Multi-part housing for form-fitting connection of electromechanical brakes and method for producing same

Abstract

The invention relates to a method for producing an electromechanical brake device (1), in particular for use in a motor vehicle, comprising connecting a load-bearing housing (02) and a motor housing (04) by means of a form-fitting connection, the load-bearing housing (02) being designed for at least partially accommodating a screw drive (3), preferably a ball screw drive, and the motor housing (04) being designed for at least partially accommodating the screw drive (3), preferably a ball screw drive, by means of a form-fitting connection. The motor housing (04) is designed to accommodate an electric drive motor and a drive unit (06), preferably a motor worm, which meshes with the spindle drive (03) in the connected state.

Description

TECHNICAL FIELD

[0001] The invention relates to a method for producing an electromechanical brake device, in particular for use in a motor vehicle. Furthermore, the invention also relates to an electromechanical brake device, which is preferably produced according to the method of the invention. BACKGROUND

[0002] In the field of motor vehicles and in other fields, hydraulic actuated disc brakes have long been known and are widely used. With the advance of the electrification of motor vehicles, electromechanical brake devices have also increasingly been proposed in the past, which generate or provide a braking force on the basis of an electromechanical action mechanism. To this end, a rotational movement of an electric motor, for example, can advantageously be converted into a translational movement by means of a screw drive, which then generates a braking force in front of the brake pads on a brake disc, for example.

[0003] In this context, the prior art has proposed arranging the electric motor and the screw drive in a common housing in order to achieve a compact design. Since the components of the housing, in particular in the region of the screw drive and its bearings or supports, are subjected to high forces and loads during each braking process, the housing is usually made of very stable but also relatively heavy steel material, such as a turned part, in the prior art. This leads to the disadvantage that the electromechanical brake device as a whole is relatively heavy.

[0004] In addition, the known design requires a relatively complex and cumbersome manufacturing process for the electromechanical brake device, since this must be successively constructed by mounting and / or fixing individual components or assemblies in the housing.

[0005] The patent document DE 102 50 843 A1 describes a wiper bearing for a wiper shaft of a wiper device and a method for producing it. Here, a tube end of a retaining tube is connected with a fastening section, for which the fastening section has a tube tenon receptacle, which also comprises radial openings through which material of the tube end is filled into the fastening section in order to fix or fasten the tube end on the fastening section.

[0006] From the patent document DE 10 2009 055 340 A1 a motor vehicle valve module and a method for producing a valve module are known, in which a housing cover is fixed on a base body by locally plastically deforming material of the housing cover into a recess of the base body. SUMMARY

[0007] It is an object of the invention to overcome the disadvantages of the prior art.

[0008] The method for producing an electromechanical brake device according to the application having the features of claim 1 and the electromechanical brake device according to the application having the features of claim 7 have the advantage that they enable a reduction in the weight of the electromechanical brake device while at the same time allowing the electromechanical brake device to be produced efficiently, in particular time- and cost-saving, without adversely affecting the stability of the housing and / or the introduction or extraction of forces acting on or through the housing.

[0009] The method for producing an electromechanical brake device, in particular for use in a motor vehicle, according to the application proposes a method step according to the application, according to which the force- bearing housing and the motor housing are connected by means of a form-fit connection, wherein the force-bearing housing is designed to at least partially accommodate a screw drive, preferably a ball screw drive, and wherein the motor housing is designed to accommodate an electric drive motor and a drive unit, preferably a motor worm, which engages with the screw drive in the connected state.

[0010] The provision of at least two housing components, namely a motor housing and a force-bearing housing, makes it possible for the respective housing properties to be optimally adapted to the respective requirements, for example with regard to stability, stiffness and / or force absorption, and thus for a less stable but correspondingly lighter housing to be used in regions which are less stressed, for example in the region of the motor housing, and on the other hand, in the region of the force-bearing housing, which necessarily absorbs and extracts greater forces, a housing or housing component can be used which meets the respective requirements with regard to stability. By forming a form-fit connection between the two housings or housing components, it can be particularly advantageously achieved that a stable overall housing, which forms the electromechanical brake device as a whole, is formed without impairing the connection of the housing components, for example due to different coefficients of thermal expansion of the materials used for the motor housing and the force-bearing housing.

