Disc brake and housing assembly for pressure transmission in a brake application device of a disc brake

Abstract

The invention describes a disc brake having a brake caliper and a brake application device arranged therein for applying a force to a brake pad of the disc brake, wherein a component of the application device is a brake lever which can be actuated by a stressing element, preferably by a pressure cylinder, and which consists of a lever arm supporting the stressing element and an application shaft. The latter abuts on one side against a pressure piece acting towards the brake pad and on the other side against a channel (6) located on the inner side of the brake caliper through the insertion of a housing (5), the curvature of the housing complementing the curvature of the channel (6). In order to improve the disc brake and housing assembly by means of a design measure in order to prevent the housing assembly from moving out of the original position even in the case of long-term use and frequent stresses caused by braking, an opening for a borehole (7) is provided in the channel (6). On the housing (5), facing the channel (6), a projection (8) is formed by deformation of the housing material, the projection (8) extending into the borehole (7) in the form of a flange and producing an interlocking connection between the housing (5) and the channel (6). A forming element (9) is arranged in the projection (8), and the outer diameter of the forming element (9) is the same or almost the same as the inner diameter of the projection (8).

Description

Technical Field

[0001] The invention relates to a disc brake according to the preamble of the claims, having a brake caliper and an engagement device arranged therein.

[0002] The invention also relates to a housing assembly according to the claimed invention for pressure transmission in an application device of a disc brake. Background Art

[0003] Disc brakes are usually equipped with an action device in their brake calipers, which transmits and amplifies the force of the brake pads arranged on both sides of the brake disc in contact with the brake disc, thereby achieving a braking effect through friction.

[0004] In conventional disc brakes, which are usually pneumatic, the brake lever, which is pivotably arranged in the brake caliper, is part of the action device. The brake lever consists of a force-amplifying lever arm and an action shaft, which is designed as an eccentric circle in cross section. The stressing element of the disc brake, such as the cylinder in pneumatic disc brakes, is supported by the lever arm. The action shaft of the brake lever is supported on one side on a pressure piece, which runs towards the brake pad inside the vehicle, and on the other side on the rear side of the brake caliper housing.

[0005] WO 2019 / 015716 A1, DE 10 2012 006 113 A1 and DE 295 10 331 U1 disclose disc brakes with the above-mentioned features, wherein the inner wall of the brake caliper is designed as a partially cylindrical channel to support the brake rod on the rear side (i.e., the brake caliper side), and the action axis of the brake rod is designed as a partially cylindrical section. In some prior arts, the action axis facing the channel on the brake caliper also includes a channel, wherein a support roller is installed between the channels, and the support roller has a roller axis extending transversely to the action direction. A housing is additionally arranged between the channel on the brake caliper side and the support roller, which acts as a sliding housing to prevent excessive material removal at the channel. Due to the repeated high compression forces during braking, there is a risk that the housing moves out of the channel on the brake caliper side in the circumferential direction. In order to counteract this, the housing assembly of WO 2019 / 015716 A1 has two plates for positive locking at the channel. The plate is configured to be supported in a complementary recess in the caliper, adjacent the channel.

[0006] However, it has been found that the tabs deform under constant load and the housing assembly begins to move out of the channel due to a reduction in the locking action. Summary of the invention

[0007] The object of the present invention is to further improve the disc brake and housing assembly by constructive measures in order to prevent the housing assembly from moving out of the original position even in the case of long-term use and frequent loads caused by braking.

[0008] The object is proposed to be achieved by a disc brake having the features of the claimed content, and a housing component in an action device of a disc brake having the features of the claimed content, which housing component is used for pressure transmission.

[0009] The disc brake is characterized in that the opening of the hole is located in the channel, a line is formed on the housing facing the channel, the line is produced by deformation of the housing material, extends into the hole in the form of a collar, a positive fit is established between the housing and the channel, and a shaped element is arranged in the line, the outer diameter of which is equal to the inner diameter of the line.

