Unit system for a brake force device and method for manufacturing a brake force device from the unit system

Abstract

The present invention provides a unit system for a brake force device (10), comprising a system housing (H) usable for an assist brake and / or auxiliary power brake and / or pressure generating device, having a predetermined system length (L) and a longitudinal inner cutout (A), a brake cylinder device (HZ) having at least one brake cylinder and a predetermined cylinder length (HL) that can be fitted into the cutout (A) of the system housing (H), and a return spring (RF) having a predetermined spring length and a predetermined cross-sectional shape that can be fitted into the cutout (A) of the system housing (H).

Description

[Technical Field]

[0001] The present invention relates to a unit system for a braking force device and a method for manufacturing a braking force device from the unit system. [Background technology]

[0002] The brake force device may be configured in particular as an electromechanical brake booster or as a pressure brake device (a component of a brake-by-wire brake device). These two concepts generally have different dimensional designs for their system housing and other components and therefore must be manufactured separately. In these two concepts, the brake components (of the brake mechanism for actuating the brake cylinders) are driven via electric motors, which may each be connected to a transmission.

[0003] The transmission consists of a worm gear / threaded spindle transmission, and in this case, in the case of an electromechanical brake booster, the integration of motor and driver actuation is carried out in a so-called Driver Demand Unit (DDU) in the central area of ​​the housing. Furthermore, the differential stroke between the electric motor position and the driver rod is calculated, which is the control variable for operating the electromechanical brake booster.

[0004] Patent Document 1 describes a drive train for a vehicle capable of all-wheel drive. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2013 / 083243 Brochure Summary of the Invention

[0006] The present invention provides a unit system for a braking force device as claimed in claim 1 and a method for manufacturing a braking force device from the unit system as claimed in claim 14.

[0007] Preferred embodiments are the subject of the dependent claims. [Effects of the Invention]

[0008] The idea underlying the present invention is to provide a unit system for a braking force device and a method for manufacturing a braking force device from the unit system, in which as many identical parts as possible can be used for the various embodiments.

[0009] According to the present invention, a unit system for a brake force device comprises a system housing usable for an assist brake and / or auxiliary power brake and / or pressure generating device, the system housing having a predetermined system length and a longitudinal inner recess, a brake cylinder device having at least one brake cylinder and a predetermined cylinder length that can be fitted into the recess of the system housing, and a return spring, for example for a transmission, having a predetermined spring length and a predetermined cross-sectional shape that can be fitted into the recess of the system housing.

[0010] The unit system corresponds to a preset of components and associated tools, providing a base structure that can then be further processed or equipped to a given device. The system housing may be one piece or comprised of multiple parts. The longitudinal recess may extend along the main extension direction of the system housing. The brake cylinder device may have, for example, a tandem master brake cylinder. The predetermined cylinder length may be selected, for example, so that many different types of brake force devices can be produced. The predetermined spring length and its predetermined cross-sectional shape may be provided depending on the spring characteristics, for example, depending on the spring force required for a given return force.

[0011] The assist brake may be configured as a so-called servo brake or brake booster and has in its interior a so-called "driver demand unit DDU", i.e. a driver demand detection device (e.g. a reaction disk or rubber disc for combining the driver force and the actuator force) for detecting the driver's demand. The DDU can detect the driver's demand and amplify the driver's pedal force.

[0012] The power-assisted brakes may be so-called power brakes. The braking force is provided completely externally by an actuator. This type of brake may have a simulator, meaning that the pedal force can be disposed of in the simulator (outside the fallback level in the event of an error in the brake system). The simulator can generate a pedal sensation for the driver.

[0013] The pressure generator does not have a DDU or simulator. The actuator directly operates the master brake cylinder (TMC), which may also be a type of auxiliary power brake unit.

[0014] In the pressure generator, actuation (of the brake force) is performed solely by the electric motor, which may have an electronically commutated motor rotor position sensor or an integral rotor position sensor (in the housing or brake components). A threaded spindle may be provided, which preferably directly operates a TMC (Tandem Master Brake Cylinder).

