JPH11294499A - Disc brake assembly for vehicle and welding method of rustproof shim in the assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To fit a rustproof shim to a caliper easily and surely by spot-welding a dacryo-treated rustproof shim to the fitting face of a caliper supporting bracket to be fixed. SOLUTION: A rustproof shim 1 is a ring-like shim of steel plate, for example, the plate thickness is 0.4 mm, and three minute projections of 0.1 mm height are projectingly provided on the concentric circle on the nearly center by dowel working. It is coated with a dacryo film of 6-8 μm thickness. A caliper supporting bracket (a) is placed on a welding electrode (A), and the decryo- treated rustproof shim 1 is placed on the specified position of the caliper supporting bracket (a). Thereafter, they are pressure by a welding electrode (B) and electrically welded, and the minute projection parts are welded to the fitting face of the caliper supporting bracket (a). The rustproof shim 1 does not require special working, and utilization factor is improved at pick-up material. Further the fitting work of the shim to the caliper supporting bracket (a) is simplified and the positional dislocation can be surely prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mechanism for mounting a rust preventive shim in a vehicle disk brake assembly, which simplifies the shape and structure of the shim and simplifies the work of mounting the shim on a caliper. , So that the manufacturing cost can be reduced.

[0002]

2. Description of the Related Art In a disk brake device for a vehicle, a rust-preventing shim is interposed between a mounting surface of a caliper supporting member (for example, a flange of an axle, a knuckle arm, etc.) and a mounting surface of a caliper supporting bracket. . By the way, since the work of assembling the vehicle disc brake assembly to the vehicle body is performed in a narrow space, the rust prevention shim is inserted between the mounting surface of the caliper support member and the mounting surface of the caliper support bracket during this mounting operation. Bolting is not easy. For this purpose, it is conventionally known that an anticorrosion shim is previously fixed to the mounting surface of the caliper support bracket at the stage of the brake assembly. In such a conventionally known device, the rust-preventing shim is fixed at an accurate position on the mounting surface of the caliper support bracket, and a positional shift is caused when packing, transporting, or assembling to the vehicle body of the brake assembly. Various measures have been taken to prevent this from happening (for example, Japanese Patent Publication No. 1-60700,
JP-A-9-303440). Such a contrivance is, for example, that an elastic claw is provided on the rust-preventive shim, the caliper is held between the elastic claws, and the rust-preventive shim is fixed to the caliper. Any of the rust-preventing shims with elastic claws are specially processed for the attachment of elastic claws to accurately position them on the mounting surface of the caliper support bracket and prevent displacement. Manual work such as sandwiching the mounting surface of the caliper support bracket between the elastic claws is necessary in the assembly work of the brake assembly. In this case, since the rust-preventing shim is not a simple flat plate, there is much waste in removing the material, and the utilization rate of the plate material is reduced.

[0003]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problem so that the rust-preventing shim can be easily and securely attached to the caliper without processing the rust-preventing shim into a special shape for mounting on the brake caliper support bracket. It is an object to devise a mounting mechanism.

[0004]

Means taken to solve the above problem is to fix the rust preventive shim subjected to the dacro treatment to the mounting surface of the caliper support bracket by spot welding.

[0005]

[Operation] The rust preventive shim is simply spot-welded with the dacro-treated shim in contact with the mounting surface of the caliper support bracket. Therefore, the rust preventive shim has a simple flat plate shape. Because of the spot welding, the dacro coating layer is destroyed only in a very limited area, and this does not impair the rust prevention performance of the rust preventive shim. Further, since a part of the rust preventive shim is welded and fixed to the caliper support bracket, the rust preventive shim is securely fixed to the caliper support bracket, and therefore no displacement occurs.

[0006]

[Embodiment 1] A plurality of minute projections are projected from the back surface of a rustproof shim subjected to a dacro treatment, and the minute projections are welded to a mounting surface of a caliper support bracket by electric welding.

[0007]

[Operation] Since the above-mentioned minute projections can be made to protrude from the back surface of the shim when punching the rust-proof shim, the shape of the rust-proof shim is a simple flat plate. No special processing is required. In addition, positioning work of rust prevention shim on the mounting surface of the caliper support bracket,
The electric welding operation can be performed by an automatic machine.

[0008]

Embodiment 2 In Embodiment 1, the dacro coating on the surface of the microprojections is destroyed by the electric pulse of the first stage,
The minute projections are welded to the caliper support bracket by the electric pulse at the stage.

[0009]

[Operation] Since the dacro coating layer of the minute projections is destroyed by the short-time large current of the first stage, the range of the destruction can be minimized.

[0010]

[Embodiment 3] Spot welding of a rustproof shim subjected to dacro treatment to a mounting surface of a caliper support bracket by a laser beam.