[0011] Advantageous refinements of the method according to the application are listed in the dependent claims.

[0012] In a first preferred embodiment of the method, it can be provided that the force-bearing housing and the motor housing are brought into a connection position in which material of the motor housing is shaped from the outside into a recess provided on the outer surface of the force-bearing housing in order to form the form-fit connection. This shaping connection process is sometimes also referred to as "crimping" in the technical field, which has the advantage that it is relatively easy to automate and produces a very stable and durable form-fit connection.

[0013] The connection position can be selected such that a portion or contour of the motor housing and an opposite portion or opposite contour of the force-bearing housing are arranged in abutment or in butt joint with one another. The connection position of the motor housing and the force-bearing housing as the relative position of the two components in which the material of the motor housing is shaped can thus be achieved relatively reliably and easily.

[0014] It can be provided in a further preferred variant of the method that the forming position of the motor housing and the force transmission housing, preferably both already in the connected position, relative to the forming tool is set by the position of the punching contour, preferably in particular the position of the punching ring on the outer surface of the motor housing. A particular advantage here is that the force transmission housing and the motor housing can be positioned simply and reliably, wherein preferably first the connected position of the two housings or housing parts is produced, and then in this relative arrangement of the housing parts, the positioning of the housing parts relative to the forming tool is established using the motor housing and its visually recognizable outer surface and the punching contour formed therein, so that the forming position is reached.

[0015] It can be provided in a particularly preferred refinement of the method that the forming is carried out using a forming tool, preferably a punch, which has a greater height extension than the punching contour, preferably the punching ring. This is particularly advantageously achieved in such a way that even if the positioning of the housing parts relative to the forming tool has only moderate accuracy, the successful establishment or formation of the form-fit connection is achieved in that even if the positioning of the housing parts is slightly incorrect or deviates from the ideal position, the entire punching contour or at least a part of the punching contour is formed inwardly over the entire height, since the tolerable deviation of the positioning of the housing parts and thus of the punching contour is compensated by the correspondingly greater, in particular higher, punch or alternative forming tool.

[0016] Likewise, it can be provided in a particularly ideal design of the method that the motor housing and the force transmission housing are loaded into the connected position and / or preloaded into the connected position, in particular in the axial direction, by the material of the motor housing being formed into the recess of the force transmission housing in the radial direction, for which purpose the recess has a bottleneck-like cross section. By virtue of the design of the recess, preferably using a portion of the recess wall which is angled or inclined in the radial direction, which portion advantageously also transitions into a circular-arc transition, it can be particularly advantageously achieved that, during the forming of the material, a force or component of force in the axial direction can be generated by the forming tool contacting the bottleneck-like cross section of the recess of the force transmission housing, despite the forming direction of the forming tool extending only or predominantly in the radial direction, wherein the bottleneck-like cross section is oriented in such a way that the motor housing loads and / or preloads the force transmission housing in the axial direction. It is thereby ensured that the housings connected by the form-fit connection, including the motor housing and the force transmission housing, are securely and reliably connected in the connected position and remain connected, so that the engagement or meshing engagement between the lead screw transmission (on the one hand) and the transmission unit, preferably the motor worm (on the other hand), can be securely and reliably ensured in an advantageous manner.

[0017] In a further particularly advantageous design of the method it can be further provided that prior to the joining of the force shell and the motor housing, the spindle drive is preassembled in the force shell and / or the drive motor and / or the transmission unit and / or the control unit are preassembled in the motor housing. Thereby it can be achieved that the motor housing and the force shell each accommodate or support a largely integrated assembly, so that these assemblies can be pre-fabricated individually and thus efficiently on the one hand and by the joining of the motor housing and the force shell not only a mechanical connection of the assemblies is achieved, but also a largely functional coupling of the assemblies.

