BRAKE ACTUATOR UNIT, ELECTROMECHANICAL BRAKE, AND SPINDLE DRIVE FOR A BRAKE ACTUATOR UNIT

Abstract

The present disclosure relates to a brake actuator unit and to an electromechanical brake. The brake actuator unit has a spindle, which is driven in rotation by an electric motor, and a brake piston in the form of a spindle nut, which surrounds the spindle and is configured to press against a brake lining.

Claims

1. The brake actuator unit for an electromechanical brake, comprising: a spindle, which is driven in rotation by an electric motor, and a brake piston in a form of a spindle nut, which surrounds the spindle and is configured to press against a brake lining.

2. The brake actuator unit according to claim 1, wherein there is provided an axial bearing, which mounts the spindle axially, wherein the spindle is supported on the axial bearing on operation of the brake.

3. The brake actuator unit according to claim 2, wherein there is provided a spindle drive having a core diameter of a thread of the brake piston for axial displaceability of the brake piston, wherein the core diameter of the thread is larger than an outside diameter of the axial bearing.

4. The brake actuator unit according to claim 3, wherein the spindle has on a brake lining side a shaft portion which is thickened in cross-section and has a transmission thread of the spindle drive on an outer lateral surface, and a drive shaft prolongation of comparatively smaller cross-section, and a transition portion between the shaft portion and the drive shaft prolongation, wherein the axial bearing abuts a contact face provided by the transition portion.

5. The brake actuator unit according to claim 1, wherein there is provided a brake housing which has a base and which accommodates the brake piston in its interior.

6. The brake actuator unit according to claim 2 wherein the axial bearing is supported on a base of a brake housing.

7. The brake actuator unit according to claim 6, wherein an axial bearing washer is arranged axially between the axial bearing and the base of the brake housing and is pressed in the brake housing by frictional engagement and/or interlocking engagement in such a manner that it is secured against rotation.

8. The brake actuator unit according to claim 6 wherein a rotation lock is provided between the brake housing and the brake piston accommodated in a linearly displaceable manner therein, which rotation lock permits a linear displacement of the brake piston but prevents the brake piston from rotating relative to the brake housing.

9. The brake actuator unit according to claim 6, wherein a gasket is provided on a brake lining side between the brake piston and the brake housing.

10. The brake actuator unit according to claim 1, wherein a cup-shaped bushing is provided, wherein the cup-shaped bushing accommodates and mounts the brake piston, and the cup-shaped bushing is accommodated in the brake housing.

11. The brake actuator unit according to claim 1, wherein the brake piston has on a brake lining side an end wall which presses against the brake lining when the brake is operated.

12. The brake actuator unit according to claim 3, wherein the spindle drive has a ball screw.

13. An electromechanical brake, having a brake actuator unit according to claim 1, wherein brake linings which can be moved towards one another, and an electric motor which is coupled in a torque-transmitting manner with the spindle.

14. A spindle drive for a brake actuator unit according to claim 1, wherein a spindle to be driven, and a brake piston in a form of a spindle nut, which surrounds the spindle and is configured to press against a brake lining.

15. A spindle drive according to claim 14, wherein the spindle has on the brake lining side a shaft portion which is thickened in cross-section and which has a transmission thread on an outer lateral surface, and a drive shaft prolongation of comparatively smaller cross-section, and a transition portion between the shaft portion and the drive shaft prolongation, wherein a spherical bearing contact face for an axial bearing is formed on the transition portion.

16. The brake actuator unit according to claim 4, wherein there is provided a brake housing which has a base and which accommodates the brake piston in its interior.

17. The brake actuator unit according to claim 7, wherein a rotation lock is provided between the brake housing and the brake piston accommodated in a linearly displaceable manner therein, which rotation lock permits a linear displacement of the brake piston but prevents the brake piston from rotating relative to the brake housing.

