Method for producing an intermediate plate mountable between housing parts of a control system for pressure-operated consumers

Abstract

Method for producing an intermediate plate (30) which can be mounted between housing parts (12, 14) of a control for pressure-medium-operated consumers and which has at least one functional plate layer (54) and has an aperture (50) arranged in a passage (44) of the functional plate layer (54), characterized in that in the at least one functional plate layer (54) by a punching process an opening (112) extending between a first layer side (56) and a second layer side (58) along a central axis (M) through the functional plate layer (54) is produced, that starting from one (58) of the layer sides (36, 58) an embossing process coaxial to the central axis (M) of the opening (112) is carried out with an embossing tool (122), in which layer material is pressed from a layer surrounding the opening (112) and adjoining one (58) of the layer sides (56,58) adjacent annular region (132) flows into the opening (112) to form an annular bead (62) forming the aperture (50) and projecting radially inwardly beyond an inner opening wall (114), and that the annular bead (62) forms the aperture (50) with a radially inner annular bead inner contour (65) formed during the stamping process.

Description

The invention relates to a method for producing an intermediate plate which can be mounted between housing parts of a control for consumers operated by pressure medium and which has at least one functional plate layer and an aperture opening arranged in a passage of the functional plate layer.Such a method is known, for example, from DE 10 2014 104 656 A1.DE 20 09 950 A discloses an intermediate plate having an aperture opening arranged in a passage of the functional plate position.In the aforementioned method, an aperture opening is produced solely by material displacement, as a result of which, however, elevations are produced around the aperture opening.The object of the invention is therefore to provide a simplified method for producing such an intermediate plate having an aperture opening.This object is achieved in a method of the type described at the beginning according to the invention in that in the at least one functional plate layer an aperture extending through the functional plate layer along a central axis between a first layer side and a second layer side is produced by a punching process, in that starting from one of the layer sides an embossing process coaxial to the central axis of the aperture is carried out with an embossing tool, in which layer material flows from an annular region enclosing the aperture and adjoining the one of the layer sides into the aperture to form an annular bead forming the aperture and projecting radially inward via an inner aperture wall, and in that the annular bead forms the aperture with an annular bead inner contour located radially inward and forming during the embossing process.The advantage of the solution according to the invention is that it is very simple to implement on the one hand and produces a defined and reproducible diaphragm opening on the other hand.In particular, in the solution according to the invention, it is provided that during the embossing process, starting from one of the ply sides, an embossing depression is formed into the one functional plate ply which has a depression wall surface which extends circumferentially about the central axis and runs parallel to the embossing direction with at least one component.With such a configuration of the embossing depression, a sufficiently comprehensive material displacement takes place for forming the annular bead.Preferably, it is provided that the embossing depression has a diameter that is greater than a diameter of the aperture in order to sufficiently displace ply material.Moreover, it is expediently provided that the embossing depression has an annular surface facing one of the ply sides and formed by the embossing tool, which annular surface runs transversely to the depression wall surface of the embossing depression.An annular surface is to be understood here as a surface which extends around the central axis of the aperture and the inner contour and outer contour of which can have a wide variety of profiles and in particular does not necessarily have to be circular but rather can extend oval or else not rotationally symmetrically with respect to the central axis.Expediently, the embossing depression is formed in such a way that it has an annular surface facing one of the ply sides, which runs transversely to the central axis of the aperture.Furthermore, it is preferably provided that the embossing depression has an annular surface facing one of the layer sides, which runs approximately rotationally symmetrically with respect to the central axis of the passage.With regard to the type of the formation of the ring surface, no further details have so far been given.In principle, it would be conceivable to configure the annular surface as a planar annular surface.A particularly advantageous solution provides, however, that the annular surface is formed as a conical surface. This configuration facilitates the material flow during stamping for defined formation of the annular bead.Such a configuration of the annular surface requires that an embossing surface of the embossing tool also has a corresponding conical shape.Preferably, it is provided that the annular surface is formed similar to a cone surface extending around the central axis and encloses an angle with the central axis that lies in the range of 90° to 50°, preferably in the range of 85° to 60°.To form such an annular surface, the stamping tool used likewise has a conical stamping surface running at an angle in the range from 90° to 50°, preferably in the range from 85° to 60°, to the central axis.Furthermore, nothing has yet been stated with regard to the formation of the annular bead on the opposite side of the annular surface formed by the stamping tool.In principle, it would be conceivable to form the annular bead between the stamping tool and a tool which abuts the annular bead on the opposite side.A particularly simple solution of the method according to the invention