Electromechanical brake with molded or formed motor housing

Abstract

The invention relates to an electromechanical brake (10) for a motor vehicle. The electromechanical brake (10) comprises an electric motor (30) which rotaryly drives a mechanical adjusting unit (18) arranged in a brake caliper housing (40), so that a brake adjuster (22) is displaceable in an axial direction (26) of the brake caliper housing (14) for applying a braking force. A motor housing (34) radially arranged on the brake caliper housing (14) accommodates the electric motor (30), and a control unit housing (42) of a control unit (38) controlling the electric motor (30) is arranged on the motor housing (34). The motor housing (34) is formed from the brake caliper housing (14) and the control unit housing (42), and the brake caliper housing (14) is manufactured via a primary forming or forming step.A motor housing edge (46) formed by the brake caliper housing (14), between brake caliper housing (14) and control unit housing (42), is designed such that in the axial direction (26), starting from at least one axial edge side (54, 58), a radial height (h) of the motor housing edge (46) increases.

Description

[0001] The present invention relates to an electromechanical brake for a motor vehicle and a motor vehicle which has such an electromechanical brake. State of the art

[0002] The service brake is typically a brake system that uses brake fluid to press a brake piston and brake pad against a brake disc to slow the vehicle. With the increasing electrification of vehicle components, the service brake is also being developed as an electromechanical brake, thus eliminating the need for brake fluid and the associated complex valve and line system. Such an electromechanical brake could also significantly reduce maintenance requirements.

[0003] WO 2023 / 166434 A1 discloses a brake caliper for a disc brake. The brake caliper comprises a caliper housing to which a gearbox housing is attached. A control housing is mounted on the rear side of the gearbox housing, containing an electric motor and a brake control unit that controls the electric motor.

[0004] German patent application DE 10 2009 046 044 B4 discloses an electromechanically actuated disc brake for a motor vehicle. The electromechanically actuated disc brake comprises a caliper housing that surrounds a brake disc. The caliper housing has a housing-like recess in which an electric motor for the brake is arranged.

[0005] Above the electric motor and the saddle housing is a transmission unit, which drives a spindle drive unit located within the saddle housing. Above the transmission unit is a control unit mounting bracket, which allows the electric motor to be controlled. A cover seals the mounting bracket and the transmission unit.

[0006] The object underlying the invention is to provide an electromechanical brake which is simpler and more cost-effective to manufacture.

[0007] The problem is solved by an electromechanical brake according to claim 1. Preferred embodiments are set forth in the dependent claims. Disclosure of the invention

[0008] The invention discloses an electromechanical brake for a motor vehicle. The electromechanical brake comprises an electric motor which rotaryly drives a mechanical adjusting unit arranged in a brake caliper housing, such that a brake actuator for applying a braking force is displaceable in an axial direction of the brake caliper housing. A motor housing radially arranged on the brake caliper housing accommodates the electric motor, and a control unit housing for a control unit controlling the electric motor is arranged on the motor housing. The motor housing is formed from the brake caliper housing and the control unit housing, and the brake caliper housing is manufactured via a primary forming or forming step. A motor housing rim formed by the brake caliper housing, between the brake caliper housing and the control unit housing, is designed such that a radial height of the motor housing rim rises in the axial direction, starting from at least one axial rim face.

[0009] The adjustment unit is a component that converts the rotary motion of the electric motor into a translational motion. This rotary motion allows the brake actuator to be axially displaced. The brake actuator comprises a component that comes into contact with a brake disc for braking. The axial direction is the direction along which the adjustment unit and the brake caliper housing are aligned. The motor housing contains the electric motor, which is arranged in a separate housing from the adjustment unit and the control unit. The motor housing rim is a part of the motor housing that defines its circumference.

[0010] In a primary forming or forming process, the workpiece material is shaped using at least two workpiece molds. Structures of the workpiece material can therefore typically only be formed in the direction in which the workpiece molds move relative to each other. To form a recess opposite to the direction of movement of the two workpiece molds, such as an engine housing, a further workpiece mold would be necessary, which would significantly increase production costs. By forming the radially arranged engine housing, the brake caliper housing, and the control unit housing, the radial housing structure does not have to be formed solely by the brake caliper housing.

[0011] According to the invention, the motor housing rim rises axially, starting from at least one axial edge. Accordingly, at least one of the workpiece shapes can form an interior of the motor housing and an axial side of the motor housing rim from an axial edge. This eliminates the need for a further workpiece shape, so that the brake caliper housing forms part of the motor housing using only two workpiece shapes. As a result, the brake caliper housing can be manufactured simply and economically despite the radially arranged motor housing.