[0015] Furthermore, the driver demand unit (DDU) is provided only in the assist brake and has a corresponding (predetermined) structural length for the cutout (e.g., central region), but is not required in the pressure generator, so that in this case the structural space (e.g., central region) can be utilized or filled by the TMC, preferably serving to keep the overall length of the assembly components for the cutout as short as possible. Therefore, the pressure generator, assist brake, and auxiliary power brake can be approximately the same length in consideration of the components provided or required for the cutout, and can therefore be fitted into the same system housing of the unit system.

[0016] In a typical configuration of a tandem master brake cylinder, when the first piston (primary piston) is in its zero position, brake fluid is sucked in from the reservoir via an annular groove with a suction line. In electric brake force systems, the suction line is typically configured as an inclined bore, while in pressure units, the suction line may be a horizontal bore that can be sealed gas-tightly by a ball. In a preferred embodiment of the unit system, the brake cylinder device has a primary port and a sniffer bore, with the through-hole oriented horizontally between the sniffer bore and the primary port and extending at least in part along the longitudinal recess. This structure can be used as the basis for auxiliary power brakes, assist brakes, and pressure generators.

[0017] According to one preferred embodiment of the unit system, the cutout in the system housing has a front region and a central region, and the brake cylinder device can be fitted into the front region.

[0018] The front region has a smaller diameter than the central region and may have a circular or other type of cross section. Insertable components, such as (tandem) master brake cylinders, return springs, spindle elements, plungers, transmission elements, etc., are positioned in the central, front, or rear region, depending on the application, in positions defined for this purpose, and extend beyond the designated region into the other region if necessary. The rear region is oriented toward the input rod leading to the driver's pedal and is connected to the central region.

[0019] The unit system may have a return spring.

[0020] According to one preferred embodiment of the unit system, the brake cylinder device has a primary port, a sniffer hole, and a through hole, the through hole being oriented horizontally between the primary port and the sniffer hole and extending at least regionally along the longitudinal notch.

[0021] According to one preferred embodiment of the unit system, the first spacing between the primary port and the system housing has a predetermined value.

[0022] This spacing can be selected so that the positions of the primary port and the sniffer hole can be adapted to various brake force device configurations, so that, for example, the return spring can be positioned accordingly depending on the required space for the master brake cylinder and other components in the recess, and these components themselves can also be positioned accordingly for various brake force devices.

[0023] In accordance with one preferred embodiment of the unit system, the return spring has a circular or elliptical wire cross section perpendicular to the central axis of the return spring, with a predetermined radius or predetermined major or minor semi-axis, and the return spring has a predetermined length along the central axis.

[0024] Varying the wire cross section and / or radius of the return spring can affect its spring constant. Therefore, the length of the return spring can be changed within the system housing depending on the required space for the same spring performance. This is because changing the wire cross section and / or radius can change the required space for the spring within the system housing for the same (or nearly the same) spring performance (distribution of force between length and cross section or other spring characteristics). Therefore, if the space provided is smaller, a shorter spring can be used by changing the wire cross section and / or radius.

[0025] According to a preferred embodiment of the unit system, the return spring has a non-circular wire cross section.

[0026] By varying the wire cross section, the spring performance (spring constant) can be varied as needed, and the wire cross section or radius (in cross section) of the spring or its length can be changed depending on the spring position or spring performance needs.

[0027] According to one preferred embodiment of the unit system, the brake cylinder devices have the same physical dimensions and internal structure for the assist brake and / or auxiliary power brake and / or pressure generator.

[0028] Such a system housing basic structure allows the system housing to be constructed from the same parts and furthermore be used subsequently and / or subsequently for various concepts of brake cylinder arrangements.

[0029] According to a preferred embodiment of the unit system, the brake cylinder device is partially retractable into the central region.

[0030] According to a preferred embodiment of the unit system, a spindle can be inserted into the central region, which can extend up to a predetermined inner distance relative to the brake cylinder device.

[0031] According to a preferred embodiment of the unit system, the assist brake and / or auxiliary power brake and / or pressure generating device are comprised of one unit with the same transmission, in particular a worm gear transmission, provided at the same position and having the same structured brake cylinder device and / or the same structured system housing and / or the same structured spindle with the spindle nut.