[0010] In addition, the housing assembly comprises a housing, the pipeline produced by deformation of the housing material is formed on one side of the convex pressure transmission surface on the housing and is in the shape of a collar. Another component of the housing assembly is a forming element arranged in the pipeline, the outer diameter of the forming element being equal to or almost equal to the inner diameter of the pipeline.

[0011] The disc brake allows an improved and more permanent locking of the housing arranged between the brake lever or the support roller and the channel to prevent it from leaving the original housing position. The locking of the housing in the channel is achieved due to the fact that the pipe collar is complementary to the hole. In order to strengthen the collar and prevent the housing from deforming and loosening again due to constant loads, a shaped element is pressed into the pipe once the housing has been inserted into the channel and the collar has been locked in the hole. The shaped element slightly expands the collar to fix the device in the hole, wherein the shaped element additionally supports the collar against shear forces. As a result, the structural integrity of the housing and its fixed base relative to the channel in the original housing position are improved.

[0012] The housing of the housing assembly is a rectangular surface element in the form of a longitudinal channel, which therefore has a channel-like cross section with a partial annular bend. An opening in the form of a conduit is formed at the lowest point of the bend and the channel and at the geographical center point of the housing. From a manufacturing point of view, the conduit is a punched hole in the housing towards its convex side, wherein a collar is formed along the edge of the opening in the form of deformed material, the collar extending orthogonally to the convex pressure transmission surface and circumferentially surrounding the convex pressure transmission surface.

[0013] The hole opening at the bottom of the channel is preferably designed as a blind hole. Therefore, the hole does not completely penetrate the material of the channel or the brake caliper, but only penetrates to a certain depth.

[0014] The length of the hole preferably has a greater depth than the sum of the lengths of the pipeline and the profiled element protruding from the pipeline, wherein the depth of the hole is equal to or greater than 1.2 times the axial extension of the profiled element. The depth of the hole, which depends on the profiled element, is caused by the retention of the profiled element in the region of the pipeline, more precisely at the level of the collar. In particular, the profiled element must not rest too early on the bottom of the hole during assembly, so as not to be pressed in the direction of the active axis.

[0015] At the same time, the depth of the hole must be chosen so that the shaped element is prevented from sliding out of the pipe before it can do so due to loads, for example in the form of vibrations acting in the direction of the hole, by choosing the hole depth accordingly. The shaped element must therefore be held at the level of the collar or must be constantly held with its outer surface against the inner surface of the pipe.

[0016] Furthermore, there is a circumferential bevel at the bore opening to avoid shearing edges which, in the long term, could adversely affect the collar of the pipe during operation.

[0017] Due to its end face facing away from the hole, the shaped element does not protrude beyond the plane of curvature of the concave pressure-transmitting surface. Therefore, the shaped element must not extend beyond the level of the concave pressure-transmitting surface of the housing, otherwise it would contact the active shaft and possibly damage the surface of the active shaft due to the movement of the active shaft during braking. In addition, contact between the shaped element and the active shaft could lead to a stiffening of the brake lever.

[0018] The action shaft is preferably designed to accommodate a support roller between itself and the housing. The support roller is rotatably or positively mounted on the action shaft on a part of the circumference and rotatably mounted on the housing on another part of the circumference. The use of a support roller has the advantage that the brake lever must be formed with only a partial roller segment facing the pressure piece, which is difficult to manufacture, wherein the partial cylindrical recess in the brake lever preferably accommodates the support roller in a rotationally fixed manner facing the brake caliper. Despite the addition of a support roller as a further component, the partial cylindrical recess reduces the production effort compared to the second partial roller segment.

[0019] The housing of the housing assembly preferably has a friction-reducing surface coating on its concave pressure-transmitting surface. On its convex side, the housing is locked in a positive-fitting manner in the channel via the pipeline, wherein the active shaft or the support roller rests on the concave side of the housing via a sliding bearing. In order to maintain smooth operation and reduce material wear between the active shaft or the support roller and the concave pressure-transmitting surface, the friction-reducing surface coating on the housing ensures that the components slide more gently against each other.

