An electronically rectified machine, an electronically slip-controllable brake device having an electronically rectified machine, and a method for manufacturing an electronically rectified machine.

Abstract

To provide an electronically rectified machine, particularly an electronically rectified motor having a rotor attached to a rotor shaft that can be operated by rotary motion.SOLUTION: A signal transmitter 24 is provided to detect the rotation angle of a rotor shaft 16, and the signal transmitter has a holding member 28 and a magnet element 26 arranged on the holding member 28. A clamp 40 for fixing the holding member to the rotor shaft acts on a magnet element in the assembled state, and at least one fixing means 50 is formed that prevents the translational movement and the rotational movement of the magnet element relative to the holding member, thereby omitting the known adhesive connection between the magnet element and the holding member.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to an electronically rectified machine according to the features of the superordinate concept part of claim 1, an electronically slip-controllable brake device having an electronically rectified machine according to the features of the superordinate concept part of claim 10, and a method for manufacturing an electronically rectified machine according to the features of the superordinate concept part of claim 11 or claim 12.

Background Art

[0002] An electronically rectified machine is incorporated as a drive device, for example, in an electronically slip-controllable brake device of a motor vehicle in order to drive a pressure generator within the framework of brake pressure control. In this case, the electrical control of the machine is carried out as required by an electronic control unit of the brake device. In the case of electrical control, the pressure generator supplies a pressure medium into the brake circuit. Then, in proportion to the supplied volume of the pressure medium, the brake pressure is increased in the connected wheel brake. Using an additional valve device controllable by the electronic control unit, this brake pressure can be adapted individually for each wheel to the latest slip ratio occurring at the wheel of the vehicle, respectively arranged. Thereby, it is possible to prevent a wheel from being locked during a braking operation, and thus the driving stability of the vehicle can be improved. Moreover, the braking operation can be carried out depending on momentary road or driving conditions independently of the driver.

[0003] The volume of the pressure medium displaced into the brake circuit by the pressure generator is an important control value in this control process. This control value can be calculated from the operating parameters of the drive device. For this purpose, the provided sensor device detects the rotation angle and / or the rotational speed of the rotor of the drive device and further transmits the measured signal to the electronic control unit for evaluation by calculation.

[0004] A known sensor device consists of a signal transmitter that rotates with the rotor shaft and a stationary signal receiver. The signal transmitter has at least one magnetic element, which is fixed to the rotor shaft of the drive unit using a retaining member so as not to rotate relative to it.

[0005] An electronically rectified machine according to the features of the higher-level concept of claim 1 belongs to the prior art and is disclosed, for example, in Patent Document 1. A known machine is a drive unit for a pressure generator of an electronically slip-controllable vehicle brake system, shown in the side view of Figure 1 of this document.

[0006] A known drive device (10) has an electronically rectified electric motor (12) equipped with a rotor (14) that can be driven by rotational motion, and a rotor shaft (16) coupled to the rotor (14) so ​​as not to rotate relative to it. The rotor (14) is conventionally configured and has an iron core and a plurality of permanent magnets arranged adjacent to each other in the circumferential direction of the iron core.

[0007] In known methods and forms, the magnetic field of this permanent magnet interacts with the magnetic field of the stator's electric coil. For this purpose, the stator has a housing (18) which has electric coils on its inner surface facing the permanent magnet. Based on the interaction between the magnetic fields, the rotor (14) and rotor shaft (16) perform a common rotational motion.

[0008] The rotor shaft (16) is typically rotatably supported within the housing (18) of the drive unit (10) using rolling bearings (20). As shown in Figure 1, for example, multiple eccentric members (22) are arranged on the rotor shaft (16) to operate a device (not shown), such as a piston pump, which is positioned perpendicular to the vertical axis L of the rotor shaft (16).

[0009] Figure 1, detail II shows a signal transmitter (24) of a sensor device for electronically detecting and evaluating the rotation angle and / or rotational speed of the rotor (14) or rotor shaft (16). This signal transmitter (24) is located at the end of the rotor shaft (16) opposite to the rotor (14). The signal transmitter has a magnetic element (26), which is indirectly fixed to the rotor shaft (16) via a retaining member (28). The retaining element (28) is cup-shaped and has a protruding spindle (30), which is pushed into a correspondingly positioned centering hole (32) of the rotor shaft (16) and bonded to the centering hole (bonding connection is not shown). On the opposite side of the retaining member (28), a blind-hole-shaped, outward-opening receiving portion (34) is formed, and the magnetic element (26) is inserted into this receiving portion (34) so ​​that its outer surface is flush with the surface. The magnetic element (26) is similarly fixed within the receiving portion (34) of the holding member (28) by adhesive connection (not shown).

