DE102015002543B4 - Brake caliper for a disc brake - Google Patents

Abstract

Brake caliper for a disc brake, which has a caliper frame (2) designed to engage over the brake disc and a housing (12) for accommodating a clamping mechanism for clamping the brake disc, wherein the housing (12) has an outer segment (18), an inner segment (30) extending essentially parallel to the outer segment (18) and base and cover segments (38; 4) extending between the outer and inner segments, each of which is made of sheet metal, wherein at least two segments (18, 30, 38; 4, 18, 30) are formed by a uniform sheet metal element and/or provided fixed and loose bearings (64) are formed by sheet metal tubes (72) which are formed in one piece by bending at least one of the sheets, which forms at least one segment (74), characterized in that the inner and outer segments (18, 30) and the base segment (38, 74) are connected by a one-piece formed sheet metal element (36).

Description

The present invention relates to a brake caliper for a disc brake. It particularly relates to a brake caliper for a disc brake for a truck. The brake caliper has a caliper frame designed to engage over the brake disc and a housing for accommodating an application mechanism for applying the disc brake.

Such brake calipers usually have a caliper frame designed as a cast part, which forms a cover of the housing and, between the housing and a caliper back provided opposite thereto, usually forms tension struts which connect the caliper back to a fastening-side end of the brake caliper and abut a brake shoe which is supported on the caliper back, especially during braking.

From the EP 0 108 680 A1 A part of such a brake caliper is known, which is made of two pieces of sheet metal that lie against each other. The pieces of sheet metal form a holder for an application element of the application mechanism as well as cylindrical holders that are fixed and loose bearings for the mounting of a movable brake shoe. Other brake calipers made of sheet metal are made of EN 10 2013 109 861 B3 and DE 19 84 850 U known.

The saddle frames commonly used today are made from cast parts, which has various disadvantages. Cast components are very heavy. Casting with lost molds is uneconomical. The wall thickness is greater than 10mm due to the process.

The present invention is based on the problem of specifying a brake caliper which can be manufactured more cost-effectively and therefore more economically and which should have a lower dead weight.

To solve the problem, the present invention proposes a brake caliper with the features of claim 1. This brake caliper is in particular a brake caliper for a truck. The brake caliper has a housing which has an outer segment and an inner segment extending essentially parallel to the outer segment. These two segments are provided essentially parallel to the rotating brake disc and thus the braking surfaces of brake shoes held by the brake caliper. The housing is delimited on the top by a cover and on the bottom by a base segment. The housing should be essentially completely closed, particularly at the bottom, in order to prevent dirt and foreign bodies from entering the housing, as this can impair the application mechanism.

According to the invention, the four segments mentioned above are each made of sheet metal. Each individual segment is usually produced by forming and/or punching or cutting a rolled sheet metal plate. Preferably, each individual sheet is a uniform, one-piece sheet, i.e. not produced by joining different sheets. The starting material for each individual segment is always a flat, usually rolled piece of sheet metal. This can be punched and/or bent to produce the segments.

According to the invention, at least two segments are formed by a uniform sheet metal element. The two segments are then usually aligned relative to one another by bending. With a simple structure of the housing, it results that the base and cover segments extend essentially at right angles to the outer and inner segments.

Alternatively or additionally, fixed and floating bearings provided in the housing for supporting the brake shoe to be applied are formed by sheet metal tubes which are formed in one piece by bending at least one of the sheets. This at least one sheet forms at least one of the segments, preferably the base segment. The sheet metal tubes are not necessarily closed around their circumference. The sheet metal tubes are also not necessarily provided within the housing. Rather, the bearings are usually at the height of the housing and are essentially covered by the saddle frame, preferably the cover element, but outside the housing for the application mechanism.

As can be seen, the brake caliper according to the invention can then be made solely from semi-finished sheet metal products. If the bearings are not formed by forming one of the sheet metal elements, they are usually formed by deflected lengths that are formed from prefabricated tubular semi-finished products. All sheet metal materials are preferably made from a material that is easy to weld, so that the parts of the brake caliper that support and mount the moving parts of a disc brake can be firmly connected to one another by welding to form a unit. Since cast parts can be dispensed with in the manufacture of this frame, the brake caliper can be manufactured with low weight. The use of sheet metal also allows the targeted selection of a material that has been strengthened in a certain way by rolling and, if necessary, heat treatment, which best meets the mechanical requirements placed on a brake caliper. With regard to the necessary forming or bending processing, possibly also with regard to punching, the selected sheet material should have good strength on the one hand, but also good forming and/or bending processing on the other. A steel with a relatively low carbon content of between 0.01 and 0.12 wt.% is preferred, for example S135MC or S420MC.

