Mounting system for attaching a control unit to an actuator assembly, actuator module

Abstract

The invention relates to a fastening system (12) for an actuator module (1) for fastening a control unit (8) to an actuator device (2), wherein the control unit (5) has a control unit housing (6) and the actuator device (2) has an actuator housing (3). It is provided that the fastening system (7) has at least one insertion pin (9) arranged on the control unit housing (6) and at least one insertion opening (12) formed on the actuator housing (3) for receiving the insertion pin (9), wherein the insertion opening (12) extends into the actuator housing (3) and wherein the actuator housing (3) has a mounting recess (13) extending transversely to the insertion opening (12), into which a locking element (16) can be pressed in or is pressed in by elastic deformation of the actuator housing (3) and / or the locking element (16) on the one hand and by elastic and / or plastic deformation of the insertion pin (9) on the other hand.

Description

[0001] The present invention relates to a fastening system for fastening a control unit to an actuator device, wherein the control unit has a control unit housing and the actuator device has an actuator housing.

[0002] Furthermore, the invention relates to an actuator module for a motor vehicle, in particular an electric motor brake force generator or booster, parking brake actuator or ABS / ESP actuator with an actuator device comprising an actuator housing and with a control unit comprising a control unit housing, wherein the control unit housing is attached to the actuator housing by means of a fastening system.

[0003] Furthermore, the invention relates to a method for manufacturing such an actuator module with the aforementioned fastening system. State of the art

[0004] Actuator modules and mounting systems for these are already known from the prior art. Known actuator modules include not only the actual actuator assembly but also the control unit, which controls the actuator assembly. The control unit is often attached directly to the actuator assembly to ensure short signal paths and ease of use. Frequently, the control unit housing is screwed and / or glued to the actuator housing to ensure improved sealing. Disclosure of the invention

[0005] The fastening system according to the invention, with the features of claim 1, has the advantage of introducing less weight into the actuator module compared to a conventional screw connection. Furthermore, the fastening system according to the invention enables controlled process monitoring during assembly. The fastening system according to the invention is characterized in that it has at least one insertion pin arranged on the housing and at least one insertion opening formed on the actuator housing for receiving the insertion pin, wherein the insertion opening extends into the actuator housing and wherein the actuator housing has a mounting recess extending transversely to the insertion opening, into which a locking element can be pressed in by elastic deformation of the actuator housing and / or the locking element on the one hand, and by elastic and / or plastic deformation of the insertion pin on the other.The fastening system according to the invention thus provides that an additional locking element is used to deform the insertion pin in such a way that the control unit housing is permanently, and in particular positively, attached to the actuator housing. The elastic deformation of the actuator housing and / or the locking element ensures that the pressed-in locking element remains securely in the mounting recess after assembly. The mounting recess, which extends transversely to the insertion opening, moves the locking element laterally against the insertion pin, causing it to be deflected by the locking element and thereby locked in the insertion opening. The elastic and / or plastic deformation of the insertion pin causes it to engage the actuator housing, particularly in certain areas, thereby locking the control unit housing to the actuator housing.

[0006] Preferably, the mounting recess extends from a side wall of the actuator housing beyond the insertion opening and into the actuator housing. This allows the locking element of the side wall to be pressed through the mounting recess right into the insertion opening. This ensures simple and efficient installation of the mounting system or the actuator module. Because the mounting recess extends through the insertion opening, the locking element can be reliably guided to the insertion pin to deform it.

[0007] According to a preferred embodiment of the invention, the insertion pin has a longitudinal extension such that a free end of the insertion pin can be bent or is bent into the mounting recess by the locking element. The insertion pin is thus designed such that a free end lies in the area of ​​the insertion opening where the insertion opening is traversed or crossed by the mounting recess. This allows the free end of the insertion pin to be advantageously bent or bent into the mounting recess by the locking element in the direction away from the side wall. This enables the insertion pin to be brought into an advantageous shape for engagement behind the actuator housing by the locking element with minimal effort. The insertion depth of the locking element advantageously allows the deformation, and in particular the maximum deformation, of the insertion pin to be predetermined.

[0008] According to a preferred embodiment of the invention, the locking element is a locking ball whose diameter is larger than the diameter of the mounting recess. Due to its design, the locking ball exhibits high resistance to its own deformation. Because its diameter is larger than the diameter of the mounting recess, it must be pressed into the recess. Due to its spherical shape, the material of the actuator housing, in particular, is at least elastically deformed during this process and yields during pressing. Once the ball has passed a section of the mounting recess, the material of the actuator housing returns to its original position due to its inherent elasticity, thus positively engaging behind the locking ball and reliably preventing accidental and unintentional dislodgement of the locking ball from the mounting recess.Furthermore, the pressed-in locking ball ensures that the insertion pin remains permanently in its curved shape, engaging behind the actuator housing. As an alternative to the locking ball, the locking element is preferably designed as a locking wedge, cone, piston, or the like.