provides, however, that the annular bead is shaped in such a way that, on a side facing away from the annular surface formed by the stamping tool, it has an annular surface which is produced during the stamping process and runs transversely with respect to the central axis of the passage.This means that the annular surface of the annular bead opposite the annular surface formed by the stamping tool is formed without tools, i.e. by no tools, but only arises during the course of the material flow for forming the annular bead.It is particularly advantageous if the annular bead is shaped such that the aperture opening formed by it has an average diameter which is in the range from 0.1 to 0.8 times the average diameter of the aperture, better in the range from 0.2 to 0.7 times the average diameter of the aperture, even better in the range from 0.3 to 0.6 times the average diameter of the aperture.Furthermore, it is preferably provided that an average outer diameter of the embossing depression is in the range from 1.3 times to 2.5 times the average diameter of the aperture, more preferably in the range from 1.5 times to 2 times the average diameter of the aperture.Furthermore, it is preferably provided that a mean extension of the annular bead in the direction of the central axis lies in the range from 0.7 times to 1 times the radial extension of the annular bead starting from the breakthrough wall up to the inner annular bead contour.Furthermore, it is expediently provided that the mean extent of the annular bead in the direction of the central axis is in the range from 0.3 times to 1 times, more preferably in the range from 0.4 times to 1 times, the mean diameter of the diaphragm opening.In addition, the invention is used in an intermediate plate for mounting between two duct sides of housing parts of a control for pressure-medium-operated consumers, which can be placed against the intermediate plate, wherein at least one of the housing parts has at least one valve controlling the pressure medium and / or at least one slide controlling the pressure medium, wherein the pressure medium flows through a plurality of passages of the intermediate plate and at least one passage of the intermediate plate with a defined aperture opening, and wherein the intermediate plate has at least one functional layer plate and is each provided with a sealing element on mutually opposite layer sides.According to the object mentioned at the beginning, such an intermediate plate is designed according to the method features mentioned above, wherein in particular the diaphragm opening is formed by an annular bead which is produced by material removal and subsequent material displacement and is located between mutually opposite depressions, which, starting from the layer sides, penetrate into the functional layer plate.This intermediate plate has the same advantages as the production method according to the invention.In order to achieve the most turbulent possible flow through the diaphragm opening and to improve the effect of the diaphragm opening, it is preferably provided that the annular bead has a thickness which is less than half the thickness of the functional layer plate in the region of its mutually opposite layer sides.With such a dimensioning of the annular bead, a substantially turbulent flow is ensured when flowing through the diaphragm opening, so that the diaphragm opening develops an optimum effect.In particular, it is of great advantage in the intermediate plate according to the invention that a region around the depressions is free of material elevations and therefore the surface of the functional layer plate does not have any surface shapes which reject its original shape and which can prove to be problematic in the case of the required sealing with respect to the housing parts.It is particularly advantageous if the depressions have walls running essentially cylindrically with respect to a central axis.An essentially cylindrical course is understood to mean a course of the walls which deviates by a maximum of 10° from an exactly cylindrical course.Furthermore, it is preferably provided that the respective annular surfaces between the walls of the depressions and the diaphragm opening lie between which the annular bead extends.In particular, it is provided that the depressions in the functional layer plate separated by the annular bead have cross-sectional areas which are larger than a cross-sectional area of the diaphragm opening.For example, the cross-sectional areas of the depressions are at least twice as large, preferably at least three times as large, as the cross-sectional area of the diaphragm opening.Furthermore, it is expediently provided that the diaphragm opening is formed by forming the annular bead during a material displacement process and is not produced in a defined tool manner.The material displacement process could take place starting from both sides of the layer.An advantageous solution provides that the annular bead is produced by a material displacement process starting from one of the layer sides.Preferably, the material displacement process for producing the annular bead is an embossing process.In order to achieve an optimum effect of the diaphragm opening, the diaphragm opening is designed such that a turbulent pressure medium flow is formed in the diaphragm opening when the throttling effect occurs.Furthermore, the turbulent pressure medium flow is also promoted in that the annular bead acts together with the diaphragm opening like a flow diaphragm.Preferably, it is provided that the annular bead has an inner diameter (in the region of the diaphragm opening) / height ratio which is greater than 1.In addition, the invention is used in a control for pressure medium-operated consumers, comprising a control housing having two housing parts and an intermediate plate arranged between channel sides of the housing parts, wherein at least one of the housing parts has at least one valve controlling the pressure medium and / or at least one slide controlling the pressure medium, wherein the pressure medium flows through a plurality of passages of the intermediate plate and at least one passage of the intermediate plate with a defined aperture opening, and wherein the intermediate