[0012] In a preferred embodiment of the invention, the height of the motor housing rim rises radially from both axial edge faces. The interior of the motor housing is thus formed by both workpiece shapes. Such a design of the motor housing has the advantage that the machining required to complete the motor housing can be further reduced.

[0013] In a further preferred embodiment of the invention, the brake caliper housing produced by the primary forming or forming step is post-machined in the area of ​​the motor housing. Advantageously, the motor housing is post-machined on the inside. This allows for a sufficiently large interior space to accommodate the electric motor. The post-machining process improves the manufacturing tolerance of the brake caliper housing produced by the primary forming or forming step. Furthermore, it reduces the weight of the electromechanical brake on the unsprung wheel, thus increasing driving comfort.

[0014] Preferably, the brake caliper housing is designed as a forged part. Manufacturing the brake caliper housing as a forged part results in higher strength compared to cast parts, at the same or lower weight. Furthermore, a forged part exhibits excellent mechanical properties. Manufacturing the brake caliper housing by forging is also suitable for mass production.

[0015] In an alternative design, the brake caliper housing is manufactured as a die-cast part. The die-casting process allows for the production of complex geometries. Furthermore, it reduces the manufacturing costs of such a brake caliper housing. Additionally, the die-casting process achieves a high-quality surface finish, minimizing the need for post-processing.

[0016] In a further advantageous embodiment, the brake caliper housing is designed as a flow-formed part. Designing the brake caliper housing as a flow-formed part has the advantage that such a manufacturing process is particularly suitable for mass production. Furthermore, flow forming achieves optimal material utilization and strengthens the workpiece.

[0017] In another advantageous embodiment, the control unit housing is made of a plastic material. Manufacturing the control unit housing from a plastic material has the advantage that it can be easily produced using an injection molding process. With such a control unit housing, it is easy to adapt the engine housing edge formed by the control unit housing to the engine housing edge of the brake caliper housing. Additionally, such a housing is lightweight and has low manufacturing costs.

[0018] In a practical design, a seal between the control unit housing and the brake caliper housing is formed by the control unit housing itself. This seal protects the interior of the engine housing from dirt and moisture. The seal is provided by the control unit housing. This has the advantage that the seal can be provided more easily and economically in the control unit housing, which is advantageously made of plastic, compared to the brake caliper housing, which is made of metal. This eliminates the need for an additional step in forming a groove for a seal in the brake caliper housing.

[0019] The invention further specifies a motor vehicle which has such an electromechanical brake. The advantages and properties described above are achieved with such a motor vehicle.

[0020] Exemplary embodiments of the invention are shown in the drawing and explained in more detail in the following description. It shows: Fig. 1 Sectional view of an electromechanical brake according to an embodiment of the invention, Fig. 2 Side view of the brake caliper housing, Fig. 3 Perspective view of the brake caliper housing according to Fig. 2, Fig. 4 View of the brake caliper housing after Fig. 3 after machining, Fig. 5 Perspective view of the brake caliper housing according to a further embodiment of the invention, Fig. 6 Side view of the brake caliper housing according to a further embodiment of the invention, Fig. 7 Perspective view of the brake caliper housing according to Fig. 6, and Fig. 8 Perspective view of the brake caliper housing according to Fig. 7 after machining.

[0021] In Fig. Figure 1 shows a sectional view of an electromechanical brake 10 according to an embodiment of the invention. The electromechanical brake 10 comprises a brake caliper housing 14 in which an adjusting unit 18 is arranged. In the illustrated embodiment, the brake caliper housing 14 is made of two parts, both of which are rigidly connected to each other. In an embodiment not shown, however, the brake caliper housing 14 can also be made of one part. In the illustrated embodiment, the adjusting unit 18 is designed as a spindle drive unit, at the end of which a brake adjuster 22 is arranged. This brake adjuster 22 is displaceable in an axial direction 26 of the brake caliper housing. The adjusting unit 18 is driven by an electric motor 30, which is provided radially to the brake caliper housing 14.

[0022] The electric motor 30 is arranged in a motor housing 34, which is also provided radially to the adjustment unit 18. A control unit 38 is positioned downstream of the motor housing 34, via which the electric motor 30 can be controlled. The control unit 38 is arranged in a control unit housing 42 made of plastic. According to the invention, the motor housing 34 is formed from a part of the brake caliper housing 14 and a part of the control unit housing 42. The brake caliper housing 14 and the control unit housing 42 each form part of a motor housing rim 46. A seal 50 is positioned between the motor housing rim 46 formed by the brake caliper housing 14 and the motor housing rim 46 formed by the control unit housing 42. This seal is provided in the motor housing rim 46 formed by the control unit housing 42. The electric motor 30 is thus protected against external influences such as dirt or moisture.

