DE102020006379A1 - Disc brake and manufacturing method for a disc brake - Google Patents

Abstract

The present invention relates to, inter alia. a disc brake having a brake caliper, which engages around at least one brake disc, and a brake actuation mechanism with a reinforcement mechanism (A) for introducing an application force, an adjustment device (B) to compensate for lining wear with a torque clutch, a pressure element for transmitting the application force to the brake disc, and a resetting device which is mounted in the brake caliper in a functionally cooperating manner by means of a rod (1) mounted immovably in the axial direction in the housing of the brake caliper, the reinforcement mechanism (A) having a lever (2) which is located on at least one transverse to the rod ( 1) running eccentric bearing (11) is rotatably supported, and wherein the eccentric bearing (11) is firmly connected to the housing of the brake caliper and the rod (1) is connected to the eccentric bearing (11) via at least one means (14).

Description

The present invention relates to a disc brake, in particular for commercial vehicles, and to a method for producing such a disc brake.

In this case, the invention encompasses disc brakes which either have a sliding caliper or a fixed caliper and which overlap one or more brake discs. The invention relates primarily, but not exclusively, to partial lined disc brakes.

Disc brakes, especially for heavy goods vehicles, are known in a wide variety of embodiments, both in terms of the type of brake actuation mechanism, the manner in which the braking force is transmitted to one or more brake disks and the type of adjustment to compensate for wear on the brake pads.

A special embodiment of a brake actuation device that is used in disc brakes is, for example, from the international application WO 2011/113554 A2 known to the applicant. The brake actuation mechanism known from this application is characterized by an extremely compact design, which is associated with a smaller space requirement in the housing of the brake caliper and with a lower weight. All components of this brake actuation mechanism are mounted in the brake caliper in a functionally cooperating manner by means of a rod mounted in the housing of the brake caliper in the axial direction so that they act parallel to the axis of rotation of the brake disc. As a result of a displacement movement of the reinforcement mechanism, a pressure element, together with an adjustment device, executes a translational movement in the direction of the brake disc in order to transmit the application force.

For the exact functioning with regard to the delivery and transmission of the braking force and the adjustment movement in the brake actuation mechanism known from the prior art, the disclosure content of the WO 2011/113554 A2 referenced. Further, similarly designed brake actuation mechanisms are, for example, from WO 2013/083857 A2 , the WO 2014/106672 A2 or the WO 2015/140225 A2 known to the applicant, to which reference is hereby also expressly made.

Another brake actuation mechanism of the aforementioned type, in which the components are arranged around a rod and are held together to form a preassembled unit by means of the rod, is also shown, for example, in FIG WO 2018/015565 A1 of the applicant.

All of the aforementioned brake actuation mechanisms have the common advantage that they can be mounted as preassembled units in the housing of the brake caliper by means of the rod. In the prior art, as exemplified by the sectional view of 1 shows, for this purpose a lock nut was attached from outside the housing of the brake caliper to an external thread of the rod, whereby a wedge element is braced in a correspondingly configured opening in the rear section of the housing of the brake caliper, ie opposite the brake disc, and thereby the brake actuation mechanism in the housing of the Caliper was fixed.

Proceeding from this, the present invention is based on the object of further simplifying the assembly of such brake actuation mechanisms in which a rod is used for the arrangement and fastening of individual components thereof for assembly purposes and / or for the purpose of realizing a certain functionality.

This object is achieved with a disc brake according to claim 1 and with a method for producing a disc brake according to claim 11.

