阅读说明：本技术 调节制动组件间隙的方法和制动组件 (Method for adjusting the clearance of a brake assembly and brake assembly ) 是由 J·绍博 M·布莱辛 R·特里姆普 W·帕勒 M·克林格纳 A·布赫 A·塞伯斯 H· 于 2019-08-28 设计创作，主要内容包括：本发明涉及一种用于调节制动组件间隙的方法,该制动组件包括：制动盘；制动衬块；促动器,该促动器具有输出轴,沿正向方向驱动输出轴使制动衬块和制动盘进入限定制动位置的摩擦接合,沿反向方向驱动输出轴使制动衬块和制动盘脱离接合并将制动衬块移动到闲置位置；以及间隙调节器,用于调节制动衬块与制动盘之间的预定轴向间隙距离,其中制动衬块从闲置位置沿反向方向移动到预定参考位置,并且启动制动衬块与制动盘之间的轴向间隙距离的调节。(The invention relates to a method for adjusting the clearance of a brake assembly, comprising: a brake disc; a brake pad; an actuator having an output shaft, driving the output shaft in a forward direction to bring the brake pads and the brake rotor into frictional engagement defining a braking position, driving the output shaft in a reverse direction to disengage the brake pads and the brake rotor and move the brake pads to an idle position; and a clearance adjuster for adjusting a predetermined axial clearance distance between the brake pad and the brake disc, wherein the brake pad is moved in a reverse direction from an idle position to a predetermined reference position and the adjustment of the axial clearance distance between the brake pad and the brake disc is initiated.)

1. A method for adjusting the clearance of a brake assembly (100) comprising a brake disc (9), a brake pad (11), an actuator (1) having an output shaft (2) driven in a forward direction (F) into frictional engagement with the brake pad (11) and brake disc (9) defining a braking position, and in a reverse direction (R) to disengage the brake pad (11) and brake disc (9) and move the brake pad (11) to a rest position, and a clearance adjuster for adjusting a predetermined axial clearance distance between the brake pad (11) and brake disc (9), wherein:

-the brake pad (11) is moved from the rest position in the reverse direction (R) to a predetermined reference position; and

-initiating the adjustment of the predetermined axial clearance distance between the brake pad (11) and the brake disc (9).

2. Method according to claim 1, wherein an axial clearance value is measured, preferably the axial amplitude of the brake pad (11) between the braking position and the rest position, in particular the axial amplitude of the brake pad (11) between the braking position and the reference position, and/or the level of wear of the brake pad (11) and/or of the brake disc (9).

3. Method according to claim 2, wherein the step of adjusting is initiated if an undesired wear level and/or an undesired clearance value is detected, preferably the brake pad (11) is moved in the reverse direction (R).

4. Method according to claim 2 or 3, wherein the measured wear level and/or the measured clearance value of the brake pads (11) and/or the brake disc (9) are compared with respective predetermined threshold values and an adjustment step is initiated if a deviation between a measured value and the respective predetermined threshold value is detected, wherein in particular the adjustment step is initiated only if the deviation between the measured value and the respective predetermined threshold value exceeds a predetermined deviation tolerance.

5. Method according to any of claims 2 to 4, wherein the brake pad (11) is moved in the reverse direction (R) against an energy absorption and/or storage unit (33), the energy absorption and/or storage unit (33) being arranged to absorb forces acting on the output shaft (2) in the reverse direction (R) in predetermined operating situations.

6. A brake assembly (100) comprising:

a brake disc (9) in rotational engagement with a wheel of the vehicle;

a brake pad (11) that frictionally engages the brake disc (9) when an actuator force is applied to the brake pad (11);

an actuator (1) having an output shaft (2), driving the output shaft (2) in a forward direction (F) bringing the brake pads (11) and brake disc (9) into the frictional engagement defining a braking position, driving the output shaft (2) in a reverse direction (R) bringing the brake pads (11) and brake disc (9) out of frictional engagement, and moving the brake pads (11) to a rest position;

a slack adjuster that adjusts a predetermined axial clearance distance between the brake pad (11) and the brake disc (9) in the rest position of the brake pad (11), wherein the slack adjuster is configured such that, to initiate an adjustment step, the brake pad (11) is moved by the actuator (1) in the reverse direction (R) to a predetermined reference position.

7. Brake assembly (100) according to claim 6, wherein the actuator force required to move the brake pad (11) to the predetermined reference position is higher, preferably more than 5%, 10%, 20%, 30%, 40% or 50%, than the actuator force required to drive the output shaft (2) into the frictional engagement in the forward direction (F) and to drive the output shaft (2) out of the frictional engagement in the reverse direction (R), wherein the brake pad (11) is moved at least 10 mm and/or at most 100 mm in the reverse direction (R).

