阅读说明：本技术 液压控制单元 (Hydraulic control unit ) 是由 D·F·罗伊特 S·佩蒂迪尔迪 S·加因 M·德斯潘德 于 2019-10-18 设计创作，主要内容包括：液压控制单元。一种液压控制单元包括：HCU块,该HCU块限定了容纳旋转偏心件的偏心腔室,所述HCU块限定了电机孔,该电机孔具有柱形形状、沿着电机轴线延伸到底板并且容纳用于经由电机轴驱动所述旋转偏心件的电机；其中,所述电机包括电机壳体,该电机壳体具有侧壁,该侧壁具有沿所述电机轴线在基端与动力端之间延伸的大致筒形形状；电机套筒,该电机套筒固定到所述电机壳体并且包括在所述电机壳体的所述动力端附近径向向外延伸的环形环,用于接合所述电机孔的所述底板；其中,所述HCU块在所述电机孔内限定了桩状唇部,所述电机套筒的所述环形环固定在所述桩状唇部与所述电机孔的所述底板之间,以将所述电机牢固地保持在所述电机孔内。(A hydraulic control unit. A hydraulic control unit comprising: an HCU block defining an eccentric chamber housing a rotating eccentric, the HCU block defining a motor bore having a cylindrical shape, extending along a motor axis to a base plate, and housing a motor for driving the rotating eccentric via a motor shaft; wherein the motor includes a motor housing having a sidewall with a generally cylindrical shape extending along the motor axis between a base end and a power end; a motor sleeve secured to the motor housing and including an annular ring extending radially outward near the power end of the motor housing for engaging the floor of the motor bore; wherein the HCU block defines a stake lip within the motor bore, the annular ring of the motor sleeve being secured between the stake lip and the floor of the motor bore to securely retain the motor within the motor bore.)

1. A hydraulic control unit, comprising:

an HCU block defining an eccentric chamber housing a rotating eccentric, the HCU block defining a motor bore having a cylindrical shape, extending along a motor axis to a base plate, and housing a motor for driving the rotating eccentric via a motor shaft;

wherein the motor includes a motor housing having a sidewall with a generally cylindrical shape extending along the motor axis between a base end and a power end;

a motor sleeve secured to the motor housing and including an annular ring extending radially outward near the power end of the motor housing for engaging the floor of the motor bore;

wherein the HCU block defines a stake lip within the motor bore, the annular ring of the motor sleeve being secured between the stake lip and the floor of the motor bore to securely retain the motor within the motor bore.

2. The hydraulic control unit of claim 1, wherein the motor sleeve defines a notch configured to receive a corresponding structure in the motor bore to align the motor in a predetermined radial alignment.

3. The hydraulic control unit of claim 1, further comprising a cushion of damping material disposed between a bottom of the motor sleeve and the bottom plate of the motor bore.

4. The hydraulic control unit of claim 1, further comprising a cushion of damping material extending between one side of the motor sleeve and a cylindrical sidewall of the motor bore.

5. The hydraulic control unit of claim 1, wherein the side wall of the motor bore defines a recess extending parallel to the motor axis; and is

The hydraulic control unit further includes a rubber damper disposed within the recess.

Technical Field

The present invention relates to a hydraulic control unit for an electro-hydraulic (electro-hydraulic) control unit of a vehicle brake system.

Background

In the field of electro-hydraulic control units for vehicle braking systems, it is generally known to include a hydraulic control unit having a piston pump. A conventional piston pump comprises a piston rod extending through a piston guide, which piston rod is axially displaced by a rotating eccentric driven by a motor. Conventional piston pumps may include a recessed gland seal that remains in a fixed position around the piston rod as the piston rod moves through the gland seal. An example of such an assembly is disclosed in us patent 6,866,489.

Disclosure of Invention

The present disclosure provides a Hydraulic Control Unit (HCU) comprising: an HCU block defining an eccentric chamber housing a rotating eccentric, the HCU block defining a motor bore having a cylindrical shape, extending along a motor axis to a base plate, and housing a motor for driving the rotating eccentric via a motor shaft; wherein the motor includes a motor housing having a sidewall with a generally cylindrical shape extending along the motor axis between a base end and a power end; a motor sleeve secured to the motor housing and including an annular ring extending radially outward near the power end of the motor housing for engaging the floor of the motor bore; wherein the HCU block defines a stake lip within the motor bore, the annular ring of the motor sleeve being secured between the stake lip and the floor of the motor bore to securely retain the motor within the motor bore.

