SYSTEM FOR PROVIDING A BRAKE FORCE

Abstract

The present invention relates to a system, comprising a transmission unit being arranged for converting a rotational motion into a translational motion, the transmission unit including an input and an output, wherein the input is configured to receive torque from a motor and the output is configured to provide a brake force for pressing a brake pad against a friction surface; a housing defining a hydraulic pressure chamber, wherein the housing at least partially encompasses the transmission unit; and an axially movable piston arranged in the housing and coupled to the transmission unit such that a translational motion of the piston causes a translational motion of the transmission unit for providing the brake force in a hydraulic operation mode.

Claims

1. A system, comprising a transmission unit being arranged for converting a rotational motion into a translational motion, the transmission unit including an input and an output, wherein the input is configured to receive torque from a motor and the output is configured to provide a brake force for pressing a brake pad against a friction surface; a housing defining a hydraulic pressure chamber, wherein the housing at least partially encompasses the transmission unit; and an axially movable piston arranged in the housing and coupled to the transmission unit such that a translational motion of the piston causes a translational motion of the transmission unit for providing the brake force in a hydraulic fall-back mode.

2. The system according to claim 1, further comprising said motor, the motor including an output shaft coupled to the input of the transmission unit.

3. The system according to claim 2, wherein the input of the transmission unit and the output shaft are rotatably connected by a splined connection.

4. The system according to claim 2, wherein the input of the transmission unit is slidably arranged with respect to the output shaft of the motor.

5. The system according to claim 2, wherein the motor is configured to adjust a size of a gap between the brake pad and the friction surface by driving the output shaft.

6. The system according to claim 1, wherein at least a part of the transmission unit is axially disposed between the piston and the brake pad and/or wherein the piston encompasses at least a part of the input of the transmission unit.

7. The system according to claim 1, further comprising a brake calliper for receiving the brake pad, wherein the housing is an integral part of the brake calliper or wherein the housing is connected to the brake calliper.

8. The system according to claim 1, further including a roller bearing disposed between the transmission unit and the piston, wherein the bearing is configured to enable a rotating movement of the transmission's input relative to the piston.

9. The system according to claim 1, further comprising an elastic member biasing the piston and/or the transmission unit towards a hydraulic rest position.

10. A brake system, comprising the system according to claim 1.

11. The brake system according to claim 10, the system is configured to provide the brake force to two wheels, the other two wheels are provided with a braking force by any one of an electro-mechanical brake, a hydraulic brake and an electro-hydraulic brake for providing.

12. A system, comprising a motor including an output shaft; a transmission unit being arranged for converting a rotational motion into a translational motion, the transmission unit including an input coupled to the output shaft and an output, wherein the input is configured to receive torque from the motor and slidably arranged with respect to the output shaft and the output is configured to provide a brake force for pressing a brake pad against a friction surface; a housing defining a hydraulic pressure chamber, wherein the housing at least partially encompasses the transmission unit; and an axially movable piston arranged in the housing and moved by pressurized brake fluid filled in the hydraulic pressure chamber, wherein the piston encompassesd at least a part of the input of the transmission unit such that a translational motion of the piston causes a translational motion of the input and the output for providing the brake force in a hydraulic operation mode.

Description

DESCRIPTION OF DRAWINGS

[0027] FIG. 1 shows schematically a perspective view of a vehicle with a brake system.

[0028] FIG. 2 shows a cross-sectional view of a detail of the brake system according to an embodiment.

[0029] FIG. 3 shows a cross-sectional view of a part of the brake system according to FIG. 2.

[0030] FIG. 4 shows a cross-sectional view of a detail of the brake system according to an embodiment.

[0031] FIG. 5 shows a cross-sectional view of a part of the brake system according to FIG. 4.

[0032] FIG. 6 shows a cross-sectional view of a detail of the brake system according to an embodiment.

[0033] FIG. 7 shows a cross-sectional view of a part of the brake system according to FIG. 6.

[0034] FIG. 8 shows a schematic of a brake system according to an embodiment.

BEST MODE

[0035] In the following, recurring and similar features in this and in the subsequent representations are provided with the same reference numerals.

[0036] The vehicle shown in FIG. 1 has four wheels and a wheel brake 10 for each of the wheels. FIG. 1 shows a brake calliper 1 and a brake disc 2 of each of these wheel brakes 10, which are of the disc brake type. The brakes 10 may be activated not only electrically but also hydraulically. The brakes 10 are part of a brake system 100 which combines electric parking brakes (EPB) and electro-mechanic service brakes with hydraulic service brakes.

