Modular system for a brake force device, and method for producing a brake force device from a modular system

Abstract

The invention relates to a modular system for a brake force device (10), comprising a system housing (H) with a specified system length (L) and an elongated inner recess (A), wherein the system housing (H) can be used for an assisted brake and / or for a power brake and / or for a pressure generator; a pressure cylinder device (HZ) which can be inserted into the recess (A) of the system housing (H), said recess comprising at least one brake cylinder and a specified cylinder length (HL); and a restoring spring (RF) which has a specified spring length and a specified cross-sectional shape and which can be inserted into the recess (A) of the system housing (H).

Description

[0001] Description

[0002] title

[0003] Modular system for a braking force device and method for producing a braking force device from a modular system

[0004] The present invention relates to a modular system for a braking force device and a method for producing a braking force device from a modular system.

[0005] State of the art

[0006] A braking force device can be designed, among other things, as an electromechanical brake booster or as a pressure brake unit (component of a brake-by-wire braking system). These two concepts typically have different dimensions for their system housings and other components and therefore require separate manufacturing. In both concepts, the brake components (the brake mechanism for actuating the brake cylinders) can be driven by an electric motor, which can be connected to a transmission.

[0007] The gearbox can consist of a worm and threaded spindle gearbox, whereby in the electromechanical brake booster a combination of the

[0008] Motor and driver actuation can be carried out in a so-called Driver Demand Unit (DDU) located in a central area of ​​the housing. Furthermore, a differential travel between the electric motor position and the driver's rod can be determined, which can represent a controlled variable for operating the electromechanical brake booster. WO 2013 / 083243 A1 describes a drivetrain for an all-wheel-drive vehicle.

[0009] Disclosure of the invention

[0010] The present invention provides a modular system for a braking force device according to claim 1 and a method for producing a braking force device from a modular system according to claim 14.

[0011] Preferred further training is the subject of the subclaims.

[0012] Advantages of the invention

[0013] The idea underlying the present invention is to provide a modular system for a braking force device and a method for producing a braking force device from a modular system, wherein as many identical parts as possible can be used for different embodiments.

[0014] According to the invention, the modular system for a braking force device comprises a system housing with a predetermined system length and an elongated inner recess, wherein the system housing can be used for an auxiliary power brake and / or for an external power brake and / or for a pressure generator; a brake cylinder device which can be inserted into the recess of the system housing and which comprises at least one brake cylinder and a predetermined cylinder length; a return spring, for example for a transmission, which has a predetermined spring length and a predetermined cross-sectional shape and can be inserted into the recess of the system housing.

[0015] The modular system can correspond to a specification of components and associated tools, with which a basic structure can be provided, which can then be expanded into a specific device through further processing or equipment. The system housing can be made in one piece or assembled from multiple parts. An elongated recess can extend along a main extension direction of the system housing. The brake cylinder device can, for example, have a tandem master brake cylinder. The predetermined cylinder length can be selectable, for example such that several different types of braking force devices can be generated. The predetermined spring length and its predetermined cross-sectional shape can be provided depending on the spring characteristic, for example a necessary spring force for a specific restoring force.

[0016] An auxiliary brake can be designed as a so-called servo brake or brake booster, which can include a so-called "driver demand unit" (DDU) in an internal area. In other words, a driver demand detection device as a unit for detecting the driver's input (for example, a reaction disc or rubber disc for combining driver and actuator force). The driver's input can be detected using the DDU. The driver's pedal force is thereby amplified.

[0017] A power brake can be a so-called power brake. The braking force is applied entirely externally by the actuator. This type of brake can incorporate a simulator, meaning the pedal force can be dissipated in the simulator (except in the fallback mode in the event of a faulty braking system). The simulator can recreate pedal feel for the driver.

[0018] The pressure generator has neither a DDU nor a simulator. The actuator directly actuates the brake master cylinder (TMC) and can also be a type of power brake unit.