According to a preferred development of the present invention, the caliper frame is formed by a uniform sheet metal element that also forms a caliper back. The caliper frame usually forms the part of the brake caliper that forms the cover segment, the two tension rods and the caliper back that connects the tension rods to one another at the ends. There is usually a free space between the cover segment and the caliper back to accommodate the brake disc.

Usually, this recess is penetrated or overlooked by the inner segment, which preferably forms a holder for at least one of the brake shoes.

According to the invention, the inner and outer segments as well as the base segment are formed by a one-piece, formed sheet metal element. The outer segment and the inner segment are usually formed by edges around axes extending parallel to one another, so that the two segments extend parallel to one another at right angles to the base segment. Between the two inner and outer segments, the base segment is usually bent upwards towards the cover segment at least at one end, regularly at both ends, in order to
to form walls that laterally delimit the housing. The outer and inner segments as well as the base segment are usually connected to one another by welding in order to initially prepare the prefabricated component claimed according to this further development as a solid unit and later to connect it to the other parts of the brake caliper.

According to a further preferred embodiment of the present invention - as already described above - the saddle back is formed in one piece on the saddle frame, preferably on the cover segment. The saddle back is stiffened with a stiffening element that leaves a hollow space between itself and the saddle back. The stiffening element usually forms the contact surface for one of the brake shoes, which is supported by the saddle back.

The saddle back or the stiffening element preferably carries a fastening element which serves to hold a brake pad retaining bracket which extends over the saddle frame and spans the brake disc. This fastening element is usually butt-welded.

According to a preferred development of the present invention, the segments are aligned with one another in such a way that individual weld seams, preferably all of the sheets or sheet segments, are designed as fillet welds. This means that weld seam preparation before welding the segments can be dispensed with, which can save further manufacturing costs.

According to a further preferred embodiment of the present invention, a one-piece forged bearing block element is provided, which is preferably located in the housing and which is welded to the housing via a weld seam that can be applied to the outer segment from the outside. Applying the weld seam from the outside allows fully automated production, since a welding robot can work unhindered from the outside. In addition, welding spatter is prevented from entering the housing. The outer segment usually has at least one welding opening through which the weld seam is applied. The weld seam is preferably applied against a wall that surrounds this recess.

According to a preferred development of the present invention, the bearing block element has a positive locking projection which is received in a recess of the outer segment in a positive locking manner for positioning the bearing block element in the housing. A positive locking mount is already achieved by the fact that the fit between the recess and the projection creates a pre-positioning of the bearing block element. The positive locking projection and the associated recess can, for example, be rotationally symmetrical, so that this positive locking does not yet create a rotation lock. However, this is preferable because in such a case the bearing block element is received exactly in the installation position after the positive locking projection has been introduced into the recess.

Further details and advantages of the present invention will become apparent from the description struction of embodiments in conjunction with the drawing.

• 1 eine perspektivische Seitenansicht eines ersten Ausführungsbeispiels eines Bremssattels;
• 2 eine perspektivische Seitenansicht der Einhausung des in 1 gezeigten Ausführungsbeispiels ausbildenden Bauelementes ohne Abdeckung;
• 3 eine perspektivische Seitenansicht gemäß 1 eines die Abdeckung ausbildenden Bauteils des ersten Ausführungsbeispiels;
• 4 eine perspektivische Draufsicht eine in dem Bauteil nach 3 verbauten Versteifungselementes;
• 5 eine perspektivische Längsschnittansicht des ersten Ausführungsbeispiels;
• 6 eine perspektivische rückseitige Ansicht eines Lagerbockelementes des ersten Ausführungsbeispiels;
• 7 eine perspektivische Draufsicht auf das in 6 gezeigte Lagerbockelement;
• 8 eine perspektivische Draufsicht eines zweiten Ausführungsbeispiels eines Bremssattels nach der vorliegenden Erfindung;
• 9 eine perspektivische Seitenansicht gemäß 1 eines die Abdeckung ausbildenden Bauteils des zweiten Ausführungsbeispiels;
• 10 eine perspektivische Draufsicht auf eine Innenfläche eines äußeren Segmentes des zweiten Ausführungsbeispiels;
• 11 eine Draufsicht auf das innere Segment des zweiten Ausführungsbeispiels;
• 12 eine perspektivische Draufsicht eines das Bodensegment bildenden Blechteils des zweiten Ausführungsbeispiels;
• 13 eine perspektivische Längsschnittansicht des die Abdeckung ausbildenden Bauteils des zweiten Ausführungsbeispiels;
• 14 eine Draufsicht auf das äußere Segment gemäß 10 des zweiten Ausführungsbeispiels;
• 15 eine perspektivische Längsschnittansicht des die Abdeckung ausbildenden Bauteils mit einem daran angeschweißten Versteifungselement; und
• 16 eine perspektivische Längsschnittansicht eines dritten Ausführungsbeispiels der vorliegenden Erfindung.