8. Brake assembly (100) according to claim 6 or 7, wherein the brake assembly (100) comprises a sensor unit for measuring an axial clearance value, preferably an axial amplitude of the brake pad (11) between the braking position and the rest position, in particular an axial amplitude of the brake pad (11) between the braking position and the reference position.

9. Brake assembly (100) according to claim 7, wherein the sensor unit is arranged and/or adapted with respect to the actuator (9) such that it measures the level of wear of the brake pads (11) and/or brake disc.

10. The brake assembly (100) according to claim 8 or 9, wherein the sensor unit comprises an optical sensor and/or an acoustic sensor.

11. Brake assembly (100) according to any one of claims 8 to 10, wherein the brake assembly, in particular the actuator, comprises a control unit connected to the sensor unit such that the actuator (9) initiates a regulating step in case the sensor unit detects an undesired wear level and/or an undesired clearance value.

12. Brake assembly (100) according to claim 11, wherein the control unit compares the measured wear level and/or the measured clearance value of the brake pads (11) and/or the brake disc (9) with respective predetermined threshold values and activates the adjusting step in case of a deviation between a measured value and the respective predetermined threshold value, wherein in particular the control unit activates the adjusting step only in case of a deviation between the measured value and the respective predetermined threshold value exceeding a predetermined deviation tolerance.

13. Braking assembly (100) according to any one of claims 6 to 12, wherein an energy absorption and/or storage unit (33) for absorbing a force acting on the output shaft (2) in a reverse direction under predetermined operating conditions is arranged such that the energy absorption and/or storage unit (33) applies a force directed in the forward direction to the output shaft when the brake pad (11) is moved in the reverse direction (R) to the predetermined reference position.

14. Brake assembly (100) according to claim 13, wherein the predetermined reference position is defined by a predetermined force value applied by the energy absorption and/or storage unit.

Technical Field

The invention relates to a method for adjusting the clearance of a brake assembly. Further, the present invention provides a brake assembly.

Background

Generally, an electrically actuated brake assembly includes a brake pad and a brake disc for frictionally engaging each other and establishing a braking force. The frictional contact between the brake pads and the brake disc is typically established by an actuator that applies an actuator force to the brake pads to move the brake pads in the direction of the brake disc. Due to the frictional contact between the brake pads and the brake disc, brake pad wear and brake disc wear occur, which results in a change of the distance between the brake pads and the brake disc in an idle position or rest position, in which no actuator force is applied and thus no braking force is built up. The increase in wear results, firstly, in that the maximum braking force may no longer be reached and, secondly, in that the desired braking force differs from the braking force actually applied.

A mechanical adjuster mechanism that compensates for pad wear is known from US 2008/0156593a 1. In the case of an engaged braking of the brake pad with the brake disc, or alternatively in an idle position, i.e. a rest position, in which no braking force is applied and after each braking operating condition the brake pad is moved to the idle position with respect to the brake disc, the mechanical adjustment is continuously triggered.

However, such mechanical adjustment mechanisms are not suitable for many brake assembly applications or environments, respectively.

For example, to avoid damage to the brake components, particularly when the wheel brake actuators are operating at high speeds and are malfunctioning or losing power, the energy absorption and/or storage unit may be arranged to absorb the actuator forces under predetermined operating conditions.

As a result of these energy-absorbing devices, the actuator rest position, or idle point, at which the wheel brake actuator does not apply an actuating or braking force, is not precisely defined, but depends on the brake dynamics. In particular, the output shaft of the actuator returns to a slightly different axial position after each brake actuation, so that the idle point, which is normally used for triggering the lash adjustment, varies axially and is therefore undefined.

The known mechanical play adjustment devices are therefore not suitable for wheel brake actuators with energy absorption units, nor for other applications where the idle point cannot be accurately defined. Furthermore, it has been found that in order to provide a reliable function of the brake assembly, it is not necessary to continuously perform the adjustment process at each brake actuation.

Disclosure of Invention

It is an object of the present invention to overcome the disadvantages of the prior art and in particular to provide a more efficient method of adjusting the clearance of a brake assembly, which is particularly suitable for applications where the idle point cannot be accurately defined and/or where an energy absorbing unit is required.

This object is solved by the subject matter of independent claims 1 and 6.

According to one aspect of the present invention, a method for adjusting brake assembly clearance is provided. The brake assembly includes a brake rotor, brake pads, and an actuator having an output shaft that is driven in a forward direction to frictionally engage the brake pads with the brake rotor. The location at which the brake pads and rotor frictionally engage is referred to as the braking position. The output shaft may be driven in a reverse direction to disengage the brake pads from the brake disc and move the brake pads to an idle position. The rest position refers to a position in which no actuator force or no braking force is applied, and may also refer to a rest position in which the brake pads return after a braking operation, in particular during a dynamic or service braking operation.