[0023] Fig. Figure 2 shows a side view of the brake caliper housing 14. The brake caliper housing 14 shown in this figure corresponds to the one in Fig. The embodiment shown in Figure 1. The height h of the motor housing rim 46 formed by the brake caliper housing 14 increases from a first axial rim 54 to a second axial rim 58 of the motor housing 34. A perspective view of the brake caliper housing 14 from Fig. 2 is in Fig. Figure 3 shows that the motor housing edge 46 has the same height h on the first axial edge 54 as the motor housing base 62 formed by the brake caliper housing 14. This makes it possible for a primary forming or forming tool to produce the entire brake caliper housing 14, including the part of the motor housing 34 formed by the brake caliper housing 14, in the axial direction 26. Therefore, no transverse slide is necessary to form a radial structure in the motor housing 34.

[0024] Fig. Figure 4 shows a view of the brake caliper housing 14. Fig. 3 after machining. During machining, the thickness of the motor housing base 62 formed by the brake caliper housing 14 has been reduced. This also creates a height h for the motor housing edge 46 on the first axial edge 54. The machining improves the manufacturing tolerances. In addition, the weight of the brake caliper housing 14 can be reduced.

[0025] Another embodiment of the invention is described in Fig. 5 shown. In contrast to the embodiment shown in the Fig. In this embodiment, the height h of the motor housing edge 46 formed by the brake caliper housing 14 increases from the second axial edge side 58 to the first axial edge side 54 of the motor housing 34. Otherwise, this embodiment corresponds to the embodiment described above.

[0026] A side view of the brake caliper housing 14 is shown according to a further embodiment of the invention in Fig. Figure 6 shows that in this embodiment, the height h of the motor housing rim 46 formed by the brake caliper housing 14 increases both from the first axial edge 54 and from the second axial edge 58 of the motor housing 34. This makes it possible to form the interior of the part of the motor housing 34 formed by the brake caliper housing 14 from both axial edge 54 and 58 using primary forming tools.

[0027] A perspective view of the in Fig. The brake caliper housing shown in section 6 (section 14) is in Fig. Figure 7 shows that the motor housing edge 46 is chamfered from both axial edge sides 54, 58. Both chamfers meet at the maximum height h of the motor housing edge 46. In this embodiment as well, machining, as in Fig. 8 shown, take place. In contrast to the machining process from Fig. In this brake caliper housing 14, the inner surface of the engine housing rim 46 has also been machined. This increases the interior space of the engine housing 34 and also reduces the weight of the brake caliper housing 14. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2023 / 166434 A1

[0003] DE 10 2009 046 044 B4

[0004]

Claims

[1] Electromechanical brake (10) for a motor vehicle, comprising an electric motor (30) which rotaryally drives a mechanical adjustment unit (18) arranged in a brake caliper housing (40), so that a brake adjuster (22) is displaceable in an axial direction (26) of the brake caliper housing (14) for applying a braking force, wherein a motor housing (34) arranged radially on the brake caliper housing (14) accommodates the electric motor (30), and a control unit housing (42) of a control unit (38) controlling the electric motor (30) is arranged on the motor housing (34), characterized by, that the motor housing (34) is formed from the brake caliper housing (14) and the control unit housing (42), and the brake caliper housing (14) is manufactured via a primary forming or forming step, wherein a motor housing edge (46) formed by the brake caliper housing (14) is formed between the brake caliper housing (14) and the control unit housing (42) such that a radial height (h) of the motor housing edge (46) rises in the axial direction (26) starting from at least one axial edge side (54, 58). [2] Electromechanical brake (10) according to claim 1, characterized by , that the height (h) of the motor housing edge (46) increases in the radial direction from both axial edge sides (54, 58). [3] Electromechanical brake (10) according to claim 1 or 2, characterized by , that the brake caliper housing (14) produced by the primary forming or forming step is machined in the area of ​​the motor housing (34). [4] Electromechanical brake (10) according to any of the preceding claims, characterized by , that the brake caliper housing (14) is designed as a forged part. [5] Electromechanical brake (10) according to any one of claims 1 to 3, characterized by , that the brake caliper housing (14) is designed as a die-cast part. [6] Electromechanical brake (10) according to one of claims 1 to 3, characterized by , that the brake caliper housing (14) is designed as a flow-formed part. [7] Electromechanical brake (10) according to any one of the preceding claims, characterized by , that the control unit housing (42) is made of a plastic material. [8] Electromechanical brake (10) according to any one of the preceding claims, characterized by , that a seal (50) between control unit housing (42) and brake caliper housing (14) is formed by the control unit housing (42). [9] Motor vehicle comprising an electromechanical brake (10) according to any of the preceding claims.

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