[0010] Under the operating conditions of this drive system, the rotor (14) is often strongly accelerated or decelerated. In this case, the adhesive connection is subjected to high dynamic loads and is therefore considerably prone to failure. The fixing of the magnet element in the retaining member is subjected to a predetermined elasticity based on the adhesive connection, thereby resulting in relatively large measurement errors when detecting the sensor position or rotation angle. Even disregarding these factors, adhesive connections require expensive centralized control adjustments, such as for metering and curing of the adhesive, during mass production. The retaining member and centering hole required for the rotor shaft further increase costs. [Prior art documents] [Patent Documents]

[0011] [Patent Document 1] German Patent Application Publication No. 102017218648 [Overview of the project] [Effects of the Invention]

[0012] In contrast, the electronically rectified machine according to the features of claim 1 has the advantage that the fixing of the magnet element on the rotor shaft is performed by friction fastening or shape fastening rather than by material bonding, and is therefore more robust than in the prior art. As a result, the detection of the rotation angle signal or rotor rotation speed is performed with greater accuracy, which ultimately leads to an improvement in the electrical controllability of the machine, and thus a reduction in any possible error between the actually supplied pressure medium volume and the desired target value, or between the adjusted brake pressure and the target brake pressure. Furthermore, the manufacturing process of the machine is shortened because there is no need to wait for the time required for the necessary preparation of the bonding points or for the adhesive to cure. Measuring devices for the adhesive, or UV irradiation devices which may be required for the adhesive to cure, are omitted. Moreover, the friction fastening / shape fastening operation can be easily monitored from a process engineering perspective.

[0013] It has been proposed to use a clamping body to fix a holding member for the magnetic element to the rotor shaft, and the clamping body further includes means for fixing the magnetic element.

[0014] As a possible clamping body, a tolerance ring further improved in this regard, for example, made of spring steel, is suitable, and this tolerance ring is placed in the gap between the inner contour of the retaining member and the outer contour of the rotor shaft. Such a tolerance ring enables the use of inexpensive rotor shafts with a consistently constant shaft diameter. Based on the provision of the clamping body, the radial dimension of the retaining member is increased, and therefore the retaining member provides a larger mounting space for the magnet element. A correspondingly larger magnet element that protrudes beyond the cross-section of the rotor shaft provides a stronger, more uniform magnetic field that can be more easily detected and evaluated by the signal receiver. This allows for detection of advanced rotation angle or rotation speed of the rotor shaft with greater precision, or enables the use of less expensive signal receivers and magnet elements with coarser tolerances. Furthermore, magnet elements with coarser tolerances simplify the interchangeability of components such as control units and electromechanical devices.

[0015] Other advantages and preferred variations of the present invention can be derived from the dependent claims and / or the following description.

[0016] According to the present invention, the clamping body has fixing means. A first fixing means is provided that engages with one end face of the magnet element, causing the magnet element to abut against the bottom of a simply constructed cup-shaped retaining member under axial preload, while a second fixing means abuts against the magnet element, for example, a flat portion of the magnet element, or engages with a notch opening toward the end face of the magnet element, thereby fixing the magnet element to the retaining member so that it cannot rotate relative to it. The fixing means is inexpensively constructed in a single component and is preferably configured only on the side of the clamping body facing the magnet element, and is distributed along the circumferential surface of the clamping body. The fixing means extends in the longitudinal or radial direction of the clamping body and can be easily formed, for example, by appropriately deforming a tongue formed on the clamping body. The number, shape, and arrangement or positioning of the fixing means in the clamping body can be selected as needed. The clamping body has a sleeve shape, at least when mounted. This sleeve may have slits formed on its circumferential side, which allows it to be manufactured simply and inexpensively, for example, by punching and stamping metal sheet strips. [Brief explanation of the drawing]

[0017] [Figure 1] This is a longitudinal cross-sectional view of a major component of an electronically rectified machine known by prior art, as described at the beginning of the specification. [Figure 2] Figure 1 is a three-dimensional view of a detailed II of one embodiment of the present invention shown in Figure 1. [Figure 3] This is a plan view of the solution according to the present invention, with the retaining member removed. [Modes for carrying out the invention]

[0018] Embodiments of the present invention shown in the drawings will be described in detail in the following description.

[0019] The drawings consist of two figures in total, and in these figures, the same reference numerals are consistently used for corresponding components.