[0032] According to a preferred embodiment of the unit system, the assist brake has a driver-operated device that is disposed between the brake cylinder device and the spindle nut, the spindle being hollow, and a plunger supported within the spindle and connected to the driver that operates the driver-operated device.

[0033] According to a preferred embodiment of the unit system, in the assist brake and / or pressure generating device, the anti-rotation torque of the spindle transmission is supported by at least two finger elements of an anti-rotation plate connected to the spindle in at least two grooves in the system housing, which grooves are preferably rectangular.

[0034] According to a preferred embodiment of the unit system, in the pressure generating device, unlike the assisted brake, the spindle nut takes the place of the driver-operated device, whereby the anti-rotation torque is induced around the spindle nut using a bowl-shaped member or two hook-shaped levers before being supported via two finger elements.

[0035] According to a preferred embodiment of the unit system, the unit system has adapter plates on the lateral sides of the system housing for fixing the braking force device to a vehicle splashboard in the engine compartment.

[0036] According to a preferred embodiment of the unit system, the pressure generating device has a cover for sealing the system housing.

[0037] Preferably, one unit system can be provided that uses as many identical parts as possible, which can be commonly used for many brake force device concepts.

[0038] In this case, the system housing and components for the brake force device can be assembled on one assembly line for all applicable concepts. The maximum overall length of the system housing and / or the cutout can be predetermined.

[0039] According to the unit system of the present invention, the first interval may have a predetermined minimum length. Depending on the use of this system housing, an integrated TMC (or separate brake cylinder) for various types of braking force devices can be used. The outer diameter (cross-sectional area) of the return spring can be selected to be smaller than that of the usual structure of the braking force device. By using a smaller diameter, the spring can be extended beyond the predetermined length, which can of course be influenced in this case by the selection of the wire cross-section.

[0040] According to the present invention, a method for manufacturing a brake force device from a unit system includes the steps of: providing a system housing usable for an assist brake and / or auxiliary power brake and / or pressure generating device, having a predetermined system length and an elongated inner cutout; providing a brake cylinder device having at least one brake cylinder and a predetermined cylinder length that can be fitted into the cutout of the system housing; and providing a return spring having a predetermined spring length and a predetermined cross-sectional shape that can be fitted into the cutout of the system housing.

[0041] This unit system also excels in the features and advantages mentioned in connection with the method, and vice versa.

[0042] Further features and advantages of embodiments of the invention will become apparent from the following description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0043] [Figure 1a] 1 is a schematic diagram of a braking force device consisting of a one-unit system according to one embodiment of the present invention. [Figure 1b] 1 is a schematic diagram of a pressure generator consisting of a single unit system according to one embodiment of the present invention. [Figure 2] FIG. 1 is a diagram showing a cross section of a wire rod for a return spring made up of a unit system according to one embodiment of the present invention. [Figure 3] 1 is a block diagram of method steps of a method for manufacturing a braking force device according to one embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0044] The invention will be explained in more detail below using several exemplary embodiments shown in the diagrammatic drawings.

[0045] In the drawings, like reference numbers indicate like or functionally similar elements.

[0046] FIG. 1a shows a schematic diagram of a braking force device comprising a unit system according to one embodiment of the present invention.

[0047] FIG. 1a shows a longitudinal section of a brake force device, in which a recess A is provided in a system housing H, which recess A indicates a front region VB and a central region MB. The system housing H has a predetermined system length L and a longitudinal inner recess A, and the system housing H can be used for auxiliary power braking or assisted braking, and also for a pressure brake system, as shown in FIG. 1b. A brake cylinder device HZ, such as a tandem master brake cylinder, can be fitted into the recess A of the system housing H. A return spring RF can also be provided, which has a predetermined spring length and a predetermined wire cross-sectional shape and can be fitted 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 may have a primary port PP, and the through hole DB extends horizontally between the sniffer hole SB and the primary port PP (leading to the reservoir).

