3 shows a manufacturing process until the block body is processed and the housing 30 is formed.
4 will be described.

Each valve body (1a-4a), motor (7), pump (60a, 60b, 61a, 61
b) Attaching the accumulator (9, 12) to the housing (30) and drilling holes to provide a liquid tube. Since the drilling method employs a known drilling method, detailed description thereof will not be given here.

After the hole is formed in the housing, usually, the process of attaching each part to the housing is started. However, in the manufacturing method according to the present invention, surface cutting of the first side surface (30a) is performed before the part is attached.

First, the housing is fixed by a clamping tool (40) for cutting. At this time, the housing is fixed from the fourth side surface (30d) side where cutting is not performed. The clamping tool is inserted from the motor mounting hole (31g), and the tip housing flange portion is pressed against the motor hole opening side wall surface (41) of the pocket portion (41) provided immediately below the pump insertion hole, so that the entire housing is Fix it. The pocket portion is for temporarily storing brake fluid leaked by the operation of the pump, and such a pocket portion is usually provided in a brake fluid pressure control unit equipped with a pump. Therefore, by using this pocket portion as a fixing place for fixing the housing at the time of cutting, it is not necessary to provide a hole for fixing the housing at the time of cutting on the motor surface.

The cutting depth at the time of cutting is determined at an arbitrary position in (i) to (ii) of FIG. In the figure, the state of cutting out at the position (iii) is shown. The surface of the entire pump surface is cut at the position (iii), and the flat portion of the pump surface is enlarged in the region “d” before and after the processing. Although the object of the present invention can be achieved by scraping at an arbitrary position of (i) to (ii), it has a structure in which a complicated liquid pipe is arranged inside the housing like a brake fluid pressure control unit. In this case, the optimum position can be obtained in consideration of the distance to the liquid pipe / mounting hole located closest to the cutting surface and the size of the flat surface to be enlarged.

The second side surface, the third side surface, the fifth side surface, and the sixth side surface may be cut while the housing is fixed. As a result, a surface that requires cutting surface processing can be performed by fixing it once.

Next, the process of attaching the components of the brake fluid pressure control unit to each attachment hole provided in the housing by drilling will be described with reference to FIG.

First, the outer peripheral portions of the accumulator elastic members 9a and 12b are attached to the accumulator cover 9b.
12b, and is fixed by press-fitting into an opening hole (not shown) provided in the housing 30. Next, each valve body 1a, 2a, 3a, 4a is attached to the mounting holes 31a, 31b, 31c, 31d.
Press-fit into. Next, waterproofing and silicon as an adhesive are applied to the fixing portion of the motor 7 to the housing, and the motor 7 is brought into contact with the housing so that the shaft of the motor 7 and the power supply line to the ECU are accommodated in the housing. After that, the motor 7 is fixed by screwing.
Next, after inserting a piston and a spring (not shown) for the pump, the pump members 5a and 5b
Is pressed into the housing.

The housing portion of the ECU housing 8b is coated with waterproofing and silicon as an adhesive so that the valve body can be received in the corresponding hole of the ECU housing 8
b is adhered and fixed to the housing.

The coil unit 8a has a structure in which a coil that drives the valve body is sandwiched between a lower plate (not shown) that supports the coil and a U-shaped plate (8a).
The lower plate and the U-shaped plate are provided with through holes for receiving the valve bodies 1a to 1d. The coil unit is inserted from above the ECU housing so that the valve body can be accommodated in the coil through a through hole provided in the lower plate, and fixed to the housing by screwing.

The electronic board is configured such that a coil pin for connecting the coil and the electronic board 8c and a connector pin provided in a connector part for the hydraulic pressure control unit to receive power supply from the outside are press-fitted into through holes provided in the electronic board, respectively. To fix.

Waterproofing and applying silicon as an adhesive are applied to the fixed part of the ECU cover 8d on the ECU housing 8b, and the cover locking claw (not shown) provided on the ECU housing is EC-coated.
The cover is fixed by bringing the cover into close contact so that a locking portion (not shown) of the U cover engages.

As mentioned above, although the case where the said invention was applied to a brake hydraulic-pressure control unit was demonstrated, it is applicable to the general use which mounts control equipment on one surface of the block body formed by the high-speed extrusion molding method.

1a, 2a, 3a, 4a ... Valve body 5a, 5b ... Pump member 7 ... Motor 8 ... ECU unit 9, 12 ... Accumulator 30 ... Housing 30a-30f ... Housing First side surface to sixth side surface 31 ... Mounting hole 40 ... Clamp tool 41 ... Pocket part 42 ... Motor hole opening side wall surface

Claims (2)

A method for manufacturing a brake hydraulic pressure control unit in which a motor for operating at least a solenoid valve and a pair of hydraulic pumps is mounted on a housing,
A block body forming step of forming a block body which is a base of the housing into a substantially rectangular parallelepiped by drawing or extrusion molding;
A plurality of mounting holes for assembling the solenoid valve on the first surface of the block body,
A mounting hole forming step of forming holes for mounting the motor on the second surface opposite to the first surface;
An attachment step of attaching the solenoid valve and the motor to the attachment hole;
The manufacturing method comprising a cutting step of cutting the entire surface of the first surface flatly at a predetermined depth before the attaching step. The manufacturing method according to claim 1,
The housing has a pocket portion that communicates with a hole for mounting the motor and is formed so as to dig down in a direction perpendicular to the axis of the previous motor,
The above-mentioned housing is fixed when the cutting process is performed by pressing the front flange portion of a substantially L-shaped clamp tool to the motor hole opening side wall surface of the pocket portion. Method

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