An adapter member for connecting a brake force amplifier to a vehicle receiving bracket, a manufacturing method thereof, a brake force amplifier assembly, and a mounting method thereof

Abstract

The invention relates to an adapter member for connecting a brake force amplifier to a receiving bracket of a vehicle, comprising a planarly extending base part having at least two first connection openings for receiving first connection pins for securing the brake force amplifier, a collar protruding from the base part in an axial direction extending transversely to the base part, and a flange protruding radially outward from the collar, the flange having at least two second connection openings for receiving second connection pins for securing at the receiving bracket.

Description

Technical Field

[0001] The present invention relates to an adapter member and adapter assembly for connecting a brake force amplifier to a housing bracket of a vehicle, a brake force amplifier assembly, a method for manufacturing the adapter member, and a method for installing the brake force amplifier assembly. Background Technology

[0002] Brake force amplifiers, such as electromechanical brake force amplifiers, are constructed to amplify the force generated by the brake pedal or brake lever, or to generate an output force based on the adjustment stroke of the brake pedal or brake lever. This typically occurs using an electric servo drive, which is kinematically coupled to a joystick via a transmission mechanism.

[0003] The brake force amplifier is mounted in the vehicle at a receiving bracket, such as in a wall section. For this purpose, a fixing opening is typically constructed at the receiving bracket, and a retaining pin located at the brake force amplifier is fastened into this fixing opening. Therefore, it is necessary to match the arrangement of the retaining pin at the brake force amplifier with the arrangement of the fixing opening in the receiving bracket.

[0004] EP 1 547 890 A1 discloses an adapter assembly for fixing a brake force amplifier to a housing bracket of a vehicle, the adapter assembly having an adapter member that can be fastened to the housing bracket by a retaining pin. Summary of the Invention

[0005] According to the present invention, an adapter component for connecting a brake amplifier to a housing bracket of a vehicle, an adapter assembly, a brake amplifier assembly, a method for manufacturing the adapter component, and a method for installing the brake amplifier assembly are specified.

[0006] According to a first aspect of the invention, an adapter component for connecting a brake force amplifier to a housing bracket of a vehicle includes: a planar extending base portion having at least two first connection openings for receiving a first connecting pin for securing the brake force amplifier; a retaining ring projecting from the base portion along an axial direction extending transversely to the base portion; and a flange projecting radially outward from the retaining ring having at least a second connection opening for receiving a second connecting pin for securing to the housing bracket.

[0007] According to a second aspect of the invention, an adapter assembly for connecting a brake force amplifier to a housing bracket of a vehicle includes an adapter member as described in the first aspect of the invention and a number of second connecting pins corresponding to the number of second connecting openings, wherein each of the second connecting pins is fastened in a second connecting opening.

[0008] According to a third aspect of the invention, the braking force amplifier assembly includes the adapter assembly as described in the second aspect of the invention and a braking force amplifier with a housing, wherein the housing is provided with a number of first connecting pins corresponding to the number of first connecting openings in the base portion of the adapter member, wherein each of the first connecting pins is fastened in a first connecting opening in the base portion of the adapter member.

[0009] According to a fourth aspect of the invention, a method for manufacturing an adapter component according to a first aspect of the invention is provided. The method includes: forming a base portion, a retaining ring, and a flange by deep drawing a slab blank; creating a first connection opening in the base portion; and creating a second connection opening in the flange.

[0010] According to a fifth aspect of the invention, a method for installing the braking force amplifier assembly according to a third aspect of the invention is provided. The method includes: securing a second connecting pin in a second connection opening of a flange of an adapter member; and securing a first connecting pin in a first connection opening of a base portion of the adapter member.

[0011] The present invention is based on the idea of ​​securing a braking amplifier to a housing bracket via an adapter member disposed between the braking amplifier and the housing bracket, wherein the adapter member is implemented as a substantially cap-shaped, thin-walled component. For this purpose, the adapter member can be implemented, for example, as a shaped sheet material having a thickness in the range of 2 mm to 4 mm. The adapter member typically has: a base portion or substrate with a first surface and a second surface opposite to the first surface; a retaining ring or axial tab protruding from the first surface axially transverse to the first surface; and a flange or radial tab. The flange extends radially, i.e., transversely to the retaining ring, particularly with respect to the geometric midpoint of the base portion from one end of the retaining ring facing away from the base portion. The base portion has a plurality of first through openings or connecting openings into which a connecting pin disposed at the braking amplifier can be inserted. Furthermore, the flange also includes a plurality of second connecting openings arranged in a pattern corresponding to the hole pattern of the housing bracket.