[0018] Furthermore, the present application also encompasses an electromechanical brake device, in particular for use in a motor vehicle. The electromechanical brake device according to the present application is preferably manufactured according to one of the above-mentioned methods. According to the present application it is provided that the force shell and the motor housing are connected to each other by a form-fit connection, that the spindle drive, preferably a ball screw drive, is at least partially accommodated in the force shell and that the electric drive motor and the transmission unit, preferably a motor worm, which engages with the spindle drive in the connected state, are accommodated in the motor housing.

[0019] With regard to the advantageous effects and advantages of the electromechanical brake device according to the present application, reference is made to the above-mentioned method according to the present application.

[0020] In a further advantageous design of the electromechanical brake device it can be provided that the form-fit connection between the force shell and the motor housing is formed by shaping the material of the motor housing from the outside into a groove opened on the outer surface of the force shell. By this connection, also referred to as a crimp connection, a secure, reliable and durable connection of the motor housing and the force shell can be established particularly advantageously.

[0021] In a further particularly advantageous design of the electromechanical brake device it can be provided that the motor housing has or is made of an aluminum material and / or the force shell has or is made of a steel material. The force shell, which is preferably a turned part, made of steel can absorb and dissipate larger forces and loads in a particularly advantageous manner. The motor housing made of or having an aluminum material can particularly advantageously reduce the overall weight of the electromechanical brake device. Since the motor housing hardly needs to absorb and dissipate forces, the motor housing can also be implemented as an aluminum part, in particular a milled aluminum part. Furthermore, the aluminum material is particularly easy to realize material variants and shaping.

[0022] In a particularly advantageous design, it can be specified that multiple form-fit connections are formed by shaping the material of the motor housing from the outside into grooves opened on the outer surface of the load-bearing housing. This can particularly advantageously reduce the load at each individual form-fit connection and improve the overall connection stability of the various form-fit connections. For example, the form-fit connections can be arranged to be evenly distributed in the circumferential direction. For example, four forming parts can be formed, which are staggered at an angle of approximately 90° in the circumferential direction, each forming a corresponding individual form-fit connection.

[0023] In another particularly advantageous design of the electromechanical braking device, a stamped profile, preferably a stamped ring, can be formed on the outer surface of the motor housing, particularly defined by grooves on both sides. The stamped profile is formed only in the region of the connected housing (especially the motor housing and the load-bearing housing) or also in areas where the material is not yet formed. The advantage of designing it as a stamped ring is that the forming of the material can be performed with considerable freedom in terms of rotation about the longitudinal axis or in the axial direction, or at least with varying degrees of precision, thus not requiring excessively high positioning accuracy for the motor housing and / or the load-bearing housing.

[0024] If the stamping profile or both sides of the stamping ring are particularly advantageously defined by grooves, the advantage lies in the fact that, during the forming process of the form-fit connection, especially during the pressing process, a forming tool that is larger than the stamping profile in its extension or extension perpendicular to the groove can be used, and thus, during the forming process, the forming tool is also placed in the region of the groove according to the positioning of the motor housing relative to the forming tool. The groove has a particularly advantageous effect here, namely that little or no material forming occurs in the region of the groove, so that ultimately only the stamping profile or a portion of the stamping profile (along the extension direction) deforms inward. Therefore, the groove is particularly advantageous as a buffer or tolerance device, which enables reliable forming of a sufficient amount of material in the correct position even if the relative arrangement of the forming tool and the motor housing is not highly precise.

[0025] Other advantages, features and details of the present invention will become apparent from the following description and drawings of preferred embodiments of the invention. Attached Figure Description

[0026] Figure 1 A perspective view of an electromechanical braking device for forming a shape-fitting connection according to the present invention is shown;

[0027] Figure 2 A portion of an exemplary cross-section of a load-bearing shell is shown;

[0028] Figure 3 A portion of an exemplary cross-section of an exemplary motor housing is shown;

[0029] Figure 4 It shows Figure 2 A magnified view of the local area;

[0030] Figure 5 It shows Figure 3 A magnified view of the local area. Detailed Implementation

[0031] The same elements or elements with the same function in the figure are represented by the same reference numerals.