• - einem Verstärkungsmechanismus zum Einleiten einer Zuspannkraft,
• - einer Nachstelleinrichtung zum Ausgleich eines Belagverschleißes mit einer Momentkupplung,
• - einem Druckelement zum Übertragen der Zuspannkraft auf die Bremsscheibe, und
• - einer Rückstelleinrichtung,

wobei der Verstärkungsmechanismus, die Nachstelleinrichtung, das Druckelement und die Rückstelleinrichtung mittels eines in dem Gehäuse des Bremssattels in Axialrichtung unbeweglich gelagerten Stabs funktional zusammenwirkend in dem Bremssattel montiert sind,
wobei der Verstärkungsmechanismus einen Hebel aufweist, der sich auf zumindest einer quer zu dem Stab verlaufenden Exzenterlagerung drehbar abstützt,
und wobei die Exzenterlagerung mit dem Gehäuse des Bremssattels fest verbunden und der Stab mit der Exzenterlagerung über zumindest ein, vorzugsweise wieder lösbares Mittel verbindbar ist.In a first aspect, the invention accordingly relates to a disc brake having a brake caliper which engages around at least one brake disc, and a brake actuation mechanism

• - a reinforcement mechanism for introducing a clamping force,
• - an adjustment device to compensate for lining wear with a torque clutch,
• - A pressure element for transmitting the application force to the brake disc, and
• - a reset device,

wherein the reinforcement mechanism, the adjusting device, the pressure element and the resetting device are functionally cooperatively mounted in the brake caliper by means of a rod that is immovably mounted in the housing of the brake caliper in the axial direction,
wherein the reinforcement mechanism has a lever which is rotatably supported on at least one eccentric bearing running transversely to the rod,
and wherein the eccentric bearing is firmly connected to the housing of the brake caliper and the rod can be connected to the eccentric bearing via at least one, preferably releasable, means.

The eccentric bearing is usually implemented as at least one eccentric roller or a cylinder body, at least one partial cylinder body, on which the lever of the reinforcement mechanism is rotatably supported. The lever is designed and configured relative to the at least one eccentric roller in such a way that upon a pivoting movement around the eccentric roller, an eccentric displacement of the lever relative to it occurs, which ultimately leads to an amplification of the force introduced into the lever by an actuator before it is passed on via the other components of the brake actuation mechanism, in particular then via the pressure element as a clamping force on the brake disc. The eccentric displacement is achieved in that the axis of the cylinder body coincides with the center point of the inner concave pivot bearing surface of the lever, while the center point of the outer convex pivot bearing surface of the lever is correspondingly offset with respect to a force transmission element of the brake actuation mechanism in relation to the center point of the concave pivot bearing surface. For the exact design and functioning of such an eccentric mounting of the lever, reference should be made to the disclosure of the above-mentioned international patent applications or to the international patent application WO 2004/027281 A2 the applicant, the disclosure of which is hereby expressly referred to.

The rod is used to mount the individual brake components of the brake actuation mechanism in the housing of the brake caliper in such a way that they act parallel to the axis of rotation of the brake disc, the rod being designed so that the individual brake components in different modular units and / or the brake actuation mechanism in its entirety as each self-supporting, at least partially preassembled units on the rod on the one hand and thereby carried and held in the rear housing area of the brake caliper facing away from the brake disc on the other hand. For the functionality of the rod and the associated mountability of the brake actuation mechanism or its subcomponents as preassembled units, express reference should also be made to the disclosure content of the aforementioned international patent applications.

The essence of the invention lies in the fact that the eccentric bearing or the at least one eccentric roller is firmly connected to the housing of the brake caliper, preferably screwable to the housing, the screws being screwed into and through corresponding bores with possibly internal threads from outside the rear housing section are passable.

As a result, the eccentric roller is fixed in a positionally and rotationally fixed manner on the inside of the housing, wherein the housing for receiving and mounting the eccentric roller can have a correspondingly dimensioned, concave inner cylinder surface there.

At the same time, according to the invention, the entire brake actuation mechanism, as it is held together as a self-supporting unit by means of the rod, is attached to or on the rod via at least one means. In other words, by attaching the eccentric bearing or roller by means of fastening means, such as screws, to the rear, inside housing section of the brake caliper, the entire self-supporting unit of the brake actuation mechanism, i.e. including the eccentric bearing, is fixed in its functional position in the housing of the brake caliper.