[0012] Because the flange protrudes radially outward from the retaining ring, the second connection openings within the flange can be arranged in a simple manner at intervals from each other, a spacing different from that of the first connection openings in the base portion. Another advantage is that the adapter components can be manufactured cost-effectively, for example, through deep drawing.

[0013] Advantageous and extended design options are derived from the further dependent claims and the description with reference to the accompanying drawings.

[0014] According to some implementation methods, the base, retaining ring, and flange can be integrally manufactured by deep drawing, particularly of sheet metal. The implementation method, designed as a thin-walled sheet metal component, offers the advantage of providing a lightweight, mechanically robust member.

[0015] According to some embodiments, the base portion may have a central recess for the operation device of the braking amplifier. The central recess may be arranged, for example, coaxially with respect to the geometric midpoint of the base portion, wherein a first connecting opening is located radially between the circumferential edge of the base portion and the central recess.

[0016] According to some implementations, the base portion may be specified to have a substantially circular outer circumference. The geometric midpoint may be defined here, for example, by the midpoint of the circle corresponding to the outer circumference. Generally speaking, even in other shapes of the outer circumference of the base portion, the geometric midpoint may be defined, for example, by the center of gravity of the base portion, particularly the first surface of the base portion.

[0017] According to some implementation methods, the first connecting opening may be radially arranged within the retaining ring. Therefore, the first connecting opening is radially arranged between the geometric midpoint of the base portion and the retaining ring.

[0018] According to some implementations, the retaining ring can be configured as a closed, surrounding frame. The retaining ring can be constructed, for example, in a ring-like or substantially ring-like manner. The advantage of a surrounding retaining ring is that it can be easily manufactured in a deep-drawing process. Furthermore, this can further improve the rigidity of the adapter component.

[0019] In some implementations, the retaining ring can be arranged radially in the edge region of the base portion. The retaining ring can, for example, be configured as a folded edge of the base portion or extend from the outer circumference of the base portion. This configuration can be easily manufactured in a deep drawing process.

[0020] In some implementations, the number of second connection openings may differ from the number of first connection openings. This advantageously expands the adapter's applicability to different hole patterns at the housing bracket and brake amplifier.

[0021] According to some embodiments of the adapter assembly, the second connecting pin may be specified to be force-fitted and / or form-fittedly fastened in the second connecting opening, particularly by means of a slit.

[0022] According to some embodiments, the fastening of the second connecting pin in the second connection opening of the flange of the adapter member includes the converging of the second connecting pin. Here, the connecting pin is plastically deformed such that a force-transmitting fit and / or a form-fit fastening of the connecting pin at the adapter member is achieved.

[0023] According to some implementations, the fastening of the first connecting pin in the first connecting opening of the base portion of the adapter component includes passing the first connecting pin through the first connecting opening and screwing a nut onto each of the first connecting pins. Attached Figure Description

[0024] The invention will now be explained with reference to the accompanying drawings.

[0025] Figure 1 This is a perspective view of a braking force amplifier assembly according to an embodiment of the present invention; Figure 2 This is a perspective view of an adapter assembly according to an embodiment of the present invention; Figure 3 is in Figure 2 A detailed sectional view of the area marked with the letter Y; Figure 4 is Figure 1 A detailed sectional view of the area marked with the letter Z; Figure 5 It is a broken half-section of the brake amplifier assembly according to one embodiment of the present invention, in the state of being installed at the receiving bracket of the vehicle. Figure 6 This is a flowchart of a method for manufacturing an adapter component according to an embodiment of the present invention; and Figure 7 This is a flowchart of a method for installing a braking force amplifier assembly according to an embodiment of the present invention.

[0026] In the accompanying drawings, unless otherwise specified, the same reference numerals denote the same or functionally identical parts. Detailed Implementation

[0027] Figure 1 A brake amplifier assembly 400 is shown as an example only, including a brake amplifier 300 and an adapter assembly 200 for connecting the brake amplifier 300 to a housing bracket 500 of the vehicle.

[0028] The brake force amplifier 300 can be, in particular, an electromechanical brake force amplifier 300. Such a brake force amplifier is typically constructed to amplify the force generated by the brake pedal or brake lever, or to generate an output force based on the adjustment stroke of the brake pedal or brake lever. For this purpose, the brake force amplifier 300 includes an electrical servo drive (not shown) kinematically coupled to a joystick (not shown) via a transmission mechanism (not shown). The servo drive and transmission mechanism are housed in a housing 310. To transmit force from the brake pedal or brake lever to the joystick, an actuation device, for example in the form of an input lever 350, can be provided. Figure 1 It extends from the housing 310 as exemplarily shown.

