Modular system for a brake force device and method for manufacturing a brake force device from a modular system

Abstract

The invention proposes a modular system for a braking force device (10), comprising: a system housing (H) having a predetermined system length (L) and an elongated inner recess (A), the system housing (H) being usable for a booster brake and / or an external force brake and / or a pressure generator; a brake cylinder device (HZ) which can be inserted into the recess (A) of the system housing (H) and which has at least one brake cylinder and a predetermined cylinder length (HL); and a return spring (RF) which has a predetermined spring length and a predetermined cross-sectional shape and which can be inserted into the recess (A) of the system housing (H).

Description

Technical Field

[0001] The invention relates to a modular system for a brake device and a method for producing a brake device from the modular system. Background Art

[0002] The braking force device can be designed, in particular, as an electromechanical brake booster or a pressure brake unit (part of a brake-by-wire braking system). The system housings and other components of these two approaches typically have different dimensions and therefore need to be manufactured separately. In both approaches, the brake component (the brake mechanism for actuating the brake cylinder) can be driven by an electric motor, which can be connected to a transmission.

[0003] The transmission can consist of a worm gear and a threaded spindle. In the case of an electromechanical brake booster, the motor actuator and the driver actuator can be combined in a so-called driver demand unit (DDU) located in the central area of ​​the housing. Furthermore, the differential travel between the position of the electric motor and the driver's lever can be determined and used as a manipulated variable for the operation of the electromechanical brake booster.

[0004] A drive train for an all-wheel drive vehicle is described in document WO 2013 / 083243 A1. Summary of the Invention

[0005] The invention proposes a modular system for a braking device according to claim 1 and a method for producing a braking device using the modular system according to claim 14 .

[0006] Preferred developments are the subject matter of the dependent claims.

[0007] Advantages of the present invention

[0008] The invention is based on the idea of ​​providing a modular system for a brake device and a method for producing a brake device from the modular system, wherein as many identical components as possible can be used for different embodiments.

[0009] According to the present invention, a modular system for a braking force device comprises: a system housing having a predetermined system length and an elongated internal recess, wherein the system housing can be used for a power-assisted brake (Hilfskraftbremse) and / or an external-force brake (Fremdkraftbremse) and / or a pressure generator; a brake cylinder device that can be inserted into the recess of the system housing, the brake cylinder device having at least one brake cylinder and a predetermined cylinder length; and a return spring, for example for a transmission device, having a predetermined spring length and a predetermined cross-sectional shape and being insertable into the recess of the system housing.

[0010] A modular system can be configured with specific components and associated tools, providing a basic structure that can then be expanded into a specific device during further processing or assembly. The system housing can be a single piece or composed of multiple parts. The elongated recess can extend along the main extension direction of the system housing. The brake cylinder arrangement can, for example, have a tandem master brake cylinder. The predetermined cylinder length can be selected, for example, to enable the creation of a variety of different types of brake force arrangements. The predetermined spring length and its predetermined cross-sectional shape can be set based on the spring characteristics, such as the spring force required for a specific return force.

[0011] A power-assisted brake can be designed as a so-called servo brake or brake booster, which may include a so-called "driver demand unit" (DDU) (in other words, driver demand detection device) in its internal area as a unit for detecting the driver's demand (e.g., a reaction disk or rubber disk for combining the forces applied by the driver and the actuator). The DDU can detect the driver's demand and thereby amplify the driver's pedal force.

[0012] Externally applied brakes can be so-called power brakes. The braking force is applied entirely externally by an actuator. These types of brakes can have a simulator, meaning the pedal force is dissipated in the simulator (except for the fallback level in the event of a brake failure). The simulator can also create a pedal feel for the driver.

[0013] The pressure generator has neither a DDU nor a simulator. The actuator directly actuates the master brake cylinder (TMC, Tandem-Hauptbremszylinder) and can also be an externally powered brake unit.

[0014] In the pressure generator, the actuation (of the braking force) can be accomplished solely by the electric motor, and the rotor position sensor of the electronically commutated electric motor (housing or brake component) can be integrated. A threaded spindle can be provided, and this advantageously directly actuates the TMC (tandem master cylinder).