plate has at least one functional layer plate which is provided on mutually opposite layer sides in each case with a sealing element, wherein the intermediate plate is produced according to one of the preceding method features.Further features and advantages are the subject matter of the following description and of the graphical representation of some exemplary embodiments. In the drawing, the following are shown: FIG. 1 is an exploded perspective view of a control for pressure-medium-operated consumers with two housing parts and an intermediate plate arranged between these housing parts; FIG. 2 shows a section through the housing parts with intermediate plate lying between them in the fully assembled state; FIG. 3 shows a schematic illustration of a functional layer plate before the production of an opening by means of a punching tool; FIG. 4 is a view similar to FIG. 3 after the opening has been produced by means of the punching tool; and FIG. 5 shows an illustration of the functional layer plates in the region of the opening before carrying out an embossing process with an embossing tool, and FIG. 6 is a representation of the passage with the annular bead and the diaphragm opening after termination of the stamping process.A control system for pressure medium-operated consumers, for example for pressure medium-operated transmission units, in particular transmission units for motor vehicles, which is schematically illustrated in FIG. 1 and is denoted as a whole by 10, comprises a control housing 11, formed from a first housing part 12, in particular made of metal, and a second housing part 14, in particular made of metal, of which, for example, the first housing part 12 has valves 16, 18 and the second housing part 14 has, for example, a slide 22, wherein these each control or regulate a flow of pressure medium in the respective housing part 12, 14.The two housing parts 12, 14 have mutually facing channel sides 24 and 26, which are designed such that the pressure medium can pass from the one housing part 12, 14 into the respective other housing part 14, 16.Between these channel sides 24 and 26 of the housing parts 12, 14 an intermediate plate designated as a whole as 30 is inserted, which rests on the channel side 24 of the first housing part 12 with a first side 32 and on the channel side 26 of the second housing part 14 with a second side 34 and each tightly closes off with the channel sides 24, 26, wherein passages, for example the passages 42, 44, 46 and possibly even further passages, are provided in the intermediate plate 30, through which the pressure medium passes from one housing part 12, 14 into the other housing part 14, 16.In this case, some of the passages, for example the passages 42 and 44, allow unhindered passage of the pressure medium from the one housing part 12, 14 into the respective other housing part 14, 12, additionally serve for this purpose by some of the passages, for example the passage 44, as a throttle for the pressure medium passing from the one housing part 12, 14 into the other housing part 14, 12, wherein a specifically adaptable throttle effect for controlling sequences, in particular time sequences during switching operations, can be achieved by means of such a passage 44.For example, as shown in FIG. 2, the passage denoted as a whole by 44 is provided with an orifice opening 50, which generates a flow having turbulent components in the pressure medium passing through and therefore throttling the flow.In the exemplary embodiment shown in FIG. 2, the passage 44 is formed by a first depression 52, which is formed in a functional layer plate 54 made of metal of the intermediate plate 30, specifically in such a way that it extends, starting from a first layer side 56 of the functional layer plate 54, in the direction of a second layer side 58 of the functional layer plate 54, wherein the first depression 52 is closed off by an annular bead 62, which in turn encloses the aperture opening 50 by an annular surface 64 delimiting the first depression 52, which aperture opening is bounded by an annular bead inner contour 65, which extends, starting from the annular surface 64 formed by the annular bead 62, as far as a second annular surface 66 of the annular bead 62 formed by the annular bead 62 and opposite the first annular surface 64.Opposite the first depression 52, a second depression 72 is provided, which extends from the second layer side 58 into the functional layer plate 54, specifically as far as the annular bead 62, which together with the second annular surface 66 delimits the second depression 72.In the first exemplary embodiment shown, the annular surface 64 delimiting the first depression 52 and the annular surface 66 delimiting the second depression 72 thus extend at a distance from a first flat-side plane FE 1 predefined by the first layer side 56 and a second flat-side plane FE 2 predefined by the second layer side 58, and between these.A thickness DR of the annular bead 62 is preferably less than half, more preferably less than one third and even more preferably less than one quarter of a thickness DT of the functional layer plate 54 measured between the flat side planes FE 1 and FE 2 layer sides 56 and 58.The absolute values for the thickness DT of the functional layer 54 are, for example, in the range from 1.5 mm to 3 mm, preferably in the range from 1.8 mm to 2 mm, in particular in the case of steel, and 2 mm to 2.5 mm, in particular in the case of aluminum.The annular bead 62 preferably has a thickness DR in the direction of the central axis M which corresponds at most to a diameter DO of the diaphragm opening 50, the annular bead 62 having a radius of curvature of less than 1 mm on its side delimiting the bend end opening 50 in cross-sectional areas running through the central axis M.In particular, the diameter DO of the diaphragm opening 50 is preferably always greater than the thickness DR of the annular bead 62, which has the result that a flow through the diaphragm opening, when the diaphragm opening 50 develops its full effect, takes place in the form of a turbulent flow, wherein the turbulent flow has the advantage that the flow resistance of the diaphragm opening 50 is thereby greater than it would be in the case