[0019] In the pressure generator, the actuation (of the braking force) can be carried out by the electric motor alone, and the housing or a brake component can have an integrated rotor position sensor from the electronically commutated electric motor. A threaded spindle can be provided and advantageously directly actuates the TMC (tandem master brake cylinder).

[0020] Furthermore, a driver actuation device (DDU) can only be present with a power brake and has a corresponding (predetermined) installation length for the recess (e.g., the central area). It is not required for the pressure generator. Its installation space (e.g., the central area) can therefore be used or filled by the TMC, advantageously contributing to keeping the overall length of the components for the recess as short as possible. Therefore, the pressure generator, the power brake, and the external power brake can be approximately the same length with regard to the components present or required for the recess and can therefore be integrated into the same system housing of the modular system.

[0021] In the event that the first piston (primary piston) in the tandem master cylinder is in the zero position, the TMC can, in a typical design, draw brake fluid from the reservoir via an annular groove with a suction line. In the electric brake force unit, the suction line can typically be designed as an inclined bore, while in the pressure unit, it can be a horizontal bore, which can be tightly sealed with a ball. According to the modular system, the brake cylinder device can advantageously have a primary port and a sniffer bore, with a through bore extending horizontally between the sniffer bore and the primary port and at least partially along the elongated recess.

[0022] This structure can be used as a basic structure for the external power brake as well as for the auxiliary power brake and the pressure generator.

[0023] According to a preferred embodiment of the modular system, the recess of the system housing comprises a front region and a central region, wherein the brake cylinder device can be inserted into the front region.

[0024] The front section may have a smaller diameter than the center section and a round or other cross-section. The applicable components, such as the (tandem) master brake cylinder, the return spring, spindle elements, plungers, gear elements, or other components, can then be positioned at a specific location in the center section, the front section, or a rear section, depending on the application, and, if necessary, extend from one section into another. The rear section may face an input rod to the driver pedal and connect to the center section.

[0025] The modular system can include the return spring.

[0026] According to a preferred embodiment of the modular system, the brake cylinder device comprises a primary port, a sniffer bore and a through-bore which extends in a horizontal alignment between the primary port and the sniffer bore and at least partially along the elongated recess.

[0027] According to a preferred embodiment of the modular system, a first distance between the primary port and the system housing has a predetermined value.

[0028] The distance can be selected so that the position of the primary port and the sniffer hole can be suitable for the design of different braking force devices. For example, a

[0029] Return spring depending on the necessary space requirement of the master brake cylinder and other components in the recesses, and also these components themselves, can be positioned accordingly for different braking force devices.

[0030] According to a preferred embodiment of the modular system, the return spring has a circular or elliptical wire cross-section perpendicular to a central axis of the return spring with a predetermined radius or a predetermined major or minor semi-axis, and wherein the return spring has a predetermined length along the central axis.

[0031] By varying the wire cross-section and / or radius of the return spring, its spring constant can be influenced. For example, the length of the return spring can be varied for the same spring performance depending on the space required in the system housing. Varying the wire cross-section and / or radius while maintaining constant (or nearly constant) spring performance (force distributed over length and cross-section or other spring characteristics) can result in a change in the space required for the spring in the system housing. Thus, if the available space is limited, a shorter spring may be sufficient by varying the wire cross-section and / or radius.

[0032] According to a preferred embodiment of the modular system, the return spring has a non-circular wire cross-section.

[0033] By varying the wire cross-section, the spring performance (spring constant) can be varied as required and a wire cross-section or radius of the spring (in cross-section) or its length can be varied according to the need for space or performance of the spring.

[0034] According to a preferred embodiment of the modular system, the brake cylinder device for an auxiliary power brake and / or for an external power brake and / or for a pressure generator has the same physical dimensions and internal structure.

[0035] With such a basic configuration of the system housing, it can consist of identical parts and can subsequently and / or be used for different concepts of the brake cylinder device.

[0036] According to a preferred embodiment of the modular system, the brake cylinder device can be partially pushed into the central region.

[0037] According to a preferred embodiment of the modular system, a spindle can be inserted into the central region, which spindle extends to a predetermined internal distance from the brake cylinder device.