[0015] Furthermore, the driver demand unit (DDU) can be present only in the power-assisted brake and have a corresponding (predetermined) structural length for the recess (e.g., the intermediate region), while the pressure generator does not require this structural length. Its installation space (e.g., the intermediate region) can thus be used or filled by the TMC, thereby advantageously contributing to keeping the overall length of the structural components for the recess as short as possible. Thus, the pressure generator, power-assisted brake, and externally powered brake can have approximately the same length with respect to their existing or required components for the recess and can therefore be installed in the same system housing of the modular system.

[0016] When the first piston (master piston) in the tandem master brake cylinder is in the neutral position, the TMC, in a conventional design, draws brake fluid from the reservoir via an annular groove and a suction line. In electric brake systems, the suction line is typically designed as an inclined bore; in pressure units, the suction line can be a horizontal bore that can be sealed with a ball seal. According to the modular system, the brake cylinder assembly advantageously includes a main port and a vent hole, with the perforation extending horizontally between the vent hole and the main port and at least partially along the elongated recess. This design can be used for both externally powered brakes and as a basic structure for power-assisted brakes and pressure generators.

[0017] According to a preferred embodiment of the modular system, the recess of the system housing comprises a front region and a central region, wherein the brake cylinder arrangement can be inserted into the front region.

[0018] The front region can have a smaller diameter than the middle region and a circular or other cross-sectional shape. Depending on the application, the components that can be installed, such as the (tandem) master brake cylinder, return spring, spindle element, plunger, transmission element, etc., can then be positioned at specific locations in the middle, front, or rear regions, extending from one region to the other as required. The rear region can face the input rod connected to the driver's pedal and connect to the middle region.

[0019] The modular system may include a return spring.

[0020] According to a preferred embodiment of the modular system, the brake cylinder arrangement comprises a main port, a vent hole, and a through-hole extending in a horizontal orientation between the main port and the vent hole and extending at least partially along the elongated recess.

[0021] According to a preferred embodiment of the modular system, the first distance between the main port and the system housing has a predetermined value.

[0022] The distance can be selected so that the position of the main port and the vent hole can be adapted to the configuration of different brake devices. Thus, for example, the return spring and the components themselves can be positioned accordingly for different brake devices, depending on the space required for the master brake cylinder and other components in the recess.

[0023] According to a preferred embodiment of the modular system, the return spring has a wire cross-section that is a perfect circle or an ellipse perpendicular to the central axis of the return spring, the cross-section having a predetermined radius or a predetermined semi-major axis or semi-minor axis, and wherein the return spring has a predetermined length along the central axis.

[0024] By varying the wire cross-section and / or radius of the return spring, its spring constant can be influenced. Thus, for the same spring performance, the length of the return spring can be varied depending on the required space in the system housing. This is because, while maintaining constant (or nearly constant) spring performance (force distributed over length and cross-section or other spring characteristics), varying the wire cross-section and / or radius results in a change in the space required for the spring in the system housing. Thus, if the available space is limited, a shorter spring may be sufficient by varying the wire cross-section and / or radius.

[0025] According to a preferred embodiment of the modular system, the return spring has a non-circular wire cross section.

[0026] By varying the wire cross section, the spring properties (spring constant) can be varied as desired, and the wire cross section or radius (in cross section) or length of the spring can be varied depending on the space or performance requirements of the spring.

[0027] According to a preferred embodiment of the modular system, the brake cylinder devices for the power-assisted brake and / or the externally-forced brake and / or the pressure generator have identical physical dimensions and internal structure.

[0028] With this basic structure of the system housing, it can be composed of identical components and can be used in subsequent and / or further processing for various variants of brake cylinder arrangements.

[0029] According to a preferred embodiment of the modular system, the brake cylinder arrangement can be partially pushed into the intermediate region.

[0030] According to a preferred embodiment of the modular system, a threaded spindle can be introduced into the intermediate region, said threaded spindle extending up to a predetermined inner distance from the brake cylinder arrangement.

