Method, device and apparatus for connecting components

Abstract

The invention relates to a method for connecting components, wherein a first component (2) having at least one first projection (8) is provided, wherein a second component (3) having at least one hook section (13) is provided, wherein the second component (3) is arranged on the first component (2) such that the hook section (13) abuts the first projection (8), wherein a first punching step (S4) is performed, and wherein, in the first punching step (S4), a punch (20) is pressed against the first projection (8) by moving in a punching direction (21) such that the first projection (8) is plastically deformed while forming an outer camber (15) that engages the hook section (13) from behind, in order to connect the first component (2) to the second component (3) in a form-fitting manner. Provision is made for the punch (20) to be temporarily moved in a decompression direction (22) opposite to the punching direction (21) in the first punching step (S4) in order to temporarily reduce the punching force (N) acting on the first projection (8).

Description

Technical Field

[0001] The invention relates to a method for connecting components, wherein a first component having at least one first projection is provided, wherein a second component having at least one hook section is provided, wherein the second component is arranged on the first component in such a way that the hook section adjoins the first projection, wherein a first punching step is performed, and wherein in the first punching step, a punch is pressed against the first projection by a movement in the punching direction in such a way that the first projection is plastically deformed while forming an outer camber that engages behind the hook section, in order to connect the first component to the second component in a form-fitting manner.

[0002] Furthermore, the present invention relates to a device having a first component and a second component connected to the first component.

[0003] The present invention also relates to a device for connecting components, which device has a controller. Background Art

[0004] Connecting components by means of stamping is known from the prior art. For example, it is known to connect components made of metal materials by means of stamping. It is also known to connect components made of plastic by means of hot stamping.

[0005] Here, a first component and a second component are provided, which are to be connected by stamping. The first component has at least one first protrusion. The second component has at least one hook section. The second component is arranged on the first component such that the hook section abuts the first protrusion. For example, the second component is arranged such that the hook section directly abuts the first protrusion or such that the hook section is slightly spaced apart from the first protrusion.

[0006] To connect the first and second components to one another, a first stamping step is performed, in which the punch is pressed against the first projection by moving it in the stamping direction, so that the first projection is plastically deformed, forming an outer camber that engages the hook section from behind. Because the outer camber engages the hook section from behind, a positive connection between the first and second components is achieved by the first stamping step or stamping. Summary of the Invention

[0007] The method according to the present invention, with the features of claim 1, has the advantage of increasing the stability of the form-fitting connection between the first and second components. According to the present invention, for this purpose, the punch is temporarily moved in a direction of relief, opposite to the punching direction, during the first punching step to temporarily reduce the punching force acting on the first projection. Punching force refers to the force generated by the punch pressing against the contact surface of the first projection. According to the present invention, the punch is temporarily moved in the direction of relief. Therefore, immediately following the punch movement in the direction of relief, the punch is moved again in the punching direction. Punching is thus performed stepwise during the first punching step. It is known from the prior art to perform punching under tension, that is, without temporarily moving the punch in the direction of relief. However, this approach, at higher punching depths, may result in the material to be punched or the first projection not being further deformed. Instead, cracks may form in the material to be deformed. In contrast, the approach according to the present invention has the advantage of achieving a larger punching depth and a correspondingly higher degree of deformation. This allows the size of the outer camber that engages the hook section from behind to be increased. The stability of the form-fitting connection is correspondingly increased.

[0008] According to a preferred embodiment, the punch is temporarily moved in the first punching step so far in the direction of the pressure relief that the punching force is eliminated. The punch then no longer exerts a punching force on the first protrusion. By completely reducing the pressure of the first protrusion, a particularly high punching depth can be achieved.

[0009] The punch is preferably moved temporarily several times in the direction of reduced pressure during the first stamping step, wherein the punch is moved in the stamping direction between the first movement in the direction of reduced pressure and the subsequent second movement in the direction of reduced pressure. The punch is therefore first moved in the stamping direction and pressed against the first protrusion. The punch is then moved in the direction of reduced pressure. This corresponds to the first movement in the direction of reduced pressure. The punch is then moved again in the direction of stamping and pressed against the first protrusion. This is followed by a further movement of the punch in the direction of reduced pressure. This corresponds to the second movement in the direction of reduced pressure. The punch is then moved again in the direction of stamping and pressed against the first protrusion. This approach can also further increase the achievable stamping depth. The punch is preferably moved temporarily in the direction of reduced pressure more than twice.

