Hydraulic brake-by-wire system plunger structure

Abstract

A kind of hydraulic brake-by-wire system plunger structure, by setting up multistage ladder structure on plunger end cover, and with corresponding riveting groove opened on valve body riveting fixed, this design not only enhances the connection strength between plunger end cover and valve body, also improves the stability and reliability of entire hydraulic brake-by-wire system plunger structure.The design of multistage ladder structure makes plunger end cover can better disperse stress when bearing pressure, avoid local stress concentration caused by structural damage, and plays the role of multi-seal.At the same time, the way of riveting fixed also ensures the close fit between plunger end cover and valve body, effectively prevents the leakage of hydraulic oil, so as to improve the working efficiency and safety of entire brake system.

Description

Technical Field

[0001] This utility model relates to the field of automotive hydraulic technology, specifically to a plunger structure for a hydraulic brake-by-wire system. Background Technology

[0002] Brake-by-wire integrates the functions of the master cylinder, vacuum booster, and Electronic Stability Control (ESC) system, enabling stable operation without relying on a vacuum source. Furthermore, its fully decoupled design between the brake pedal and brake actuator allows for efficient regenerative braking, converting energy generated during braking into electrical energy for storage and extending the driving range of new energy vehicles. Simultaneously, the system's active safety features, such as anti-lock braking, electronic stability control, and traction adjustment, significantly enhance the driving safety of new energy vehicles. Its active pressure-building capability supports the automatic braking requirements of current intelligent driving scenarios. The plunger structure is the core actuator in the brake-by-wire system; the plunger precisely regulates the pressure changes in the hydraulic circuit through reciprocating motion, serving as the pressure regulation power source for active braking and energy recovery within the brake-by-wire system. Summary of the Invention

[0003] In view of this, the present invention provides a plunger structure for a hydraulic brake-by-wire system.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A piston structure for a hydraulic brake-by-wire system includes a valve body, a piston assembly, and a piston end cap. A valve cavity is formed within the valve body, and the piston assembly is disposed within the valve cavity. The piston end cap is disposed at the top of the valve body and seals one side of the valve cavity. The piston end cap has a multi-stage stepped structure, and the valve body has riveting grooves corresponding to the multi-stage stepped structure. The multi-stage stepped structure extends into the riveting grooves and is riveted and fixed to the valve body.

[0005] Preferably, the plunger end cap has a cover portion and a riveting portion, the riveting portion is formed on the bottom outer edge of the cover portion, the multi-stage stepped structure is disposed on the riveting portion, the top of the valve body is recessed to form an annular groove, the riveting groove is recessed on the side wall of the annular groove away from the center of the valve body, and the multi-stage stepped structure extends into the riveting groove and is riveted and fixed to the valve body.

[0006] Preferably, the piston assembly includes a piston, a ball screw, and a guide pin. The ball screw is disposed within the valve cavity, the piston is sleeved on the ball screw, and the guide pin is vertically disposed between the piston and the inner wall of the valve cavity, and the guide pin is in a guiding engagement with the piston.

[0007] Preferably, the piston has a piston body and a piston guide, the piston guide is disposed at the bottom edge of the piston body, and a plurality of arc-shaped grooves are formed on the piston guide, one side of the guide pin extends into the corresponding arc-shaped groove and connects with the piston guide.

[0008] Preferably, the ball screw is provided with a positioning pin at the bottom, and four positioning pins are provided, with an included angle of 90° between each positioning pin.

[0009] Preferably, the ball screw includes a screw body, a screw seat, and steel balls. The screw body extends into the valve cavity and connects to the piston. The screw seat has an annular structure. The steel balls are disposed between the screw seat and the screw body. The end faces of the screw seat and the screw body are concave to form steel ball grooves. The two sides of the steel balls extend into the corresponding steel ball grooves and connect with the screw body and the screw seat. The edge of the screw seat protrudes towards the valve body to form a seat riveting part. The seat riveting part is riveted and fixed to the valve body.

[0010] Preferably, a lead screw seat slot is provided at the bottom of the valve body. The lead screw seat slot is arranged in a ring structure. The groove wall on the side of the lead screw seat slot away from the center of the valve body is recessed to form a riveting bottom groove. The riveting part of the seat body protrudes to form a riveting end corresponding to the riveting bottom groove. The riveting end extends into the riveting bottom groove and is riveted and fixed to the valve body.