[0031] According to a preferred embodiment of the modular system, the power-assisted brake and / or external-force brake and / or pressure generator made of modules are provided with the same transmission device, in particular a worm gear transmission device, at the same position, and have a brake cylinder device with the same structure and / or a system housing with the same structure and / or a screw and screw nut with the same structure.

[0032] According to a preferred embodiment of the modular system, the power-assisted brake has a driver actuator, which is arranged between the brake cylinder arrangement and the spindle nut, wherein the spindle is hollow and a driver-dependent plunger mounted in the spindle actuates the driver actuator.

[0033] According to a preferred embodiment of the modular system, in a power-assisted brake and / or pressure generator, the anti-rotational torque of the screw drive is borne by at least two fingers of an anti-rotation plate connected to the screw at at least two grooves of the system housing, wherein the grooves are preferably rectangular grooves.

[0034] According to a preferred embodiment of the modular system, unlike the power-assisted brake, in the pressure generator the spindle nut takes the place of the driver actuator, so that the anti-rotational torque bypasses the spindle nut by means of a pot or two crankshafts before being absorbed by the two fingers.

[0035] According to a preferred embodiment of the modular system, the modular system has an adapter plate on the side of the system housing for fastening the brake device to the vehicle bulkhead in the motor compartment.

[0036] According to a preferred embodiment of the modular system, the pressure generator has a cover for sealing the system housing.

[0037] Advantageously, a modular system can be provided that can be used jointly for a plurality of brake device concepts while using as many identical components as possible.

[0038] Here, the system housing and components for the brake device can be assembled on one assembly line for all available options. A maximum overall length of the system housing and / or the recess can be specified.

[0039] According to the modular system of the present invention, the first distance can have a specified minimum length. Depending on the application of the system housing, a uniform TMC (or other brake cylinder) can be used for different types of brake devices. Compared to conventional designs of brake devices, the outer diameter (in cross section) of the return spring can be selected to be smaller. This smaller diameter can cause the spring to extend beyond a predetermined length, which can be influenced by the selected wire cross section.

[0040] According to the present invention, in a method for manufacturing a braking force device from a modular system, the following are performed: providing a system housing having a predetermined system length and an elongated internal recess, wherein the system housing can be used for a power-assisted brake and / or an external-force brake and / or a pressure generator; providing a brake cylinder device that can be installed in the recess of the system housing, the brake cylinder device having at least one brake cylinder and a predetermined cylinder length; and providing a return spring that has a predetermined spring length and a predetermined cross-sectional shape and can be installed in the recess of the system housing.

[0041] The modular system may also be characterized by features and advantages associated with the method, and vice versa.

[0042] Further features and advantages of the embodiments of the present invention will be apparent from the following description with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The invention is explained in more detail below with reference to an embodiment shown in the schematic drawings of the accompanying drawings.

[0044] in:

[0045] Figure 1a A schematic diagram of a braking device made of a modular system according to an embodiment of the present invention is shown;

[0046] Figure 1b A schematic diagram showing a pressure generator made from a modular system according to an embodiment of the present invention is shown;

[0047] Figure 2 shows a diagram of a wire cross section of a return spring from a modular system according to an embodiment of the present invention;

[0048] Figure 3 A block diagram shows method steps for a method for producing a braking device according to an exemplary embodiment of the present invention.

[0049] In the figures, the same reference numerals indicate identical or functionally identical elements. DETAILED DESCRIPTION

[0050] Figure 1a A schematic diagram of a braking device made of a modular system according to an embodiment of the present invention is shown.

[0051] Figure 1a The longitudinal section of the braking device is shown, wherein a recess A is provided inside the system housing H, which has a front area VB and a middle area MB. The system housing H has a predetermined system length L and an elongated inner recess A, wherein the system housing H can be used for an external brake or a power brake, and can also be used for Figure 1b The pressure brake unit shown. A brake cylinder device HZ (e.g., a tandem master brake cylinder) can be installed in recess A of a system housing H. A return spring RF can also be provided, having a predetermined spring length and a predetermined wire cross-sectional shape, and can be installed in recess A of the system housing H. The brake cylinder device HZ is arranged in a front region VB, and the return spring RF extends into a middle region MB. The brake cylinder device HZ can include a main port PP and a through-hole DB extending horizontally between a vent SB and the main port (connected to the reservoir) PP.