[0011]

[Operation] There is no particular need for processing such as projecting minute projections on the back surface of the rust-preventing shim. Positioning of the rust-preventing shim on the mounting surface of the caliper support bracket, and spot welding with a laser beam are automatic machines. Can be done by

[0012]

Next, an embodiment will be described with reference to the drawings.
1 and 2, the rust-preventing shim of this embodiment is a ring-shaped shim of an iron steel plate, and the thickness t is 0.4 mm. The height h is 0.1 m on the concentric circle almost at the center of this rust preventive shim.
The three small protrusions 2 of m are protruded by doweling. The rust preventive shim 1 is covered with a dacro coating having a thickness of 6 to 8 μm (see FIG. 5 for the sectional structure of the dacro coating). The caliper support bracket a is placed on the welding electrode a, the rustproof shim 1 subjected to the dacro treatment is placed on a predetermined position of the caliper support bracket a, and the welding is performed by the welding electrode b to perform electric welding. In this electric welding, the first-stage energization by a short-time large current (approximately 5000 A, 0.01 A)
Second), the dacro coating of the microprojections 2 is skipped, and the second-stage energization with a relatively small current (approximately 3000 A, 0.
02 seconds), the minute projections 2 are welded to the mounting surface of the caliper support bracket a. Due to its composition structure (see FIG. 5), the current flows easily in the direction perpendicular to the surface of the dacro coating layer, but the electric resistance in the direction parallel to the surface is extremely high and the current hardly flows in this direction. Therefore, a current for welding flows vertically through the microprojections 2, so that only the dacro coating of the microprojections 2 is blown off and only the microprojections are welded. In FIG. 3, when the caliper supporting bracket a to which the rustproof shim 1 subjected to the dacro treatment is welded and fixed is brought into contact with a caliper supporting member b such as an axle flange, the caliper supporting bracket a and the supporting member b
The anticorrosion shim 1 is sandwiched between the mounting surfaces. In this state, the caliper support bracket a is fixed to the support member b with the bolt c, so that the caliper d is assembled to the support member b. If the magnet M is embedded in the center of the lower surface of the welding electrode B, and the rust-preventing shim 1 is adsorbed by its magnetic force (see FIG. 4), the welding electrode B is attached with the rust-preventing shim 1 adsorbed. By pressing the caliper support bracket a positioned with respect to the welding electrode a, the rust preventive shim 1 can be welded to an accurate position of the caliper support bracket a. In the case of using a laser beam, it is not necessary to provide the micro projections on the rust preventive shim. The surface of the rust-proof shim located on the lower surface of the jig is irradiated with a laser beam by an optical fiber connected to a predetermined position of the jig, and the portion irradiated with the laser beam is locally and instantly heated to a high temperature to be spotted. Weld. The shorter the irradiation time of the laser beam is, the smaller the welding spot is. However, the shorter the irradiation time is, the stronger the laser beam to be irradiated must be. For example, the number of welding spots is three, and the diameter of the welding spot is about 1 mm. The irradiation time and the intensity of the irradiation light may be adjusted to fit. In this case, the irradiation time and the intensity of irradiation light can be reduced by forming a recess on the upper surface of the rust preventive shim to make the portion to be welded somewhat thinner.

[0013]

[Effect] As described above, at the disc brake assembly stage, the rust preventive shim is welded and fixed to the mounting surface of the caliper support bracket at the stage of disc brake assembly, so that the shape and structure of the rust preventive shim is special. Therefore, it is not necessary to perform special processing for forming a special shape structure. Further, since the planar shape of the rust preventive shim is a simple shape, the utilization rate of the material in the material removal by the shim punching is increased. Therefore, the manufacturing cost of the rustproof shim can be reduced accordingly. Also, the work of attaching the rust-preventive shim to the caliper support bracket can be simplified,
The man-hour for assembling the brake assembly can be reduced, and the cost can be reduced. In addition, since it is fixed by welding, the position of the rust-proof shim must be shifted with respect to the mounting surface of the caliper support bracket during packing, unpacking, transporting, or assembling the brake assembly to the vehicle body. Therefore, the work of assembling the brake assembly to the vehicle body can be performed smoothly.

[Brief description of the drawings]

FIG. 1A is a plan view of a rust preventive shim according to an embodiment of the present invention, and FIG. 1B is a cross-sectional view taken along the line AA in FIG.

FIG. 2 is a side view of the electric welding apparatus according to the embodiment of the present invention.

FIG. 3 is a sectional view of a brake assembly according to an embodiment of the present invention.

FIG. 4 is a sectional view of another electric welding apparatus of the present invention.

FIG. 5A is a cross-sectional view of a dacro coating. (B) A perspective view of zinc flakes in the dacro coating.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Rust prevention shim 2 ... Micro projection A, B ... Welding electrode a ... Caliper support bracket b ... Caliper support member c ... Mounting bolt d ... Caliper M ... magnet

Claims (5)

[Claims] 1. A disc brake assembly for a vehicle in which a rustproof shim subjected to a dacro treatment is spot welded and fixed to a mounting surface of a caliper support bracket. 2. The disk brake assembly according to claim 1, wherein a plurality of minute projections project from the back surface of the rust-preventing shim, and the minute projections are welded to a mounting surface of the caliper support bracket by electric welding. 3. The method according to claim 1, wherein the electric pulse of the first stage destroys the dacro coating on the surface of the minute projection, and the second stage of the electric pulse welds the minute projection to the mounting surface of the caliper support bracket. An electric welding method for a rustproof shim in a vehicle disk brake assembly. 4. The disc brake assembly for a vehicle according to claim 1, wherein said rustproof shim is spot welded to a mounting surface of said caliper support bracket by a laser beam. 5. An electric welding method for a rust-proof shim in a vehicle disk brake assembly according to claim 3, wherein a magnet is buried in the center of the end face of the electrode, and the rust-proof shim is attracted and held on the electrode end face by the magnetic force of the magnet. .