[0032] Figure 1 An electromechanical braking device 01 is shown. This device has a load-bearing housing 02, within which a pre-assembled lead screw drive 03 is housed or arranged. Furthermore, the device includes a motor housing 04, within which a motor 05 (not shown in detail) is arranged, and a transmission unit 06, particularly a motor worm gear, meshes with the lead screw drive 03 when the motor housing 04 and the load-bearing housing 02 are connected. This transmission unit 06 is driven by an electric motor.

[0033] Advantageously, the components of the load-bearing housing 02 and the motor housing 04 are in such a way as Figure 1 Provided in the pre-assembled state shown, so as to perform the method according to the invention. Figure 1 The method steps following the illustration can specify that the load-bearing housing 02 and the motor housing 04 are moved to the connection position. For this purpose, a tubular overlap can be created between the load-bearing housing 02 and the motor housing 04, in which, for example, the abutment profile 07 of the load-bearing housing 02 abuts with an abutment profile of the motor housing 04 (not shown in detail). In this connection position, in a subsequent method step according to the invention, a form-fit connection is formed between the motor housing 04 and the load-bearing housing 02. These housing components are interconnected by the form-fit connection, and the transmission unit 06 engages with the end-side engagement segment 08 of the lead screw drive 03. Advantageously, one or more form-fit connections can be designed as a so-called press-fit connection, for which the material of the motor housing 04, advantageously partially made of aluminum, is formed from the outside into a groove opened on the outer surface of the load-bearing housing.

[0034] Figure 2 An exemplary view shows a portion of a cross-section taken through a portion of the load-bearing housing 02. Components of the lead screw drive 03 (for clarity, Figure 2 (Not shown) It can be abutted against and / or supported on the inner surface 09 of the load-bearing housing 02. A groove 11 is formed on the outer surface 10 of the load-bearing housing 02 in a circumferential direction. The shape of the groove 11 will be... Figure 4 The accompanying drawings describe this in more detail. If the motor housing 04 ( Figure 2If a material (not shown) is formed in the region of the groove 11 in the radial direction R, the formed material will cause a form-fit connection that fixes the load-bearing housing 02 relative to the motor housing 04 in the axial direction A.

[0035] Since the lead screw drive 03 needs to absorb force during braking, the load-bearing housing 02 is particularly advantageously made of steel, preferably constructed as a steel machined part.

[0036] Figure 3 A portion of a cross-section taken through the motor housing 04 is shown. A stamped profile 13 is formed circumferentially on the outer surface 12 of the motor housing 04 (in the shown portion or part, the motor housing is advantageously made of aluminum or an aluminum alloy). This stamped profile can be partially or partially deformed inward in the radial direction R by a forming tool, such as a punch (not shown). The stamped profile 13 is preferably constructed as a stamped ring. Details of the stamped profile 13 are shown in... Figure 5 It is shown in the figure, which shows Figure 3 A magnified view of part B.

[0037] As mentioned above, Figure 4 It shows Figure 2 The magnified portion, the magnified portion in Figure 2 The letter C represents the middle. Figure 4 A magnified cross-section of the groove 11 is shown. The groove has sloping edges in the region of the groove wall 14 and an arcuate transition 15 towards the bottom 16 of the groove. This bottle-shaped cross-section of the groove 11 results in the material being shaped in the radial direction R, causing the load-bearing housing 02 to also be subjected to force in the axial direction A. Preferably, the load-bearing housing 02 and the motor housing 04 are already abutting each other in the connected position. However, it can also be additionally achieved by the shape of the groove 11, inducing additional force loading during the shaping of the material of the motor housing 04 and / or pre-tightening the load-bearing housing 02 to the motor housing 04 in the axial direction A, which ensures that the two housing components remain in the desired relative position in the connected position and are connected together.

