Actuator device for a motor vehicle and methods for its manufacture

Abstract

Actuator device (1) for an adjustable roll stabilizer (2) for a motor vehicle with a housing (3) having an outer surface (4) that is at least partially curved, and an actuator (5) arranged in the housing (3), characterized in that a receiving element (6) for attaching a heat protection device (7) for the actuator (5) is welded to the housing (3) on at least one section of the curved outer surface (4) of the housing (3).

Description

[0001] The invention relates to an actuator device for an adjustable roll stabilizer for a motor vehicle according to the preamble of claim 1, a receiving element for attaching a heat protection device for use on such an actuator device according to claim 5, and a method for manufacturing an actuator device according to claim 10.

[0002] In automotive engineering, particularly chassis engineering, it is common practice to equip vehicles with a so-called roll stabilizer to increase vehicle stability and ride comfort. In its simplest form, this is essentially a C-shaped torsion bar spring, which is rotatably mounted relative to the vehicle body in its central section, with its outer, opposing ends each connected to a wheel suspension. This design ensures that, when cornering, the vehicle body not only compresses on the outside side (due to centrifugal force), but also that the inside wheel is slightly lowered (resulting in a copying effect).

[0003] To increase vehicle stability and ride comfort, it is known from the prior art to design such roll stabilizers to be adjustable. The roll stabilizer comprises an actuator assembly with a housing and an actuator arranged therein, and is divided into two stabilizer sections that can be rotated relative to each other by means of the actuator assembly. By rotating the stabilizer sections relative to each other, a roll movement of the vehicle body is deliberately generated, or a roll movement of the vehicle body caused by external influences is deliberately counteracted. Roll stabilizers are known in which an electric motor serves as the drive for the actuator. In order to keep the size of the electric motor within reasonable limits, adjustable roll stabilizers typically also employ a mechanical transmission, in particular in the form of a single- or multi-stage planetary gear unit, to transmit the torque or...to appropriately translate the speed of the electric motor.

[0004] The actuator assembly typically has a housing that is essentially cylindrical in its outer shape, in which the electric motor and the gearbox are housed in a coaxial arrangement with respect to a common axis of rotation. The stabilizer sections arranged on either side of the actuator assembly are connected to each other via the actuator assembly. When the electric motor is stationary, the two stabilizer sections are rigidly connected to each other via the actuator assembly. When the electric motor is in operation, the stabilizer sections can be rotated relative to each other about the axis of rotation, depending on the direction of rotation of the electric motor. For more general information, see DE 10 2014 208 803 A1.

[0005] DE 10 2015 206 274 A1 further discloses an actuator device for an adjustable roll stabilizer of a motor vehicle. The housing of the actuator device has a substantially cylindrical outer surface. A casing plate is attached to this surface by means of two circumferentially extending, axially spaced tension bands (10, 11), which serves to receive and guide supply and signal cables of the actuator device.

[0006] Since an actuator assembly, such as those known from DE 10 2014 208 803 A1 or DE 10 2015 206 274 A1, comprises, for example, an electric motor and possibly electronic components, higher external temperature exposure can lead to damage. External temperature exposure can occur particularly when the actuator assembly is located in close proximity to heat sources of the vehicle that emit high levels of heat. These could be, for example, components of the exhaust system, which, depending on the design of the vehicle underbody, may be located close to the actuator assembly.

[0007] It is an object of the present invention to provide an actuator device of the type mentioned at the outset, which can be protected in a structurally simple manner from the heat influence of other heat sources arranged on the motor vehicle. In addition, a method for manufacturing such an actuator device is to be provided.

[0008] The problem is solved by an actuator assembly with the features of claim 1. This assembly is an actuator assembly for an adjustable roll stabilizer for a motor vehicle, comprising a housing having an outer surface that is at least partially curved, and an actuator arranged in the housing. According to the invention, the actuator assembly is characterized in that a receiving element for attaching a heat shield for the actuator to the housing is welded to at least one section of the curved outer surface of the housing.

[0009] It was initially recognized that, with a view to ensuring the long-term reliable operation of the actuator, it was necessary to protect it from external heat influences. However, a protective functional element, such as a heat shield, cannot be easily installed due to the typically complex structures found in the vehicle underbody. Attaching it to an adjustable roll stabilizer also initially appears difficult due to its inherent mobility and its movement relative to the vehicle body. According to the invention, however, an advantageous solution was found to attach a receiving element to at least one section of the curved outer surface of the housing, to which a functional unit, in particular a heat shield, could then be attached. This measure ensures a suitable positioning in the immediate vicinity of the actuator.Furthermore, assembly as a single unit is made possible.

