WO2015163579A1

WO2015163579A1 - Integrated type brake pedal and die casting manufacturing method therefor

Info

Publication number: WO2015163579A1
Application number: PCT/KR2015/002561
Authority: WO
Inventors: 김한구; 이정호
Original assignee: 주식회사 코다코
Priority date: 2014-04-25
Filing date: 2015-03-17
Publication date: 2015-10-29

Abstract

The present invention relates to an integrated type brake pedal and a die casting manufacturing method therefor, and the brake pedal comprises: a pedal part receiving pedal effort of a driver when the driver brakes a vehicle; an arm part rotated by the pedal effort; a hinge part supporting the arm part such that the arm part is rotated; and a bracket part coupled to one end of the hinge part, wherein the pedal part, the arm part, the hinge part and the bracket part are integrally die-casted by using aluminum alloy. Accordingly, the present invention provides effects of decreasing manufacturing costs and manufacturing time by reducing the weight of the brake pedal and, simultaneously, integrating the brake pedal by integrally die-casting the pedal part, the arm part, the hinge part and the bracket part of the brake pedal by using aluminum alloy.

Description

Integrated brake pedal and diecasting method thereof

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an integrated brake pedal and a die casting manufacturing method thereof, and more particularly, to an integrated brake pedal and a die casting manufacturing method thereof for braking a vehicle by the driver's effort during driving of the vehicle.

In general, a brake device applied to a vehicle is classified into a brake pedal used for temporary stop or sudden stop while driving the vehicle, and a parking brake used to end the driving of the vehicle and park the vehicle in a predetermined parking space.

In the case of the parking brake, as the driver manually operates the hand brake lever installed between the driver's seat and the passenger's seat, a braking force is applied to the rear wheel so that the parking brake can be operated.

Since the brake pedal is used while driving, it should be able to be operated quickly and accurately with little force. To this end, hydraulic brakes, which can be reliably braked with relatively low effort, are mainly used for brake pedals.

In particular, in the conventional brake pedal, the pedal, arm, hinge shaft and bracket are made of steel material as their respective components, and the pedal, arm, hinge shaft and bracket are combined by an assembling process such as welding work or fastening work with each other. Made into an assembled assembly.

Therefore, such a conventional brake pedal is made of steel material, which causes the weight of the vehicle to increase, and because each component is assembled by an assembly process such as welding work or fastening work, manufacturing time and manufacturing cost are increased. There was a problem as well.

Disclosure of Invention The present invention has been made to solve the above-mentioned conventional problems, and an object of the present invention is to provide an integrated brake pedal and a die casting manufacturing method thereof, which can reduce the manufacturing cost and manufacturing time by reducing the weight and integrating the brake pedal. do.

It is another object of the present invention to provide an integrated brake pedal and a die casting manufacturing method thereof which can reduce the weight of the aluminum alloy and at the same time improve the supporting rigidity.

In addition, another object of the present invention is to provide an integrated brake pedal and a die casting manufacturing method thereof, which can improve the workability of a product by improving the injection property of a molten metal into a mold and at the same time shortening the cooling time of the product.

In addition, another object of the present invention is to provide an integrated brake pedal and a die casting manufacturing method thereof, which can reduce the defect rate by maintaining the die casting conditions according to the flow characteristics of the aluminum alloy to improve the compactness of the product.

In order to achieve the above object, the present invention provides a pedal unit 10 that receives a driver's foot force when braking a vehicle, an arm part 20 that is rotated by the foot force, and supports the arm part 20 to rotate. In the brake pedal having a hinge portion 30 and a bracket portion 40 coupled to one end of the hinge portion 30, the pedal portion 10, the arm portion 20, the hinge portion 30 And the bracket portion 40 is die cast integrally using an aluminum alloy.

The aluminum alloy of the present invention comprises 80.3 to 86.2 wt% of aluminum (Al), 9.6 to 12.0 wt% of silicon (Si), 1.5 to 3.5 wt% of copper (Cu), and 0.1 to 0.5 wt% of manganese (Mn). ), 0.1-0.5 wt% magnesium (Mg), 0.1-0.5 wt% nickel (Ni), 0.1-0.9 wt% iron (Fe), 0.1-0.5 wt% titanium (Ti), 0.1-1.0 weight Zinc (Zn), and 0.1 to 0.5% by weight of tin (Sn).

The aluminum alloy of the present invention is characterized in that it further comprises at least one of 0.1% by weight of lead (Pb) and 0.1% by weight of chromium (Cr).

In addition, the present invention provides a die casting manufacturing method of the integrated brake pedal described above, comprising: a melt dissolving step of dissolving an aluminum alloy in a melt; A mold preheating step of preheating the die casting mold; A die casting step of injecting the molten aluminum alloy into a die casting mold; Trimming the die cast integral brake pedal; And a finishing step of removing burrs of the die cast integral brake pedal.