For this purpose, the eccentric bearing or the cylinder body according to the invention can have a receptacle for the means running transversely to the rod. The means can preferably be designed as a bolt which engages in the receptacle in such a way that the brake actuation mechanism is held as a preassembled unit together with the eccentric bearing and can therefore be handled. For this purpose, the bolt reaches through a corresponding hole in the rod.

The dimensions and tolerances of the receptacle in the eccentric roller as well as the bore in the rod on the one hand and the bolt on the other hand are selected so that a press fit is formed between them that is sufficient to withstand the forces occurring in such brake actuation mechanisms without loosening, in particular not due to the vibration stress caused by driving the vehicle, and which can be released mechanically at any time for the purpose of dismantling the brake actuation mechanism.

If the entire unit is fastened to the rod by the bolt or any other suitable means, this unit can be screwed into or with the housing of the brake caliper via the eccentric roller by inserting corresponding screw bolts from the outside into the bores in the housing and in the eccentric roller become.

In one embodiment of the eccentric bearing according to the invention, these bores are arranged in such a way that the fastening means or screws are axially aligned with the cylinder axis of the eccentric roller, i.e. intersect it.

In a preferred embodiment of the disc brake, the means is designed as a nut which is in a receptacle of the eccentric bearing is received and screwed onto a rear threaded section of the rod, preferably in such a way that the brake actuation mechanism can be handled as a preassembled unit together with the eccentric bearing.

For this purpose, the receptacle of the eccentric bearing, viewed in the axial direction, can have at least partially shape-complementary abutment surfaces on which the nut with its corresponding surfaces comes to rest.

In particular, the eccentric mounting of the receptacle for the nut can have a further receptacle opposite, into which a correspondingly shaped shoulder of the rod can engage at least partially in a form complementary to the shape. This ensures that the eccentric roller is correctly positioned from a functional point of view on the rod.

The solution according to the invention considerably simplifies the assembly of such brake actuation mechanisms, since only a simple screw connection is necessary for fastening the entire brake actuation mechanism, which can optionally be formed by means of defined holding torques. Furthermore, the solution according to the invention increases the rigidity of the brake caliper, since no larger-sized through opening for the rod has to be provided in the rear housing section, as in the prior art. There is no need for further measures to seal off such an opening.

• - einem Verstärkungsmechanismus zum Einleiten einer Zuspannkraft,
• - einer Nachstelleinrichtung zum Ausgleich eines Belagverschleißes mit einer Momentkupplung,
• - einem Druckelement zum Übertragen der Zuspannkraft auf die Bremsscheibe, und
• - einer Rückstelleinrichtung,

wobei der Verstärkungsmechanismus, die Nachstelleinrichtung, das Druckelement und die Rückstelleinrichtung mittels eines in dem Gehäuse des Bremssattels in Axialrichtung unbeweglich lagerbaren Stabs funktional zusammenwirkend als eine vormontierte Einheit zusammengehalten werden,
und wobei der Verstärkungsmechanismus einen Hebel aufweist, der sich auf zumindest einer quer zu dem Stab verlaufenden Exzenterlagerung drehbar abstützt,
aufweisend die Schritte

• - Befestigen der Exzenterlagerung an dem Stab über zumindest ein Mittel unter Ausbildung des Bremsbetätigungsmechanismus als eine vormontierte Einheit, und
• - Befestigen der vormontierten Einheit in dem Gehäuse des Bremssattels durch Einfügen von zumindest einem, mit der Exzenterlagerung zusammenwirkenden Befestigungsmittel von außerhalb des Gehäuses des Bremssattels, dieses durgreifend.