[0020] Figure 2 shows the end of the rotor shaft (16) of an electronically rectified machine equipped with a signal transmitter (24). This end faces a second end (not shown) to which the rotor of the electromachine is attached (see Figure 1). The rotor shaft (16) has a consistently constant outer diameter and is cut perpendicular to the longitudinal axis L, i.e., has an end face aligned perpendicular to this longitudinal axis L. The transition from the end face to the circumferential face is configured as an annular chamfer, but may be selectively rounded.

[0021] A clamping body (40) having the form of a tolerance ring is attached to the illustrated end of the rotor shaft (16). This clamping body is configured as a cylindrical sleeve, which may be closed on the circumferential side or have a slit formed on the circumferential side. A slitted sleeve can be manufactured more cheaply by bending a thin metal strip. Viewed in the direction of the longitudinal axis L of the rotor shaft (16), the clamping body (40) consists of a first clamping body section (40a) on the rotor side, which is in coplanar contact with the outer circumference of the rotor shaft (16) under an adjustable radial preload. The first clamping body section (40a) transitions into a central section (40b), in which a molded portion (42) is formed that protrudes radially outward from the clamping body (40). In this embodiment, multiple such molded portions (42) are arranged adjacent to one another at regular intervals along the entire circumference of the clamping body (40). For example, these molded portions have the same shape as one another and are aligned parallel to one another. The molded portions (42) have a trapezoidal cross-section with a sufficiently flat bottom, which is physically connected to the rest of the clamping body via an annular inclined surface. The molded portions (42) mainly extend in the direction of the longitudinal axis L of the rotor shaft (16) or the clamping ring (40). An air chamber is confined between each molded portion (42) and the outer circumference of the rotor shaft (16), and this air chamber imparts radial elasticity to the clamping body (40) by the molded portions (42).

[0022] An end section (40c) follows the central section (40b) of the clamping body (40), and this end section (40c) is again divided into a plurality of axial regions in the direction of the longitudinal axis L. The first axial region (44) arranged adjacent to the central section abuts flush against the circumferential surface of the rotor shaft (16) under a selectable radial preload, whereas the second axial region (46) following on the side opposite the central region projects beyond the end of the rotor shaft (16). The end section (40c) generally has the length of the central section (40b) of the clamping body (40) as a whole and is configured to be longer than the first axial region (44) when viewed in the direction of the longitudinal axis L of the rotor shaft (16). Fixing means (50, 52) are integrally formed with the clamping body (40) in the second axial region (46) that projects beyond the rotor shaft (16). This fixing means (50, 52) is a tongue-shaped projection of the clamping body (40). The first fixing means (50) extends inward at a right angle from the circumferential surface of the clamping body (40) or projects radially inward from the circumferential surface of the clamping body (40), whereas the second fixing means (52) is aligned parallel to the axis with respect to the longitudinal axis L. There is an axial spacing or gap in the direction of the longitudinal axis L in the mounted state shown in the figure between the inward-facing first fixing means (50) and the end face of the rotor shaft (16). The first and second fixing means (50, 52) are each provided in a plurality that can be defined according to the application and are arranged side by side along the circumferential surface of the clamping body (40). In this case, an alternating arrangement of the fixing means (50, 52) is not necessarily required. The first fixing means (50) directed radially inward can be manufactured, for example, by folding these tongue-shaped projections along the circumferential surface of the clamping body (40) individually once.

[0023] The problem of the fixing means (50, 52) is to fix the magnet elements (26) of the signal transmitter (24) inside the cup-shaped holding member (28) in a friction-locking or form-fitting manner without the magnet elements (26) performing a relative axial translational movement and a circumferential rotational movement with respect to this holding member (28) and without requiring a material-bonded fixing of the magnet elements (26).

[0024] For this purpose, the magnet element (26) is configured sufficiently cylindrical and has plane-parallel end faces aligned perpendicular to the longitudinal axis L. The first fixing means (50) of the clamping body (40) engages with the end face facing the end of the rotor shaft (16), and the magnet element (26) abuts against the bottom (54) of the cup-shaped holding member (28) with an adjustable axial preload at the end face opposite the first fixing means (50). A pair of flat key surfaces (56) facing each other are formed on the peripheral surface of the magnet element (26), and the second fixing means (52) of the clamping body (40) engages with these key surfaces (56), whereby any possible rotational movement of the magnet element (26) relative to the holding member (28) is no longer possible. Instead of the key surfaces (56), the magnet element (26) may have, for example, an axially directed notch, and the fixing means (52) may engage within this notch.