The melt dissolution step of the present invention is characterized in that the temperature of the melt is maintained at 600 ~ 720 ℃. The mold preheating step of the present invention is characterized by preheating the temperature of the mold to 150 ~ 300 ℃.

As described above, the present invention can reduce the manufacturing cost and manufacturing time by integrating the pedal, arm, hinge, and bracket of the brake pedal by integrally die-casting using aluminum alloy to reduce the weight of the brake pedal and at the same time. Provide effect.

In addition, by reducing the content of aluminum as an aluminum alloy, increasing the content of silicon and adding a small amount of nickel, titanium, tin or chromium, it is possible to reduce the weight of the aluminum alloy and at the same time improve the supporting rigidity.

In addition, by dissolving the aluminum alloy in the molten metal and pre-heating the die, die casting improves the injection property of the molten metal into the mold and at the same time reduces the cooling time of the product, thereby improving the workability of the product.

In addition, by limiting the temperature of the molten metal and the preheating temperature of the mold to a certain range of temperature, it maintains the die casting conditions according to the flow characteristics of the aluminum alloy to improve the compactness of the product to provide the effect of reducing the defective rate.

1 is a block diagram showing an integrated brake pedal according to an embodiment of the present invention.

Figure 2 is a side view showing an integrated brake pedal according to an embodiment of the present invention.

3 is a flowchart illustrating a die casting manufacturing method of an integrated brake pedal according to an exemplary embodiment of the present invention.

10: pedal part 20: arm part

30: hinge portion 40: bracket portion

Hereinafter, with reference to the accompanying drawings will be described in detail a preferred embodiment of the present invention.

1 is a block diagram showing an integrated brake pedal according to an embodiment of the present invention, Figure 2 is a side view showing an integrated brake pedal according to an embodiment of the present invention, Figure 3 is according to an embodiment of the present invention It is a flowchart which shows the die-casting manufacturing method of an integrated brake pedal.

As shown in Figs. 1 and 2, the integrated brake pedal of the present embodiment includes a pedal unit 10 provided with a driver's pedaling force when braking the vehicle, an arm 20 that is rotated by the pedaling force, and the arming unit 20. ) Is a brake pedal having a hinge portion (30) for supporting rotation and a bracket portion (40) coupled to one end of the hinge portion (30), the pedal portion (10), the arm portion (20), the hinge portion ( 30 and the bracket part 40 are integral brake pedals which are die-casting integrally using aluminum alloy.

In addition, the aluminum alloy used in the die casting of such an integrated brake pedal includes 80.3 to 88.2% by weight of aluminum (Al), 9.6 to 12.0% by weight of silicon (Si), 1.5 to 3.5% by weight of copper (Cu), and 0.1 to 0.5 weight percent manganese (Mn), 0.1-0.5 weight percent magnesium (Mg), 0.1-0.5 weight percent nickel (Ni), 0.1-0.9 weight percent iron (Fe), 0.1-0.5 weight percent titanium ( Ti), 0.1 to 1.0% by weight of zinc (Zn) and 0.1 to 0.5% by weight of tin (Sn) are preferably included.

As described above, the aluminum alloy used in the die casting of the integrated brake pedal may further include at least one of 0.1 wt% lead (Pb) and 0.1 wt% chromium (Cr).

In particular, such an aluminum alloy reduces the aluminum content and increases the silicon content and adds a small amount of nickel, titanium, tin or chromium in comparison with conventional aluminum, thereby reducing the weight of the aluminum alloy and supporting it. The stiffness will be improved.

Therefore, since the brake pedal is integrally die-casted using the aluminum alloy which is light in weight and has improved support rigidity, it is possible to reduce the manufacturing cost while reducing the weight of the brake pedal.

Hereinafter, a die casting manufacturing method of the integrated brake pedal of the present embodiment will be described in detail with reference to the accompanying drawings.

As shown in FIG. 3, the die casting manufacturing method of the integrated brake pedal of the present embodiment includes a melt dissolving step (S10), a mold preheating step (S20), a die casting step, a trimming step (S70), and a finishing step (S80). consist of.

The melt dissolution step (S10) is a melt dissolution step of dissolving an aluminum alloy in the melt, and it is preferable to maintain the temperature of the melt at 600 to 720 ° C. The reason is that if the temperature of the molten metal is lower than 600 ° C, the injectability of the molten metal is lowered, thereby increasing the defective rate of the product. If the temperature of the molten metal is higher than 720 ° C, the fuel cost for heating is increased and the melting cost of the molten metal increases.

