汽车踏板轻量化解决方案研究与应用

Research and Application of Lightweight Solutions for Automobile Pedals

从汽车制动踏板模块设计、工艺、质量角度出发,通过应用长玻纤维、镁铝合金等新材料,将厚板料踏板臂设计优化成为双U形对扣式空心踏板臂、实心中心轴采用空心化设计,踏板支架5~6个冲焊件结构创新应用铝合金一体化压铸技术,结合CAE分析及试验验证等设计验证手段,实现踏板轻量化。在保证踏板性能要求情况下踏板制造成本降低5%,制动踏板减重率达到20%。

From the perspective of the design,process and quality of the automobile brake pedal module and by the application of new materials such as long glass fiber and magnesium-aluminum alloy,the thick plate pedal arm has been optimized into a double U-shaped double buckle hollow pedal arm,the solid central shaft has been modified to hollow design and aluminum alloy integrated die-casting technology and other technological innovations have been applied to 5~6 stamped and welded parts of pedal support.By combining design verification methods such as CAE analysis and experimental verification,lightweight pedal has been developed.The manufacturing cost of the pedal is reduced by 5%while ensuring the performance requirements of the pedal and weight of the brake pedal is reduced by 20%.