[0037] *55FIG. 2 shows a detail of the disc brake 10. Generally, the disc brake 10, includes brake calliper 1, brake disc 2 (sometimes called rotor), and two or more brake pads 3, such as an inboard brake pad and outboard brake pad mounted inside the brake calliper 1 on opposing sides of the brake disc 2. The two or more brake pads 3 are mounted such that they can move axially, parallel to the rotor axis, toward and away from the brake disc 2. During a braking action the brake pads 3 are pressed by a pushing member against the brake disc 2. The brake pads 3 wear due to the friction with the brake disc 2 or another suitable friction surface resulting in a decreased thickness of the brake pads 3.

[0038] FIG. 2 also shows a subsystem 20 that is designed for providing the necessary brake force for pressing the brake pad 3 against the friction surface. The system 20 comprises a transmission unit 30, a piston 60 and a housing 70. The system 20 may further comprise a motor 50. Said system 20 (or subsystem 20) is also shown in FIG. 3.

[0039] The transmission unit 30 is arranged for converting a rotational motion of the motor 50 into a translational motion. To this end, the transmission unit 30 includes an input 31 and an output 32, wherein the input 31 is configured to receive torque from the motor 50 and the output 32 is configured to provide a brake force for pressing the brake pad 3 against the brake disc 2. Usually, the brake pad 3 is moved by the output 32 in an axial direction that is parallel to a longitudinal axis of the output 32 and/or parallel to a rotational axis of the brake disc 2.

[0040] The input 31 of the transmission unit 30 may be coupled to an output shaft 51 of the motor 50. According to some exemplary embodiments, the input 31 of the transmission unit 32 is slidably arranged with respect to the output shaft 51 of the motor 50. In some embodiments, the input 31 of the transmission unit 32 and the output shaft 51 are rotatably connected by a splined connection 52. The motor 50 may comprise a motor gear unit (not depicted) that is connected to the output shaft 51. Preferably, the motor 50 is an electric motor, such as a DC motor or an AC motor. The motor 50 further comprises a casing 53. Said casing 53 can be a metal casing or plastic casing and may house the motor gear unit and other components of the motor 50. The motor 50 may also be referred to as EPB/EMB actuator (electric park brake actuator or electro-mechanic brake actuator).

[0041] Optionally, the transmission unit 30 is at least partially axially disposed between the piston 60 and the brake pad 3. Typically, at least the output 32 of the transmission unit 30 is axially disposed between the piston 60 and the brake pad 3.

[0042] In some embodiments, the output 32 comprises or is a pushing member for pressing the brake pad against the friction surface. The pushing member can be arranged such to directly abut the brake pad 3 or a brake pad holder 4 arranged between the brake pad 3 and the pushing member 32. Thus, the brake pad 3 and the brake pad holder 4 do not contact or abut the piston 60. Both the output 32 and the input 31 comprise threaded portions that engage each other. By rotating the input 31 the output 32 is moved axially, e.g. towards the braking pad 3 during a braking action or away from the braking pad 3 upon brake release.

[0043] The system 20 further comprises an axially movable piston 60 that is mechanically coupled to the transmission unit 20 such that a translational motion of the piston 60 causes a translational motion of the transmission unit 30. It should be mentioned that the casing 53 of the motor 50 and the output shaft 51 of the motor 50 do not axially move when the piston 60 is moved axially. The piston 60 may encompass (i.e. enclose) at least a part of transmission unit 30. For instance, the piston 60 encompasses at least a part of the input 31 of the transmission unit. The piston 60 can be a ring piston having a receiving section 63 formed therein for receiving the input 31 of the transmission unit 30.

[0044] The system 20 may further include a roller bearing 61 axially disposed between the transmission unit 30 and the piston 60. The roller bearing 61 enables rotation of the transmission unit 30 without rotating the piston 60. Preferably, the roller bearing 61 is a needle bearing. However, the invention is not limited by any particular type of roller bearing. Other bearings that enable a rotation of the transmission unit 30 with respect to the piston 60 are also conceivable. As indicated in FIGS. 2-7, one side of the roller bearing 61 is coupled to the transmission unit 30, more specifically the input 31 thereof, and the other side of the roller bearing is coupled to the piston 60.

[0045] The housing 70 defines a hydraulic pressure chamber 71 that can be filled with brake fluid to axially move the piston 60. The hydraulic pressure chamber 71 may be delimited by the housing 70 and the piston 60. The housing 70 is configured to at least partially encompass (i.e. enclose) the transmission unit 30 and the piston 60. More specifically, the input 31 of the transmission 30 and the piston 60 are arranged within the housing 70.