[0010] According to a preferred embodiment, the actual displacement position of the punch is monitored, wherein at least one target displacement position is predetermined, and wherein the punch is temporarily moved in the direction of reduced pressure when the actual displacement position corresponding to the target displacement position is detected. By predefining the target displacement position, a suitable point in time at which the temporary movement of the punch in the direction of reduced pressure provides the desired advantages can be particularly precisely predetermined. If the punch is to be temporarily moved in the direction of reduced pressure multiple times, then preferably at least two different target displacement positions are predetermined.

[0011] Preferably, a profile of the punching force is determined, wherein the punch is moved according to this profile. The profile of the punching force can also be used to precisely determine the appropriate time at which a temporary movement of the punch in the direction of pressure reduction provides the desired advantage. For example, the profile of the punching force is determined based on the motor current of an electric motor designed to move the punch. The motor current is then detected or measured accordingly to determine the profile of the punching force. Alternatively or additionally, the punching force is detected by a pressure sensor assigned to the punch. The profile of the punching force is then determined based on the sensor signal of this pressure sensor.

[0012] According to a preferred embodiment, it is provided that the slope of the variation curve is determined, wherein a maximum permissible threshold slope is predetermined, and wherein the punch is temporarily moved in the direction of pressure relief when a negative slope exceeding the threshold slope occurs. As previously explained, during punching, cracks may form in the material to be punched. This crack formation results in the punching force decreasing despite the punch moving in the punching direction. Therefore, crack formation can be understood by means of the variation curve of the punching force and in particular by means of the slope of this variation curve. In particular, the onset of crack formation can be determined by means of the slope. By presetting a suitable threshold slope and temporarily moving the punch in the direction of pressure relief, crack formation that could impair the stability of the form-fitting connection between the components can be correspondingly prevented when a negative slope exceeding the threshold slope occurs. Preferably, the threshold slope is predetermined based on this, i.e., cracks are only formed when a negative slope exceeding the threshold slope exists.

[0013] According to a preferred embodiment, a first component is provided having at least one second protrusion adjacent to the first protrusion, wherein a second stamping step is performed immediately following the first stamping step. During the second stamping step, the punch or another punch is pressed against the second protrusion by moving in the stamping direction in such a way that the size of the outer camber of the first protrusion increases due to the plastic deformation of the second protrusion. Thus, a first component is provided that has both at least one first protrusion and at least one second protrusion. The at least one second protrusion is stamped and thereby plastically deformed during the second stamping step, i.e., immediately following the first stamping step. Because the second protrusion is adjacent to the first protrusion, the size of the outer camber of the first protrusion increases due to the plastic deformation of the second protrusion. This further improves the stability of the form-fitting connection between the first component and the second component. In particular, the second protrusion directly adjoins the first protrusion. Alternatively, the second protrusion can be slightly spaced apart from the first protrusion.

[0014] According to a preferred embodiment, a first component is provided having an annular first protrusion. If the first protrusion is annular, then in addition to the form-fitting connection, an advantageous sealing effect is also provided by the first stamping step. As previously explained, a first component is preferably provided, which has at least one second protrusion in addition to the first protrusion. An annular second protrusion is preferably provided, which surrounds the annular first protrusion. In this regard, the annular shape of the second protrusion has a larger diameter than the annular shape of the first protrusion. As an alternative to this, a plurality of second protrusions are preferably provided, which are arranged radially outside the annular first protrusion and are spaced apart from each other along the peripheral direction of the annular first protrusion. It is particularly preferred that the second protrusions are evenly distributed along the peripheral direction of the annular first protrusion.

[0015] The second component preferably comprises a sleeve segment, wherein the free end of the sleeve segment comprises a hook segment that protrudes radially outward from the free end relative to the longitudinal center axis of the sleeve segment, and wherein the second component is arranged on the first component such that a first annular projection surrounds the sleeve segment. Because the first projection surrounds the sleeve segment, the first projection is easily accessible for performing the first punching step. A sleeve-shaped punch is preferably used in the first punching step, the punch surface of which matches the contact surface of the first projection. The hook segment is preferably annular in shape. The hook segment thus extends completely along the circumference of the sleeve segment, along the free end of the sleeve segment.

[0016] According to an alternative embodiment, the method according to the invention with the features of claim 1 is distinguished by providing a first component having at least one second protrusion adjacent to the first protrusion, wherein a second stamping step is carried out immediately following the first stamping step, in which the punch or a further punch is pressed against the second protrusion by moving in the stamping direction in such a way that the size of the outer arch structure increases due to the plastic deformation of the second protrusion. As explained above, the stability of the form-fitting connection can thereby be increased. According to this alternative embodiment, it is optional to carry out the first stamping step in stages. Therefore, in the first stamping step, the punch is preferably temporarily moved in the direction of pressure relief in order to temporarily reduce the stamping force acting on the first protrusion.