[0025] The retaining member (28) is configured in a cup shape as described above and has a cylindrical shaft (58) and a bottom portion (54) formed at the end of the shaft (58). By fitting the retaining member (28) onto the clamping body (40), the inner diameter of the retaining member (28) is matched to the outer diameter of the clamping body (40) within the region of the molded portion (42) so that the retaining member (28) is fixed to the clamping body (40) in an axial direction and unable to rotate relative to it, and at the same time, the radial force that fixes the clamping body (40) to the rotor shaft (16) in an axial direction and unable to rotate relative to it is adjusted. The effective radial force is structurally adjustable by matching the internal or external dimensions of the retaining member (28), the clamping body (40), and the rotor shaft (16). In the final mounted state of the signal transmitter (24), the shaft (58) of the retaining member (28) covers the clamping body (40) in the circumferential direction. The bottom (54) can cover the entire cross-section of the retaining member (28), thereby protecting the magnet element (26) located inside the retaining member (28) from damage and / or contamination, or a gap may be provided in the bottom (54). Otherwise, the cup-shaped retaining member (28), like the clamping body (40), is manufactured from a non-ferromagnetic material so as not to weaken or affect the magnetic field of the magnet element (26).

[0026] Figure 3 is a top view of the signal transmitter (24) with the retaining member (28) removed. The generally cylindrical magnet element (26) is shown to have two opposing flat key faces (56). The fixing means (52) contacts these key faces (56) in a shape-fastening manner and fixes the magnet element (26) against rotation about a vertical axis L that extends perpendicular to the plane of the drawing and can therefore be identified only as the intersection of the centerlines passing through the magnet element (26). The first fixing means (50), shown as a dashed line because it is covered by the magnet element (26), contacts the lower end face of the magnet element (26), which is not visible in the drawing, and presses the magnet element (26) upward in a friction-fastening manner in the plane of the drawing, thereby fixing the magnet element (26) so that it cannot move axially within the retaining member (28), which is removed in Figure 3. A total of four first fixing means (50) and two second fixing means (52) are shown in the diagram. Please understand that the relative arrangement and number of the fixing means (50, 52) shown in the diagram are merely examples and are not limited to these.

[0027] Various methods can be described for attaching the signal transmitter (24) to the rotor shaft (16).

[0028] The first method involves first pressing the clamping body (40) onto the rotor shaft (16) in the axial direction until just before a predetermined end position, then attaching the magnet element (26) to the clamping body (40) using the fixing means (50, 52) of the clamping body (40), and finally fitting the cup-shaped retaining member (28) onto the structure consisting of the clamping body (40) and the magnet element (26). In this way, the retaining member (28) is fitted onto the rotor shaft (16) together with the clamping body (40) and the magnet element (26) to match its dimensions, thereby adjusting the end position of the signal transmitter (24) on the rotor shaft (16).

[0029] A second, optional method involves first manufacturing the signal transmitter (24) and then fixing this pre-assembled signal transmitter (24) to the rotor shaft (16). To this end, the magnetic element (26) is first attached to the clamping body (40), and then this assembly is inserted into the holding member (28) of the signal transmitter (24), with the magnetic element (26) in contact with the bottom (54). The signal transmitter (24) is then fitted onto the rotor shaft (16) as a structural unit until it occupies its terminal position.

[0030] Of course, modifications or additions beyond this disclosure can be introduced without departing from the basic concept of the present invention described. This basic concept is, in particular, that the signal transmitter (24) is positioned to be immobile and immovable in the axial direction by friction fastening and / or shape fastening, thereby eliminating the need for adhesive bonding, which would be expensive to manufacture. [Explanation of symbols]

[0031] 10 Electronically rectified machinery and drive systems 12 Electric motor 14 rotors 16 Rotor shaft 18 Housing 20 Rolling bearings 22 Eccentric member 24 Signal Transmitter 26 Magnet Element 28 Retaining member 30 Mandrel 34 Receiving part 40. Clamping body, clamping ring 40a First clamping body classification 40b Central section, central area 40c end section 42 Molding section 44 First axial region 46 Second axial region 50 First fixing means 52 Second fixing means 54 Bottom 56 key surfaces 58 shaft L Vertical axis

Claims

1. An electronically rectified machine (10) having a rotor (14) attached to a rotor shaft (16) that is operable by rotational motion and a signal transmitter (24), wherein the signal transmitter (24) has a retaining member (28) fixed to the rotor shaft (16) so as not to rotate relative to the rotor shaft (16) and a magnetic element (26) disposed on the retaining member (28) for detecting the rotation angle of the rotor (14) and / or the rotor shaft (16), The retaining member (28) is fixed to the rotor shaft (16) using a clamping body (40) that is confined between the inner diameter of the retaining member (28) and the outer diameter of the rotor shaft (16), the clamping body (40) having at least one fixing means (50, 52) that acts on the magnet element (26), and the fixing means (50, 52) prevents the translational and rotational motion of the magnet element (26) relative to the retaining member (28) when the signal transmitter (24) is attached. An electronically rectified machine (10) characterized in that an air chamber surrounded between a molded portion (42) protruding radially outward from the clamping body (40) and the outer circumference of the rotor shaft (16) is positioned between the inner diameter of the holding member (28) and the outer diameter of the rotor shaft (16).