18. The brake actuator unit according to claim 9, wherein the spindle drive has a ball screw.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0049] The disclosure as well as further advantageous exemplary arrangements and further developments thereof will be described and explained in greater detail hereinbelow with reference to the examples shown in the drawings, in which:

[0050] FIG. 1 is a simplified schematic cross-sectional view of an electromechanical brake according to the disclosure having a brake actuator unit in accordance with an exemplary arrangement of the disclosure with an integrated spindle drive according to the disclosure,

[0051] FIG. 2 shows a second exemplary arrangement of the electromechanical brake according to the disclosure having a different brake actuator unit according to the disclosure with an integrated spindle drive according to the disclosure, and

[0052] FIG. 3 shows a spindle drive according to the disclosure provided in the brake actuator unit according to FIG. 2.

DETAILED DESCRIPTION

[0053] All the features disclosed hereinbelow in relation to the exemplary arrangement and/or the accompanying figure can be combined on their own or in any desired subcombination with features of the aspects of the present disclosure, including features of preferred exemplary arrangements, provided that the resulting feature combination is meaningful to a skilled person in the technical field.

[0054] FIG. 1 is a simplified schematic cross-sectional view of an electromechanical brake 10 according to the disclosure having a brake actuator unit 12 according to the disclosure in accordance with an exemplary arrangement of the disclosure.

[0055] The brake 10 comprises a brake housing 14 having a brake caliper 16. The brake caliper 16, as part of the brake housing 14, surrounds a brake disc 18, such as a brake disc rotor, which is enclosed in the axial direction by two brake linings 20, 22. A clamping force Fz is actively applied by the brake actuator unit 12 to the brake lining 20 that is on the inside along the axis of rotation 24 of the brake actuator unit 12. The axis of rotation 24 of the brake actuator unit 12 in the present case (in the ideal case of compensated transverse forces) also corresponds to the cylinder axis of the brake housing 54 and to the brake disc axis of rotation of the brake disc 18.

[0056] The axially displaceable brake caliper 16 ensures that the clamping force Fz is likewise applied to the brake lining 22 that is on the outside in the axial direction. The clamping force Fz is thereby distributed substantially equally in terms of magnitude between the inner brake lining 20 and the outer brake lining 22. Frictional engagement with the brake disc 18 can thus be ensured for both brake linings 20, 22 as a result of the pressing force that is provided, and this frictional engagement is used for slowing down or stopping a vehicle.

[0057] The brake 10 further has an electromechanical operating unit 26 which is used, together with the brake actuator unit 12, for generating the clamping force Fz. Relative to the brake actuator unit 12, the electromechanical operating unit 26 is arranged along the axis of rotation 24 opposite the brake disc 18. The electromechanical operating unit 26 comprises at least one electric motor 28 and a reduction gear 30.

[0058] The components of the electromechanical operating unit 26 are accommodated in the brake housing 54, which can be in the form of a skeletal frame of metal or of fibre-reinforced plastics material. The electromechanical operating unit 26 forms a closed subassembly 32 which can be mounted separately.

[0059] The brake actuator unit 12 and the spindle drive comprise a spindle 34 having a drive shaft prolongation 36, a thickened shaft portion 38 on the brake lining side, and a transition portion 40 which is arranged along the axis of rotation 24 of the spindle 34 between the drive shaft prolongation 36 and the shaft portion 38. The diameter of the drive shaft prolongation 36 of the brake actuator unit 12 is smaller in the radial direction than the diameter of the shaft portion 38 in that direction. Accordingly, the spindle 34 narrows in respect of its diameter in the region of the transition portion 40.

[0060] The brake actuator unit 12 further has a brake piston 42, which is in the form of a spindle nut. In the present case, the spindle drive 44 of the brake actuator unit 12 is in the form of a recirculating ball spindle, which is not self-locking. The spindle drive 44 comprises a transmission thread 46, in which balls 48 are arranged and roll. The spindle 34 and the brake piston 42 have mutually corresponding raceway portions. The balls 48 can make possible a translatory movement of the brake piston 42 along the ball raceways 50 of the transmission thread 46 along the axis of rotation 24 relative to the spindle 34. For this purpose, the ball raceways 50 are formed at least in part in the shaft portion 38 of the spindle 34 and in the brake piston 42.