[0017] The device according to the invention comprises a first component and a second component connected to the first component. The device with the features of claim 10 is distinguished in that the first and second components are connected to one another by the method according to the invention. This also achieves the advantages already mentioned. Further preferred features and feature combinations are derived from the previously described content and from the claims. In terms of device technology, the device according to the invention differs from previously known devices in particular in that the size of the outer arch structure of the first projection is larger in the device according to the invention. In particular, micrographs of the device in the area of ​​the form-fitting connection between the components show that the device is manufactured by the method according to the invention. Due to the stepwise execution of the first stamping step, irregularities can occur in the area of ​​the deformed first projection, which can be seen in the micrographs.

[0018] The device is preferably a hydraulic assembly for a brake system, wherein the first component is designed as a hydraulic block and the second component is designed as a pressure generating unit. In hydraulic assemblies, the form-fitting connection between the hydraulic block and the pressure generating unit is usually subject to high loads. However, there is often only limited space available for this form-fitting connection. In this regard, the method according to the present invention is particularly suitable for connecting a hydraulic block to a pressure generating unit because it provides a particularly stable form-fitting connection.

[0019] The device according to the present invention for connecting components by punching comprises a movably mounted punch and a controllable motor coupled to the punch so that the punch can be moved by the motor. The device having the features of claim 12 is distinguished by a controller that is specifically configured to control the motor so that the system performs a first punching step according to any one of claims 1 to 9. This also achieves the advantages already mentioned. Further preferred features and feature combinations are derived from the above description and the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will now be explained in more detail with the aid of the accompanying drawings.

[0021] Figure 1 An apparatus for a braking system is shown;

[0022] Figure 2 shows a micrograph of the device;

[0023] Figure 3 An apparatus for manufacturing the device is shown;

[0024] Figure 4 A method for manufacturing the device is shown; and

[0025] Figure 5The profile of the punching force during the punching step of the method is shown. DETAILED DESCRIPTION

[0026] Figure 1 The device 1 is shown in a top view. The device 1 has a first component 2 and a second component 3. The first component 2 and the second component 3 are connected to each other via a form-fitting connection 4.

[0027] In the present case, the device 1 is a hydraulic assembly 1 for a brake system. The first component 2 is a hydraulic block 2 of the hydraulic assembly 1. The second component 3 is a pressure generating unit 3 of the hydraulic assembly 1.

[0028] Next reference Figure 2 The design of the form-fit connection 4 is explained in more detail. Figure 2 Shown in Figure 1 6. The positive connection 4 is provided by the cooperation of the housing 7 of the second component 3 on the one hand and the first projection 8 of the first component 2 on the other hand.

[0029] The housing 7 of the second component 3 has a sleeve section 9, i.e., a sleeve-shaped or cylindrical section. The sleeve section 9 has a free end 10. The free end 10 has a hook section 13, which projects radially outward from the free end 10 relative to a longitudinal center axis 14 of the sleeve section 9 or of the housing 7 of the second component 3. The hook section 13 extends along the entire periphery of the sleeve section 9 along the free end 10. In this regard, the hook section 13 is annular in shape.

[0030] The first component 2 includes a housing 11 with a base plate 12, from which a first projection 8 protrudes. The first projection 8 is annular in shape. Furthermore, a plurality of boreholes 29 are formed in the base plate 12 around the first projection 8. The boreholes 29 define the maximum permissible radial extension of the first projection 8. The first projection 8 is limited by the boreholes 29 and does not exceed the specified radial extension, as otherwise the projection and the boreholes 29 would collide.

[0031] The second component 3 is arranged on the first component 2 such that the annular first projection 8 and the sleeve section 9 are arranged coaxially with each other. The longitudinal center axis of the annular first projection 8 corresponds to the longitudinal center axis 14 of the sleeve section. The annular inner contour of the first projection 8 is larger than the outer contour of the sleeve section 9. The first projection 8 thus surrounds the sleeve section 9.

[0032] Furthermore, the second component 3 is arranged on the first component 2 in such a way that the free end 10 rests directly on the base plate 12 in the axial direction relative to the longitudinal center axis 14 .

[0033] The first projection 8 has an outer camber 15 that engages behind the sleeve section 13 and thus creates a positive connection 4. To this end, the outer camber 15 projects radially inward from the base 16 of the first projection 8. In this embodiment, the positive connection 4 is designed to be play-free. To this end, the outer camber 15 exerts a preload on the hook section 13, which presses the second component 3 against the base plate 12.