The mold preheating step S20 is a step of preheating the die casting mold before injection, and preferably preheats the temperature of the die casting mold to 150 to 300 ° C. The reason is that when the temperature of the mold is lower than 150 ° C, the molten metal is cooled and the injection property is lowered. When the temperature of the mold is higher than 300 ° C, excessive time is required to cool the molten metal after injection, thereby increasing the working time.

The die casting step is a step of injecting the molten aluminum alloy into the die casting mold, and includes a mold closing step S30, an injection step S40, a mold opening step S50, and a mold cleaning step S60. .

The mold closing step (S30) is a step of forming a mold frame between the fixed mold and the movable mold of the die casting mold in close contact with the mold, inserting the insert core and the slide core into the mold and injecting molten metal into the sleeve.

Injecting step (S40) is a step of injecting molten metal between the stationary mold and the movable mold of the die casting mold, the molten metal injected into the sleeve is injected into the mold using a piston.

At this time, the casting pressure, that is, the injection pressure of the molten metal is preferably maintained at 40 to 50 MPa depending on the flow characteristics of the aluminum alloy. The reason is that if the casting pressure is lower than 40 MPa, the injection property of the molten metal decreases and the injection time is excessively consumed, and workability is lowered. Because. In particular, in the case of the molten aluminum alloy of the present embodiment, it is more preferable to maintain the injection pressure of the molten metal at 44.1 MPa in consideration of the flow characteristics of the aluminum alloy.

The mold opening step (S50) is a step of cooling the molten metal injected between the stationary mold and the movable mold of the die casting mold, and then separating the molds to take out the integrated brake pedal product. After removing the core, the integrated brake pedal product is taken out.

The mold cleaning step (S60) is a step of taking out the integrated brake pedal product and cleaning and preparing the mold for die casting of the next product. After the first cleaning, the mold release agent is applied to the inside of the mold and cleaned secondly.

The trimming step S70 is a step of trimming the die-cast integrated brake pedal, and removes the runner or the overplug and the vent hole attached to the exterior of the die-cast integrated brake pedal from the trimming die.

The finishing step S80 is a step of removing the burrs of the die cast integral brake pedal, and using a manual tool such as a grinder with a fine bur of less than 2 mm remaining after the trimming step S70 on the surface of the die cast integral brake pedal. To be removed manually.

After the burr removal is completed, the integral brake pedal is finally inspected for residual burrs, and then transported to a packaging line to print a label and to be shipped after packaging.

As described above, according to the present invention, the pedal, arm, hinge, and bracket portions of the brake pedal are integrally die cast using aluminum alloy to reduce the weight and simultaneously integrate the brake pedal, thereby reducing manufacturing cost and manufacturing time. Provide effect.

The present invention described above can be embodied in many other forms without departing from the spirit or main features thereof. Therefore, the above embodiments are merely examples in all respects and should not be interpreted limitedly.

The present invention provides an integrated brake pedal and a diecasting manufacturing method thereof for braking the vehicle by the driver's effort during driving of the vehicle.

Claims

The pedal unit 10 receives the driver's foot force when braking the vehicle, the arm part 20 rotated by the foot force, the hinge part 30 supporting the arm part 20 to rotate, and the hinge part 30. In the brake pedal provided with a bracket portion 40 coupled to one end of the

The pedal unit (10), the arm portion (20), the hinge portion (30) and the bracket portion (40), integral brake pedal, characterized in that the die cast integrally using aluminum alloy.
The method of claim 1,

The aluminum alloy is 80.3-8.2 wt% aluminum (Al), 9.6-12.0 wt% silicon (Si), 1.5-3.5 wt% copper (Cu), 0.1-0.5 wt% manganese (Mn), 0.1 -0.5 wt% magnesium (Mg), 0.1-0.5 wt% nickel (Ni), 0.1-0.9 wt% iron (Fe), 0.1-0.5 wt% titanium (Ti), 0.1-1.0 wt% zinc (Zn) and 0.1 to 0.5% by weight of tin (Sn).
The method of claim 2,

The aluminum alloy further comprises at least one of 0.1 wt% lead (Pb) and 0.1 wt% chromium (Cr).
A die casting manufacturing method of the integrated brake pedal according to claim 1,

A melt dissolving step of dissolving an aluminum alloy in the melt;

A mold preheating step of preheating the die casting mold;

A die casting step of injecting the molten aluminum alloy into a die casting mold;

Trimming the die cast integral brake pedal; And

And a finishing step of removing burrs of the die cast integral brake pedal.
The method of claim 4, wherein

The melt dissolving step, the die casting manufacturing method of the integrated brake pedal, characterized in that the temperature of the molten metal is maintained at 600 ~ 720 ℃.
The method of claim 4, wherein

The die preheating step, the die casting manufacturing method of the integrated brake pedal, characterized in that for preheating the temperature of the mold to 150 ~ 300 ℃.