[0011] Preferably, the lead screw seat has five arc grooves.

[0012] The beneficial effects of this invention are as follows: By setting a multi-stage stepped structure on the plunger end cap and riveting it to the corresponding riveting groove on the valve body, this design not only enhances the connection strength between the plunger end cap and the valve body but also improves the stability and reliability of the plunger structure in the entire hydraulic brake-by-wire system. The multi-stage stepped structure allows the plunger end cap to better distribute stress under pressure, avoiding structural damage caused by localized stress concentration, and also provides multi-stage sealing. Simultaneously, the riveting method ensures a tight fit between the plunger end cap and the valve body, effectively preventing hydraulic oil leakage, thereby improving the working efficiency and safety of the entire braking system. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Appendix Figure 1 This is a schematic diagram of the structure of this utility model; Appendix Figure 2 For the appendix Figure 1 Structural breakdown diagram; Appendix Figure 3 For the appendix Figure 1 Enlarged view of point A in the middle; Appendix Figure 4 For the appendix Figure 1 Enlarged view of section B in the middle. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] The present invention will now be further described with reference to the accompanying drawings.

[0017] This utility model provides the following technical solution: As attached Figure 1-4 As shown, this utility model discloses a plunger structure for a hydraulic brake-by-wire system, including a valve body 1, a piston assembly 2, and a plunger end cap 3. A valve cavity 4 is formed within the valve body 1, and the piston assembly 2 is disposed within the valve cavity 4. The plunger end cap 3 is disposed at the top of the valve body 1, sealing one side of the valve cavity 4. A multi-stage stepped structure 5 is provided on the plunger end cap 3, and a riveting groove 6 corresponding to the multi-stage stepped structure 5 is formed on the valve body 1. The multi-stage stepped structure 5 extends into the riveting groove 6 and is riveted to the valve body 1. Specifically, in this design, by providing a multi-stage stepped structure 5 on the plunger end cap 3 and riveting it to the corresponding riveting groove 6 on the valve body 1, this design not only enhances the connection strength between the plunger end cap 3 and the valve body 1 but also improves the stability and reliability of the entire hydraulic brake-by-wire system plunger structure. The multi-stage stepped structure 5 design allows the plunger end cap 3 to better distribute stress when under pressure, avoiding structural damage caused by local stress concentration, and also provides multi-stage sealing. Simultaneously, the riveting method ensures a tight fit between the plunger end cap 3 and the valve body 1, effectively preventing hydraulic oil leakage, thereby improving the overall efficiency and safety of the braking system.

[0018] Furthermore, the plunger end cap 3 has a cap body 7 and a riveting part 8. The riveting part 8 is formed on the bottom outer edge of the cap body 7. The multi-stage stepped structure 5 is disposed on the riveting part 8. The top of the valve body 1 is recessed to form an annular groove 9. The riveting groove 6 is recessed on the side wall of the annular groove 9 away from the center of the valve body 1. The multi-stage stepped structure 5 extends into the riveting groove 6 and is riveted to the valve body 1. Specifically, in this embodiment, the riveting part 8 is designed on the bottom outer edge of the cap body 7, and a multi-stage stepped structure 5 is provided on it. It is riveted to the riveting groove 6 on the side wall of the annular groove 9 formed by the recessed top of the valve body 1. This structural layout is both reasonable and compact. The design of the annular groove 9 provides positioning space for the riveting part 8, making the riveting process more precise, and also enhancing the connection stability between the plunger end cap 3 and the valve body 1. The close fit between the multi-stage stepped structure 5 and the riveting groove 6 further ensures a firm connection between the two, effectively resisting various forces and vibrations generated by the hydraulic system during operation, thereby ensuring the long-term stable operation of the piston structure of the hydraulic wire control braking system.

[0019] Furthermore, the piston assembly 2 includes a piston 10, a ball screw 11, and a guide pin 12. The ball screw 11 is disposed within the valve chamber 4, and the piston 10 is sleeved on the ball screw 11. The guide pin 12 is vertically disposed between the piston 10 and the inner wall of the valve chamber 4, and the guide pin 12 guides and cooperates with the piston 10. Specifically, in this embodiment, the piston 10 is sleeved on the ball screw 11, and the rotation of the ball screw 11 drives the piston 10 to perform circumferential rotation, thereby achieving precise control of the braking pressure. The guide pin 12 is vertically disposed between the piston 10 and the inner wall of the valve chamber 4, and guides and cooperates with the piston 10. This design ensures the stability and straightness of the piston 10 during movement, and avoids the deflection or jamming of the piston 10 due to uneven force during movement, thereby ensuring the normal operation of the piston structure of the hydraulic brake-by-wire system and the reliability of its pressure-building capability.