[0048] Furthermore, the first distance P between the primary port PP and the system housing H may have a predetermined value. This distance (minimum distance) may be the same for various types of brake force devices, allowing the brake cylinder device HZ to have the same physical dimensions and internal structure for the assist brake (FIG. 1a) or for the pressure generator (FIG. 1b). This assist brake has a driver control device DDU in its central region, which is not necessary for the pressure brake device (FIG. 1b). An anti-rotation plate ARP formed as a flat plate may be provided in the central region MB or at least on the spindle SP.

[0049] The return spring RF may have a first return spring RF1 between the brake cylinder device HZ and the DDU, and a second return spring RF2, which acts between the spindle SP and the system housing H or acts only on the transmission device GE and not on the input rod ES.

[0050] The sum of the forces of the two return springs RF1 and RF2 is comparable to the force of the return spring shown in FIG. 1b.

[0051] The input rod ES may be connected to a plunger PL.

[0052] On the lateral sides of the system housing H, adapter plates AP may be provided for fastening the braking force device 10 to a vehicle splashboard SW in the engine compartment, for example by means of a screw connection VS.

[0053] FIG. 1b shows a schematic diagram of a pressure brake device comprising a unit system according to one embodiment of the present invention.

[0054] Figure 1b shows the same system housing H as shown in Figure 1a, which also has the same length L and the same dimensions of the cutout A. In this case, the first spacing P and the dimensions of at least some of the components may also be the same, which makes it easier to use this unit system in the braking force device 10. Due to the omission of the driver operating device DDU in Figure 1b, the anti-rotation plate ARP may be configured in a cup or bowl shape.

[0055] If the driver control device DDU is omitted, the freed up structural space can be used to reduce the overall length of the structure.

[0056] The TMC can be pushed toward the ARP in the central region MB. Furthermore, the spindle nut SPM together with the spindle SP can be pushed leftward toward the TMC in the central region MB, in which case the structural length can likewise be reduced by the length of the driver control device DDU.

[0057] Advantageously, the diameter of the (single) return spring RF for the larger spacing Z (due to the omission of the DDU) can be reduced while using cheaper round wire.

[0058] The worm gear and spindle nut SPM are able to rotate. A gap SPT may be provided between the cup-shaped anti-rotation plate ARP and the rotating spindle nut SPM. The anti-rotation plate ARP may be supported in a groove NN in the system housing H by a finger element FE.

[0059] FIG. 2 shows a wire cross section for a return spring comprising a unit system according to one embodiment of the present invention.

[0060] The drawing in Figure 2 corresponds to the case of Figure 1a with a brake force device and one of two return springs, or to the case of Figure 1b with one return spring. Thus, in sub-views a, b, and c, various wire cross sections of the return spring RF with increasing ellipticity / rectangularity of wire radius R from a to c are shown. The lower area shows the associated block length BL, which is reduced by the ellipticity / rectangularity of the cross section. A smaller block length with the same characteristics allows for a shorter spring.

[0061] The return spring RF has a circular or elliptical cross-section perpendicular to a central axis of the return spring RF, with a predetermined radius or predetermined greater or lesser semi-axis, wherein the return spring RF has a predetermined length along the central axis.

[0062] FIG. 3 shows a block diagram of method steps of a method for manufacturing a braking force device according to one embodiment of the present invention.

[0063] A method for manufacturing a brake force device comprising a unit system includes providing (S1) a system housing with a predetermined system length and a longitudinal inner recess, where the system housing can be used for an assist brake and / or an auxiliary power brake and / or a pressure generating device, providing (S2) at least one brake cylinder and a brake cylinder device with a predetermined cylinder length that can be fitted into the recess of the system housing, and providing (S3) a return spring with a predetermined spring length and a predetermined cross-sectional shape that can be fitted into the recess of the system housing.