According to another aspect of the present disclosure, a hydraulic control unit includes: which includes an HCU block defining an eccentric chamber that houses a rotating eccentric. The hydraulic control unit further comprises a piston guide having a first tubular portion extending along the pump axis, the first tubular portion having a cylindrical first inner surface housing a piston rod for allowing free translation of the piston rod only in the axial direction. The first tubular portion also has a first outer surface of generally cylindrical shape about which the return spring is disposed. The piston guide includes a base surface extending annularly and radially outward from the first inner surface and facing away from the eccentric chamber. The second tubular portion of the piston guide extends axially from the base surface opposite the first tubular portion and includes a cylindrically shaped second inner surface spaced radially from the piston rod to define a first throat therebetween. A gland seal is disposed in the first throat of the piston guide about the piston rod to prevent leakage around the piston rod as the piston rod moves axially past the gland seal.

According to another aspect of the present disclosure, a hydraulic control unit includes an HCU block defining an eccentric chamber housing a rotating eccentric. A generally cylindrical piston rod extends along the pump axis between a first end and a second end and has a smooth outer surface extending substantially the entire length between the first end and the second end. An end cap is disposed around the first end of the piston rod adjacent the rotating eccentric and is fixed for axial movement with the piston rod. The end cap includes a flange portion extending annularly outwardly from the piston rod. The hydraulic control unit also includes a piston guide defining a first shoulder extending annularly and radially outward and facing the eccentric chamber. The piston guide further comprises a first tubular portion having a cylindrical first inner surface, the first tubular portion accommodating the piston rod and allowing the piston rod to freely translate only in an axial direction. A return spring extends between the first shoulder of the piston guide and the flange portion of the end cap for axially biasing the piston rod towards the rotating eccentric.

According to another aspect of the present disclosure, a hydraulic control unit includes an HCU block defining an eccentric chamber housing a rotating eccentric. The HCU block defines a pump bore extending laterally from a surface (face) of the HCU block along a pump axis intersecting the eccentric chamber. The hydraulic control unit further includes a piston pump including a piston rod and an outlet valve housing defining an outlet valve seat for receiving an outlet closure member separating the pumping chamber from the outlet fluid chamber. An outlet spring retainer defines an internal boss facing the eccentric chamber for engaging an outlet valve spring configured to bias the outlet closure member into the outlet valve seat. The outlet spring retainer further includes a plurality of tapered posts extending axially away from the eccentric chamber to engage an outlet cover for retaining the piston pump in the pump bore of the HCU block. The tapered post is configured to deform a predetermined amount during assembly.

The subject invention provides several advantages over the prior art. The subject invention provides a hydraulic control unit design that is versatile in different configurations and constructions with one or more piston pumps driven by a common motor. The subject invention provides a piston pump that can be optimized for relatively low fluid flow rates, such as for motorcycle applications. It also provides several advantages in manufacturability, including a piston rod with a smooth outer surface and an outer gland seal secured within the first throat of the piston rod. This design allows the pump assembly to be assembled and tested separately from the rest of the hydraulic control unit before being installed into the pump bore of the HCU block.

Drawings

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of an electro-hydraulic control unit of the present disclosure;

FIG. 2 is a partially transparent dual channel hydraulic control unit of the electro-hydraulic control unit of the present disclosure;

FIG. 3A is a rear view of a single channel hydraulic control unit of the electro-hydraulic control unit of the present disclosure;

FIG. 3B is a front view of the single channel hydraulic control unit of FIG. 3A;

FIG. 4 is a cross-sectional view of a single channel hydraulic control unit of the present disclosure;

FIG. 5A is an exploded cross-sectional view of a motor assembly for a hydraulic control unit according to one aspect of the present disclosure;

FIG. 5B is an assembled cross-sectional view of the motor assembly of FIG. 5A within a hydraulic control unit according to one aspect of the present disclosure;

FIG. 6 is a perspective view of a spacer of the motor assembly of FIG. 5A;

FIG. 7 is a transparent perspective view of an accumulator assembly and inlet check valve for a hydraulic control unit according to one aspect of the present disclosure;

FIG. 8 is a cross-sectional view of a piston pump for a hydraulic control unit according to an aspect of the present disclosure;

FIG. 9 is an isolated perspective view of a piston pump according to one aspect of the present disclosure;

FIG. 10 is a cross-sectional view of an enlarged portion within a hydraulic control unit according to an aspect of the present disclosure;

FIG. 11 is a cross-sectional view of an enlarged portion within a hydraulic control unit according to an aspect of the present disclosure;

FIG. 12 is a schematic diagram of a hydraulic brake system for a motorcycle including a hydraulic control unit that regulates a single brake circuit;

FIG. 13 is a schematic diagram of a hydraulic brake system for a motorcycle including a hydraulic control unit that regulates two separate brake circuits;

FIG. 14 is a profile view of a housing cover for a motor of an electro-hydraulic control unit according to one aspect of the present disclosure;