In this show:

• 1 a perspective side view of a first embodiment of a brake caliper;
• 2 a perspective side view of the housing of the 1 shown embodiment forming component without cover;
• 3 a perspective side view according to 1 a component forming the cover of the first embodiment;
• 4 a perspective top view of a in the component according to 3 installed stiffening element;
• 5 a perspective longitudinal sectional view of the first embodiment;
• 6 a perspective rear view of a bearing block element of the first embodiment;
• 7 a perspective view of the 6 shown bearing block element;
• 8th a perspective top view of a second embodiment of a brake caliper according to the present invention;
• 9 a perspective side view according to 1 a component forming the cover of the second embodiment;
• 10 a perspective top view of an inner surface of an outer segment of the second embodiment;
• 11 a plan view of the inner segment of the second embodiment;
• 12 a perspective top view of a sheet metal part forming the floor segment of the second embodiment;
• 13 a perspective longitudinal sectional view of the cover forming component of the second embodiment;
• 14 a plan view of the outer segment according to 10 of the second embodiment;
• 15 a perspective longitudinal sectional view of the component forming the cover with a stiffening element welded thereto; and
• 16 a perspective longitudinal sectional view of a third embodiment of the present invention.

The 1 shows a perspective view of an embodiment of a brake caliper, the essential components of which are described below. This general description applies to all embodiments.

A brake caliper identified by reference number 1 has a caliper frame 2 which is formed exclusively by cut or punched, deep-drawn sheet metal elements which are usually connected to one another by welding. This caliper frame 2 comprises a cover segment 4 which is designed as a one-piece sheet metal element and forms tension struts 6 and a caliper back 8 which connects the two tension struts 6 to one another. The tension struts 6 extend from a cover 10 formed by the cover segment 4 which delimits and covers a housing 12 which will be described in more detail below. This housing 12 is - as 1 - mirror-symmetrical relative to an axis of symmetry marked with reference symbol S. The cover 10 has an upper cover dome 14 which covers a central upper bore 16 which is recessed on an outer segment 18 and is designed to allow an actuating rod of a brake cylinder to pass through.

Smaller holes 20 recessed at the level of this hole 16 on the outer segment 18 serve to attach a brake cylinder and are located above, i.e. outside the cover 10 and next to the cover dome 14.

On the axis of symmetry S and under the bore 16, a recess 22 is cut out in the outer segment 18, which serves to accommodate a form-fitting projection 24, which is attached to a 6 and 7 shown bearing block element 26. Essentially symmetrical to the axis of symmetry S and at the level of the recess 22, further holes 28 are cut out on the outer segment 18, which serve to connect a wear potentiometer for measuring the lining wear or allow access to an adjuster for adjusting or turning back the braking distance wear.The 1 also shows an inner segment 30 which, like the outer segment 18, slightly protrudes above the cover 10 and encloses it at the sides. The inner segment 30 forms a first fastening element 32 in the form of a tab for receiving a brake pad retaining bracket (not shown) which protrudes above the saddle frame 2. At the level of the saddle back 8, an eyelet can be seen which is designed as a second fastening element 34 of this brake pad retaining bracket. 2 illustrates a first special feature of the first embodiment. The housing 12 is The first sheet metal element 36 is formed by a first sheet metal element 32, which is produced by cutting or punching and bending, and the part of the one-piece cover segment 4 which forms the cover 10. In addition to the two outer and inner segments 18, 30, which extend essentially parallel to one another, the first sheet metal element 36 comprises a base segment 38, which extends between the two segments 18, 30 and has bent-up side walls 40, the front contact surfaces 42 of which are designed to rest against the cover 10. The free ends of the side walls 40 are slightly inclined outwards, so that the inclination of the contact surfaces 42 corresponds to the inclination of the cover 10 in this area (cf. 1 ).