[0020] Furthermore, the piston 10 has a piston body 13 and a piston guide 14. The piston guide 14 is located at the bottom edge of the piston body 13, and several arc-shaped grooves 15 are formed on the piston guide 14. One side of the guide pin 12 extends into the corresponding arc-shaped groove 15 and connects with the piston guide 14. Specifically, in this embodiment, the piston body 13 is sleeved on the ball screw 11, and the piston guide 14 is located at the bottom edge of the piston body 13. The several arc-shaped grooves 15 formed on it provide precise positioning and mating space for the guide pin 12. One side of the guide pin 12 extends into the corresponding arc-shaped groove 15 and is tightly connected with the piston guide 14. This design not only enhances the guiding accuracy of the piston 10 during movement but also ensures a stable fit between the piston 10 and the guide pin 12. The design of the arc-shaped grooves 15 allows the guide pin 12 to better disperse stress when under force, avoiding structural damage caused by stress concentration, thereby improving the durability and reliability of the piston assembly 2. Meanwhile, this structural layout also makes the piston 10 move more smoothly during operation, reducing noise and wear caused by vibration or deflection, further ensuring the long-term stable operation of the piston structure of the hydraulic wire control braking system. In addition, the cooperation between the guide pin 12 and the piston guide part 14 forces the piston 10 to move only along the axial direction to avoid "tilting / deflection" when the piston 10 moves, which further reduces the wear of the main / auxiliary cups and extends the sealing life.

[0021] Furthermore, four positioning pins 16 are provided at the bottom of the ball screw 11, with an included angle of 90° between each positioning pin 16. Specifically, in this embodiment, the positioning pins 16 are inserted and fixed to the bottom of the screw body 17 in the ball screw 11, and are evenly distributed to ensure uniform load distribution under working conditions, maximizing load-bearing capacity and lifespan, reducing vibration and noise, ensuring gear meshing synchronization, and avoiding motion interference and jamming.

[0022] Furthermore, the ball screw 11 includes a screw body 17, a screw seat 18, and steel balls 19. The screw body 17 extends into the valve cavity 4 and connects to the piston 10. The screw seat 18 has an annular structure. The steel balls 19 are disposed between the screw seat 18 and the screw body 17. The end faces of the screw seat 18 and the screw body 17 are both concave to form steel ball grooves 20. The two sides of the steel balls 19 extend into the corresponding steel ball grooves 20 and connect with the screw body 17 and the screw seat 18. The edge of the screw seat 18 protrudes towards the valve body 1 to form a seat riveting part 21, which is riveted and fixed to the valve body 1. Specifically, in this embodiment, the screw body 17 extends into the valve cavity 4 and is tightly connected to the piston 10, realizing the transmission of power. The screw seat 18 has an annular structure, providing a stable running track for the steel balls 19. The steel ball 19 is positioned between the lead screw seat 18 and the lead screw body 17, and is precisely positioned and engaged by the steel ball groove 20 formed by the concave end faces of the lead screw seat 18 and the lead screw body 17, ensuring the stability and smoothness of the steel ball 19 during rolling. This design not only reduces frictional resistance and improves transmission efficiency, but also extends the service life of the ball screw 11. At the same time, the seat riveting part 21 formed by the protruding edge of the lead screw seat 18 towards the valve body 1 is riveted and fixed to the valve body 1, further enhancing the connection stability between the ball screw 11 and the valve body 1, effectively resisting various forces and vibrations generated by the hydraulic system during operation, thereby ensuring the long-term stable operation of the piston structure of the hydraulic wire control brake system.