In addition, in a further aspect, the invention relates to a method for producing a disc brake having a brake caliper which engages around at least one brake disc and a brake actuation mechanism

• - a reinforcement mechanism for introducing a clamping force,
• - an adjustment device to compensate for lining wear with a torque clutch,
• - A pressure element for transmitting the application force to the brake disc, and
• - a reset device,

wherein the reinforcement mechanism, the adjustment device, the pressure element and the return device are held together functionally cooperating as a preassembled unit by means of a rod that can be immovably mounted in the housing of the brake caliper in the axial direction,
and wherein the reinforcement mechanism has a lever which is rotatably supported on at least one eccentric bearing extending transversely to the rod,
having the steps

• - Fastening the eccentric bearing on the rod via at least one means with the formation of the brake actuation mechanism as a preassembled unit, and
• - Fastening the preassembled unit in the housing of the brake caliper by inserting at least one fastening means interacting with the eccentric bearing from outside the housing of the brake caliper, reaching through it.

The fastening means, for example screws, can be inserted from outside the housing of the brake caliper, bores being provided at corresponding points in the housing, which are preferably aligned exactly with the cylinder axis of the roller body of the eccentric bearing.

However, the bores can also be provided on both sides of the rod in the axial direction to this, inclined to it, transversely thereto and / or to the side of the cylinder body, whereby the availability of the installation space as well as the force conditions can be taken into account. Preferably, however, two bores or screw connections are provided which are aligned on both sides of the rod and parallel to its axial direction and are arranged on a common plane below the rod, which usually extends above the cylinder axis, but with an alignment to the cylinder axis To be able to effectively counteract leverage as a result of the rotation of the lever when the brake is applied.

• 1 eine Querschnittsdarstellung durch einen Bremsbetätigungsmechanismus aus dem Stand der Technik;
• 2 eine Explosionsdarstellung des Bremsbetätigungsmechanismus gemäß der Erfindung mit seinen einzelnen Komponenten in einer ersten Ausführungsform;
• 3 eine Rückansicht des Bremsbetätigungsmechanismus;
• 4 einen Querschnitt durch den Bremsbetätigungsmechanismus entlang J-J aus 3;
• 5 eine Explosionsdarstellung des Bremsbetätigungsmechanismus gemäß der Erfindung mit seinen einzelnen Komponenten in einer zweiten Ausführungsform;
• 6 eine Rückansicht dieses Bremsbetätigungsmechanismus;
• 7 einen Querschnitt durch diesen Bremsbetätigungsmechanismus entlang J-J aus 6;
• 8 eine Querschnittsansicht der Exzenterlagerung gemäß der Erfindung im Gehäuse eines Bremssattels;
• 9 ausschnittweise eine Querschnittsansicht durch die Exzenterlagerung entlang der Achse einer Befestigungsschraube; und
• 10 ausschnittsweise eine Rückansicht des Gehäuses des Bremssattels.

Further features and advantages of the present invention emerge from the description of the embodiments shown in the accompanying drawings. Show it

• 1 a cross-sectional view through a brake actuation mechanism from the prior art;
• 2 an exploded view of the brake actuation mechanism according to the invention with its individual components in a first embodiment;
• 3 a rear view of the brake operating mechanism;
• 4th a cross-section through the brake operating mechanism along JJ 3 ;
• 5 an exploded view of the brake actuation mechanism according to the invention with its individual components in a second embodiment;
• 6th a rear view of this brake operating mechanism;
• 7th a cross-section through this brake operating mechanism along JJ 6th ;
• 8th a cross-sectional view of the eccentric bearing according to the invention in the housing of a brake caliper;
• 9 a detail of a cross-sectional view through the eccentric bearing along the axis of a fastening screw; and
• 10 a detail of a rear view of the housing of the brake caliper.

In 1 a generic brake actuation mechanism is shown in sectional view, such as this from the Int. Patent application WO 2011/113554 A2 is known to the applicant.

All components of such a brake actuation mechanism, an adjustment device, a pressure element and a return device are on a common rod 1 arranged. Likewise, the staff carries 1 a boosting mechanism for boosting the braking force introduced by an actuator. The reinforcement mechanism is realized in that there is a lever 2 rotatable and eccentric on a cylinder body or on an eccentric roller 3 is supported, which causes the lever to turn 2 sets an eccentric displacement, which increases the force accordingly and by means of a force transmission element 4th initiates in the adjustment device.