2. The holding member (28) is configured in a cup shape and receives the magnet element (26) inside it. The electronically rectified machine (10) according to claim 1, characterized in that the first fixing means (50) brings the magnet element (26) into contact with the bottom (54) of the holding member (28).

3. The electronically rectified machine (10) according to claim 2, characterized in that the first fixing means (50) is aligned perpendicular to the vertical axis L of the clamping body (40) and abuts against the end face of the magnet element (26) facing the rotor shaft (16).

4. The electronically rectified machine (10) according to claim 2 or 3, characterized in that the magnet element (26) is pressed against the bottom (54) of the holding member (28) under axial preload by the first fixing means (50).

5. An electronically rectified machine (10) according to any one of claims 1 to 4, characterized in that at least one second fixing means (52) is provided, the second fixing means (52) cooperates with the magnet element (26) while forming a shape fastening portion.

6. The electronically rectified machine (10) according to claim 5, characterized in that the second fixing means (52) extends parallel to the axis L of the clamping body (40) and contacts at least one key surface (56) disposed corresponding to the circumferential surface of the magnet element (26).

7. The electronically rectified machine (10) according to claim 5 or 6, characterized in that the first and second fixing means (50, 52) are each integrally configured with the clamping body (40) and are arranged along the circumferential surface of the clamping body (40).

8. The electronically rectified machine (10) according to any one of claims 1 to 7, characterized in that the fixing means (50, 52) are formed on the side of the clamping body (40) facing the magnet element (26).

9. The electronically rectified machine (10) according to any one of claims 1 to 8, characterized in that the magnetic element (26) can be positioned with respect to the holding member (28) using the fixing means (50, 52) without adhesive so as to be immovable in the axial direction and immovable relative to rotation.

10. An electronically slip-controllable brake system for an automobile, comprising a pressure generator and an electronically rectified machine (10) having the features of any one of claims 1 to 9 for driving the pressure generator.

11. A method for manufacturing an electronically rectified machine (10), comprising a rotor (14) mounted on a rotor shaft (16) that is operable by rotational motion, and a signal transmitter (24), wherein the signal transmitter (24) includes a retaining member (28) firmly fixed to the rotor shaft (16) and a magnetic element (26) fixed to the retaining member (28) for detecting the rotation angle of the rotor (14) and / or the rotor shaft (16), A clamping body (40) equipped with fixing means (50, 52) is attached to the rotor shaft (16), The magnetic element (26) of the signal transmitter (24) is placed on the clamping body (40) using the fixing means (50, 52). The cup-shaped holding member (28) of the signal transmitter (24) is placed over the clamping body (40) equipped with the magnetic element (26). An air chamber enclosed between the molded portion (42) that protrudes radially outward from the clamping body (40) and the outer circumference of the rotor shaft (16) is located between the inner diameter of the holding member (28) and the outer diameter of the rotor shaft (16). A method for manufacturing an electronically rectified machine (10), characterized by the above.

12. A method for manufacturing an electronically rectified machine (10), comprising a rotor (14) mounted on a rotor shaft (16) that is operable by rotational motion, and a signal transmitter (24), wherein the signal transmitter (24) has a retaining member (28) fixed to the rotor shaft (16) so as not to rotate relative to it, and a magnetic element (26) disposed on the retaining member (28) for detecting the rotation angle of the rotor (14) and / or the rotor shaft (16), First, the magnetic element (26) of the signal transmitter (24) is placed on the clamping body (40) using the fixing means (50, 52) of the clamping body (40). Next, the component unit consisting of the clamping body (40) and the magnet element (26) is inserted into the cup-shaped holding member (28) of the signal transmitter (24). Next, the holding member (28) having the magnetic element (26) and the clamping body (40) is fitted onto one end of the rotor shaft (16). An air chamber enclosed between the molded portion (42) that protrudes radially outward from the clamping body (40) and the outer circumference of the rotor shaft (16) is located between the inner diameter of the holding member (28) and the outer diameter of the rotor shaft (16). A method for manufacturing an electronically rectified machine (10), characterized by the above.

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