The brake assembly also includes a clearance adjuster for adjusting a predetermined axial clearance distance between the brake pad and the brake rotor. The predetermined axial clearance distance is set by the vehicle manufacturer or garage personnel repairing the vehicle such that optimum braking operating characteristics can be achieved, in particular maximum braking force can be applied and/or the delay between a user or driver actuating the brake pedal and the brake pads to transfer braking force to the brake disc is optimum. The lash adjusters serve to ensure reliable braking function of the brake assembly despite increased wear of the brake pads and/or brake disc. In other words, the lash adjuster compensates for wear of the brake pad and/or rotor, particularly by reducing and/or increasing the axial clearance distance between the brake pad and the rotor.

According to the invention, the brake pad is moved from the rest position in the opposite direction and the adjustment of the axial clearance distance between the brake element and the brake disc is initiated. The brake pad is moved in the reverse direction starting from the rest position, which movement may be referred to as a negative stroke, which is preferably performed by the actuator applying a reverse-directed actuating force to the output shaft, which movement, as a result of which, ensures that the clearance adjustment step is only performed when desired or needed. Furthermore, preferably, by actively moving the brake pad beyond the rest position in the reverse direction into the predetermined reference position, a constant reference point for determining the actual axial clearance distance is provided.

In an exemplary embodiment of the invention, the axial clearance value and/or the wear level of the brake pads and/or the brake disc is measured. Preferably, the axial clearance value may be defined as an axial movement amplitude of the brake pad between the braking position and the rest position, in particular between the braking position and the reference position. For the measurement, a suitable measuring device may be provided and coupled to the brake assembly, in particular the actuator, so that the clearance adjustment step may be initiated. In other words, after the clearance adjustment step is initiated, the clearance and/or wear values are measured.

According to a further development of the invention, the adjusting step is initiated if an undesired wear level and/or an undesired clearance value is detected. Preferably, if such an undesired wear level and/or an undesired clearance value is measured, the brake pad is moved from the rest position in the reverse direction to a predetermined reference position. Preferably, the amount of clearance adjustment is dependent on the measured wear level of the brake pads and/or brake disc.

In an exemplary embodiment of the invention, the measured wear level and/or the measured clearance value of the brake pad and/or the brake disc is compared with predetermined respective threshold values, wherein preferably a threshold value for the wear level of the brake pad and/or the brake disc and a threshold value for the axial clearance distance are provided. If a deviation between the measured value and the respective predetermined threshold value is detected, in particular if the measured wear level of the brake pad and/or the brake disc deviates from the predetermined wear level threshold value and/or if the measured clearance value deviates from the clearance value threshold value, an adjustment step may be initiated, preferably moving the brake pad in a reverse direction from the rest position. According to a further development of the invention, the adjusting step is only activated if the deviation between the measured values and the respective predetermined threshold value exceeds a predetermined deviation tolerance. For example, the tolerance for deviation may be less than 5%, ± 7%, ± 10%, ± 15%.

According to another exemplary embodiment of the invention, the brake pad is moved in the reverse direction against an energy absorption and/or storage unit arranged for absorbing and/or adapted to absorb forces acting on the output shaft in the reverse direction in predetermined operating situations. Preferably, the energy absorption and/or storage unit is adapted to store energy, preferably absorbed energy, for re-use. The energy absorption and/or storage unit may also be referred to as a protection unit, since damage to the brake assembly and brake assembly components is prevented.

The predetermined operating condition may occur in an uncontrolled condition of the brake assembly, for example in the event of an accidental cut-off of the energy supply or any internal failure of the brake actuator. During braking, the force transmitting member of the brake assembly is preloaded according to the braking force level. Under control, the actuator moves the force transfer member back to the initial unloaded position, preferably the rest position, and smoothly brakes the movement of the deceleration (brake down) force transfer member. If an error, such as a malfunction or loss of power, occurs during a brake slow down (brake down) motion without the use of a protection unit, the brake actuator member will be further accelerated by the pre-stressed brake assembly member, preferably the caliper unit, and stopped by a shock-like impact or bump at the end of motion position, resulting in damage to the brake assembly member, preferably the actuator.

In an exemplary embodiment of the invention, the energy absorption and/or storage unit is adapted to dissipate the absorbed force, preferably the absorbed energy is associated with a force acting on the output shaft in predetermined operating situations. For example, the absorbed force or the absorbed energy may be dissipated by friction, electrical resistance, or viscous damping. Due to the arrangement and function of the energy absorbing unit, in particular due to the dissipation of forces acting on the output shaft in the reverse direction under predetermined operating conditions, excess forces or excess energy is removed from the brake assembly system to prevent damage.