[0020] Preferably, the shaped element is a cylindrical pin, wherein the cylindrical pin is preferably made of unhardened austenitic stainless steel. The cylindrical pin is manufactured according to the tolerances and dimensions of EN ISO 2338:1997, wherein the cylindrical pin can also be selected from ISO 3269:1988, ISO 3506-1:1997, ISO 4042:- and ISO 9717:1990.

[0021] However, other standard cylindrical pins may also be selected. However, their corrosion resistance is necessary to counteract corrosion and increase the life of the formed element in case of continuous, potentially corrosive contact with the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Further advantageous measures are explained in more detail below with reference to the description of preferred exemplary embodiments in conjunction with the accompanying drawings. In the drawings:

[0023] Figure 1 An exploded view of the brake caliper, two support rollers and the brake lever is shown, with the housing fastened to the brake caliper;

[0024] Figure 2 shows a schematic cross section of a housing assembly which is locked by means of a shaped element and a line to the channel on the brake caliper side; and

[0025] Figure 3 A perspective view of the housing assembly is shown, with the integrated shaped element in a locked position on the channel on the brake caliper side. DETAILED DESCRIPTION

[0026] Figure 1 An exploded view of a brake caliper 1 is shown, having a housing 5 inserted into two part-cylindrical channels 6 of the caliper, a brake lever 2 and two support rollers 10. The brake caliper 1 is designed as a sliding or floating caliper like a disc brake, in particular a pneumatic disc brake.

[0027] The integrally cast brake caliper 1 consists of three parts. When a disc brake is installed, a first caliper part 13 located inside the vehicle is provided with a cavity 15 in its interior, which provides space for the brake application device. When a disc brake is installed, a second caliper part 14 located outside the vehicle is arranged on the opposite side of a brake disc (not shown) of the disc brake. The two caliper parts 13, 14 are connected to each other by a bridge part 16, which bridges the brake disc (not shown) so as to provide available space for at least part of the brake disc and brake pads (also not shown).

[0028] Here, the brake caliper 1 is one-piece, in that the two caliper parts 13, 14 and the bridge part 16 are formed integrally. The first caliper part 13 is open toward the available space of the bridge part 16 and thus toward the brake disc. This opening serves in particular as an assembly opening and is large enough to be able to mount the action device through it. After the brake is assembled, the opening is closed by a cover.

[0029] The brake lever 2, which can be actuated by a pneumatic brake cylinder, is forked in its entirety, since it branches out into two legs starting from a lever arm 3 arranged on the pivot center line. A first longitudinal portion is located on the first leg, and a second longitudinal portion of an actuation shaft 4 formed integrally with the lever arm 3 is located on the second leg. Due to the division of the actuation shaft 4 into two longitudinal portions, two separate channels are formed on the brake lever 2, but the two channels are aligned with each other, each channel being used to support a support roller 10 designed as a roller.

[0030] In the installed state, the action shaft 4 is supported on one side via rollers or support rollers 10 on the first caliper part 13 and on the other side on a pressure piece facing the inner brake pad of the disc brake, so as to exert a force on the brake pad of the disc brake inside the vehicle.

[0031] The housing 5, which is replaceable in the event of wear, is arranged as a sliding bearing housing between each of the two longitudinal sections of the active shaft 4 and the channel 6 formed on the inner side of the first caliper part 13 and forms a component for supporting the active shaft 4. This is because, due to wear of the channel 6, it is more advantageous to replace only the housing 5 than to replace the brake caliper.

[0032] The two channels 6 arranged at a distance from each other on the inner wall of the first saddle part 13 are both designed as part-cylindrical recesses for mounting the housing 5. This simplifies the producibility of the channels 6, in particular because the channels 6 are aligned with each other in such a way that they can be processed in one working step.