[0061] The diameter of the ball raceways 50 corresponds to the diameter of the balls 48, taking into consideration manufacturing tolerances and required clearances.

[0062] As a result of the translator)/movement of the brake piston 42 in the direction towards the brake disc 18, the brake piston 42 is moved in the direction towards the inner brake lining 20 and thus ensures that the clamping force Fz is actively applied to the inner brake lining 20.

[0063] The brake housing 14 is also part of the brake actuator unit 12. The brake housing 14 has a side wall 56 and a base 58. The open end of the brake housing 14 is arranged on the brake lining side along the axis of rotation 24. This means that the base 58 is provided at the end of the brake housing 14 opposite the brake disc 18. The base 58 has a through-hole 60 for the drive shaft prolongation 36 of the spindle 34, which is held therein by means of a radial bearing 62.

[0064] The brake housing 14 is coupled with the electromechanical operating unit 26 by means of an interlocking connection which is displaceable along the axis of rotation 24, such that the reduction gear 30 is centred relative to the brake housing 14. The displaceable interlocking connection can comprise, for example, a shaft-hub connection with multiple splining or a bolt-and-groove connection.

[0065] The side wall 56 and the base 58 define an interior 64 of the brake housing 14, in which at least the spindle 34 and the brake piston 42 are arranged at least in part. Owing to the linear displaceability of the brake piston 42, the brake piston can also be arranged at least in part outside the interior 64.

[0066] The brake housing 54 allows the brake actuator unit 12 to be in the form of a separate subassembly 66, which can be mounted as a whole in the brake housing, for example with the aid of a cup-shaped bushing 90, which is shown in FIG. 2, in which the spindle drive 44 and the brake piston 42 are arranged.

[0067] The brake piston 42 is linearly guided and secured against rotation inside the brake actuator unit 12 relative to the brake housing 54 by a rotation lock 70. For this purpose, the brake piston 42 can have an axial groove which is in engagement with an anti-rotation element.

[0068] The rotation of the spindle 34 is thereby ensured by the electric motor 28, which is in engagement with the drive shaft prolongation 36 of the spindle 34 via the reduction gear 30. The rotation of the spindle 34 in conjunction with the rotational blocking of the brake piston 42 provides for a translatory movement of the brake piston 42. This movement is transmitted to the brake linings 20, 22. The clamping force Fz which is generated is proportional to the torque which is affected at the drive shaft prolongation 36 by the electric motor 28 and the reduction gear 30.

[0069] As a result of the clamping force Fz that is generated, a reaction force Fr opposing the clamping force Fz occurs along the axis of rotation 24. Owing to the elastic expansion of the components of the brake 10, an angular offset between the brake disc axis of rotation and the cylinder axis of the brake housing 54 can generally occur, so that the reaction force Fr has eccentric force components. These eccentric force components can lead to an instability of the components of the brake actuator unit 12 in the radial direction, for example when the core diameter DK of the thread of the brake piston 42 is smaller than the outside diameter DL of a bearing which is to absorb the reaction force Fr.

[0070] Therefore, the saving of an otherwise conventional spindle nut, because the brake piston 42 also performs the function thereof, means that the brake piston 42 can be enlarged in the radial direction. As a result, although the radial installation space of the brake 10 remains the same, it is possible to increase the core diameter DK.

[0071] For example, the core diameter DK can be increased radially such that it is larger than the outside diameter DL in the radial direction of an axial bearing 72 of the brake actuator unit 12, which absorbs the reaction force Fr. It is thus possible to displace the force application point of the eccentric force components of the reaction force radially outwards such that the effect of the eccentric force components is weakened, and compensation by the axial bearing 72 is ensured even without particular bearing geometries of the axial bearing 72. The orientation and mounting of the individual components of the brake actuator unit 12 and the application of force to the brake linings 20, 22 are thus improved.