[0029] Adapter assembly 200 includes adapter member 100 and a plurality of second connecting pins 231. Adapter assembly 200 in Figure 2 As shown in the 3D diagram. Figure 2 As shown, the adapter component 100 has a base part 1, a retaining ring 2, and a flange 3.

[0030] The base portion 1 is typically implemented as a planar, extending, for example, plate-shaped portion, and has a first surface 1a and a second surface 1b opposite to this first surface. The first and second surfaces 1a and 1b can be as follows: Figure 2 It is constructed as a flat or substantially flat surface, as exemplarily shown. The axial direction A1 extends transversely to the base portion 1, particularly transversely to the first surface 1a of the base portion 1. The radial direction R1 extends transversely to or perpendicular to the axial direction A1.

[0031] If still Figure 2 As shown, the base portion 1 has a substantially circular outer circumference 12. "Substantially circular" includes both continuous circles and circumferential shapes having multiple circular segments 12A separated by intermediate segments 12B, the segments sharing a common midpoint, as shown in... Figure 2 As exemplarily illustrated, the outer circumference 12 typically defines the geometric midpoint of the base portion 1, which may, for example, be defined by the centroid of the surface of the face enclosed by the outer circumference 12. Figure 2 The example shows a base portion 1 with a substantially circular outer circumference 12, wherein a central axis C1 extending along the axial direction A1 through the geometric midpoint of the base portion 1 is shown.

[0032] If still Figure 2 As shown, the base portion 1 also has a plurality of first connection openings 11 extending between the first and second surfaces 1a, 1b. These connection openings 11 are used to receive first connection pins 211 for securing the braking amplifier 300, as will be explained in detail below. Figure 2 Only one connection opening 11 can be seen in the middle. The base part 1 can typically have at least two connection openings 11. The first connection opening 11 can be constructed with respect to the radial direction R1, particularly in the edge region of the base part 1, such as in Figure 1 As illustrated in the example.

[0033] If still Figure 2 As exemplarily shown, the base portion 1 may optionally have a central recess 10 for the actuation device 350 of the braking power amplifier 300. The central recess 10 is as shown in... Figure 2As exemplified in the example, it can be, for example, circular. Furthermore, it can be specified that the central axis of the central recess 10 and the central axis C1 of the base portion 1 are as follows: Figure 2 The components are arranged concentrically or coaxially as exemplarily shown. In this case, the first connection opening 11 is arranged radially R1 between the central recess 10 and the outer circumference 12. Furthermore, a circumferential, flat sealing area, for example at least 4 mm wide, may be provided on the second surface 1b of the base portion 1 to improve the seal between the base portion 1 and the brake amplifier 300.

[0034] The retaining ring 2 can be specifically implemented as a connector for connection with the base part 1. For example, in... Figure 2 As exemplarily shown, the retaining ring 2 extends along the axial direction A1 and therefore transversely to the base portion 1. The retaining ring 2 protrudes specifically from the first surface 1a of the base portion 1 along the axial direction A1. The retaining ring 2 may optionally be configured as a surrounding frame. As in... Figure 2 As exemplarily shown, the retaining ring 2 can be implemented as a substantially annular frame. "Substantially annular" includes both continuous rings and annular shapes having multiple annular or cylindrical segments separated by intermediate sections and sharing a common midpoint, as in... Figure 2 As exemplarily shown in the example. Alternatively, it can be specified that the retaining ring 2 is arranged radially with respect to R1 in the edge region of the base portion 1. Figure 2 The example illustrates that the retaining ring 2 extends from the outer circumference 12 of the base portion 1 and has a frame shape corresponding to the orientation of the outer circumference 12. The first connection opening 11 of the base portion 1 is therefore preferably located within the retaining ring 2 with respect to the radial direction R1.

[0035] Flange 3 is also constructed in plate or tab shape and connects to retaining ring 2, particularly to the end 22 of retaining ring 2 facing away from base part 1 with respect to axial direction A1. Flange 3 extends radially outward from retaining ring 2. Therefore, flange 3 protrudes from retaining ring 2 in one direction away from the geometric midpoint of base part 1, as shown in... Figure 2 As shown in the diagram. The flange 3 can be configured to extend around, or preferably along, the entire circumference of the retaining ring 2, as in... Figure 2 As illustrated in the example.

[0036] In addition, such as in Figure 2 As shown, flange 3 has multiple second connection openings 31. Figure 2The example shown indicates that flange 3 has a total of four connection openings 31. However, it is of course possible to have more or fewer than four second connection openings 31. Flange 3 typically includes two or more second connection openings 31. The number of second connection openings 31 may differ from the number of first connection openings 11 in the base portion 1. Furthermore, a surrounding, flat sealing area (not shown), for example at least 4 mm wide, may be provided at flange 3 to improve the seal between flange 3 and housing bracket 500.