[0064] Although the present invention has been fully described above with reference to preferred embodiments, it is not limited to these embodiments and can be modified in various ways and forms. [Explanation of symbols]

[0065] 10 Brake force device A notch AP adapter plate ARP Anti-Rotation Plate DB through hole DDU Driver Control Unit ES input rod FE Finger Element GE Transmission H System Housing HL Cylinder length HZ brake cylinder device, tandem master brake cylinder L System length MB central area NN groove P first interval PP Primary Port RF return spring RF1 First return spring RF2 Second return spring S1 System Housing Available S2 Brake cylinder device provision S3 return spring provided SB sniffer hole SP Spindle SPM spindle nut SPT Gap SW vehicle splash board TMC Tandem Master Brake Cylinder VB front area VS threaded connection Z spacing

Claims

1. A unit system for a braking force device (10), comprising: a system housing (H) capable of being used for an assist brake and / or auxiliary power brake and / or pressure generator, the system housing (H) having a predetermined system length (L) and a longitudinal inner cutout (A); a brake cylinder device (HZ) that can be fitted into the notch (A) of the system housing (H) and has at least one brake cylinder and a predetermined cylinder length; a return spring (RF) having a predetermined spring length and a predetermined cross-sectional shape, which can be fitted into the notch (A) of the system housing (H); A unit system for a braking force device (10) comprising:

2. 2. The unit system according to claim 1, wherein the notch (A) of the system housing (H) has a front region (VB) and a central region (MB), and the brake cylinder device (HZ) can be fitted into the front region (VB).

3. 3. A unit system as described in claim 2, wherein the brake cylinder device (HZ) has a primary port (PP) and a sniffer hole (SB), and a through hole (DB) is oriented horizontally between the primary port (PP) and the sniffer hole (SB) and extends at least regionally along the longitudinal notch (A).

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

5. 5. A unit system according to claim 1, wherein the return spring (RF) has a circular or elliptical wire cross-section perpendicular to a central axis of the return spring (RF) with a predetermined radius or predetermined major or minor semi-axis, and the return spring (RF) has a predetermined length (Z) along the central axis.

6. 6. The unit system of claim 5, wherein said return spring (RF) has a non-circular wire cross section.

7. 7. A unit system according to any one of claims 1 to 6, wherein the brake cylinder device (HZ) has the same physical dimensions and internal structure for the assist brake and / or auxiliary power brake and / or pressure generator.

8. 8. A unit system according to claim 1, wherein the assist brake and / or the auxiliary power brake and / or the pressure generating device are comprised of one unit with the same transmission (GE), in particular a worm gear transmission, provided at the same position, and having a brake cylinder device (HZ) of the same structure and / or a system housing (H) of the same structure and / or a spindle of the same structure with a spindle nut.

9. 9. The unit system according to claim 8, wherein the assist brake has a driver operated unit (DDU), the driver operated unit (DDU) is arranged between the brake cylinder unit (HZ) and a spindle nut, the spindle is hollow-bored, and a plunger connected to the driver and supported within the spindle is adapted to operate the driver operated unit (DDU).

10. 10. A unit system according to claim 8 or 9, wherein in the assist brake and / or the pressure generating device, the anti-rotation torque of the spindle transmission device is supported by at least two grooves (NN) in the system housing via at least two finger elements (FE) of an anti-rotation plate (ARP) connected to the spindle (SP), and these grooves (NN) are rectangular grooves.

11. 11. A unit system according to claim 9 or 10, wherein in the pressure generating device, unlike the assist brake, the spindle nut (SPM) occupies the position of the driver operated device (DDU), whereby the anti-rotation torque is induced around the spindle nut using a bowl-shaped member or two hook-shaped levers before being supported via the two finger elements (FE).

12. 12. The unit system according to claim 9, wherein the unit system has an adapter plate (AP) on a lateral side of the system housing (H) for fixing the braking force device (10) to a vehicle splash board (SW) in an engine compartment.

13. 13. A unit system according to any one of claims 9 to 12, wherein the pressure generating device has a cover for sealing the system housing (H).

14. A method for manufacturing a braking force device (10) from a unit system, comprising: providing a system housing (H) (S1) for an assist brake and / or auxiliary power brake and / or pressure generator, the system housing (H) having a predetermined system length (L) and a longitudinal inner cutout (A); a step (S2) of providing a brake cylinder device (HZ) that can be fitted into the notch (A) of the system housing (H) and has at least one brake cylinder and a predetermined cylinder length (HL); providing a return spring (RF) having a predetermined spring length and a predetermined cross-sectional shape, the return spring (RF) being fittable within the notch (A) of the system housing (H); 1. A method for manufacturing a braking force device (10) from a unit system, comprising:

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