of a non-turbulent flow, for example a laminar flow.Moreover, the first recess 52 has a first cross-sectional area QV 1 that is larger than a cross-sectional area QDO of the diaphragm aperture 50, preferably the first cross-sectional area QV 1 of the recess 52 is at least 3 times, more preferably at least 5 times, larger than the cross-sectional area QDO of the diaphragm aperture 50.Further, the second recess 72 has a cross-sectional area QV 2 that is larger than the cross-sectional area QDO of the diaphragm aperture 50 and larger than the cross-sectional area QV 1 of the first recess 52, preferably the second cross-sectional area QV 2 of the second recess is at least 4 times, more preferably at least 7 times larger than the cross-sectional area QDO of the diaphragm aperture 50 and at least 2 times, more preferably at least 3 times larger than the first cross-sectional area QV 1 of the first recess 52.For example, the absolute values for the diameter of the first depression 52 are in the range from 1 mm to 2.5 mm, the values for the diameter of the second depression 72 are in the range from 1.5 mm to 5 mm, the values for the diameter of the diaphragm opening 50 are in the range from 0.3 mm to 1.3 mm, and the values for the thickness DR of the annular bead 62, as seen in the direction of the central axis M, are in the range from 0.3 mm to 0.5 mm.In addition, the values for the embossing depth PT are, for example, in the range from 0.3 mm to 1 mm.The intermediate plate 30 further comprises sealing elements 82 and 84 applied to the carrier plate 54, namely to the first flat side 56 and the second flat side 58, which sealing elements are formed for example from elastomer material applied linearly or flatly, in particular applied linearly or flatly in individual partial surfaces, and are applied to the flat sides 56 and 58, respectively, of the carrier plate 54.These sealing elements 82 and 84 can be applied to the flat sides 56 and 58, for example, by a screen printing method or a similar method.The sealing elements 82 and 84 serve to seal between the carrier plate 54 and the channel sides 24, 26 of the housing parts 12, 14 and therefore, in the assembled state of the housing parts 12, 14, abut tightly against the latter, as shown in FIG. 2, so that a reliable seal is effected in each case, for example around each of the passages 42, 44, 46.In order to produce a passage 44 according to the invention having an aperture 50, as shown in FIG. 3, a punching process which runs from the first layer side 56 to the second layer side 58 is carried out in an unprocessed functional layer plate 54, for example starting from the first layer side 56 using a punching tool 102, said punching process leading to an aperture 112 (FIG. 4 ) which passes through the functional layer plate 54 and is designed in this case as a punching channel and extends substantially coaxially with respect to a central axis M through the functional layer plate 54 and preferably has wall surfaces 114 which run cylindrically with respect to the central axis M, in particular in a circular cylindrical manner, wherein the punching channel has a diameter DS.After the opening 112 with the diameter DS has been formed, the embossing tool 122 has an embossing surface 124 which extends conically to its central axis 126 and in the process has an angle in the range from 60° to 85° with its central axis 126, for example, an effect on the ply side 58 (FIG. 5 ).The embossing die 122 is oriented with its central axis 126 coaxially to the central axis M of the aperture 112 and is brought into effect by movement in an embossing direction 128 on the ply side 58 of the functional ply plate 54, namely such that it acts on the functional ply plate 54 only over an embossing depth PT and displaces material up to the embossing depth PT from an annular region 132 adjoining the second ply side 58 and surrounding the aperture 112 from the annular region 132, which material flows radially inward to the central axis M during the embossing process and narrows the aperture 112 forming the annular bead 62, as illustrated in FIGS. 5 and 6, wherein the annular bead 62 surrounding the aperture 50 is formed.The annular region 132 has in this case approximately a diameter which corresponds to the diameter DP of the stamping tool 122, and the volume of the annular bead 62 corresponds approximately to the volume of the annular region 132 surrounding the aperture 112 with the outer diameter DP and the stamping depth PT, this volume which has been displaced by the stamping process in the direction of the first layer surface 56 and the formation of the annular bead 62.The aperture opening 50 of the annular bead 62 thus has the diameter DO, wherein the first depression 52 is formed by the section of the aperture 112 which extends between the first layer side 56 and the annular bead 62, and the second depression 72 which extends as far as the annular bead 62 has been formed by the stamping tool 122, starting from the second layer side 58.The second depression 72 has a diameter which corresponds to the diameter DP of the stamping tool 122.Only the forming average diameter DO of the diaphragm opening 50 is not defined by the tool, but rather in particular solely due to the volume of the material of the functional layer plate 54 which forms the sealing bead 62 and which is displaced by the embossing die over the embossing depth PT by way of the embossing effect thereof from the annular region 132, wherein the material flow during the displacement of the material from the annular region 132 can be defined reproducibly by the suitable shaping of the embossing surface and precise maintenance of the embossing depth PT and thus-apart from low tolerances in the order of magnitude of ±100 μm or less, even better ±60 μm or less-the diaphragm opening 50 produced always has the desired cross-sectional area QDO.In particular, the tolerances of the forming average diameter DO of the diaphragm opening 50 are in the range from ±0.05% to ±20%.Specifically, in this method, the cross-sectional area QV 1 of the first recess 52 is defined by the diameter DS of the punch 102, and the cross-sectional area QV 2 of the second recess 72 is defined by the diameter DP of the punch 122.