In an exemplary embodiment of the invention, the energy absorption and/or storage unit is adapted to accumulate the absorbed force. Preferably, the energy absorbing and/or storing unit comprises a spring member, an accumulator or a battery. The accumulated force, in particular the accumulated absorbed energy, may be fed to an energy recovery system of the vehicle, preferably of the brake assembly. In this case, the absorbed accumulated energy may then be used as an energy input to the actuator in a subsequent braking operation.

In another example embodiment of the invention, the energy absorbing and/or storing unit is adapted to counteract forces acting on the output shaft in a reverse direction under predetermined operating conditions. In a further development, the reaction force acts such that the kinetic energy of the output shaft, which is caused by the force acting on the output shaft in the opposite direction, is converted into kinetic energy, thermal energy and/or electrical energy of the absorption unit. Thus, depending on the available energy storage space or the energy required for a subsequent braking operation, at least part of the absorbed output shaft force may be accumulated and dissipated.

In an exemplary embodiment of the invention, the energy absorbing and/or storing unit is realized in that the actuator comprises an electric motor for driving the output shaft in the reverse direction and in the forward direction. The electric machine may be operated in a generator mode adapted to absorb output shaft forces under predetermined operating conditions. A generator mode is understood to be an operating mode in which mechanical energy, preferably kinetic energy of another driving output shaft, such as an output shaft or an actuator, is converted into electrical power or electrical energy. Thus, the excess energy present in the predetermined operating situation may be used to feed the generator mode and may be used to supply the energy absorbed by the energy absorbing unit to other electrical components of the vehicle.

In another example embodiment of the invention, the brake assembly includes a brake end position in which the brake pads are frictionally engaged with the brake rotor. Furthermore, an idle end position of the brake assembly is given, in which the brake pads and the brake disc are disengaged. The stop element may be arranged such that it limits the axial movement of the output shaft beyond the rest position in the reverse direction. This means that the stop element is offset in the reverse direction with respect to the rest position. Furthermore, the energy absorbing and/or storing unit may be arranged to prevent impact of the output shaft against the stop element, thereby preventing damage to the brake assembly.

In a further development of the invention, the energy absorption and/or storage unit comprises a spring member or a viscous damper associated with the stop element, so that when the output shaft moves in the reverse direction from the rest position, preferably an oppositely directed spring force and/or damping force is applied to the output shaft. The generated spring force and/or damping force counteracts a threshold force acting on the output shaft in the reverse direction at a predetermined operating condition. Thus, the axial movement of the output shaft in the reverse direction is slowed, preferably stopped.

According to an exemplary embodiment of the invention, the energy absorption and/or storage unit is an electrical energy absorption and/or storage unit. Preferably, the energy absorbing and/or storing unit is electrically activated or deactivated and/or coupled to the actuator such that under predetermined operating conditions the energy absorbing and/or storing unit is automatically activated in order to absorb the output shaft force. According to a further development of the invention, in predetermined operating situations, the actuator engages a corresponding protection circuit, i.e. in the form of an electronic resistor for dissipating at least part of the absorbed energy and/or in the form of an electronic accumulator for storing at least part of the absorbed energy, even if the actuator is not supplied with energy.

In another example embodiment of the invention, the energy absorption and/or storage unit comprises an eddy current brake, also referred to as an induction brake, an electric brake or an electric retarder, which slows or stops the axial movement of the output shaft, e.g. by dissipating the kinetic energy of the output shaft as heat. When the output shaft moves in the reverse direction, preferably beyond the rest position, under predetermined operating conditions, a current is induced, preferably through the coil of the energy absorption unit, preferably through the eddy current brake, wherein in particular the induced current can be accumulated or dissipated by the energy absorption unit. According to the functional principle of eddy current brakes, a current is induced as a result of an external magnetic field acting on the moving part of the actuator or, for example, on the output shaft, and the induced current induces a magnetic field which is oriented oppositely with respect to the external magnetic field. Due to the fact that the magnetic field is oppositely directed with respect to the original magnetic field, the movement of the output shaft is slowed down, preferably stopped, thereby preventing damage to the brake components caused by the high inertia and high dynamics of the brake actuator. The resistor may be implemented internally by the actuator itself or externally by a separate electronic resistor component.

In an example embodiment of the invention, the actuator is coupled to the energy absorbing and/or storing unit and is configured such that the force absorbed by the energy absorbing and/or storing unit is dissipated by the actuator, wherein in particular the actuator comprises a resistor. For example, according to this embodiment, a braking resistor is provided which, in the normal operating mode, can be connected by default to a normally closed circuit and actively opened via a switch, preferably if no predetermined operating situation occurs. Alternatively and/or additionally, a capacitor may be connected to the circuit in order to store the absorbed energy, preferably for reuse.

According to another exemplary embodiment of the invention, the actuator may be a pneumatic, electromechanical or hydraulic actuator. It is clear that the inventive concept according to the invention is therefore not limited to the particular type of actuator used in the corresponding brake assembly.