The rod 1 and thus the brake operating mechanism in the assembled state are in a rear portion of a housing 5 a caliper attached by the fact that the rod 1 an opening that widens conically outwards 6th interspersed in this section so that an external thread of the rod 1 a lock nut 7th can accommodate a wedge ring element 8th with intermediate storage of a sealing ring 9 in the opening 6th braced, causing the rod 1 and thus the brake operating mechanism fixed in the rear portion of the housing 5 of the caliper is held.

In the 2 to 4th a first embodiment of a disc brake according to the invention is shown with its essential components, wherein 2 an exploded view and the 3 and 4th each reproduced an assembled state.

The brake operating mechanism has a booster mechanism A. , an adjusting device B and a restoring device C and a pressure element not shown in detail. for the exact functioning of such a brake actuation mechanism, the disclosure content of the Int. Patent application WO 2018/015565 A1 be referred to the applicant.

The reinforcement mechanism A. has a lever 2 on, which has appropriate bearing elements 10 with its convex swivel surface opposite the force transmission element 4th and with its concave swivel surface opposite an eccentrically offset cylinder body 11 is rotatably mounted, whereby the eccentric bearing is realized.

The cylinder body or the eccentric roller 11 has a horizontal through hole 12th for the staff 1 on. Perpendicular and offset to the cylinder axis Z and also perpendicular and transverse to the through hole 12th is in the eccentric roller 11 a vertical recess 13th provided that the inclusion of a pin bolt 14th serves.

In the assembled state, which is in the 4th is shown, penetrates the pin bolt 14th a vertical hole 15th in the staff 1 that are in the 2 can be seen, whereby the entire brake actuation mechanism together with the eccentric bearing 11 on the stick 1 braced as a preassembled unit and thus held together. Stud bolts 14th and drilling 15th can, for example, form a press fit that is dimensioned sufficiently large so that it cannot be released automatically when the disc brake is in operation.

This now makes it possible, according to the invention, that the brake actuation mechanism preassembled in this way can be fastened in a simple manner in the rear section of the housing of the brake caliper by the eccentric roller 11 is screwed from the outside through the housing wall. The eccentric roller has to accept appropriately configured screw bolts 11 on either side of the staff 1 and on a common level below this one receiving bore 16 as exemplified by the dashed line in the 4th is indicated.

The axis of the holes 16 or the screw bolt, not shown, is exactly on the cylinder axis Z of the eccentric roller according to the invention 11 aligned, ie both axes intersect in one plane.

In the 5 to 10 a second embodiment of a disc brake according to the invention is shown.

In this embodiment, the means is by means of which the eccentric bearing or the eccentric roller 11 with the stick 1 captive and firmly connected as a mother 20th formed, which in a correspondingly dimensioned receptacle or Recess 21 in the eccentric roller 11 is recorded.

Like in particular the 7th and 8th will show the mother 20th on a thread 22nd of the staff 1 screwed, which is provided at its rear end.

The mother 20th comes with its surfaces on abutment surfaces correspondingly designed complementary in shape 23 in the recess 21 for a two-dimensional system.

At the same time, the staff points 1 a circumferential shoulder 25th or the like on that in one of the recording 21 opposite recording or recess 24 in the eccentric roller 11 intervenes in a complementary manner. This causes the eccentric roller 11 between the shoulder 25th and the mother 20th positioned precisely on the rod.

As the 9 and 10 show, according to the invention, the eccentric roller 11 by means of fasteners in the form of screws 30th on either side of the staff 1 on a common to the cylinder axis Z the eccentric roller 11 aligned plane with the housing 5 of the brake caliper is firmly screwed, whereby at the same time the entire preassembled unit of the brake actuation mechanism in the brake caliper is precisely positioned in functional terms. The eccentric roller lies here 11 on a corresponding half-shell-like storage surface 29 in the rear, inner section of the housing 5 at.