[0072] In the present case, the axial bearing 72 is rotationally symmetrical and is in contact with the transition portion 40 of the spindle 34, which for this purpose has a complementary planar contact face 74. In this exemplary arrangement, the axial bearing 72 is in the form of an axial rolling bearing.

[0073] Between the axial bearing 72 and the base 58 of the brake housing 14 there is additionally arranged an axial bearing washer 76, which has opposing planar contact faces along the axis of rotation 24 and is pressed into the brake housing 14 in a rotationally secure manner by frictional and/or interlocking engagement. One of the contact faces of the axial bearing washer 76 is in contact with the base 58 of the brake housing 14. The bearing bodies of the axial bearing 72 roll on the other of the two contact faces of the axial bearing washer 76 and on the planar contact face 74 of the transition portion 40 of the spindle 34.

[0074] The reaction force Fr that occurs is thus transmitted from the shaft portion 38 of the spindle 34 via the transition portion 40 to the axial bearing 72, and from there is absorbed by the base 58 of the brake housing 14 via the axial bearing washer 76.

[0075] In order to protect the spindle drive 44, the brake housing 14 has a radially internal groove and the brake piston 42 has a radially external groove, in which a gasket 82 is arranged and which acts between the brake housing 14 and the brake piston 42.

[0076] In the present case, the brake piston 42 comprises on the brake lining side an end wall 84 having an end face which is of annular form and is provided for applying force to the inner friction lining 20. The annular form ensures optimized force distribution of the clamping force Fz over the receiving face 86 of the inner friction lining 20.

[0077] The spindle drive 44 comprises ball return channels 88 which are integrated in the spindle 34.

[0078] In a preliminary mounting step, both the transmission threads 46 of the spindle 34 and the ball return channels 88 integrated in the spindle 34 can be filled completely with balls 48. The brake piston 42 can then be pushed onto the spindle 34.

[0079] The ball return channels 88, integrated in the spindle 34, of the spindle drive 44 also ensure that the spindle drive 44, while having the same stroke, can be made axially shorter than in the case of known spindle drives without integrated ball return channels. The reason for this is the possibility that the axial bearing 72, on which the spindle drive 44 is supported at the open end of the brake piston 42, is able to project into the brake piston 42 slightly when the brake piston is in the retracted state, without the coverage of the balls 48 being released.

[0080] FIG. 2 shows a second exemplary arrangement of the brake actuator unit 12. Parts which are the same or have the same function thereby bear the reference signs already introduced.

[0081] Unlike in FIG. 1, a cup-shaped bushing 90, which accommodates and mounts the brake piston 42, is here provided between the brake housing 12 and the brake piston 42. The cup-shaped bushing 90 also carries the axial bearing 72 composed of a plurality of parts.

[0082] The cup-shaped bushing 90 is non-rotatably mounted in the brake housing 12 and has a corresponding groove 94, which receives an anti-rotation lock 70 on the brake piston 42 in order to prevent it from rotating.

[0083] The cup-shaped bushing 90 is supported axially on the brake housing 12 via a radial prolongation 96 or other fastening.

[0084] The spindle drive already shown in FIG. 2 is shown again on an enlarged scale in FIG. 3. As mentioned, the spindle drive comprises a spindle 34 and a brake piston 42, which at the same time forms the spindle nut. The balls 48 of the spindle drive in the form of a recirculating ball spindle drive run in a ball recirculation track, which is formed by the ball raceways 50 of the transmission thread 46.

[0085] The end wall 98 of the cup-shaped brake piston 42 has a central depression 99 and an annular pressing face 100 surrounding it for pressing against the inner brake lining 20.

[0086] At the transition portion 40 there is formed on the spindle 34 a spherical bearing contact face 102 on which a bearing ring 104 of the axial bearing 72 abuts with a complementary, concave counter-contact face 106.

[0087] The spindle 34 is hollow on the inside, in order to save mass.