According to another aspect of the invention, the brake assembly includes a brake disc in rotational engagement with a wheel of the vehicle. Thus, during driving of the car, the brake disc performs a rotational movement according to the rotation of the wheel. Further, the brake pads are frictionally engaged with the rotor when an actuator force is applied to the rotor, preferably in order to perform a dynamic or service braking operation. The brake assembly also includes an actuator having an output shaft driven in a forward direction to frictionally engage the brake pads and the brake rotor, the frictional engagement defining a braking position of the brake assembly. The actuator may for example comprise an electric motor coupled to the output shaft and a transmission member, such that a rotational movement of the electric motor, preferably of a rotor of the electric motor, is converted by the transmission member into an axial translational movement of the output shaft. The output shaft may also be driven in a reverse direction, opposite the forward direction, to disengage the brake pads from the brake disc and move the brake pads to the rest position. The rest position may be defined as a position where no actuator force or braking force is applied and/or a position to which the brake pads are moved after a braking operation (preferably a dynamic braking operation). The direction of movement of the brake pads need not be coaxially arranged relative to the direction of movement of the output shaft, however, forward movement of the output shaft results in the brake pads preferably moving forward into frictional engagement with the brake discs, and reverse movement of the output shaft results in reverse direction movement of the brake discs, preferably out of frictional contact with the brake discs.

According to the invention, the brake assembly comprises a clearance adjuster which adjusts or is adapted to adjust a predetermined axial clearance distance between the brake pad and the brake disc in a rest position of the brake pad. The slack adjuster may be configured such that to initiate the adjusting step, the brake pad is moved by the actuator in a reverse direction to a predetermined reference position. Thus, the reference position is axially offset in the reverse direction with respect to the rest position.

In one example of embodiment of the invention, the actuator force required to move the brake pads to the reference position (preferably starting from the rest position) is higher, preferably more than 5%, 10%, 20%, 30%, 40% or 50% higher, than the actuator force required to drive the output shaft into frictional engagement with the brake pads and brake disc in a forward direction and than the actuator force required to drive the output shaft out of frictional engagement between the brake pads and brake disc in a reverse direction. During normal operation of the brake assembly, in particular during dynamic or service braking operation, the brake assembly must perform high dynamics such that the output shaft is driven at high speed in the forward and reverse directions, and the brake pads can be moved in the reverse direction beyond the rest position for a short time and a short distance, in particular due to the inertia of the moving parts of the brake assembly when actuated. However, during these braking operations, the brake pads do not reach the reference position and therefore no adjustment step is initiated. In particular, the brake pad is moved in the reverse direction from the rest position by at least 10 mm and/or at most 100 mm.

According to a further development of the invention, the brake assembly comprises a sensor unit for measuring an axial clearance value, preferably an axial amplitude of the brake pad between the braking position and the rest position, in particular an axial amplitude of the brake pad between the braking position and a reference position. The axial clearance value may also be defined as the distance between the brake pad rest position and the brake disc.

In another exemplary embodiment, the sensor unit is arranged and/or adapted with respect to the actuator such that the sensor unit measures a wear level of the brake pad and/or the brake disc. Obviously, the sensor unit may be electrically connected to an electronic system (not shown) of the vehicle (not shown).

According to a further development of the invention, the sensor unit comprises an optical sensor and/or an acoustic sensor, preferably for independently measuring the wear level and/or the axial clearance value. Alternatively, the optical and acoustic sensors may be implemented as redundant sensor systems.

In another exemplary embodiment of the invention, the brake assembly, in particular the actuator, comprises a control unit connected to the sensor unit such that in case the sensor detects an undesired wear level and/or an undesired clearance value, the actuator initiates the adjusting step, preferably moving the brake pad to the predetermined reference position. The control unit may be physically and/or electronically connected to the sensor unit. The control unit and the sensor unit may also communicate via a wireless communication system. Alternatively, the control unit and the sensor unit may be directly connected, for example via a cable or via conductive tracks of a common Printed Circuit Board (PCB), which may be coupled to the electronic system of the vehicle.

According to a further development of the invention, the control unit compares the measured wear level and/or the measured clearance value of the brake pads and/or the brake disc with respective predetermined threshold values. The control unit may further initiate the adjusting step in case of a deviation between the measured values and the respective predetermined threshold values. Preferably, the control unit initiates the adjusting step only if the deviation between the measured values and the respective predetermined threshold values exceeds a predetermined deviation tolerance (e.g. at most 3%, 5%, 7% or at most 10%).