[0009] According to a further embodiment of the invention, the mounting recess is preferably designed as a bore with a constant diameter. By designing it as a bore, the mounting recess can be produced cost-effectively, and its diameter can be precisely adjusted, thus ensuring the advantageous interaction with the locking element, in particular with the locking ball, as described above.

[0010] The preferred insertion pin is a signal pin, such as those used in control units to establish electrical connections. Because signal pins are already commonly used, even within a single control unit, adding another signal pin as an insertion pin requires only minimal additional effort. This allows one or more insertion pins in the form of signal pins to be arranged on the control unit housing and used as described above, without significant additional costs or with virtually no increase in price.

[0011] Preferably, the insertion pin has at least a partially circular or rectangular cross-section. The cross-sectional shape allows the deformation resistance of the insertion pin to be advantageously adjusted. If the insertion pin is rectangular, the long side of the cross-section is preferably perpendicular to the insertion direction of the locking element into the mounting recess to facilitate easier deformation of the insertion pin.

[0012] Furthermore, it is preferably the case that the control unit housing is made of plastic. This makes the control unit housing cost-effective and lightweight. The actuator housing is also preferably made of metal. This gives it high robustness and load-bearing capacity, which ensures high stability, especially for the actuator or actuator assembly.

[0013] The actuator module according to the invention, comprising the features of claim 10, is characterized by the design of the fastening system according to the invention. This results in the advantages already mentioned above.

[0014] The method according to the invention, with the features of claim 10, is characterized in that at least one insertion pin of the control unit housing is inserted into at least one insertion opening of the actuator housing, and wherein a locking element is pressed into the mounting recess under elastic deformation of the actuator housing and / or the locking element on the one hand, and under elastic and / or plastic deformation of the insertion pin on the other. This results in the advantages already mentioned above.

[0015] Further advantages and preferred features and combinations of features will become apparent in particular from the foregoing and from the claims. The invention will now be explained in more detail with reference to the drawings. To this end, we show... Fig. 1. An advantageous actuator module in a simplified sectional view, Fig. 2. A detailed view of the actuator module during assembly. Fig. 3 a detailed view of the assembled actuator module in a further sectional view, and Fig. 4A and B show a plug-in pin of the actuator module in different views.

[0016] Fig. Figure 1 shows a simplified representation of an advantageous actuator module 1 for a motor vehicle not shown in detail here. The actuator module 1 is designed as an electromechanical brake force generator for a braking system of the motor vehicle, comprising an actuator assembly 2, for example, with an electric motor, a master brake cylinder, and a gearbox connecting the master brake cylinder to the electric motor. The actuator assembly 2 has at least one actuator housing 3, which in this case is made of metal, and on which the electric motor, master brake cylinder, and gearbox are arranged. In particular, the gearbox is located inside the housing 3. A control unit 5 is also mounted on a housing side 4, for example, a housing top, and the control unit housing 6 is made, in particular, of plastic.

[0017] The control unit housing 6 is permanently attached to the actuator housing 3 by an advantageous fastening system 7. With reference to the Fig. The fastening system 7 is discussed in more detail in sections 2 to 4 below.

[0018] Fig. Figure 2 shows the actuator module 1 during assembly. The control unit housing 6 has a laterally projecting mounting flange 8, on or in which several insertion pins 9 are arranged, projecting towards the actuator housing 3. In particular, the insertion pins 9 are each designed as a signal pin 10, which is inserted into the flange 8 in such a way that it is permanently attached to it. For this purpose, the flange 8 has, for example, through-holes or openings 11, with one of the insertion pins 9 being pressed into each of the through-holes 11 or being encased in the plastic material of the control unit housing 6. The respective insertion pin 9 or signal pin 10 is preferably made of metal.

[0019] The actuator housing 3 has insertion openings 12 formed according to the arrangement of the through-openings 11, which, in the mounted state of the control unit, are aligned with one of the through-openings 11. The insertion openings 12 extend straight into the actuator housing 3. Each insertion opening 12 is traversed by a mounting recess 13, which extends from a side wall 14 of the actuator housing 3 perpendicular to the longitudinal extent of the respective insertion opening 12 into the actuator housing 3. The respective mounting recess 13 is preferably designed as a bore. The respective insertion opening 12 is also preferably designed as a bore. The respective insertion pin 9 is designed to be long such that a free end 15 of the respective insertion pin 9 lies in the area of ​​the mounting recess 13.

[0020] To attach the control unit 6 to the actuator assembly 2, a locking element 16 is pressed into the mounting recess 13 from the side of the side wall 14 until the locking element 16 deforms the insertion pin 9 such that its free end 15 engages the actuator housing 3 positively in the mounting recess 13. The free end 15 is bent into the mounting recess 13 in the direction of the end furthest from the side wall 14, as shown in the example in Fig. 3 shown.

[0021] Fig. Figure 3 shows the final assembly state in which the locking element 16 is pressed into the mounting recess 13, deforming the insertion pin 9. The insertion pin 9 is deformed elastically, and optionally plastically.