FIG. 15 is an enlarged portion of a profile view of a housing cover for a motor of an electro-hydraulic control unit according to one aspect of the present disclosure;

fig. 16 is a profile view of an electric machine according to one aspect of the present disclosure;

FIG. 17A is a cross-sectional view of a motor within an electro-hydraulic control unit according to one aspect of the present disclosure;

FIG. 17B is an enlarged portion of the cross-sectional view of FIG. 17A;

FIG. 18 is a cross-sectional view of a motor within an electro-hydraulic control unit according to one aspect of the present disclosure;

FIG. 19 is a top view of a motor within an electro-hydraulic control unit according to one aspect of the present disclosure;

FIG. 20 is a profile view of a motor within an electro-hydraulic control unit according to one aspect of the present disclosure; and

FIG. 21 is a profile view of a rubber damper for an electro-hydraulic control unit according to one aspect of the present disclosure.

Detailed Description

Referring to the drawings, wherein like reference numbers refer to corresponding parts throughout the several views, an electro-hydraulic control unit 10 for a vehicle braking system is generally shown in FIG. 1. The electro-hydraulic control unit 10 includes an electronic control unit 20, the electronic control unit 20 having an electrical interface 22 for providing power and communication to external systems and devices. The electro-hydraulic control unit 10 also includes a hydraulic control unit 30 to provide and control fluid pressure in the vehicle braking system.

As illustrated in fig. 2 and 3A to 3B, the hydraulic control unit 30 includes an HCU block 32 made of a solid metal material. The HCU block 32 is preferably formed as an extrusion of aluminum having a constant cross-sectional profile extending between two opposing side surfaces 34, with a mating surface 36 for abutting the electronic control unit 20 extending perpendicular to the side surfaces 34. The HCU block 32 is secured to the electronic control unit 20 by a plurality of first fasteners 37, the first fasteners 37 preferably being screws, but bolts, clips or other types of fasteners could be used. The HCU block 32 also extends between a top surface 38 and a bottom surface 39 parallel to the top surface 38, wherein each of the top surface 38 and the bottom surface 39 are perpendicular (transpose to) the side surface 34 and the planar mating surface 36.

As shown in fig. 3A, the HCU block 32 defines a motor bore 40 having a cylindrical shape and housing a motor 42. As shown in cross-section in fig. 4 and 5B, the motor bore 40 extends transversely along a motor axis 44 from the planar mating surface 36 to a floor 46 that is parallel to the planar mating surface 36 and spaced from the planar mating surface 36. The HCU block 32 also defines an eccentric chamber 50, the eccentric chamber 50 having a generally cylindrical shape extending axially about the motor axis 44 away from the flat mating surface 36 beyond the floor 46 of the motor bore 40. The eccentric chamber 50 houses a rotating eccentric 52, the rotating eccentric 52 having an eccentric core 54 driven by a motor shaft 58 of the motor 42. The rotating eccentric 52 also comprises an eccentric bearing 56 around the eccentric core 54.

As shown in cross-section in fig. 4 and 5B, the HCU block 32 defines a bushing chamber 60, the bushing chamber 60 having a generally cylindrical shape extending axially about the motor axis 44 beyond the eccentric chamber 50, the bushing chamber 60 holding a guide bushing 62 for supporting the motor shaft 58 on the motor axis 44. The HCU block 32 also defines an axial bore 64, the axial bore 64 extending axially along the motor axis 44 away from the flat mating surface 36 beyond the bushing cavity 60 for receiving a portion of the motor shaft 58 extending axially beyond the guide bushing 62. The radial width of the shaft bore 64 is less than the radial width of the bushing chamber 60, thereby preventing the guide bushing 62 from falling into the shaft bore 64.

The HCU block 32 also defines a pump bore 66 that houses a piston pump 68 of the hydraulic control unit 30. The pump bore 66 extends laterally from one of the sides 34 along a pump axis 70 that intersects the eccentric chamber 50. The pump bore 66 includes a plurality of bore sections 72, 74, 76, 78, each having a cylindrical shape with progressively larger radii moving axially outward from the eccentric chamber 50.

In the exemplary embodiment shown in fig. 1, 3A-3B, and 4, the hydraulic control unit 30 includes a single piston pump 68. In the exemplary embodiment shown in fig. 2, the hydraulic control unit 30 comprises two separate piston pumps 68, each piston pump 68 being driven by a common rotating eccentric 52. The piston pump 68 may be used to supply fluid to a separate circuit, as shown in the schematic of FIG. 13. Alternatively or additionally, multiple piston pumps 68 may supply fluid to a common fluid conduit to provide a higher flow rate than a single piston pump 68 can supply.