In another example embodiment of the invention, the brake assembly may comprise an energy absorbing and/or storing unit adapted to absorb forces acting on the output shaft in the reverse direction under predetermined operating conditions. The predetermined operating condition may occur in an uncontrolled condition of the brake assembly, for example in the event of an accidental cut-off of the energy supply or any internal failure of the brake actuator. During braking, the force transmitting member of the brake assembly is preloaded according to the braking force level. Under control, the actuator moves the force transmission member back to the initial unloaded position, preferably the rest position, and smoothly brakes the movement of the deceleration force transmission member. If an error, such as a malfunction or loss of power, occurs during the brake deceleration motion without the use of the protection unit, the brake actuator member will be further accelerated by the pre-stressed brake assembly member (preferably the caliper member) and stopped by a shock-like impact or bump at the end of the motion, resulting in damage to the brake assembly member (preferably the actuator).

In an exemplary embodiment of the invention, the energy absorption and/or storage unit is adapted to dissipate the absorbed force, preferably in predetermined operating situations the absorbed energy is associated with a force acting on the output shaft. For example, the absorbed force or the absorbed energy may be dissipated by friction, electrical resistance, or viscous damping. Due to the arrangement and function of the energy absorbing unit, in particular due to the dissipation of forces acting on the output shaft in the reverse direction under predetermined operating conditions, excess forces or excess energy is removed from the brake assembly system to prevent damage.

In an exemplary embodiment of the invention, the energy absorption and/or storage unit is adapted to accumulate the absorbed force. Preferably, the energy absorbing and/or storing unit comprises a spring member, an accumulator or a battery. The accumulated force, in particular the accumulated absorbed energy, may be fed to an energy recovery system of the vehicle, preferably of the brake assembly. In this case, the absorbed accumulated energy can then be used as energy input for the actuator in a subsequent braking operation.

In another example embodiment of the invention, the energy absorbing and/or storing unit is adapted to counteract a force acting on the output shaft in a reverse direction under predetermined operating conditions. In a further development, the reaction force acts such that the kinetic energy of the output shaft, which is caused by the force acting on the output shaft in the reverse direction, is converted into kinetic energy, thermal energy and/or electrical energy of the absorption unit. Thus, depending on the available energy storage space or the energy required for a subsequent braking operation, at least part of the absorbed output shaft force may be accumulated and dissipated.

In an exemplary embodiment of the invention, an energy absorbing and/or storing unit is realized in that the actuator comprises an electric motor for driving the output shaft in the reverse direction and in the forward direction. The electric machine may be operated in a generator mode adapted to absorb output shaft forces under predetermined operating conditions. A generator mode may be understood as a mode of operation in which mechanical energy, preferably kinetic energy of another driving output shaft, such as an output shaft or an actuator, is converted into electrical power or electrical energy, respectively. Thus, the excess energy present in the predetermined operating situation may be used to feed the generator mode and may be used to supply the energy absorbed by the energy absorbing unit to other electrical components of the vehicle.

In another example embodiment of the invention, the brake assembly includes a brake end position in which the brake pads are frictionally engaged with the brake rotor. Furthermore, an idle end position of the brake assembly is given, in which the brake pads and the brake disc are disengaged. The stop element may be arranged such that it limits the axial movement of the output shaft beyond the rest position in the reverse direction. This means that the stop element is offset in the reverse direction with respect to the rest position. Furthermore, the energy absorbing and/or storing unit may be arranged to prevent impact of the output shaft against the stop element, thereby preventing damage to the brake assembly.

In a further development of the invention, the energy absorption and/or storage unit comprises a spring member or a viscous damper associated with the stop element, so that when the output shaft moves in the reverse direction from the rest position, preferably an oppositely directed spring force and/or damping force is applied to the output shaft. The generated spring force and/or damping force counteracts a threshold force acting on the output shaft in the reverse direction at a predetermined operating condition. Thus, the axial movement of the output shaft in the reverse direction is slowed, preferably stopped.

According to an exemplary embodiment of the invention, the energy absorption and/or storage unit is an electrical energy absorption and/or storage unit. Preferably, the energy absorbing and/or storing unit is electrically activated or deactivated and/or coupled to the actuator such that under predetermined operating conditions the energy absorbing and/or storing unit is automatically activated in order to absorb the output shaft force. According to a further development of the invention, in predetermined operating situations, the actuator engages a corresponding protection circuit, i.e. in the form of an electronic resistor for dissipating at least part of the absorbed energy and/or in the form of an electronic accumulator for storing at least part of the absorbed energy, even if the actuator is not supplied with energy.