[0010] As already mentioned, the housing of the actuator assembly has an outer surface that is at least partially curved. According to an advantageous embodiment of the invention, the receiving element for the functional unit has a curved contour facing the curved outer surface of the housing that is complementary to it. This ensures, among other things, that the receiving element, when mounted, comes into secure contact with the housing.

[0011] Advantageously, the housing has an essentially cylindrical outer surface and the complementary contour of the receiving element is concave.

[0012] According to the invention, the receiving element is materially bonded to the housing, namely welded to the housing.

[0013] The mounting element attached to the actuator assembly can serve various purposes. According to the invention, the mounting element is suitable for attaching a thermal protection device, in particular a thermal shield, to protect the actuator assembly from external temperature influences, especially strong heat radiation.

[0014] To ensure secure mounting of the functional unit, particularly the thermal insulation device, a mounting element is arranged on several, in particular four, sections of the curved outer surface of the housing of the actuator assembly. These multiple mounting elements serve to jointly secure the functional unit, particularly the thermal insulation device. In this case, the functional unit, particularly the thermal insulation device, can thus be supported against the housing of the actuator assembly via multiple mounting points, thereby ensuring its secure relative position to the actuator assembly.

[0015] The invention further relates to a receiving element according to claim 5 for attaching a heat protection device for use on an actuator device as described above. According to the invention, the receiving element is characterized by a curved contour formed thereon, which is complementary to a curved outer surface of the housing of the actuator device, in order to be weldable to the housing at least on a section of the curved outer surface.

[0016] Advantageously, the receiving element has a thread, in particular an internal thread, which can be used to fasten the functional unit. This ensures easy fastening of the functional unit.

[0017] Advantageously, the receiving element has a comprehensive external attack contour before being attached to the housing, facilitating handling, positioning, and / or alignment. This contour can be designed in various ways; in a simple version, it can be designed as a double flat.

[0018] According to an advantageous embodiment of the receiving element, at least one, preferably several, material accumulations projecting from the plane of the contour are formed in the area of ​​the curved contour, which serve as contact points at the beginning of a welding process and / or as welding material when welding to the housing.

[0019] By forming several, in particular three or four, material accumulations distributed around the circumference of the receiving element, these accumulations serve as suitable contact points to bring the receiving element into a defined orientation relative to the housing. This significantly simplifies correct assembly.

[0020] The invention further relates to a method for manufacturing an actuator assembly, in particular an actuator assembly as described above, and has the features of claim 10. The method according to the invention for manufacturing an actuator assembly comprises the following steps: providing a housing for receiving an actuator with an outer surface that is at least partially curved; providing at least one receiving element having a curved contour for attaching a heat shield for the actuator; positioning and aligning the at least one receiving element on the housing such that the curved contour of the receiving element faces a section of the curved outer surface of the housing; attaching the at least one receiving element to the housing by welding; and attaching the heat shield to the at least one receiving element.

[0021] It is understood that the manufacturing process according to the invention also takes into account the effects and advantages of the actuator device or the receiving element described above. To avoid repetition, reference is made to the preceding explanations.

[0022] The invention is explained in more detail below with reference to an embodiment described in the following drawing. Further effects and advantages of the invention will become apparent from this. The drawing shows: Fig. 1. A schematic view of an adjustable roll stabilizer of a motor vehicle, Fig. 2 an actuator device for a motor vehicle according to an embodiment of the invention without a heat shield attached to it Fig. 3 a receiving element according to an embodiment of the invention in side view, Fig. 4 the recording element from Fig. 3 in view from below, Fig. 5 A detailed view of a receiving element welded onto the housing of an actuator device in a side view along the axis of rotation, Fig. 6 An actuator device in schematic section view with attached heat shield.