As best shown in fig. 8-9, the piston pump 68 includes a piston rod 80 made of metal, the piston rod 80 having a generally cylindrical shape extending along the pump axis 70 between a first end 82 and a second end 84, the piston rod 80 having a smooth outer surface extending substantially the entire length between the first end 82 and the second end 84. The ends 82, 84 define a terminal end surface of the piston rod 80 that extends perpendicular to the pump axis 70. In other words, the piston rod 80 has a smooth cylindrical side wall without any grooves, dimples or protrusions. The piston rod 80 may include a fillet or chamfer at each of the ends 82, 84, as shown in fig. 8. Thus, the piston rod 80 may be easily and/or inexpensively manufactured. Such a piston rod 80 can be produced, for example, from a section of a coil, similar to the needle rollers of a needle bearing. An end cap 86 made of drawn metal (e.g., steel plate) is press fit near the first end 82 of the piston rod 80 adjacent the rotating eccentric 52. The end cap 86 includes a flange portion 88, the flange portion 88 extending annularly outwardly from the piston rod 80 and being axially spaced from the first end 82 of the piston rod 80. The end cap 86 may be secured to the piston rod 80 by other means, such as by welding or by crimping. Thus, the end cap 86 is fixed for axial movement with the piston rod 80 through the pump bore 66.

As best shown in fig. 8, a piston guide 90 is disposed in the pump bore 66 about the piston rod 80 and defines a first shoulder 92, the first shoulder 92 extending annularly radially outward toward the HCU block 32 and facing the eccentric chamber 50. A return spring 94 is disposed about the piston guide 90 and extends between the first shoulder 92 and the flange portion 88 of the end cap 86 for biasing the piston rod 80 axially toward the rotating eccentric 52. Thus, the return spring 94 keeps the piston rod 80 in continuous contact with the rotating eccentric 52 when the piston rod 80 reciprocates along the pump axis 70.

The piston guide 90 comprises a first tubular portion 96, the first tubular portion 96 having a first inner surface 98, the first inner surface 98 having a cylindrical shape, the first tubular portion 96 housing the piston rod 80 and allowing the piston rod 80 to freely translate only in the axial direction. In other words, the first tubular portion 96 allows the piston rod 80 to reciprocate axially while restricting the piston rod 80 from moving or tilting in other directions. Thus, the first tubular portion 96 provides a "guiding" function for the piston rod 80. The first tubular portion 96 has a first outer surface 100, the first outer surface 100 having a generally cylindrical shape, the return spring 94 being disposed about the first outer surface 100 and the first outer surface 100 being spaced from the HCU block 32, the return spring 94 extending between the first outer surface 100 and the HCU block 32.

As also shown in fig. 8, the piston guide 90 includes a base surface 106, the base surface 106 extending annularly and radially outward from the first inner surface 98 and facing away from the eccentric chamber 50. A second tubular portion 108 extends axially from the base surface 106 opposite the first tubular portion 96 and defines a second inner surface 110, the second inner surface 110 having a cylindrical shape radially spaced from the piston rod 80 to define a first throat 112. The second tubular portion 108 also includes a second outer surface 114, the second outer surface 114 having a generally cylindrical shape that engages the HCU block 32 to retain the piston guide 90 in a fixed position within the pump bore 66. In other words, the second outer surface 114 of the piston guide 90 tightly engages the second bore section 74 of the HCU block 32, aligning the piston guide 90 with the pump axis 70.

A gland (gland) seal 120 is disposed in the first throat 112 of the piston guide 90. The gland seal 120 includes a first O-ring 122, the first O-ring 122 sealingly surrounding the piston rod 80 to prevent leakage around the piston rod 80 as the piston rod 80 moves axially past the first O-ring 122 to pump fluid. The gland seal 120 also includes an optional support gasket 124 disposed on either side of and adjacent to the first O-ring 122. Each optional backup washer 124 has a generally flat shape extending annularly about piston rod 80 and radially outward to second inner surface 110 of piston guide 90. The depth of the first throat 112 may be adjusted depending on the number of optional support washers 124 employed.

The piston pump 68 also includes an outlet valve housing 130 disposed in the pump bore 66. The outlet valve housing 130 has a generally tubular shape defining a pumping chamber 132 for receiving the piston rod 80 and having a volume that varies as the piston rod 80 moves axially within the pumping chamber 132. As shown in fig. 8, the outlet valve housing 130 defines an annular boss 134, the annular boss 134 extending radially outward and facing the eccentric chamber 50 to engage a second shoulder 136 of the HCU block 32 between two adjacent ones of the bore sections 72, 74, 76, 78. Thus, the annular boss 134 holds the outlet valve housing 130 at a fixed axial position within the pump bore 66. The outlet valve housing 130 also includes a tubular projection 138, the tubular projection 138 extending axially from the annular boss 134 toward the eccentric chamber 50 and into the first throat 112 of the piston guide 90. The tubular projection 138 retains the gland seal 120 in a fixed position in the first throat 112 and prevents the gland seal 120 from being displaced by action of the piston rod 80. This provides an improved seal and protects the gland seal 120 from premature wear that may be caused when free to move axially. In some embodiments, the outlet valve housing 130 may include two or more tubular projections 138.