In another example embodiment of the invention, the energy absorption and/or storage unit comprises an eddy current brake, also referred to as an induction brake, an electric brake or an electric retarder, which slows or stops the axial movement of the output shaft, e.g. by dissipating the kinetic energy of the output shaft as heat. When the output shaft moves in the reverse direction, preferably beyond the rest position, under predetermined operating conditions, a current is induced, preferably through the coil of the energy absorption unit, preferably through the eddy current brake, wherein in particular the induced current can be accumulated or dissipated by the energy absorption unit. According to the functional principle of eddy current brakes, a current is induced as a result of an external magnetic field acting on the moving part of the actuator or, for example, on the output shaft, and the induced current induces a magnetic field which is oriented oppositely with respect to the external magnetic field. Due to the fact that the magnetic field is oppositely directed with respect to the original magnetic field, the movement of the output shaft is slowed down, preferably stopped, thereby preventing damage to the brake components caused by the high inertia and high dynamics of the brake actuator. The resistor may be implemented internally by the actuator itself or externally by a separate electronic resistor component.

In an example embodiment of the invention, the actuator is coupled to the energy absorbing and/or storing unit and is configured such that the force absorbed by the energy absorbing and/or storing unit is dissipated by the actuator, wherein in particular the actuator comprises a resistor. For example, according to this embodiment, a braking resistor is provided which, in the normal operating mode, can be connected by default to a normally closed circuit and actively opened via a switch, preferably if no predetermined operating situation occurs. Alternatively and/or additionally, a capacitor may be connected to the circuit in order to store the absorbed energy, preferably for reuse.

According to another exemplary embodiment of the invention, the actuator may be a pneumatic, electromechanical or hydraulic actuator. It is clear that the inventive concept according to the invention is therefore not limited to the particular type of actuator used in the corresponding brake assembly.

In particular in wheel brake applications, where such an energy absorption and/or storage unit is necessary to prevent damage to the wheel brake assembly components, the idle position is not suitable for initiating the clearance adjustment step, since during dynamic braking operation of the brake assembly the actuator or the output shaft respectively returns to a slightly different axial direction after each braking operation, depending on the dynamics and the force of the respective brake application. It is therefore an advantage of the invention that a further reference position is defined which reliably triggers or initiates the gap adjustment step.

The axial clearance distance and/or the actual wear level of the brake pads and/or the brake disc is measured by the sensor unit and transmitted to the control unit of the actuator in order to adjust the axial clearance distance. Via the sensor unit and the control unit, measurements can be continuously performed and evaluated in order to decide when to perform the gap adjustment step. Advantageously, the gap adjustment step is only initiated or triggered when required. The decision is made based on a predetermined threshold axial clearance distance value and a threshold wear level value for the brake pad and/or brake rotor.

In an exemplary embodiment, the reference position is defined by a predetermined force value applied by the energy absorbing and/or storing unit. This means that when the brake pad is moved from the rest position to the reference position, thereby causing the energy absorbing and/or storing unit force to point in the opposite direction, i.e. the forward direction, for example, the dynamometer may be configured to measure the force value, thereby limiting the axial movement of the brake pad in the reverse direction, in order to reliably define the predetermined reference position. Alternatively, in case the energy absorbing and/or storing unit is realized by a spring member, the reference position may be defined as a fully depressed or deformed position of the spring member.

It should be noted that the method according to the invention may be defined such that it implements a brake assembly according to the described aspect of the invention, and vice versa.

Preferred embodiments are given in the dependent claims.

The following detailed description refers to the accompanying drawings. The same reference numbers may be used in different drawings to identify the same or similar elements. In the following description, for purposes of explanation and not limitation, specific details are set forth, such as particular structures, functions, etc. in order to provide a thorough understanding of the various aspects of the claimed invention.

However, it will be apparent to one having ordinary skill in the art having had the benefit of the present disclosure that the various aspects of the invention claimed may be practiced in other examples that depart from these specific details. In certain instances, descriptions of well-known devices and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.

Drawings

Figure 1 shows a schematic view of a brake assembly according to the invention in a first operating condition;

FIG. 2 shows a schematic view of a brake assembly according to the present invention in another operating condition; and

fig. 3 shows another schematic view of the brake assembly according to the invention in a further operating situation.

Detailed Description

In the following detailed description of the preferred embodiment of the present invention, a brake assembly in accordance with the present invention is generally indicated by reference numeral 100.

In fig. 1, an active braking operation of the brake assembly 100 is shown. During a braking operation, the brake pads 11 are in frictional engagement with the brake disc 9, and the brake disc 9 is in rotational engagement with a wheel (not shown) of the vehicle. During braking operation, the brake pads 11 apply a clamping force to the brake disc 9. Actuation of the brake pads 11 is achieved by the arrangement of the levers 13. The arrangement of the lever 13 is coupled to the output shaft 2, which output shaft 2 can be actuated by the actuator 1. The arrangement of the lever 13 may be positively and/or non-positively coupled to the output shaft by a coupling member 6 arranged at the distal end 15 of the output shaft 2. The arrangement of the lever 13 comprises a pivoting member 7, which pivoting member 7 is pivotally mounted on a mounting 17, which mounting 17 is normally fixedly arranged on the chassis (not shown) of the vehicle with one end 19 of the lever 7. At the other end 21 of the lever 7, which is arranged diametrically with respect to the end 19, the lever 7 is preferably coupled to the output shaft 2 by means of a coupling member 6, so that the lever 7 can perform a pivoting movement with respect to the mount 17 and so that the output shaft 2 can perform a translational movement in the forward direction F and in the reverse direction R. For the purposes of the present invention, the forward direction F defines the direction of movement of the brake pad 9 into the brake operating position, or into frictional engagement with the brake disc 9. Furthermore, the reverse direction R defines the opposite direction, i.e. the direction of movement of the brake pads 11 when disengaging the brake disc 9 and moving to the rest position in which no braking force is applied.