In 2 The reference numeral 44 denotes joints for fillet welds (not shown) that serve to weld the individual segments 18, 30, 38 so that they are not only provided in the desired relative alignment to one another by bending a sheet of metal, but are also firmly connected to one another. The overlap of the respective edges of the segments 18, 30, 38 is selected such that no weld seam preparation is necessary. Fillet welds alone are sufficient to form the first sheet metal element 36 in the rectangular shape shown.

In particular 3 As illustrated, the cover segment 4 is designed as a shell segment with a spherical outer surface. The saddle back 8 is essentially designed as a circular segment. The saddle back 8 is in any case formed by deep drawing the uniform sheet metal material forming the cover segment 4.

The 4 shows a stiffening element 46 that is welded to the cover element 4 in order to reinforce the saddle back 8. The reinforcing element 46 is formed as a sheet metal plate and is therefore flat. In the top view, a basically ring-segment-shaped design is shown. On the convex upper edge, a shoulder 50 is formed that is offset and protrudes by steps 48 and, when joined, projects beyond an opening 52 formed between the tension struts 6. The steps 48 are received in a form-fitting manner between the inner edges of the tension struts 8 and are thus fixed.

How 3 , the end of the saddle back 8 facing away from the opening 52 is bent towards the opening 52 and thus the inner segment 30. The stiffening element 46 rests against a free end face 54 of the cover segment 4 formed thereby in such a way that a fillet weld can also be welded there (see joint 44 in 5 ). The same applies to the opposite joint between the stiffening element 46 and an end face 56 which delimits the opening 52 on the upper side and which is also formed by the cover element 4.

In 5 Further reference numerals 44 indicate further locations at which different sheet metal segments or elements of the saddle frame 2 can be connected to one another by a fillet weld. It can be seen that the sheet metal parts can be connected both on one side and on both sides by a fillet weld. Preferably, however, the welds for connecting the sheet metal segments forming the housing 12 are only made from the outside, as are the welds for connecting the form-fitting element 24 to the outer segment 18.

5 It can also be seen that the inner segment has a single central opening 58 through which elements of the application mechanism (not shown) for applying the brake disc pass. These elements are located within the housing 12 and act on a brake pad provided within the opening 52 and adjacent to the inner segment 30, which is also not shown.

Furthermore, this design creates a cavity 59 between the stiffening element 46 and the saddle back 6. The corresponding design stiffens the saddle frame 2 to counteract the feed force that acts on the brake disc via the brake shoes.

The 5 , 6 and 7 also show the forged bearing block element 26. The bearing block element 26 has a contact surface for contact against the inner surface of the outer segment 18, which in 6 with reference number 60 and which is overhung by the form-locking element 24. On the opposite inner surface, the bearing block element 26 has two machined functional surface areas 62. The bearing block element 26 is also designed symmetrically to the axis of symmetry 32 and arranged therefor. The bearing block element 26 forms both bearing blocks of the embodiment shown, which accommodate the bearings of a lever or a shaft on which a lever of the feed mechanism (not shown) acts. The machined functional surface areas 62 each form a semi-cylindrical bearing seat. As the 1 and 5 As can be seen, the bearing block element 26 can be connected to the outer segment 18 by welding from the outside. The welding point can be reached through the recess 22. This weld connection can also be made in a fillet weld, which in 5 indicated by reference numeral 44.

The feed movement of the brake calliper, which is moved by the application mechanism, is guided by guide rods (not shown) which are guided in bearings 64. The bearings 64 are each formed by deflected pipe sections and are 1 The bearings 64 each form a fixed bearing and a floating bearing for the mounting of the brake calliper.

The 8 to 15 illustrate another example of the present invention. Identical components are identified by the same reference numerals.

In the second embodiment, the inner segment 30 has further holes 70. The respective bearings 64 are aligned with these holes and are welded there by fillet welds. The bearings 64 are formed by cylindrical sleeve segments 72 with a circular cross-section, which are formed by bending a base segment 74, which is in 12 and is formed from a single sheet metal. This base segment 64 forms - like the previously discussed base segment 38 - a base 76 and the side walls 40 of the base segment 74.

This in 9 The sheet metal part shown can be formed from two initially separately deep-drawn sheet metal elements which, after deep-drawing, are joined in the axis of symmetry S by welding using a butt weld.