[0022] According to the present embodiment, the locking element 16 is designed as a locking ball having a predetermined diameter D. The diameter is advantageously larger than the diameter d of the mounting recess 13, so that the locking element 16 can only be pressed into the mounting recess 13 under elastic and / or plastic deformation. In this embodiment, the locking ball is harder than the actuator housing 3, so that during pressing in, the material of the actuator housing 3 is elastically deformed or displaced until the locking ball reaches its mounting position. In the insertion direction behind the locking element 16, the actuator housing 3 deforms back, at least partially, due to its inherent elasticity, as shown in Fig. Figure 3 shows an example, so that the locking ball is held not only by friction but also by positive locking in the mounting recess 13 when assembly is complete. This reliably prevents unintentional removal of the locking element 16 from the mounting recess 13 and simultaneously prevents a decrease in the fastening force acting on the insertion pin 9, which holds it deformed in its positive-locking rear grip position.

[0023] For example, a punch is used to press in the locking element 16, which is inserted into the lateral mounting recess 13. The force-fit and form-fit connection is ensured by the unformed insertion pin 9 and the pressing in of the locking ball to a defined insertion depth.

[0024] Fig. Figures 4A and B show a preferred embodiment of the insertion pin 9 in a front view ( Fig. 4A) and in a side view ( Fig. 4B). In the present case, the insertion pin 9, in particular the signal pin 10, has a rectangular cross-section with a long and a short side, as is common for signal pins. In the latter case, for mounting, the insertion pin 9 is oriented such that the long side of the cross-section is oriented transversely to the direction of extension of the mounting recess 13 or bore, in order to ensure advantageous deformation of the insertion pin 9 when the locking element 16 is pressed in. According to an alternative embodiment, not shown here, the insertion pin 9 preferably has a circular cross-section.

[0025] Advantageously, the insertion force and insertion path of the locking element 16 are monitored during the pressing into the mounting recess 13, ensuring reliable detection of the pin's deformation and confirmation of the desired connection between the control unit and the actuator assembly. Compared to designs using fastening screws, the advantageous design of the present fastening system 7 offers a cost-effective and lightweight solution. Furthermore, pressing in the locking element 16 is faster than screwing in a fastening screw. If additional sealing is required, the control unit and actuator assembly are preferably bonded together.

Claims

[1] Mounting system (12) for an actuator module (1) for mounting a control unit (8) to an actuator assembly (2), wherein the control unit (5) has a control unit housing (6) and the actuator assembly (2) has an actuator housing (3), characterized by , that the fastening system (7) has at least one insertion pin (9) arranged on the control unit housing (6) and at least one insertion opening (12) formed on the actuator housing (3) for receiving the insertion pin (9), wherein the insertion opening (12) extends into the actuator housing (3) and wherein the actuator housing (3) has a mounting recess (13) extending transversely to the insertion opening (12), into which a locking element (16) can be pressed in or is pressed in by elastic deformation of the actuator housing (3) and / or the locking element (16) on the one hand and by elastic and / or plastic deformation of the insertion pin (9) on the other hand. [2] Fastening system according to claim 1, characterized by , that the mounting recess (13) extends from a side wall (14) of the actuator housing (31) beyond the insertion opening (12) into the actuator housing (3). [3] Fastening system according to one of the preceding claims, characterized by , that the insertion pin (9) has a longitudinal extension such that a free end (15) of the insertion pin (9) can be bent or is bent into the mounting recess (16) by the locking element (16). [4] Fastening system according to one of the preceding claims, characterized by , that the locking element (16) is a locking ball whose diameter (D) is larger than a diameter (d) of the mounting recess (13). [5] Fastening system according to any one of the preceding claims, characterized by , that the mounting recess (13) is a bore with a constant diameter. [6] Fastening system according to any one of the preceding claims, characterized by , that the insertion pin (9) is a signal pin. [7] Fastening system according to any one of the preceding claims, characterized by , that the insertion pin (9) has at least a section having a circular or a rectangular cross-section. [8] Fastening system according to one of the preceding claims, characterized by , that the control unit housing (9) is made of plastic and / or the actuator housing (6) is made of metal. [9] Actuator module (1) for a motor vehicle, in particular an electromechanical brake force generator or booster, by-wire actuator, parking brake actuator or ABS / ESP actuator, comprising an actuator assembly (2) and a control unit (5) having a control unit housing (6), wherein the control unit (5) is attached to an actuator housing (3) of the actuator assembly (2) by means of a fastening system (7), characterized bythe design of the fastening system (7) according to one of claims 1 to 8. [10] Method for manufacturing an actuator module (1) for a motor vehicle, in particular an electromechanical brake force generator or amplifier, by-wire actuator, parking brake actuator or ABS / ESP actuator, comprising an actuator assembly (2) and a control unit (5) comprising a control unit housing (6), wherein the control unit (5) is attached to an actuator housing (3) of the actuator assembly (2) by means of a fastening system (7) according to one of claims 1 to 8, wherein at least one insertion pin (9) is inserted into an insertion opening (12), and wherein a locking element (16) is pressed into the mounting recess (13) under elastic deformation of the actuator housing (3) and / or the locking element (16) on the one hand and under elastic and / or plastic deformation of the insertion pin (9) on the other hand.

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