The outlet valve housing 130 also defines an outlet valve seat 140 extending annularly about the pump axis 70 for receiving an outlet closure member 142 separating the pumping chamber 132 from an outlet fluid chamber 144. In an exemplary embodiment, outlet closure member 142 is a metal ball. However, the outlet closure member may be conical, frusto-conical or otherwise shaped and may be made of any suitable material. Outlet closure member 142 is biased into sealing engagement with outlet valve seat 140 by outlet valve spring 146 to provide a closing force and prevent fluid from passing out of outlet fluid chamber 144 into pumping chamber 132. The outlet valve spring 146 is illustrated as a coil spring, however other types of springs may be used including, for example, a flexible beam or rod, or a spring formed as a dome or wave. Outlet closure member 142 is movable away from outlet valve seat 140 by fluid pressure opposing the closing force from outlet valve spring 146 to allow fluid to pass out of pumping chamber 132 and into outlet fluid chamber 144. The outlet valve housing 130 also includes an annular wall 150, the annular wall 150 extending axially beyond the outlet valve seat 140 and away from the eccentric chamber 50 to define a second throat 152 that houses an outlet spring retainer 156.

The outlet spring retainer 156 is shown in detail in fig. 10, and the outlet spring retainer 156 has a generally tubular shape about a central bore 158 and includes a first section 160 adjacent the outlet valve housing 130 for receiving the outlet closure member 142. The outlet spring retainer 156 also includes a second section 162 axially spaced from the outlet valve housing 130 for retaining the outlet valve spring 146. The outlet spring retainer 156 also includes a third section 164, the third section 164 being axially spaced from the outlet valve housing 130 beyond the second section 162, and the sections 160, 162, 164 tapering away from the outlet valve housing 13. The outlet spring retainer 156 defines an interior boss 166 between the second and third sections 162, 164 and facing the eccentric chamber 50 for engaging the outlet valve spring 146 opposite the outlet closure member 142.

The outlet spring retainer 156 also includes a plurality of tapered posts 170 extending axially away from the eccentric chamber 50 to engage an outlet cover 172 for retaining the piston pump 68 in the pump bore 66 of the HCU block 32. The tapered post 170 is configured to deform a predetermined amount during assembly to hold the piston pump 68 in a fixed position in the pump bore 66 and prevent rattle (ratetle). In other words, the deformation of the tapered column 170 maintains a compressive force between several components of the piston pump 68, which maintains these components in a fixed position within the HCU block 32. As shown in fig. 10, the HCU block 32 defines a first stake lip 174 within the pump bore 66 for securing the outlet cover 172 therein. The material of the HCU block 32 is formed into the first stake lip 174 at one or more locations to secure the outlet cover 172 and other portions of the piston pump 68 within the pump bore 66.

An inlet check valve 230 is disposed in the inlet valve bore 231 of the HCU block 32 to allow fluid flow into the piston pump 68 while preventing fluid flow in the opposite direction. The inlet check valve 230 is shown in detail in fig. 7 and includes an inlet valve housing 232, the inlet valve housing 232 being generally cylindrical with a hollow bore extending axially therethrough. The inlet valve housing 232 defines an inlet valve seat 234 for sealingly receiving an inlet closure member 236, preferably a metal ball. However, the outlet closure member may be of another shape, for example conical or frusto-conical, and may be made of any suitable material. Inlet check valve 230 also includes an inlet valve spring 238, inlet valve spring 238 configured to bias inlet closure member 236 into sealing engagement with inlet valve seat 234. The inlet valve spring 238 is illustrated as a coil spring, however other types of springs may be used including, for example, a flexible beam or rod, or a spring formed as a dome or wave. The inlet closure member 236 is movable away from the inlet valve seat 234 by fluid pressure opposing the closing force from the inlet valve spring 238 to allow fluid communication into the pumping chamber 132 of the piston pump 68.