Claims

Method for producing an intermediate plate (30) which can be mounted between housing parts (12, 14) of a control for consumers operated by pressure medium and has at least one functional plate layer (54) and an aperture opening (50) arranged in a passage (44) of the functional plate layer (54), characterized in that an aperture (112) which extends through the functional plate layer (54) between a first layer side (56) and a second layer side (58) along a central axis (M) is produced in the at least one functional plate layer (54) by a punching process, in that an embossing process which is coaxial with the central axis (M) of the aperture (112) is carried out by an embossing tool (122) starting from one (58) of the layer sides (36, 58), in which sheet material is produced from one aperture (112) which surrounds the aperture (112) and to the one (58) of the layer sides (56, 58), 58 ) adjacent to the aperture (112) for forming an annular bead (62) forming the aperture (50) and projecting radially inwardly beyond an inner aperture wall (114), and that the annular bead (62) forms the aperture (50) with an inner annular bead contour (65) formed radially inside during the stamping process.Method according to Claim 1, characterized in that, during the embossing process, starting from the one (58) of the ply sides (56, 58), an embossing depression (134) is formed into which a functional plate ply (54) is formed, which has a depression wall surface (136) which extends circumferentially about the central axis (M) and runs with at least one component parallel to the embossing direction (128).Method according to claim 1 or 2, characterised in that the embossing depression (134) has a diameter (DV) which is greater than a diameter (DS) of the aperture (112).Method according to one of the preceding claims, characterized in that the embossing depression (134) has an annular surface (66) which faces one of the ply sides (56, 58) and is formed by the embossing tool and runs transversely with respect to the depression wall surface (136) of the embossing depression (134).Method according to one of the preceding claims, characterized in that the embossing depression (134) has an annular surface (66) which faces one (58) of the ply sides (56, 58) and runs transversely with respect to the central axis (M) of the aperture (112).Method according to one of the preceding claims, characterized in that the embossing depression (134) has an annular surface (66) which faces the one (58) of the ply sides (56, 58) and runs approximately rotationally symmetrically with respect to the central axis (M) of the passage (44).Method according to Claims 4 to 6, characterized in that the annular surface (66) is designed as a conical surface.Method according to claim 7, characterised in that the annular surface (66) encloses an angle with the central axis (M) of the passage, which angle lies in the range from 90° to 50°.Method according to one of the preceding claims, characterized in that the annular bead (62) is shaped in such a way that, on a side facing away from the annular surface (66) formed by the stamping tool, it has an annular surface (64) which is produced during the stamping process and runs transversely with respect to the central axis (M) of the passage (44).Method according to one of the preceding claims, characterized in that the annular bead (62) is shaped in such a way that the aperture (50) formed by it has an average diameter (DO) which is in the range from 0.1 times to 0.8 times the average diameter (DS) of the aperture (112).Method according to one of the preceding claims, characterized in that an average outer diameter (DP) of the embossing depression (134) is in the range from 1.3 times to 2.5 times the average diameter (DS) of the aperture (112).Method according to one of the preceding claims, characterized in that a mean extent of the annular bead (62) in the direction of the central axis (M) is in the range from 0.7 times to 1 times the radial extent of the annular bead (62), which extends from the aperture wall (114), up to the inner annular bead contour (65).Method according to one of the preceding claims, characterized in that the mean extent of the annular bead (62) in the direction of the central axis (M) is in the range from 0.3 times to 1 times the mean diameter (DO) of the diaphragm opening (50).

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