[0038] According to a preferred embodiment of the modular system, the auxiliary power brake and / or the external power brake and / or the pressure generator are provided from a modular system with the same gear, in particular a worm gear, in the same position and have an identical brake cylinder device and / or an identical system housing and / or an identical spindle with spindle nut. According to a preferred embodiment of the modular system, the auxiliary power brake has a driver actuation device arranged between the brake cylinder device and a spindle nut, wherein the spindle is hollow and a plunger mounted therein, which is connected to the driver, actuates the driver actuation device.

[0039] According to a preferred embodiment of the modular system, in the auxiliary power brake and / or the pressure generator, an anti-rotation torque of the spindle gear is supported via at least two finger elements of the anti-rotation plate, which are connected to the spindle, on at least two grooves of the system housing, wherein the grooves are preferably rectangular grooves.

[0040] According to a preferred embodiment of the modular system, in contrast to the auxiliary power brake, the spindle nut in the pressure generator takes the place of the driver actuation device, whereby the anti-rotation torque is directed around the spindle nut by means of a pot or two cranked levers before being supported by two finger elements.

[0041] According to a preferred embodiment of the modular system, it has an adapter plate on a lateral side of the system housing for fastening the braking force device to a vehicle bulkhead in the engine compartment.

[0042] According to a preferred embodiment of the modular system, the pressure generator has a cover for sealing the system housing.

[0043] It is advantageous to provide a modular system that can be used jointly for several braking force device concepts using as many identical parts as possible.

[0044] The system housing and the components for the braking force device can be assembled on one assembly line for all applicable concepts. A maximum overall length of the system housing and / or the recess can be specified. According to the modular system according to the invention, a first distance can have a predetermined minimum length. After application of the system housing, a uniform TMC (or other brake cylinder) can be used for different types of braking force devices. Compared to conventional designs of braking force devices, the outer diameter (in cross-section) of a return spring can be selected to be smaller. A smaller diameter can lengthen the spring and lead to the predetermined length being exceeded, although this can be influenced by the choice of wire cross-section.

[0045] According to the invention, in a method for producing a braking force device from a modular system, a system housing with a predetermined system length and an elongated inner recess is provided, wherein the system housing can be used for an auxiliary power brake and / or for an external power brake and / or for a pressure generator; a brake cylinder device is provided which can be inserted into the recess of the system housing and which comprises at least one brake cylinder and a predetermined cylinder length; and a return spring is provided which has a predetermined spring length and a predetermined cross-sectional shape and can be inserted into the recess of the system housing.

[0046] The modular system can also be characterized by the features and advantages mentioned in connection with the process and vice versa.

[0047] Further features and advantages of embodiments of the invention will become apparent from the following description with reference to the accompanying drawings.

[0048] Short description of the drawings

[0049] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing. They show:

[0050] Fig. 1a is a schematic representation of a braking force device from a modular system according to an embodiment of the present invention;

[0051] Fig. 1 b is a schematic representation of a pressure generator from a modular system according to an embodiment of the present invention;

[0052] Fig. 2 is a representation of a wire cross-section for a return spring from a modular system according to an embodiment of the present invention; and

[0053] Fig. 3 is a block diagram of method steps of the method for producing a braking force device according to an embodiment of the present invention.

[0054] In the figures, the same reference symbols denote the same or functionally identical elements.

[0055] Fig. 1a shows a schematic representation of a braking force device from a modular system according to an embodiment of the present invention.

[0056] Fig. 1a shows a longitudinal section of a braking force device in which a recess A is present in the interior of the system housing H, which recess shows a front region VB and a central region MB. The system housing H has a predetermined system length L and an elongated inner recess A, wherein the system housing H can be used for an external power brake or for an auxiliary power brake but also for a pressure brake unit, as shown in Fig. 1b. A brake cylinder device HZ, for example a tandem master brake cylinder, can be inserted into the recess A of the system housing H. Furthermore, a return spring RF can be present, which has a predetermined spring length and a predetermined wire cross-sectional shape and can be inserted into the recess A of the system housing H. The brake cylinder device HZ is arranged in the front region VB and the return spring RF extends into the central region MB.The brake cylinder device HZ can comprise a primary port PP and a through hole DB extending in a horizontal alignment between the sniffer hole SB and the primary port (connection to the reservoir) PP.