[0046] The hydraulic pressure chamber 71 is connected via dedicated fluid lines to a hydraulic circuit 80 for supplying a pressurized brake fluid (see also FIG. 8). By pressurizing the hydraulic pressure chamber 71 the piston 60 can be moved in an axial direction. In some instances, the piston 60 will move towards the brake calliper 1 when the hydraulic pressure chamber 71 is filled with pressurized brake fluid. Since the transmission unit 30 is coupled to the piston 60, the transmission unit 30 will move along with the piston 60. In this way, the brake pad 3 can be moved towards the brake disc 2 even in case of a power net failure of a malfunction of the electric motor 50. Thus, in a hydraulic operation mode (sometimes called “emergency mode” or “hydraulic fall-back mode”) the piston 60 provides the brake force via the transmission unit 30 for actuating the brake pad 3. In an electric or electro-mechanic operation mode, the motor 50 provides the brake force via the transmission unit 30 for actuating the brake pad 3. Said mode may be also referred to as “normal operating mode”.

[0047] At least one seal member 65 may be disposed between the piston 60 and the housing 70. In the embodiment of FIGS. 2 and 3, two seal members 65 are provided 65, wherein the hydraulic pressure chamber 71 is located axially between the seal members 65. The at least one seal member 65 makes sure that the hydraulic fluid cannot escape from the hydraulic pressure chamber 71. In some instances, the seal member 65 is an O-ring that is arranged in a corresponding groove of either the piston 60 or the housing 70. The at least one seal member 65 is arranged such that it allows axial movement of the piston 60 in the hydraulic operation mode.

[0048] An elastic member 72 is configured to bias the piston 60 and the transmission unit 30 towards a hydraulic rest position. The elastic member 72 may be a spring such as a coil spring. The elastic member 72 may ensure that the piston 60 and/or the transmission unit 30 are pushed away from the brake pad 2 and the brake calliper 1 when the hydraulic pressure chamber 71 is depressurized. In the electric operation mode, the piston 60 and the transmission unit 30 are typically in the hydraulic rest position. The elastic member 72 may define an opening that receives the transmission unit 30.

[0049] The housing 70 functions as a cylinder for the piston 60. The housing 70 can be connected to the motor 50. For example, the housing 70 is connected to the casing 53 of the motor 50. According to some embodiments, the housing 70 is in direct contact with (i.e. abuts) the casing 53 of the motor 50.ss In the embodiment shown in FIGS. 2-3 and 8, the housing 70 is connected to the brake calliper 1 by mechanical fasteners such as screws. It should be noted that the housing 70 of the system 20 does not need to be a separate part. Instead, the housing 70 can be an integral part of the brake calliper 1, see the embodiments shown in FIGS. 4-7. In the embodiments shown in FIGS. 4-7 an additional cover element 75, such as a plate, disc or ring, is envisaged for closing the housing 70 formed by the brake calliper 1. A sealing member 76 may be disposed between the housing 70 and the cover element 75. In this case, the hydraulic pressure chamber 71 is delimited by the housing 70, the cover element 75 and the piston 60.

[0050] The system 20 may comprise an anti-rotational feature (not shown) for preventing rotation of the output 32, e.g. for preventing of the output 32 rotation relative to the calliper 1. The anti-rotation feature can be coupled to a non-rotating part of the system, such as the brake calliper 1, the brake pad 3 and/or the housing 70. For example, the anti-rotational feature may comprise a radially extending protrusion protruding into an elongated slot. Importantly, the anti-rotational feature should enable the output 32 to move axially.

[0051] The input 31 may have a first portion 40, a centre portion 41 and a second portion 42, wherein the first portion 40 and the second portion 42 are located on opposite sides of the input 31. Often, the first portion 40 is connected to the second portion 42 by the centre portion 41. The first and second portions 40, 42 may form end portions of the input 31, respectively. The first portion 40, the centre portion 41 and/or the second portion 42 may each have a different outer diameter. In particular, the outer diameter of the centre portion 41 exceeds the outer diameter of the first and second portions 40, 42. However, as shown in FIG. 7, the first and second portions 40, 42 may have a similar outer diameter. The centre portion 41 extends radially from an input axis (i.e. longitudinal axis of the input 31) and towards the piston 60. The centre portion 41 may be fully or at least partially disposed in the receiving section 63 of the piston 60. The input 31, or more specifically the centre portion 41, may define a bearing surface 43 which may extend in a radial direction, i.e. perpendicular to the longitudinal axis of the input 31. The roller bearing 61 may be connected and/or coupled to said bearing surface 43. The output shaft 51 of the motor 50 may axially protrude into a recess formed in the input 31. More specifically, the recess can be formed in the first portion 40 of the input 31. Both the recess and the output shaft 51 may include splines that matingly engage each other and form a splined connection 52. The second portion 42 is disposed in a dedicated bore of the brake calliper 1.