[0023] First, it shows Fig. Figure 1 illustrates the application area of ​​the invention with a schematic view of an adjustable roll stabilizer 2. The roll stabilizer 2 is part of a chassis (not shown in its entirety) of a vehicle (not shown). A first wheel 12a and a second wheel 12b, located on the opposite side of the vehicle, are each connected to the vehicle body via a control arm 13a and 13b, respectively, as well as other chassis components not shown here for the sake of simplicity. Wheel 12a and control arm 13a, and wheel 12b and control arm 13b, thus each form – in simplified terms – a wheel suspension. Each of these wheel suspensions is coupled to one end of a corresponding stabilizer section 14a and 14b of the adjustable roll stabilizer 2. The two stabilizer sections 14a and 14b are connected to each other centrally via an actuator 3.

[0024] The roll stabilizer 2 is mounted to rotate about an axis of rotation 15 relative to the vehicle body in a manner known per se (not shown). The actuator assembly 1, shown here as a cylindrical body, essentially comprises a housing 3 with a cylindrical outer surface 4, in which an electric motor and a gearbox (both not shown) are housed. The stabilizer sections 14a and 14b are connected via the electric motor and gearbox. When the electric motor is stationary, the two stabilizer sections 14a and 14b are rigidly connected to each other via the actuator assembly 1. The operation of the electric motor allows the stabilizer sections 14a and 14b to be rotated relative to each other about the axis of rotation 15, depending on the direction of rotation of the electric motor. Thus, the roll stabilizer 2 can be adjusted in a manner known per se.

[0025] Based on the Fig. 2, Fig. 3, Fig. 4, Fig. 5 to Fig. Section 6 below describes an embodiment of an actuator device, a receiving element and the method for manufacturing the actuator device according to the invention.

[0026] Fig. Figure 2 shows in detail an actuator device 1 according to the invention for a motor vehicle, in particular for an adjustable roll stabilizer (as, for example, in Fig. (1 shown and previously explained). The actuator assembly 1 has a substantially cylindrical basic shape with rotational symmetry about the axis of rotation 15. A housing 3 extends parallel to the axis of rotation 15 and has a curved outer surface 4 in the region of its lateral surface. An actuator 5 is arranged inside the housing 3, which is indicated in the drawing only by the reference numeral but is not shown in the drawing. The actuator essentially comprises an electric motor and a multi-stage planetary gear arranged coaxially thereto. According to the invention, a total of four receiving elements 6 are attached to the housing 3. Two of these receiving elements 6 are arranged on opposite circumferential sections near a first end of the actuator assembly 1, and two further receiving elements 6 are arranged near the opposite end of the actuator assembly 1, each on the curved outer surface 4 of the housing 3.Each of the receiving elements 6 is designed as a weld nut and essentially has a cylindrical ring shape.

[0027] How the Fig. 3 and Fig. As can be seen in Figure 4, which shows a receiving element 6 before it is attached to the housing of an actuator device, the receiving element 6 is a ring body. As shown in Fig. As can be seen in Figure 4, this has a central passage on which a thread 9 in the form of an internal thread is formed. In the assembled state, the thread 9 serves to fasten the thermal insulation device 7 (see Figure 4). Fig. 6). The receiving element 6 has an external dimension, such as the Fig. 3 and Fig. As can be seen from Figure 4, the basic shape is essentially cylindrical, but flattened on two opposite sides to form an outer attack contour 10. The outer attack contour 10 serves to facilitate the handling, positioning and / or alignment of the receiving element 6, in particular before its attachment to the housing 3.

[0028] How the Fig. 3 and Fig. 4 can still be seen, the recording element 6 has on one side, according to Fig. 3 on the underside, a curved contour 8 in the sense of a concavity. The curved contour 8 is designed so that it is complementary to the curved outer surface 4 of the housing 3. In other words, in a way like in Fig. In the installed state shown in Figure 5, the receiving element 6 lies not only in a linear but also in a planar position against the cylindrically curved outer surface 4 of the housing 3.

[0029] First, i.e., before attaching the receiving element 6 to the housing 3, the receiving element 6, as shown in the Fig. 3 and Fig. As can be seen in Figure 4, at least one, preferably several, material accumulations 11 projecting from the plane of the contour 8 are also present in the area of ​​the curved contour 8. These material accumulations 11 can serve as contact points and / or as welding material when welding to the housing 3 at the beginning of a welding process. When performing an electric welding process, the material accumulations 11 can also serve as contact electrodes between the welding partners to be joined. In the attached state to the housing 3, as shown in Figure 4, the material accumulations 11 can be used as contact electrodes between the welding partners. Fig. As shown in Figure 5, the material accumulations 11 of the original state are no longer present; the material has spread over the welded area.