[0057] Furthermore, a first distance P between the primary port PP and the system housing H can have a predetermined value. Due to this distance (minimum distance), which can be the same for different types of braking force device, the brake cylinder device HZ can have the same physical dimensions and internal structure for a power brake (Fig. 1a) or for a pressure generator (Fig. 1b). In the central region, the power brake has a driver actuation device DDU, which is not required for a pressure brake unit (Fig. 1b). In the central region MB or at least on the spindle SP, an anti-rotation plate ARP can be formed as a flat plate.

[0058] The return spring RF can comprise a first return spring RF1 between the brake cylinder device HZ and DDU and a second return spring RF2, the latter acting between the spindle SP and the system housing H or only acting on the gearbox GE and not on the input rod ES.

[0059] The sum of the forces of the two return springs RF1 and RF2 is comparable to the force of one return spring from Fig. 1 b.

[0060] The input rod ES can be connected to a plunger PL.

[0061] An adapter plate AP for fastening the braking force device 10 to a vehicle bulkhead SW in the engine compartment, for example by means of a screw connection VS, can be provided on a lateral side of the system housing H. Fig. 1 b shows a schematic representation of a pressure brake unit from a modular system according to an embodiment of the present invention.

[0062] Fig. 1 b shows the same system housing H as can be seen in Fig. 1 a, also with the same dimensions of length L and recess A.

[0063] The first distance P and the dimensions of at least some components can also be the same, which favors the use of the modular system for the braking force device 10. Due to the omission of the driver actuation device DDU in Fig. 1b, the anti-rotation plate ARP can be cup-shaped or pot-shaped.

[0064] If the driver actuation device DDU is omitted, the freed-up installation space can be used to reduce the length of the overall structure.

[0065] The TMC can be moved into the center section MB toward the ARP. Furthermore, the spindle nut SPM with the spindle SP can be moved to the left into the center section MB toward the TMC, whereby the overall length can also be reduced by the length of the driver actuation device DDU.

[0066] It is advantageous to reduce the diameter of the (one) return spring RF at a larger distance Z (by omitting the DDU) while retaining the cost-effective round wire.

[0067] A worm gear and the spindle nut SPM can rotate. A gap SPT can exist between the cup-shaped anti-rotation plate ARP and the rotating spindle nut SPM. The anti-rotation plate ARP can be supported by finger elements FE against a groove NN in the system housing H.

[0068] Fig. 2 shows a representation of a wire cross-section for a return spring from a modular system according to an embodiment of the present invention. The representation in Fig. 2 can relate to the case of Fig. 1a with the braking force device and one of the two return springs or the case of Fig. 1b with the one return spring. In the partial representations a, b and c, different wire cross-sections of the return spring RF are shown, with an ellipticity / rectangularity of the wire radius R increasing from a to c. The lower area shows the corresponding block lengths BL, which decrease due to the elliptical / rectangular cross-section. With the same characteristics, the shorter block length enables a shorter spring.

[0069] The return spring RF may have a circular or elliptical cross-section with a predetermined radius or a predetermined major or minor semi-axis perpendicular to a central axis of the return spring RF, and wherein the return spring RF may have a predetermined length along the central axis.

[0070] Fig. 3 shows a block diagram of method steps of the method for producing a braking force device according to an embodiment of the present invention.

[0071] In the method for producing a braking force device from a modular system, a system housing with a predetermined system length and an elongated inner recess is provided S1, wherein the system housing can be used for an auxiliary power brake and / or for an external power brake and / or for a pressure generator; a brake cylinder device is provided S2, which can be inserted into the recess of the system housing and which comprises at least one brake cylinder and a predetermined cylinder length; and a return spring is provided S3, which has a predetermined spring length and a predetermined cross-sectional shape and can be inserted into the recess of the system housing.