[0052] As can be seen from FIGS. 2-7, the input 31 and the output 32 of the transmission 30 can be implemented in various ways. According to the embodiment shown in FIGS. 2-5, the input 31 is embodied as a spindle 31. Further, in the embodiments shown in FIGS. 2-5, the output 32 can be a nut or sleeve receiving the spindle 31. Depending on the rotational direction of the spindle 31 the nut 32 (or sleeve) is moved towards the brake pad 3 or away from the brake pad 3. In the embodiment shown in FIGS. 6, 7 the input 31 is a nut (or sleeve) while the output 32 is embodied as spindle. As mentioned above, the both the output 32 and the input 31 may comprise threaded portions 33 that engage each other. In this way, rotation of the input 31 causes translational movement of the output 32.

[0053] The system described above can be part of a brake system 100 (see FIG. 8). In some instances, the system 20 is or comprises an electric parking brake to be activated by the motor 50. Additionally or alternatively, the system 20 can be or comprise an electro-mechanical brake serving as a service brake. Additionally or alternatively, the system 20 can be or comprise a hydraulic service brake to be activated by pressurizing a brake fluid within the hydraulic pressure chamber 71.

[0054] In FIG. 8 a brake system 100 is shown. The brake system 100 may include a hydraulic circuit 80, a brake pedal 90, a master cylinder 91 and a reservoir 92 for storing brake fluid. The hydraulic circuit 80 may connect the reservoir 92 to the hydraulic pressure chambers 71 of each disc brake 10 via a plurality of hydraulic fluid lines and dedicated valves, e.g. solenoid valves. An electro-hydraulically controlled brake pressure supply may provide hydraulic brake pressure, e.g. to the disc brakes 10 of the front right (FR) wheel and the rear left wheel. Alternatively, an electro-mechanical brake which provides a braking force only by motor may be applied to the front right (FR) wheel and the rear left wheel. Otherwise, a hydraulic brake which provides a braking force only by hydraulic pressure generated by the operation of the brake pedal may be applied to the front right (FR) wheel and the rear left wheel.

[0055] The remaining disc brakes 10 of the front left (FL) wheel and the rear right wheel may be provided with the subsystem 20 for providing a brake force. Other wheel combinations are also contemplated by the present invention. In some systems, each wheel of the vehicle is provided with a disc brake 10 including sub-system 20.

[0056] The system 20 and the system 100 are particularly suited for compensating break pad wear.

[0057] In some instances, the motor 50 is configured to adjust a size of a gap 5 between the brake pad and the friction surface for compensating break pad wear. To this end, the piston 60 and the transmission unit 30 should be in their hydraulic rest position. Then, the input 31 is rotated such that the output 31 is moved towards the brake pad 3. A touch point will be sensed, e.g. by a dedicated sensor. Now, the size of the gap 5 can be set by rotating the input 32 a predefined angle. Notably, the size of the gap 5 is set without moving the piston 60. In other words, the brake pad wear can be compensated without having to vary the stroke of the piston 60 or the amount of braking fluid. The process may be performed after release of the electric park brake (EPB). The motor 50 can be configured such that the size of said gap 5 can be kept smaller than a predetermined value. Once the gap 5 is calibrated it remains more or less stable until pad wear adjustment is needed or an EPB actuation is performed. A controller may be envisaged that controls the motor, in particular based on the input from the sensor mentioned.

[0058] Thus, the gap 5 (sometimes called air gap) can be electronically adjusted after EPB actuation. In addition, the brake 10 can be activated electro-mechanically for normal service brake function and can be activated hydraulically in case of power net failure for hydraulic fall back function. This allows that in case of a power net failure in a rear axle EMB system still all four wheels can be activated or in case of a full EMB no redundant power net is needed, because a hydraulic fall back will be available for one or two axles.

[0059] Thus, according to some embodiments of the invention pad wear can be compensated by the system 20.

[0060] Since the transmission unit 30 transmits the brake force from the motor to the brake pad 3 or from the piston 60 to the brake pad 3, the piston 60 and the housing 70 (cylinder 70) can be manufactured in a particular short fashion as compared to pistons according to conventional solutions that directly provide a brake force to the brake pad (i.e. without any intermediate parts). In this way, also less brake fluid is needed.

[0061] Furthermore, as can be seen from FIGS. 2-8 all components 20, 30, 60, 50 can be assembled from the outside of the brake calliper 1. Moreover, the system 20 provides a hydraulic fallback operation mode.

[0062] It is clear for a skilled person that any features shown in the FIGS. 1-8 may be combined with each other or may be separately claimed as long as they do not contradict each other.