A pressure accumulator assembly 240 is associated with each piston pump 68 and serves as a reservoir of excess fluid as a source of stored energy to maintain fluid pressure. Each pressure accumulator assembly 240 is disposed within an associated pressure accumulator bore 241, the pressure accumulator bore 241 having a generally cylindrical shape, extending into the HCU block 32, through the bottom surface 39 and generally perpendicular to the bottom surface 39 and perpendicular to the pump axis 70. As shown in detail in fig. 7, each accumulator assembly 240 includes an accumulator piston 242 having a generally cylindrical shape, the accumulator piston 242 having an annular seal 244 (e.g., an O-ring), the annular seal 244 being disposed in a circumferential groove 246 of the accumulator piston for sealing with the accumulator bore 241 as the accumulator piston 242 moves axially therein. A coil spring 248 biases the piston 242 away from the accumulator cover 250, and the accumulator cover 250 is press-fit into the accumulator bore 241 adjacent the bottom surface 39 of the HCU block 32. The accumulator cover 250 may also be secured within the HCU block 32 by other means, such as staking, welding, by adhesive, and/or by threaded connection. As best shown in fig. 1, the inlet valve bore 231 is coaxial with the pressure accumulator bore 241, the inlet valve bore 231 having a smaller diameter than the pressure accumulator bore 241 and extending axially from the pressure accumulator bore 241 away from the bottom surface 39 of the HCU block 32.

As shown in detail in the cross-sectional views of fig. 4 and 5B, the motor 42 includes a motor housing 180, the motor housing 180 having a side wall 182 with a generally cylindrical shape extending along the motor axis 44 between a base end 184 and a power end 186. Each of the base and power ends 184, 186 extend parallel to each other and perpendicular to the motor axis 44. The base end 184 surrounds a base bushing 188 for rotatably supporting the motor shaft 58. The base bushing 188 may be a plain bearing made of one or more materials such as bronze or nylon. Alternatively, the base bushing 188 may be a bearing that includes a plurality of roller elements. Similarly, the power end 186 surrounds an output bushing 190 for rotatably supporting the motor shaft 58. The output bushing 190 may be a plain bearing made of one or more materials such as bronze or nylon. Alternatively, the output bushing 190 may be a bearing including a plurality of roller elements. The output bushing 190 may have a generally cylindrical shape that projects axially beyond the power end 186, away from the base end 184.

The hydraulic control unit 30 may also include two or more solenoid valves 220, 222, the solenoid valves 220, 222 including an apply valve 220 and a release valve 222, each of the apply valve 220 and the release valve 222 having a respective valve stem 224 protruding from the mating face 36 of the HCU block 32 for actuation by a respective magnetic coil in the electronic control unit 20.

The hydraulic control unit 30 also includes a pump sump 260, the pump sump 260 having a sump bore 262, the sump bore 262 having a stepped cylindrical shape extending into the HCU block 32 for retaining any fluid that seeps out of the gland seal 120 of the piston pump 68. As shown in fig. 1 and 2, the sump bore 262 extends generally perpendicular to the bottom surface 39 of the HCU block 32 to intersect the eccentric chamber 50. As shown in fig. 11, the pump sump 260 includes a sump cover 264 press-fit within a sump bore 262 adjacent the bottom surface 39 of the HCU block 32. The sump cover 264 may also be secured within the HCU block 32 by other means, such as riveting, welding, by adhesive, and/or by a threaded connection. The sump cover 264 and the outlet cover 172 that closes the pump aperture 66 may be identical to one another. In other words, a member having a common structure may be used for both the sump cover 264 and the outlet cover 172, which may be a stamped and drawn sheet metal.

In one embodiment of the hydraulic control unit, and as shown in FIG. 4, the mounting plate 192 is secured to the power end 186 of the motor housing 180 with fasteners 194. The fasteners 194 are preferably screws, but bolts, rivets, clips, or any other suitable fasteners may be used. The mounting plate 192 is generally flat for engaging the bottom plate 46 of the motor aperture 40. The HCU block 32 defines one or more second stake lips 196 within the motor bore 40 and the mounting plate 192 is secured between the one or more second stake lips 196 and the floor 46 of the motor bore 40 to securely retain the motor 42 within the motor bore 40. In other words, the HCU block 32 may be deformed into one or more second stake lips 196 to securely retain the mounting plate 192 and the motor 42 in the motor bore 40.

In another embodiment, and as shown in fig. 5A-5B, a spacer ring 200 having an annular shape is used to center the motor 42 within the motor bore 40 and center the motor shaft 58 along the motor axis 44. The spacer ring 200 includes a radially innermost inner surface 202 that closely surrounds and engages the output liner 190 of the electric machine 42 with the radially innermost inner surface 202. The spacer ring 200 also includes a discontinuous outer surface 206, the discontinuous outer surface 206 configured to engage an annular inner wall 208 of the HCU block 32, the annular inner wall 208 extending parallel to the motor axis 44 beyond the base plate 46 toward the eccentric chamber 50. The spacer ring 200 is preferably made of a rigid but resilient material, such as plastic. As shown in fig. 6, the spacer ring 200 may include a plurality of tabs 204, the plurality of tabs 204 being sized carefully to control the size of the press fit with the annular inner wall 208, wherein each tab 204 has a wedge shape that is equally spaced around the spacer ring 200 and extends radially outward to the outer surface 206.