As in particular in the 10 can be seen, the invention is associated with the advantage that the rear section of the housing 5 of the brake caliper only relatively small openings 28 for the screws 30th which increases the strength of the brake caliper at this point.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• WO 2011/113554 A2 [0004, 0005, 0028]
• WO 2013/083857 A2 [0005]
• WO 2014/106672 A2 [0005]
• WO 2015/140225 A2 [0005]
• WO 2018/015565 A1 [0006, 0032]
• WO 2004/027281 A2 [0011]

Claims (11)

Disc brake having a brake caliper, which engages around at least one brake disc, and a brake actuation mechanism with - a reinforcement mechanism (A) for introducing an application force, - an adjustment device (B) to compensate for lining wear with a torque clutch, - a pressure element for transmitting the application force to the brake disc and - a restoring device (C), wherein the reinforcement mechanism (A), the adjusting device (B), the pressure element and the restoring device (C) functionally cooperate by means of a rod (1) immovably mounted in the housing (5) of the brake caliper in the axial direction are mounted in the brake caliper, the reinforcement mechanism (A) having a lever (2) which is rotatably supported on at least one eccentric bearing (11) extending transversely to the rod (1), characterized in that the eccentric bearing (11) with the Housing (5) of the brake caliper firmly connected and that the rod (1) with the eccentric storage (11) can be connected via at least one means (14; 20). Disc brake after Claim 1 , in which the means (14; 20) engages in a receptacle (13, 21) of the eccentric bearing (11). Disc brake after Claim 2 , in which the means (14; 20) with the receptacle (13; 21) of the eccentric bearing (11) forms a form fit and / or force fit. Disc brake according to one of the Claims 1 to 3 , in which the eccentric bearing (11) is connected to the housing (5) of the brake caliper via at least one fastening means (30) which is inserted from outside the housing (5) of the brake caliper, extending through it. Disc brake after Claim 4 , in which the eccentric bearing (11) is designed as at least one partial cylinder body and an axis of the fastening means (30) intersects the cylinder axis (Z). Disc brake according to one of the Claims 1 to 5 , in which the eccentric bearing (11) has a receptacle (13) for the means (14) running transversely to the rod (1). Disc brake after Claim 6 , in which the means is designed as a bolt (14) which engages in the receptacle (13) in such a way that the brake actuation mechanism can be handled as a preassembled unit together with the eccentric bearing (11). Disc brake according to one of the Claims 1 to 5 , in which the means is designed as a nut (20) which is received in a receptacle (21) of the eccentric bearing (11) and screwed onto a rear thread (22) of the rod (1) such that the brake actuation mechanism as a preassembled unit can be handled together with the eccentric bearing (11). Disc brake after Claim 8 , in which the receptacle (21) of the eccentric bearing (11) in the axial direction has at least partially shape-complementary abutment surfaces (23) on which the nut (20) comes to rest. Disc brake after Claim 8 or 9 , in which the eccentric bearing (11) of the receptacle (21) has a further receptacle (24) opposite, into which a shoulder (25) of the rod (1) engages at least partially in a complementary manner. A method for producing a disc brake having a brake caliper that engages around at least one brake disc, and a brake actuation mechanism with - a reinforcement mechanism (A) for introducing an application force, - an adjustment device (B) for compensating for lining wear with a torque clutch, - a pressure element for transmitting the Clamping force on the brake disc, and - a restoring device (C), wherein the reinforcement mechanism (A), the adjusting device (B), the pressure element and the restoring device (C) by means of a rod that can be immovably mounted in the housing (5) of the brake caliper in the axial direction ( 1) are held together functionally cooperating as a preassembled unit, and wherein the reinforcement mechanism (A) has a lever (2) which is rotatably supported on at least one eccentric bearing (11) running transversely to the rod (1), characterized by the steps - Attach the eccentric bearing (11) to the rod ( 1) via at least one means (14; 20) forming the brake actuation mechanism as a preassembled unit, and - fastening the preassembled unit in the housing (5) of the brake caliper by inserting at least one fastening means (30) cooperating with the eccentric bearing (11) ) from outside the housing (5) of the brake caliper, reaching through.

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