[0034] exist Figure 3 , a simplified illustration of a device 18 for connecting components is shown. Device 18 is designed to connect components to one another by means of stamping. Device 18 comprises a holding unit, in this case a carrier plate 19, on which the components to be connected can be arranged. Device 18 also comprises a punch 20 that can be moved in a stamping direction 21 and in a pressure relief direction 22 opposite to stamping direction 21. By moving punch 20 in stamping direction 21, it can feed carrier plate 19 or components arranged thereon.

[0035] The device 18 also has a controllable electric motor 23. The drive shaft of the electric motor 23 is coupled to the punch 20 in such a way that the punch 20 can be moved by the electric motor 23. The device 18 also has a controller 24, which is designed to control the electric motor 23.

[0036] Next reference Figure 4 An advantageous method for connecting the first component 2 to the second component 3 by means of the device 18 is explained in more detail. By means of the method, a form-fitting connection 4 is formed. For this purpose, Figure 3 The method is illustrated with the aid of a flow chart.

[0037] In a first step S1 , a first component 2 is provided.

[0038] In a second step S2 , the first component 2 is arranged on the carrier plate 19 in such a way that the first projection 8 faces the punch 20 .

[0039] In a third step S3 , the second component 3 is provided.

[0040] In the fourth step S4, the second component 3 is arranged on the first component 2 so that the first projection 8 surrounds the sleeve section 9, as explained above. The outer camber 15 is not yet present at this point in time. More precisely, the contour of the first projection 8 is depicted by the dashed lines 17 and 27. Line 17 depicts the course of the first projection's contact surface facing the punch 20. Because the outer camber 15 is not yet present, the sleeve section 9 can be easily fitted onto the first projection 8.

[0041] According to an alternative embodiment, the second component 3 is first arranged on the first component 2 and then the components 2 and 3 are arranged together on the carrier plate 19 .

[0042] In the first stamping step S5 , the controller 24 controls the electric motor 23 so that the punch 20 is pressed against the contact surface of the first protrusion 8 by moving in the stamping direction 21 so that the first protrusion 8 is plastically deformed to form the outer camber 15 .

[0043] Next reference Figure 5 The first punching step S5 is explained in more detail. Figure 5 Graph A is shown, which illustrates the punching force N acting on the contact surface of the first protrusion 8 according to the actual displacement position SS of the punch 20. In the first actual displacement position SS0, the punch 20 strikes the contact surface of the first protrusion 8, so that when the punch 20 moves further in the punching direction 21, the punching force N increases and the first protrusion 8 is deformed.

[0044] The first line L1 describes the variation curve of the punching force N according to a particularly advantageous first embodiment of the first punching step S5. According to the first embodiment of the first punching step S5, a plurality of mutually different set displacement positions SS1, SS2 and SS3 are predetermined. If the actual displacement position of the punch 20 reaches one of the predetermined set displacement positions SS1, SS2 or SS3, the controller 24 drives the electric motor 23 so that the punch 20 moves again in the decompression direction 22. Figure 5 As can be seen, the punching force N is thus reduced. The punch 20 is moved so far in the decompression direction 22 that the punching force N is released. The punching force N thus drops to a value of 0. Immediately after the punch 20 has moved in the decompression direction 22, the controller 24 controls the electric motor 23 so that the punch 20 moves again in the punching direction 21, thereby continuing the punching of the first protrusion 8. The punch 20 is thus temporarily moved in the decompression direction 22. Because a plurality of different target displacement positions are predetermined, the punch 20 is temporarily moved in the decompression direction 22 multiple times.

[0045] Line L2 describes the variation curve of the punching force N according to the second embodiment of the first punching step S5. According to the second embodiment, the punch 20 is continuously moved in the punching direction 21. The predetermined set displacement position is canceled, thereby temporarily stopping the punch 20 from moving in the pressure relief direction 22.

[0046] As can be seen from the line L2, the punching force N in the second embodiment decreases significantly in the actual displacement range 25, even if the punch 20 is moved in the punching direction 21. This is achieved by forming a crack in the material of the first protrusion 8. Due to the crack formation, instead of further deformation, the material is deformed, especially along the Figure 2 The line 28 shown is cut.

[0047] As can be seen from line L1, in the first embodiment, there is virtually no drop in the punching force N within the actual displacement range 25. In this regard, in the first embodiment, crack formation is prevented or at least reduced by the stepwise punching of the first projection 8. This ultimately results in a more stable, form-fitting connection 4 between the first component 2 and the second component 3.

[0048] The second punching step S6 is performed immediately after the first punching step S5 .