[0030] Fig. Figure 6 shows a lateral section of an actuator assembly 1 according to the invention, with a heat shield 7 attached thereto and with stabilizer sections 14a, 14b attached thereto. In essential features, the actuator assembly 1 corresponds to the Fig. 6 of the in Fig. The actuator assembly shown and already explained in section 2 is described below. To avoid repetition, reference is made to the explanations given there as well as to the explanations regarding the... Fig. 3, Fig. 4 to Fig. 5 referred. The representation from Fig. Figure 6 shows that the mounting elements 6 serve to hold a heat shield 7, which partially encloses the actuator assembly 1, radially spaced from the outer surface 4 of the actuator assembly 1. Screws are screwed into each of the mounting elements 6 to fasten the heat shield 7, thus enabling additional adjustment.

[0031] To create something like in Fig.To manufacture the actuator device 1 shown in 6, the following steps are carried out according to the invention: - Providing the enclosure, - Providing the receiving element 6, which has a curved contour, - Positioning and aligning the receiving element 6 on the housing 3 such that the curved contour 8 of the receiving element 6 faces a section of the curved outer surface 4 of the housing 3, - Attaching the receiving element 6 to the housing 3 by welding, - Attaching the thermal insulation device 7 to at least one receiving element 6.

[0032] The described invention provides a constructively simple way to protect an actuator device of the type mentioned from damaging temperature effects. Reference sign 1 actuator device 2. Roll stabilizer 3 cases 4 Outdoor area 5 Actuator 6 weld nuts 7 Heat shield 8 concave contour 9 internal thread 10 Outer attack contour 11 lead 12a, 12b Wheel 13a, 13b wishbone 14a, 14b Stabilizer section 15 Rotation axis

Claims

Actuator device (1) for an adjustable roll stabilizer (2) for a motor vehicle with a housing (3) having an outer surface (4) that is at least partially curved, and an actuator (5) arranged in the housing (3), characterized in that a receiving element (6) for attaching a heat protection device (7) for the actuator (5) is welded to the housing (3) on at least one section of the curved outer surface (4) of the housing (3). Actuator device (1) according to claim 1, characterized in that the receiving element (6) has a curved contour (8) facing the curved outer surface (4) of the housing (3) and complementary thereto. Actuator device (1) according to claim 2, characterized in that the housing (3) has a substantially cylindrical outer surface (4) and the complementary contour (8) of the receiving element (6) is concave. Actuator device (1) according to one of the preceding claims, characterized in that a receiving element (6) is arranged on several sections of the curved outer surface (4) of the housing (3), wherein the several receiving elements (6) serve for the common fastening of the heat protection device. Receiving element (6) for attaching a heat protection device (7) for use on an actuator device (1) according to one of the preceding claims, characterized by a curved contour (8) formed thereon, which is complementary to a curved outer surface (4) of the housing (3) of the actuator device (1) in order to be weldable to the housing (3) at at least one section of the curved outer surface (4). Receiving element (6) according to claim 5, characterized in that it has a thread (9) which can be used to fasten the functional unit (7). Receiving element (6) according to claim 5 or 6, characterized in that it has a circumferential outer attack contour (10) to facilitate handling, positioning and / or alignment before its attachment to the housing (3). Receiving element (6) according to one of claims 5 to 7, characterized in that at least one material accumulation (11) projecting from the plane of the contour (8) is formed in the area of ​​the curved contour (8), which serves as contact points at the beginning of a welding process and / or as welding material when welding with the housing (3). Receiving element (6) according to claim 8, characterized in that several material accumulations (11) are formed distributed over the circumference of the receiving element (6). A method for manufacturing an actuator device (1) according to one of the preceding claims, comprising the following steps: providing a housing (3) for receiving an actuator (5) with an outer surface (4) that is at least partially curved; providing at least one receiving element (6) having a curved contour (8) for attaching a heat protection device (7) for the actuator (5); positioning and aligning the at least one receiving element (6) on the housing (3) such that the curved contour (8) of the receiving element (6) faces a section of the curved outer surface (4) of the housing (3); attaching the at least one receiving element (6) to the housing (3) by welding; and attaching the heat protection device to the at least one receiving element (6).

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