[0052] Furthermore, the first distance P between the primary port PP and the system housing H may have a predetermined value. This distance (minimum distance) may be the same for different types of braking force devices, whereby the brake cylinder device HZ may be adapted for power-assisted brakes ( Figure 1a ) or pressure generator ( Figure 1b) have the same physical dimensions and internal structure. In the middle area, the power brake has a driver actuation unit DDU, while the pressure brake unit ( Figure 1b ) then does not need this driver execution device. Can be configured with anti-rotation plate ARP as flat plate in middle area MB or at least at screw spindle SP place.

[0053] The return spring RF can comprise a first return spring RF1 between the brake cylinder device HZ and the DDU and a second return spring RF2 , the latter acting between the spindle SP and the system housing H, more precisely only on the transmission GE and not on the input rod ES.

[0054] The sum of the forces of the two return springs RF1 and RF2 is equal to Figure 1b The force of a return spring in the .

[0055] The input rod ES may be connected to the plunger PL.

[0056] An adapter plate AP may be provided on a side surface of the system housing H for fixing the brake device 10 to a vehicle dashboard SW in the motor compartment, for example, via a screw connection VS.

[0057] Figure 1b A schematic diagram of a pressure brake unit made from a modular system according to an embodiment of the present invention is shown.

[0058] Figure 1b Shown with Figure 1a The same system housing H also has the same dimensions, namely the length L and the recess A. Here, the first distance P and the dimensions of at least some components can also be the same, which facilitates the use of a modular system for the braking device 10. Figure 1b The driver actuator unit DDU is omitted, so the anti-rotation plate ARP can be designed into a cup shape or a pot shape.

[0059] If the driver actuator unit DDU is omitted, the freed installation space can be used to shorten the length of the overall structure.

[0060] The TMC can be pushed into the middle region MB in the direction of the ARP. In addition, the spindle nut SPM and the spindle SP can be pushed to the left in the direction of the TMC into the middle region MB, wherein the overall length can also be shortened by the length of the driver actuator DDU.

[0061] Advantageously, (by omitting the DDU) the diameter of the return spring RF can be reduced at a greater distance Z, while retaining a cost-effective round wire.

[0062] The worm wheel and the screw nut SPM can rotate. A gap SPT can exist between the cup-shaped anti-rotation plate ARP and the rotating screw nut SPM. The anti-rotation plate ARP can be supported at a groove NN on the system housing H using a finger FE.

[0063] Figure 2 A diagram showing a wire cross section of a return spring from a modular system according to an embodiment of the invention is shown.

[0064] Figure 2 The icon can be used with Figure 1a with a braking device and one of the two return springs or Figure 1b The case with a return spring is relevant. Therefore, the partial illustrations a, b and c show various wire cross sections of the return spring RF, with the ovality / rectangularity of the wire radius R increasing from a to c. The associated solid length is shown in the lower area. BL, this solid length is reduced due to the oval / rectangular cross section. With the same characteristics, a shorter solid length allows a shorter spring.

[0065] The return spring RF may have a perfect circular or elliptical cross section perpendicular to the central axis of the return spring RF, the cross section having a predetermined radius or a predetermined major or minor semi-axis, and wherein the return spring RF may have a predetermined length along the central axis.

[0066] Figure 3 A block diagram shows method steps of a method for producing a braking device according to an exemplary embodiment of the present invention.

[0067] In a method for manufacturing a braking force device from a modular system, the following are performed: step S1, i.e., providing a system housing having a predetermined system length and an elongated internal recess, wherein the system housing can be used for a power-assisted brake and / or an external-force brake and / or a pressure generator; step S2, i.e., providing a brake cylinder device that can be installed in the recess of the system housing, the brake cylinder device having at least one brake cylinder and a predetermined cylinder length; and step S3, i.e., providing a return spring that has a predetermined spring length and a predetermined cross-sectional shape and can be installed in the recess of the system housing.