[0033] according to Figure 1 , the application shaft 4 is eccentrically mounted to achieve a high application force. This is because the pivot bearing supported on the brake caliper 1 is offset in height compared to the pivot axis (not shown) arranged between the application shaft 4 and the pressure piece (not shown). Therefore, when the eccentrically mounted application shaft 4 rotates, the pressure piece moves forward in the application direction, and in response, the pressure on the housing 5 increases accordingly, so that the brake is applied and exerts a braking force.

[0034] The lever arm 3 integrally formed on the application shaft 4 serves to rotate the latter. The lever arm is provided with a support point near its free end, on which the pressure acts. In the case of pneumatic disc brakes, the force application device is a pneumatic brake cylinder, which is supplied with compressed air from the vehicle's compressed air system.

[0035] Figure 2 Schematic cross-section of a housing 5 locked in a channel 6 by means of a pipe 8 and a shaped element 9. Each of the two housings 5 ​​consists of an originally horizontal metal sheet produced by stamping and deformation.

[0036] according to Figure 2 and Figure 3 The housing 5 has a side surface, wherein the side surface has a partially circular cross section in the longitudinal direction of the actuation axis 4. Therefore, the housing 5 has a concave pressure transmission surface 11a on one side for supporting the brake lever 2 of the actuation device, and a convex pressure transmission surface 11b on the other side for supporting the seat of the channel 6 formed inside the brake caliper.

[0037] The opening of the bore 7 in the caliper is located at the lowest point of the channel 6. A conduit 8 is formed on the housing 5 by deformation of the housing material, facing the channel 6. The conduit 8 extends into the bore 7 of the caliper in the form of a collar and ensures a positive fit between the housing 5 and the channel 6.

[0038] The shaped element 9 designed as a cylinder is arranged in a fixed position in the pipeline 8, and its outer diameter is equal to the inner diameter of the pipeline 8. Preferably, the shaped element 9 is pressed into the pipeline 8 by a transition fit or a press fit. The housing 5, the pipeline 8 and the shaped element 9 together form a housing assembly.

[0039] The hole 7 is a blind hole perpendicular to the longitudinal axis of the channel 6. The length of the hole 7 is greater than the sum of the lengths of the pipe 8 and the shaped element 9 extending therefrom, wherein the hole 7 has a depth of 1.2 times the axial extension of the shaped element 9, for example.

[0040] The end face of the shaped element 9 of the housing assembly facing away from the hole 7 is designed not to protrude beyond the plane of curvature of the concave pressure transmission surface 11a of the housing 5. In other words, the hole depth B must be large enough to exceed the length C of the shaped element 9 locked in the pipe 8, the remaining length A of which protrudes from the pipe 8, plus the height of the collar D of the pipe 8. In addition, the hole depth B must not exceed the length C of the shaped element 9, so that when the shaped element 9 is loose in the pipe 8, the shaped element 9 can slide completely from the pipe 8 into the hole 7.

[0041] Figure 3 A perspective view of the housing assembly is shown, comprising the housing 5 and the integral shaped element 9 locked onto the channel 6 .

[0042] To form the channel 6, a plateau 17 is formed inside the first caliper part 13, the plateau 17 being formed integrally with the brake caliper 1. The configuration of the plateau 17 and the channel 6 formed therein results in a production-advantageous arrangement to reduce the number of work steps and the complexity of production.

[0043] In order to increase the service life of the housing assembly, the housing 5 has a friction-reducing surface coating 12 on its concave pressure-transmitting surface 11 a , on which the support roller 10 can rotate with less friction than on an uncoated surface.