[0049] The first member 2 has a plurality of second protrusions 26 adjacent to the first protrusions 8. Figure 1 It can be seen that the second protrusion 26 is adjacent to the annular first protrusion 8 from the outside in the radial direction. Figure 2 It can be seen that the second protrusion 26 and the first protrusion 8 are now integrally constructed. Figure 1 In the illustrated embodiment, a total of five second protrusions 26 are provided, which are evenly spaced apart along the circumference of the annular first protrusion 8 .

[0050] In the second punching step S6, the punch 20 or another punch is pressed against the second projection 26 by a movement in the punching direction 21 such that the size of the outer curvature 15 of the first projection 8 is increased by the plastic deformation of the second projection 26. Figure 2 1 shows the device 1 before the second punching step S6 is performed. If the second punching step S6 is performed based on this illustration, the radial distance between the sleeve section 9 and the outer camber structure 15 becomes smaller and an outer camber structure protruding radially in the direction of the sleeve section 9 is also formed at the second protrusion 26.

[0051] The second punching step S6 is optional. According to another embodiment of the method, the second punching step S6 is eliminated, and only the first punching step S5 is performed.

Claims

1. A method for connecting components, wherein: A first component (2) having at least one first protrusion (8) is provided, wherein a second component (3) having at least one hook section (13) is provided, wherein the second component (3) is arranged on the first component (2) such that the hook section (13) abuts the first protrusion (8), wherein a first punching step (S4) is performed, and wherein, in the first punching step (S4), the punch (20) is pressed against the first protrusion (8) by moving in a punching direction (21) such that the first protrusion (8) is plastically deformed while forming an outer arch structure (15) that engages the hook section (13) from behind, so as to connect the first component (2) to the second component (3) in a form-fitting manner, characterized in that the punch (20) is temporarily moved in a decompression direction (22) opposite to the punching direction (21) in the first punching step (S4) so ​​as to temporarily reduce the punching force (N) acting on the first protrusion (8).

2. The method according to claim 1, characterized in that In the first punching step (S4), the punch (20) is temporarily moved so far in the decompression direction (22) that the punching force (N) is released.

3. The method according to any one of the preceding claims, characterized in that The punch (20) is temporarily moved multiple times toward the decompression direction (22) in the first punching step (S4), wherein the punch (20) is moved toward the punching direction (21) between a first movement toward the decompression direction (22) and a subsequent second movement toward the decompression direction (22).

4. The method according to any one of the preceding claims, characterized in that The actual displacement position of the punch (20) is monitored, wherein at least one set displacement position (SS1, SS2, SS3) is predetermined, and wherein the punch (20) is temporarily moved in the decompression direction (22) when detecting the actual displacement position corresponding to the set displacement position (SS1, SS2, SS3).

5. The method according to any one of the preceding claims, characterized in that A variation curve of the punching force (N) is determined, wherein the punch (20) is moved according to the variation curve.

6. The method according to claim 5, characterized in that The slope of the curve is determined, wherein a maximum permissible threshold slope is predetermined, and wherein the punch (20) is temporarily moved in the decompression direction (22) when a negative slope occurs that exceeds the threshold slope.

7. The method according to any one of the preceding claims, characterized in that A first component (2) is provided having at least one second protrusion (26) adjacent to the first protrusion (8), wherein a second punching step (S5) is performed immediately after the first punching step (S4), in which the punch (20) or another punch is pressed against the second protrusion (26) by moving in the punching direction (21) so that the size of the outer arch structure (15) is increased by plastic deformation of the second protrusion (26).

8. The method according to any one of the preceding claims, characterized in that A first member (2) is provided having a first annular protrusion (8).

9. The method according to claim 8, characterized in that A second component (3) is provided having a sleeve section (9), wherein the free end (10) of the sleeve section (9) has a hook section (13) which projects radially outward from the free end (10) relative to a longitudinal center axis (14) of the sleeve section (9), and wherein the second component (3) is arranged on the first component (2) such that the annular first projection (8) surrounds the sleeve section (9).

10. A device comprising a first component (2) and a second component (3) connected to the first component (2), characterized in that The first and second components (2, 3) are connected to one another by a method according to any of the preceding claims.

11. The device according to claim 10, characterized in that The device (1) is a hydraulic assembly (1) for a brake system, wherein the first component (2) is designed as a hydraulic block (2) and the second component (3) is designed as a pressure generating unit (3).

12. A device for connecting components by means of punching, comprising: a punch (20) supported in a movable manner and a controllable motor (23), the motor being coupled to the punch (20) in such a way that the punch (20) can be moved by the motor (23), characterized in that A controller (24) is specifically designed to control the motor (23) in such a way that the device (18) performs a first punching step according to any one of claims 1 to 9.

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