[0068] Although the present invention has been described in detail above with reference to preferred embodiments, the present invention is not limited thereto but can be modified in various ways.

Claims

1. A modular system for a braking device (10), comprising: a system housing (H) having a predetermined system length (L) and an elongated inner recess (A), wherein the system housing (H) can be used for a power-assisted brake and / or an externally powered brake and / or a pressure generator; a brake cylinder device (HZ) which can be installed in the recess (A) of the system housing (H), the brake cylinder device comprising at least one brake cylinder and a predetermined cylinder length; A return spring (RF) having a predetermined spring length and a predetermined cross-sectional shape and being insertable into the recess (A) of the system housing (H).

2. The modular system according to claim 1, wherein: The recess (A) of the system housing (H) comprises a front region (VB) and a middle region (MB), wherein the brake cylinder arrangement (HZ) can be inserted into the front region (VB).

3. The modular system according to claim 2, wherein: The brake cylinder device (HZ) comprises a primary port (PP) and a vent hole (SB), and a through hole (DB) extends horizontally between the primary port (PP) and the vent hole (SB) and at least partially along an elongated recess (A).

4. The modular system according to claim 3, wherein: A first distance (P) between the primary port (PP) and the system housing (H) has a predetermined value.

5. The modular system according to any one of claims 1 to 4, wherein: The return spring (RF) has a wire cross-section that is a perfect circle or an ellipse perpendicular to the central axis of the return spring (RF), the wire cross-section has a predetermined radius or a predetermined major semi-axis or minor semi-axis, and wherein the return spring (RF) has a predetermined length (Z) along the central axis.

6. The modular system according to claim 5, wherein: The return spring (RF) has a non-circular wire cross-section.

7. A modular system according to any one of claims 1 to 6, wherein: The brake cylinder devices (HZ) for the power-assisted brake and / or the externally-assisted brake and / or the pressure generator have the same physical dimensions and internal structure.

8. A modular system according to any one of claims 1 to 7, wherein: The power-assisted brake and / or the external-force brake and / or the pressure generator manufactured from modules are provided with the same transmission device (GE), in particular a worm gear transmission device, at the same position, and have a brake cylinder device (HZ) of the same structure and / or a system housing (H) of the same structure and / or a screw and screw nut of the same structure.

9. The modular system of claim 8, wherein: The power-assisted brake has a driver actuator unit (DDU), which is arranged between the brake cylinder device (HZ) and the spindle nut, wherein the spindle is hollow and a driver-related plunger supported in the spindle actuates the driver actuator unit (DDU).

10. A modular system according to claim 8 or 9, wherein: In the power-assisted brake and / or the pressure generator, the anti-rotational torque of the screw drive is absorbed by at least two fingers (FE) of an anti-rotation plate (ARP) connected to the screw (SP) at at least two grooves (NN) of the system housing, wherein the grooves (NN) are rectangular grooves.

11. The modular system according to any one of claims 9 to 10, wherein: In contrast to the power-assisted brake, in the pressure generator the spindle nut (SPM) takes the place of the driver actuator unit (DDU), so that the anti-rotational torque bypasses the spindle nut by means of a pot or two bent rods before being absorbed by two fingers (FE).

12. A modular system according to any one of claims 9 to 11, wherein the modular system has an adapter plate (AP) on the side of the system housing (H) for fixing the braking force device (10) to the vehicle front panel (SW) in the motor compartment.

13. A modular system according to any one of claims 9 to 12, wherein: The pressure generator has a cover for sealing the system housing (H).

14. A method for manufacturing a braking device (10) from a modular system, comprising the following steps: - Step (S1): providing a system housing (H) having a predetermined system length (L) and an elongated inner recess (A), wherein the system housing (H) can be used for a power-assisted brake and / or an external-force brake and / or a pressure generator; - Step (S2): providing a brake cylinder device (HZ) that can be installed in the recess (A) of the system housing (H), the brake cylinder device having at least one brake cylinder and a predetermined cylinder length (HL); and - Step (S3): providing a return spring (RF), which has a predetermined spring length and a predetermined cross-sectional shape and can be installed in the recess (A) of the system housing (H).

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