[0023] Furthermore, a screw seat slot 22 is provided at the bottom of the valve body 1. The screw seat slot 22 has an annular structure. The side wall of the screw seat slot 22 away from the center of the valve body 1 is recessed to form a riveting bottom groove 23. The riveting end 24 is protruding from the seat riveting part 21 corresponding to the riveting bottom groove 23. The riveting end 24 extends into the riveting bottom groove 23 and is riveted and fixed to the valve body 1. Specifically, in this embodiment, the screw seat slot 22 at the bottom of the valve body 1 has an annular structure, providing a precise installation space for the screw seat 18. The recessed side wall of the slot away from the center of the valve body 1 forms a riveting bottom groove 23, which cooperates with the corresponding protruding riveting end 24 on the seat riveting part 21 to achieve a tight fixation through the riveting process. This design not only ensures the stable installation of the screw seat 18 within the valve body 1, effectively preventing loosening or displacement due to hydraulic shock or vibration, but also further enhances the connection strength between the ball screw 11 and the valve body 1 through the tight fit between the riveting end 24 and the riveting groove 23. Simultaneously, the annular slot design allows the screw seat 18 to automatically position itself during installation, improving assembly efficiency and precision, thereby ensuring the overall performance and reliability of the hydraulic wire-controlled brake system's plunger structure.

[0024] Furthermore, the lead screw seat 18 has five arc-shaped grooves 25. The arc-shaped grooves and the riveted and deformed valve body material form a mechanical interlock structure, effectively resisting the working torque of the ball screw and preventing its axial rotation. The arc-shaped grooves also provide a mechanical interlock for the locking position.

[0025] A main cup 26 and a secondary cup 27 are provided between the piston assembly and the inner wall of the valve chamber. The main cup 26 and the secondary cup 27 work together to seal the sealing ring with the mounting groove, ensuring that they can withstand high sealing pressure during pressure build-up.

[0026] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A plunger structure for a hydraulic brake-by-wire system, characterized in that: The valve includes a valve body, a piston assembly, and a plunger end cap. A valve cavity is formed inside the valve body, and the piston assembly is disposed inside the valve cavity. The plunger end cap is disposed at the top of the valve body and seals one side of the valve cavity. The plunger end cap is provided with a multi-stage stepped structure. The valve body has riveting grooves corresponding to the multi-stage stepped structure. The multi-stage stepped structure extends into the riveting grooves and is riveted and fixed to the valve body.

2. The piston structure of the hydraulic brake-by-wire system according to claim 1, characterized in that: The plunger end cap has a cover body and a riveting part. The riveting part is formed on the bottom outer edge of the cover body. The multi-stage stepped structure is provided on the riveting part. The top of the valve body is recessed to form an annular groove. The riveting groove is recessed on the side wall of the annular groove away from the center of the valve body. The multi-stage stepped structure extends into the riveting groove and is riveted and fixed to the valve body.

3. The piston structure of the hydraulic brake-by-wire system according to claim 1, characterized in that: The piston assembly includes a piston, a ball screw, and a guide pin. The ball screw is disposed inside the valve cavity, the piston is sleeved on the ball screw, and the guide pin is vertically disposed between the piston and the inner wall of the valve cavity, and the guide pin guides and cooperates with the piston.

4. The plunger structure of the hydraulic brake-by-wire system according to claim 3, characterized in that: The piston has a piston body and a piston guide. The piston guide is located at the bottom edge of the piston body and has several arc-shaped grooves. One side of the guide pin extends into the corresponding arc-shaped groove and connects with the piston guide.

5. The piston structure of the hydraulic brake-by-wire system according to claim 3, characterized in that: The ball screw is provided with a positioning pin at the bottom, and four positioning pins are provided, with an included angle of 90° between each positioning pin.

6. The piston structure of the hydraulic brake-by-wire system according to claim 3, characterized in that: The ball screw includes a screw body, a screw seat, and steel balls. The screw body extends into the valve cavity and connects to the piston. The screw seat has an annular structure. The steel balls are disposed between the screw seat and the screw body. The end faces of the screw seat and the screw body are concave to form steel ball grooves. The two sides of the steel balls extend into the corresponding steel ball grooves and connect with the screw body and the screw seat. The edge of the screw seat protrudes towards the valve body to form a seat riveting part. The seat riveting part is riveted and fixed to the valve body.

7. The piston structure of the hydraulic brake-by-wire system according to claim 6, characterized in that: The bottom of the valve body has a lead screw seat slot, which is arranged in a ring structure. The side wall of the lead screw seat slot away from the center of the valve body is recessed to form a riveting bottom groove. The riveting part of the seat body protrudes to form a riveting end corresponding to the riveting bottom groove. The riveting end extends into the riveting bottom groove and is riveted and fixed to the valve body.

8. The plunger structure of the hydraulic brake-by-wire system according to claim 6, characterized in that: The lead screw seat has five arc grooves.

Images