[0044] Reference numerals list

[0045] 1 Brake caliper

[0046] 2 Brake levers

[0047] 3-bar arm

[0048] 4 Axis of action

[0049] 5 Housing

[0050] 6 channels

[0051] 7 holes

[0052] 8 Pipeline

[0053] 9 Forming elements

[0054] 10 Support roller

[0055] 11a Concave pressure transmission surface

[0056] 11b Convex pressure transmission surface

[0057] 12 Surface coatings to reduce friction

[0058] 13 First caliper part

[0059] 14 Second caliper part

[0060] 15 Cavity

[0061] 16 Bridge Section

[0062] 17 units

[0063] A Partial length of the shaped element from the end of the collar height

[0064] B hole depth

[0065] C Length of the forming element

[0066] D Collar height

Claims

1. A disc brake, comprising a brake caliper (1) and an action device arranged therein, the action device being used to apply a force to a brake pad of the disc brake, wherein: The component of the action device is a brake lever (2) that can be actuated by a stressing element, the brake lever (2) consisting of a lever arm (3) supporting the stressing element and an action shaft (4), the action shaft (4) supporting a pressure piece running in the direction of the brake pad on one side and supporting on the other side on a channel (6) arranged on the inner side of the brake caliper by insertion of a housing (5), wherein the curvature of the housing (5) is complementary to the curvature of the channel (6), characterized in that the opening of the hole (7) is located in the channel (6), a pipeline (8) is formed on the housing (5) by deformation of the housing material and faces the channel (6), the pipeline (8) extends into the hole (7) in the form of a collar to produce a positive fit between the housing (5) and the channel (6), and a shaped element (9) is arranged in the pipeline (8), the outer diameter of the shaped element (9) being equal to or almost equal to the inner diameter of the pipeline (8); A blind hole is used as the hole (7); the length of the hole (7) has a depth greater than the sum of the lengths of the pipeline (8) and the forming element (9) extending from the pipeline (8), wherein the depth of the hole (7) is equal to or greater than 1.2 times the axial extension of the forming element (9).

2. The disc brake according to claim 1, characterized in that The action shaft (4) is designed to accommodate at least one support roller (10) between itself and the housing (5), wherein the support roller (10) is rotatably or positively mounted on the action shaft (4) on a part of the circumference and rotatably mounted on the housing (5) on another part of the circumference.

3. The disc brake according to claim 1 or 2, characterized in that: The housing (5) has a friction-reducing surface coating (12) on its concave side.

4. The disc brake according to claim 1 or 2, characterized in that: The shaping element (9) is designed as a cylindrical pin.

5. The disc brake according to claim 4, characterized in that The cylindrical pin is made of unhardened austenitic stainless steel.

6. The disc brake according to claim 1 or 2, characterized in that: The end face of the shaped element (9) faces away from the hole (7), and the shaped element (9) does not protrude beyond the plane of curvature of the concave pressure transmission surface.

7. A housing assembly for pressure transmission in an actuating device of a disc brake, comprising a housing (5), a concave pressure transmission surface (11a) formed on one side of the housing (5) for supporting a brake rod of the actuating device, and a convex pressure transmission surface (11b) formed on the other side of the housing (5) for supporting a support designed as a channel, characterized in that: A pipeline (8) in the form of a collar produced by deformation of the shell material is formed on the shell (5) on the side of the convex pressure transmission surface (11b), and a forming element (9) is arranged in the pipeline (8), the outer diameter of the forming element (9) being equal to the inner diameter of the pipeline (8); The opening of the hole (7) is located in the channel (6), and the conduit (8) extends into the hole (7) in the form of a collar to produce a positive fit between the housing (5) and the channel (6); A blind hole is used as the hole (7); the length of the hole (7) has a depth greater than the sum of the lengths of the pipeline (8) and the forming element (9) extending from the pipeline (8), wherein the depth of the hole (7) is equal to or greater than 1.2 times the axial extension of the forming element (9).

8. The housing assembly according to claim 7, characterized in that: The housing (5) has a friction-reducing surface coating (12) on its concave pressure-transmitting surface (11a).

9. The housing assembly according to claim 7 or 8, characterized in that: The shaping element (9) is designed as a cylindrical pin.

10. The housing assembly according to claim 9, characterized in that: The cylindrical pin is made of unhardened austenitic stainless steel.

11. The housing assembly according to claim 7 or 8, characterized in that: The end face of the shaped element (9) faces away from the hole (7), and the shaped element (9) does not protrude beyond the curvature plane of the concave pressure transmission surface (11a).

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