As best shown in the embodiment of fig. 5B, the motor 42 may include a motor sleeve 210, the motor sleeve 210 having a generally cylindrical shape about the sidewall 182 of the motor housing 180. The motor sleeve 210 includes an annular ring 212, the annular ring 212 extending radially outward adjacent the power end 186 of the motor housing 180 for engaging the floor 46 of the motor bore 40. The motor sleeve 210 is preferably secured to the motor housing 180 by resistance welding or laser welding. The HCU block 32 defines one or more second stake lips 196 within the motor bore 40 and the annular ring 212 of the motor sleeve 210 is secured between the one or more second stake lips 196 and the floor 46 of the motor bore 40 to securely retain the motor 42 within the motor bore 40.

Fig. 12 is a schematic diagram illustrating one form of hydraulic control unit 30 in a motorcycle application, wherein hydraulic control unit 30 is configured to control fluid in a single brake circuit. Hydraulic control unit 30 may be used in a similar configuration in other types of vehicles having any number of wheels or other moving devices (e.g., pedals, tracks, or legs). The first brake circuit includes a first master brake cylinder 270 coupled to a first brake input 272, which first brake input 272 is, in an exemplary embodiment, a handlebar-mounted brake release (weaver). First master brake cylinder 270 provides fluid pressure to actuate first brake actuation portion 274 to provide a braking force to first wheel 276. The apply solenoid valve 220, the release solenoid valve 222, and the piston pump 68 are each used to regulate and/or facilitate the flow of brake fluid to the first brake actuation portion 274. The second independent brake circuit includes a second master brake cylinder 280 coupled to a second brake input 282, the second brake input 282 being a brake pedal in the exemplary embodiment. Second master brake cylinder 280 provides fluid pressure to actuate second brake actuation portion 284 to provide a braking force to second wheel 286.

Fig. 13 is a schematic diagram showing one form of hydraulic control unit 30 having a motorcycle application with two independent brake circuits, each having an associated piston pump 68. Hydraulic control unit 30 may be used in a similar configuration in other types of vehicles having any number of wheels or other moving devices (e.g., pedals, tracks, or legs). Similar to the embodiment of FIG. 12, the first brake circuit includes a first master brake cylinder 270 coupled to a first brake input 272, the first brake input 272 being a handlebar-mounted brake release. First master brake cylinder 270 provides fluid pressure to actuate first brake actuation portion 274 to provide a braking force to first wheel 276. The first brake circuit has associated solenoid valves 220, 222 and piston pump 68 to regulate and/or facilitate the flow of brake fluid to the first brake actuation portion 274. The second independent brake circuit includes a second master brake cylinder 280 coupled to a second brake input 282. Second master brake cylinder 280 provides fluid pressure to actuate second brake actuation portion 284 to provide a braking force to second wheel 286. In the embodiment of fig. 13, the second brake circuit has associated solenoid valves 220, 222 and piston pump 68 to regulate and/or facilitate the flow of brake fluid to the second brake actuation portion 284. In other words, the brake system in the embodiment of fig. 13 includes two brake circuits sharing a common hydraulic control unit 30, which hydraulic control unit 30 independently regulates and/or facilitates fluid flow to each of two different brake actuators. In this manner, each wheel may provide independent automatic brake modulation for traction control, anti-lock braking system (ABS), or for other purposes.

Since the motor 42 will generate some degree of vibration, and since changes in temperature will affect the overall length of the motor 42, it is critical that a flexible type of terminal be used to make the electrical connection between the motor 42 and the ECU 20. Fig. 14 and 16 show an embodiment in which the motor 42 comprises a housing cover 300, the housing cover 300 defining a base end 184 opposite the rotating eccentric 52. Metallic terminal tabs 302 extend through the housing cover 300 for conducting electrical current to drive the motor 42. The shape of the terminal tabs 302 may be as shown in the figures, but other configurations are possible, such as circular pins.

Fig. 15 shows a cylindrical recess 304 in the housing of the ECU20 for receiving the housing cover 300 of the motor 42. The intermediate conductor 306 of conductive material includes a first connector 308 for engaging a respective one of the terminal tabs 302. The first connector 308 may be formed as a fork that clamps two opposing sides of the terminal tab 302, as shown, but other arrangements are possible. A second connector 310 is formed on an end of the intermediate conductor 306 opposite the first connector 308. The second connector 310 extends through a corresponding slot 312 in the housing of the ECU20 and makes electrical contact with a circuit board or other structure within the ECU20 to provide power to the motor 42. The intermediate conductor 306 may be a press-fit compliant pin that is first pressed into a slot in the ECU housing from below and then press-fit into the circuit board for connection. Locating pins 314 on the bottom surface may be used to assist in assembly.