This base segment 74 is arranged by fillet welds between the outer segment 18 and the inner segment 30 and is welded to it. The inner segment 30 has the additional holes 70 assigned to the two bearings 64, whereas the outer segment 18 has only one outer hole 78. There, one of the bearings 64 is welded firmly to the outer segment 18 to form the fixed bearing. On the opposite side in relation to the axis of symmetry S, a corresponding leg of the outer segment 18 is missing. There, the sleeve segment 72 is exposed to form the floating bearing. The 14 illustrates the bearing blocks 80 welded to the inside of the outer segment 18. For the design and orientation, reference is made to the previously discussed embodiment.

How 15 As can be seen, the stiffening element 82 provided in this embodiment is placed against the inner surface of the saddle back 8 and is provided with a surface segment 84 extending at right angles to the saddle back 8, which is placed on the inner surface against the saddle back 8 and welded to it. A contact surface for the brake pad provided there is formed on the one hand by a ring segment surface 86 of the stiffening element 82 and on the other hand by the free end face 56 of the cover element 4 delimiting the opening 52 (cf. 13 , 15 ).

The third embodiment illustrates 16 shows at this end of the opening 52 near the saddle back 8 a brake shoe 90, which in the previously described with reference to 15 is supported on the saddle frame 2 in the manner described.

In this third embodiment, the outer segment 18 and the inner segment 30 are formed by bending surface sections of the cover segment 4. Usually, a punching process is carried out before the bending process in order to form all the recesses on the cover element 4. Reference numeral 74 designates a bottom segment in 16 which has been welded to the cover element 4 to form a unit via fillet welds, preferably solely via external fillet welds 44.

List of reference symbols

1

Brake caliper

2

Saddle frame

4

Coverage segment

6

Tension strut

8th

Saddle back

10

cover

12

Enclosure

14

Cover dome

16

middle upper hole

18

outer segment

20

smaller hole

22

Recess

24

Form-locking element

26

Bearing block element

28

further drilling

30

inner segment

32

first fastening element

34

second fastening element

36

first sheet metal element

38

Ground segment

40

Side wall

42

Contact surface

44

Fillet weld joint for fillet weld (corner weld, T-joint, double T-joint, multiple joint)

46

Stiffening element

48

Paragraph

50

Form shoulder

52

opening

54

free frontal area

56

Frontal area

58

central opening

59

cavity

60

Contact surface

62

Functional areas

64

camp

70

further drilling

72

Sleeve segment

74

Ground segment

76

Floor

78

outer bore

80

Bearing block

82

Stiffening element

84

Area segment

86

Ring segment area

90

Brake shoe

S

Axis of symmetry

Claims (7)

Brake caliper for a disc brake, which has a caliper frame (2) designed to engage over the brake disc and a housing (12) for accommodating a clamping mechanism for clamping the brake disc, wherein the housing (12) has an outer segment (18), an inner segment (30) extending essentially parallel to the outer segment (18) and base and cover segments (38; 4) extending between the outer and inner segments, each of which is made of sheet metal, wherein at least two segments (18, 30, 38; 4, 18, 30) are formed by a uniform sheet metal element and/or provided fixed and loose bearings (64) are formed by sheet metal tubes (72) which are formed in one piece by bending at least one of the sheets, which forms at least one segment (74), characterized in that the inner and outer segments (18, 30) as well as the base segment (38, 74) are formed by a one-piece formed sheet metal element (36). Brake caliper after Claim 1 , characterized by a sheet metal element (4) which uniformly forms the saddle frame (2). Brake caliper according to one of the preceding claims, characterized in that a caliper back (8) supporting the brake disc is formed in one piece on the sheet metal element (4) forming the caliper frame (2) and is stiffened by a stiffening element (46) which leaves a hollow space (59) between itself and the caliper back (8). Brake caliper after Claim 3 , characterized in that a fastening element (34) of a brake pad retaining bracket projecting beyond the saddle frame (2) is welded onto the saddle back (8) or the stiffening element (46). Brake caliper according to one of the preceding claims, characterized in that the segments (4, 18, 30; 38) are aligned with one another in such a way that the weld seams welding the sheets or sheet metal segments (18, 30, 38) together are designed as fillet welds. Brake caliper according to one of the preceding claims, characterized by a one-piece forged bearing block element (26) which is welded to the housing (12) via a weld seam that can be applied from the outside to the outer segment (18). Brake caliper after Claim 6 , characterized in that the bearing block element (26) has a positive-locking projection (24) which is received in a recess (22) of the outer segment (18) in a positive-locking manner for positioning the bearing block element (26) in the housing (12).

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