[0037] The base part 1, the retaining ring 2, and the flange 3 can be integrally formed or made from a single part having a substantially constant thickness, for example, between 2 mm and 4 mm. In particular, the base part 1, the retaining ring 2, and the flange 3 can be made from a single sheet of metal. This can be accomplished, for example, in a deep drawing process. Figure 6 The process flow of method M for manufacturing adapter component 100 is schematically illustrated. In a first step M1, the base portion 1, retaining ring 2, and flange 3 are formed by deep drawing of a sheet metal. This can be accomplished, for example, by means of a die in a deep drawing press or by deep drawing via hydrodynamics. In a further step M2, a first connection opening 11 is created in the base portion 1. In step M3, a second connection opening M3 31 is created in the flange 3. The first and second connection openings 11 and 31 can be created, for example, by drilling or stamping. This can be performed before or after deep drawing (step M1).

[0038] If still Figure 2 As shown in Figure 3, a second connecting pin 231 is fastened in the second connecting opening 31. Figure 3 schematically shows a cross-sectional view of the second connecting opening 32 of the flange 3, with the second connecting pin 231 fastened in the second connecting opening. As exemplarily shown in Figure 3, the second connecting pin 231 may have a rod 231A with a first diameter and a head 231B, the head being disposed at the end of the rod 231A and having a second diameter larger than the first diameter of the rod 231A. The first and second diameters are thus sized such that the rod 231A can pass through the second connecting opening 32, but the head 231B cannot.

[0039] Figure 3 exemplarily illustrates that the flange 3 and the second connecting pin 231 are grouted. A rod 231A protrudes through the second connection opening 32, with its head 231B abutting against the lower surface 3a of the flange 3 facing the base plate 1. The section of rod 231A protruding from the upper surface 3b opposite the lower surface 3a of the flange 3 is plastically deformed to form a flange 231C, which defines a diameter larger than the diameter of the second connection opening 32 and applied at the upper surface 3b of the flange 3. This achieves a form-fit and optionally additional friction fit fastening of the corresponding second connecting pin 231 in the second connection recess 31. However, the invention is not limited to grouted fastening. Other form-fit and / or friction fit fastening methods, such as screwing, welding, etc., may also be specified.

[0040] Also refer to Figure 1 As can be seen, the housing 310 of the brake amplifier 300 has a number of first connecting pins 211 corresponding to the number of first connecting openings 11 on the base portion 1 of the adapter member 100. To secure the brake amplifier 300 to the adapter member 100, each of the first connecting pins 211 is fastened into each of the first connecting openings 11 on the base portion 1 of the adapter member 100. The adapter member 100 is specifically arranged on the housing 310 of the brake amplifier 300 such that the second surface 1b of the base portion 1 faces or abuts against the housing 310, as shown in Figure 4.

[0041] Figure 4 schematically shows a cross-sectional view of the first connection opening 11 of the base part 1, with a first connecting pin 211 fastened in the first connection opening. The first connecting pin 211 protrudes through the recess 311 of the housing 310 and is securely connected to the housing 310 of the brake amplifier 300, for example, with the housing seam, as schematically shown in Figure 4. Furthermore, the first connecting pin 311 protrudes through the first connection opening 11 of the base part 1 and protrudes from the first surface 1a of the base part 1. The fastening of the first connecting pin 211 in the first connection opening 11 can be accomplished, for example, by means of a nut 212, which is screwed onto the external thread of the connecting pin 211, as shown in Figure 4. Figure 1 As exemplarily shown in Figure 4. In addition, as shown in Figure 4, a washer 213 may optionally be arranged between the nut 212 and the first surface 1a of the base portion 1.

[0042] Figure 7The process of method M100 for mounting brake amplifier assembly 400 is shown schematically. In a first step M101, a second connecting pin 231 is secured to the second connection opening 31 of the flange 3 of the adapter member 100, for example by means of a slit, as illustrated above with reference to FIG. 3. In another step M102, a first connecting pin 211 is secured to the first connection opening 11 of the base portion 1 of the adapter member 100. This may, for example, involve passing the first connecting pin 211 through the first connection opening 11 and screwing a nut 212 onto each of the first connecting pins 211, as illustrated exemplary with reference to FIG. 4.