[0038] Figure 5 Enlarged to show Figure 3 The area marked with the letter B shows that the stamping profile 13 is constructed as a stamping ring, defined on both sides by grooves 17 extending in the circumferential direction. This ensures that, especially when using a forming tool or punch higher than the height h of the stamping profile 13, even if a slight misalignment occurs in the axial direction A relative to the forming tool (not shown), i.e., in the area at the height of the two grooves 17, the material of the motor housing 04 is always fully formed in the correct position.

[0039] According to Figure 3 andFigure 5 It can be seen that by dividing the stamping ring, preferably formed on the entire circumference, of the stamping profile 13 into equal or unequal parts at multiple locations on the circumference, multiple form-fit connections or multiple single form-fit connections can be formed. Furthermore, referring to the method according to the invention, it can also be specified that these single form-fit connections are formed simultaneously or sequentially.

[0040] In addition, according to Figure 3 and Figure 5 It can be clearly seen that the stamping profile 13 is particularly suitable for positioning the motor housing 04, especially together with the load-bearing housing 02, relative to the forming tool in the axial direction A. Due to the visual visibility of the stamping profile 13, the position of the motor housing 04 can be identified manually or automatically, and this position can be set or adjusted relative to the forming tool.

Claims

1. Method for manufacturing an electromechanical brake device (1), in particular for use in a motor vehicle, characterized in that a force shell (02) is connected to a motor shell (04) by means of a form-fit connection, wherein the force shell (02) is designed to at least partially accommodate a screw drive (03), preferably a ball screw drive, and wherein the motor shell (04) is designed to accommodate an electric drive motor and a transmission unit (06), preferably a motor worm, which meshes with the screw drive (03) in the connected state.

2. Method according to claim 1, characterized in that the force shell (02) and the motor shell (04) are brought into a connection position in which material of the motor shell (04) is shaped from the outside into a groove (11) opened on an outer surface (10, 12) of the force shell (02) to form the form-fit connection.

3. Method according to claim 2, characterized in that the forming position of the motor shell (04) and the force shell (02) relative to the shaping tool is set by the position of a punched contour (13), preferably a punched ring.

4. Method according to claim 3, characterized in that the shaping is carried out using a shaping tool, preferably a punch, which has a greater height extension than the punched contour (13), preferably the punched ring.

5. Method according to any one of claims 2 to 4, characterized in that the motor shell (04) and the force shell (02) are force-loaded and / or pre-tensioned into the connection position by shaping material of the motor shell (04) in the radial direction (R) into the groove (11, 17), for which the groove (11) has a bottleneck-like cross-section.

6. Method according to any one of claims 1 to 5, characterized in that the screw drive (03) is pre-assembled in the force shell (02) and / or the drive motor and / or the transmission unit (06) and / or a control unit is pre-assembled in the motor shell (04) before the connection.

7. Electromechanical brake device (1), in particular for use in a motor vehicle, which is manufactured in particular using the method according to any one of claims 1 to 6, characterized in that a force shell (02), in which a screw drive (03), preferably a ball screw drive, is at least partially accommodated, and a motor shell (04), in which an electric drive motor and a transmission unit (06), preferably a motor worm, which meshes with the screw drive (03) in the connected state, are accommodated, are connected to one another by a form-fit connection.

8. Electromechanical brake device according to claim 7, characterized in that the form-fit connection between the force shell (02) and the motor shell (04) is formed by shaping material of the motor shell (04) from the outside into a groove (11) opened on an outer surface (10) of the force shell (02).

9. Electromechanical brake device (1) according to claim 7 or 8, characterized in that the motor housing (04) has or is made of an aluminum material and / or the force- bearing housing (02) has or is made of a steel material.

10. Electromechanical brake device (1) according to any one of claims 7 to 9, characterized in that a plurality of form-fit connections are formed by shaping the material of the motor housing (04) externally into recesses (11) opened on the outer surface (10) of the force-bearing housing (02).

11. Electromechanical brake device (1) according to any one of claims 7 to 10, characterized in that the electromechanical brake device has a stamped profile (13), preferably a stamped ring, which is delimited, in particular on both sides, by recesses (17).

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