[0072] Although the present invention has been fully described above using the preferred embodiment, it is not limited thereto but can be modified in many ways.

Claims

Claims 1 . Modular system for a braking force device (10), comprising - a system housing (H) with a predetermined system length (L) and an elongated inner recess (A), wherein the system housing (H) can be used for an auxiliary power brake and / or for an external power brake and / or for a pressure generator; - a brake cylinder device (HZ) which can be inserted into the recess (A) of the system housing (H), which comprises at least one brake cylinder and a predetermined cylinder length; - a return spring (RF) which has a predetermined spring length and a predetermined cross-sectional shape and can be inserted into the recess (A) of the system housing (H) 2. Modular system according to claim 1, wherein the recess (A) of the system housing (H) comprises a front region (VB) and a central region (MB), wherein the brake cylinder device (HZ) can be inserted into the front region (VB).

3. Modular system according to claim 2, wherein the brake cylinder device (HZ) comprises a primary port (PP) and a sniffer bore (SB) and a through-bore (DB) extends in a horizontal alignment between the primary port (PP) and the sniffer bore (SB) and at least partially along the elongated recess (A).

4. Modular system according to claim 3, wherein a first distance (P) between the primary port (PP) and the system housing (H) has a predetermined value.

5. Modular system according to one of claims 1 to 4, in which the return spring (RF) has a circular or elliptical wire cross-section with a predetermined radius or a predetermined major or minor semi-axis and wherein the return spring (RF) has a predetermined length (Z) along the central axis 6. Modular system according to claim 5, wherein the return spring (RF) has a non-circular wire cross-section.

7. Modular system according to one of claims 1 to 6, in which the brake cylinder device (HZ) for an auxiliary power brake and / or for an external power brake and / or for a pressure generator has the same physical dimensions and internal structure.

8. Modular system according to one of claims 1 to 7, in which the auxiliary power brake and / or the external power brake and / or the pressure generator are provided from a modular system with an identical gear (GE), in particular a worm gear, at an identical position and have an identical brake cylinder device (HZ) and / or an identical system housing (H) and / or an identical spindle with spindle nut.

9. Modular system according to claim 8, wherein the auxiliary power brake has a driver actuation device (DDU) which is arranged between the brake cylinder device (HZ) and a spindle nut, wherein the spindle is hollow and a plunger mounted therein, which is connected to the driver, actuates the driver actuation device (DDU).

10. Modular system according to claim 8 or 9, wherein in the auxiliary power brake and / or the pressure generator, an anti-rotation torque of the spindle gear is supported via at least two finger elements (FE) of an anti-rotation plate (ARP), which are connected to the spindle (SP), on at least two grooves (NN) of the system housing, wherein the grooves (NN) are rectangular grooves.

11. Modular system according to one of claims 9 to 10, in which in the pressure generator, in contrast to the auxiliary power brake, the spindle nut (SPM) takes the place of the driver actuation device (DDU), whereby the anti-rotation torque can be adjusted by means of a pot or two cranked levers by the spindle nut is guided around before it is supported by two finger elements (FE).

12. Modular system according to one of claims 9 to 11, which has an adapter plate (AP) on a lateral side of the system housing (H) for fastening the braking force device (10) to a vehicle bulkhead (SW) in the engine compartment.

13. Modular system according to one of claims 9 to 12, wherein the pressure generator has a cover for sealing the system housing (H).

14. A method for producing a braking force device (10) from a modular system, comprising the steps: Providing (S1) a system housing (H) with a predetermined system length (L) and an elongated inner recess (A), wherein the system housing (H) can be used for an auxiliary power brake and / or for an external power brake and / or for a pressure generator; - Providing (S2) a brake cylinder device (HZ) which can be inserted into the recess (A) of the system housing (H), which comprises at least one brake cylinder and a predetermined cylinder length (HL); and - Providing (S3) a return spring (RF) which has a predetermined spring length and a predetermined cross-sectional shape and can be inserted into the recess (A) of the system housing (H).

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