The intermediate conductor 306 is designed to press fit the terminal tabs 302 of the motor 42 upon insertion and remain flexible so that there is no relative movement between the two devices. If separate servicing of the ECU20 is not required, there is no need to further limit the movement of the center conductor 306. However, if separate servicing of the ECU20 is required, it may be necessary to limit the travel of the flexible intermediate conductor 306 by incorporating a travel stop feature (not shown) in the mounting dowel due to the force of the press-fit terminals.

Fig. 16 also illustrates an embodiment of the motor sleeve 210, the motor sleeve 210 including an error-proofing feature in the form of a notch 320. A laser beam or visual camera may then be employed in the assembly fixture to pre-align the motor 42 so that the positive and negative terminals 302 and 302 are aligned on the correct side to control the direction of rotation of the motor shaft 60. Further precision alignment of the motor terminals 302 may then be achieved by incorporating pins or other locating means in the motor assembly tool (not shown) that mate with corresponding holes or slots in the base end 184 before staking the motor 42 in place.

In the embodiment shown in fig. 17A, the motor sleeve 210 is formed as a deep drawn workpiece that may be press fit around the output bushing 190 of the motor 42. The motor sleeve 210 may be further secured to the motor 42, such as by welding or using one or more fasteners. The motor sleeve 210 extends up to the surface of the HCU block 32 where the motor sleeve 210 turns radially as an outward portion 322. The outer portion 322 may then be secured in place by a staking operation that deforms a portion of the HCU block 32 over the outer portion, thereby securing the motor 42 within the motor bore 40. This makes it easier to machine and rivet the outward portion 322. The second function of the sleeve 210 is to act as a flux ring that increases the flux carrying capacity of the side wall 182 of the motor housing to improve the performance and efficiency of the motor 42.

Additionally, and as best shown in the enlarged view of fig. 17B, the motor 42 may place and compress cushions (cushions) 324, 326 of damping material, such as rubber, to minimize noise and/or vibration transmission and provide quieter operation of the hydraulic control unit 30. The cushion pads 324, 326 may include a second O-ring 324 disposed between the bottom of the motor sleeve 210 and the floor 46 of the motor bore 40. Additionally or alternatively, the cushions 324, 326 may include a third O-ring 326 extending between a side of the motor sleeve 210 and the cylindrical sidewall of the motor bore 40.

In some embodiments, the sidewall of the motor bore 40 may define one or more recesses 332, the one or more recesses 332 extending parallel to the motor axis 44. The recess 332 may provide a channel for machining to form a second staked lip 196 that secures the motor sleeve 210 and motor 42 within the motor bore 40 of the HCU block 32. In some embodiments, and as shown in fig. 19-20, one or more of the recesses 332 can have a tubular shape. As shown in fig. 18-21, one or more rubber dampers 330, which may be formed of rubber, foam, or another resilient material, may be disposed within recesses 332 in the side walls of the motor bore 40. In some embodiments, the rubber dampers 330 may have a cross-sectional shape that matches the shape of a respective one of the recesses 332. For example, the rubber damper 330 may have a crescent-shaped cross-section as shown in fig. 21. In some embodiments, and as shown in fig. 19, the sidewalls of the motor bore 40 define four recesses 332, wherein one of the rubber dampers 330 is disposed within each of the recesses 332. The rubber damper 330 is intended to minimize noise and/or vibration transmission between the motor 42 and the HCU block 32 and provide quieter operation of the hydraulic control unit 30.

One or more of the rubber dampers 330 can have the design shown in fig. 21, including an upper portion having a generally constant cross-section 340 and a tapered lower portion 342 having a gradually decreasing cross-section, which can facilitate installation of the rubber dampers 330 into the HCU block 32. As also shown in fig. 21, the rubber damper 330 defines a convex surface 344, the convex surface 344 being configured to conform to the tubular recess 332 in the sidewall of the motor bore 40. The rubber damper 332 also defines a concave surface 346, the concave surface 346 being opposite the convex surface 344 and configured to receive the barrel motor sleeve 210, thereby allowing the rubber damper 330 to fit tightly between the tubular recesses 332 in the side walls of the motor bore 40, thereby damping vibrations of the motor 42.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. These preceding statements are to be understood to encompass any combination of the novel features of the invention which finds utility in the practice of the novel aspects of the invention. Variations and modifications to the disclosed embodiments may become apparent to those skilled in the art and do fall within the scope of the invention. Accordingly, the scope of legal protection given to this invention can only be determined by studying the following claims.

The present application claims the benefit of U.S. provisional patent application serial No. 62/750,177 entitled "hydralic Control Unit with piston pump" filed 24/10/2018, the entire disclosure of which is considered to be part of the disclosure of the present application and is incorporated herein by reference in its entirety.