[0043] Figure 5 The diagram schematically shows a broken half-section of the brake amplifier assembly 400 with the assembly mounted on a receiving bracket 500 in the vehicle. (As shown in...) Figure 5 As schematically shown, flange 3 rests against receiving bracket 500 and each of the second connecting pins 231 passes through or protrudes through a receiving recess 511. The second connecting pin 231 can be fastened in the corresponding receiving recess 511, for example, by a nut 232 that is screwed onto the external thread of the second connecting pin 231.

[0044] The advantage of the described shape of the adapter component is that it allows for a simple modular design. In this modular design, the positions of the first and second connection openings 11 and 31 and the lengths of the connecting pins 211 and 231 can be easily adjusted for different installation edge conditions, while the geometry of the base part 1, the retaining ring 2, and the flange 3 remains unchanged. Only the positions of the connection openings 11 and 31 need to be adjusted.

[0045] Although the invention has been illustrated by way of example with reference to the embodiments described above, the invention is not limited thereto, but can be modified in a variety of ways. In particular, combinations of the foregoing embodiments are also conceivable.

Claims

1. An adapter component (100) for connecting a brake force amplifier (300) to a vehicle housing bracket (500), comprising: A planar extending base portion (1) having at least two first connection openings (11) for receiving first connection pins (211) used to secure the braking amplifier (300), wherein, The base part (1) has an outer circumference (12) having a plurality of circular segments (12A) separated by an intermediate section (12B). A retaining ring (2) protrudes from the base portion (1) along an axial direction (A1) extending transversely to the base portion (1), wherein the retaining ring (2) is arranged radially (R1) in the edge region of the base portion (1), wherein the retaining ring (2) is configured as a closed, surrounding frame; and A flange (3) protrudes radially (R1) outward from the retaining ring (2), the flange having at least two second connection openings (31) for receiving a second connection pin (231) for fixing to the receiving bracket (500).

2. The adapter component (100) according to claim 1, wherein, The base part (1), the retaining ring (2) and the flange (3) are integrally manufactured by deep drawing.

3. The adapter component (100) according to claim 2, wherein, The base part (1), the retaining ring (2) and the flange (3) are integrally manufactured by deep drawing of the metal sheet.

4. The adapter component (100) according to any one of claims 1 to 3, wherein, The base part (1) has a central recess (10) for the operation device (350) for passing through the brake amplifier (300).

5. The adapter component (100) according to any one of claims 1 to 3, wherein, The first connection opening (11) is arranged in the retaining ring (2) about the radial direction (R1).

6. The adapter component (100) according to any one of claims 1 to 3, wherein, The retaining ring (2) is constructed as a closed, encircling frame.

7. The adapter component (100) according to any one of claims 1 to 3, wherein, The number of the second connection openings (31) is different from the number of the first connection openings (11).

8. An adapter assembly (200) for connecting a brake force amplifier (300) to a vehicle housing bracket (500), comprising: The adapter component (100) according to any one of the preceding claims; and The number of second connecting pins (231) corresponds to the number of second connecting openings (31); in, Each of the second connecting pins (231) is fastened in the second connecting opening (31).

9. The adapter assembly (200) according to claim 8, wherein, The second connecting pin (231) is force-fitted and / or form-fitted fastened in the second connecting opening (31).

10. The adapter assembly (200) according to claim 9, wherein, The second connecting pin (231) is secured in the second connecting opening (31) by a force-transmitting fit and / or a form fit through a slit.

11. Braking force amplifier assembly (400), having: The adapter assembly (200) according to any one of claims 8 to 10; and The braking amplifier (300) with a housing (310) has first connecting pins (211) provided on the housing in a number corresponding to the number of first connecting openings (11) of the base part (1) of the adapter member (100). in, Each first connecting pin (211) is fastened in the first connecting opening (11) of the base part (1) of the adapter member (100).

12. A method for manufacturing an adapter component (100) according to any one of claims 1 to 7, comprising: The base part (1), the retaining ring (2) and the flange (3) are formed by deep drawing of the slab; The first connection opening (11) is formed in the base part (1); and The second connection opening (31) is created in the flange (3).

13. A method for installing the brake force amplifier assembly (400) according to claim 11, comprising: The second connecting pin (231) is fastened into the second connecting opening (31) of the flange (3) of the adapter member (100); and The first connecting pin (211) is fastened in the first connecting opening (11) of the base part (1) of the adapter member (100).

14. The method according to claim 13, wherein, The second connecting pin (231) is fastened to the second connecting opening (31) of the flange (3) of the adapter member (100) through a slit including the second connecting pin (231).

15. The method according to claim 13 or 14, wherein, Fastening the first connecting pin (211) to the first connecting opening (11) of the base part (1) of the adapter member (100) includes passing the first connecting pin (211) through the first connecting opening (11) and screwing a nut onto each of the first connecting pins (211).

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