Generally, during operation of the brake assembly 100, the actuator 1 (which may be an electromechanical actuator, for example) generates an actuator force that causes the output shaft 2 to be driven in the forward direction F and the reverse direction R to bring the brake pads 11 and brake discs 9 into frictional engagement defining a braking position, or to disengage the brake pads 11 and brake discs 9 to release the frictional engagement. One axial end position of the output shaft 2 is defined by the frictional engagement of the brake pads 11 and the brake disc 9 or the braking position as shown in fig. 1. The output shaft 2 is driven in the forward direction F to cause pivotal movement of the lever 7 relative to the mounting 17 such that the shift lever 23, which is connected at one end 25 to the pivot lever 7 and at the other end 27 to the brake pad 11, translates axial movement of the output shaft 2 in the forward direction F into axial movement of the brake pad 9 in the forward direction F to frictionally engage the brake disc 9. As can be seen clearly in fig. 1, the pivot lever 7 pivots relative to the mounting 17, causing axial movement of the lever 23 and thus of the brake pad 11.

The brake assembly 100 further comprises a slack adjuster 29, preferably a mechanical slack adjuster, adapted to adjust a predetermined axial clearance distance between the brake pad 11 and the brake disc 9 in the rest position of the brake pad 11. The clearance adjuster 29 may be any adjusting device adapted to adjust the axial clearance distance between the brake pads 11 and the brake disc 9. For the purpose of illustration, a lash adjuster 29 is disposed at the shift lever 23. However, it should be appreciated that lash adjuster 29 may be associated with other components of brake assembly 100. The function of the gap adjustment step, in particular its activation, is explained in more detail with reference to fig. 2 and 3.

In fig. 1, the other axial end position of the brake pad 11 or the output shaft 2 is represented by a stationary end stop 3, which is preferably fixedly attached to the chassis of the vehicle (not shown). The end stop 3 may be a thin-walled plate or disc, preferably made of metal. The end stop 3 is arranged relative to the output shaft 2 such that upon actuation of the actuator 1 the output shaft performs a translational relative movement in the forward direction F and the reverse direction R relative to the end stop 3 and such that the axial movement of the output shaft in the reverse direction R is limited by the end stop 3. For example, the end stop 3 may include a through hole 1, the through hole 1 being concentrically arranged with respect to the forward and reverse movement directions of the output shaft 2. As shown, an energy absorption and/or storage unit 33 is provided to absorb forces acting on the output shaft 2 in the reverse direction R under predetermined operating conditions. The energy absorbing and/or storing unit 33 is arranged such that during normal operation of the brake assembly 100, or during dynamic braking operation, the brake pads 11 and the output shaft 2 do not reach the end stops 3. The energy absorbing and/or storing unit 33 applies a force directed in the forward direction F to the output shaft 2 in case the output shaft 2 is moved beyond the rest position in the reverse direction R.

To perform the clearance adjustment step, the brake pads 11 and the output shaft 2 are moved to the rest position of the brake pads 11 shown in fig. 2. In this operating state of the brake assembly 100, as shown in fig. 2, there is an axial clearance distance s between the brake pads 11 and the brake disc 9 in the forward direction F and the reverse direction R. Furthermore, the output shaft 2 is moved in the reverse direction R such that the coupling member 6 contacts the energy absorbing and/or storing unit 33, which energy absorbing and/or storing unit 33 is realized by the spring unit 4 according to the shown embodiment. The spring unit 4 is supported at one end on a stationary end stop 3 and at the other end on an actuator plate 5, which actuator plate 5 is movable in accordance with the deformation of the spring unit 4. The rest position may also be referred to as a passive position in which no actuator braking force is applied, or in which no frictional engagement occurs between the brake pads 11 and the brake disc 9, and which defines a starting position of the brake pads 11 when the actuator 1 applies an actuating force to the output shaft 2 to perform a braking operation. Furthermore, if clearance adjustment is required due to, for example, an undesired actual clearance value and/or an undesired wear level of the brake pads 11 and/or the brake disc 9, the brake pads 11 are first brought into the idle position. The brake assembly 100 may for example comprise a sensor unit (not shown) for measuring the actual clearance value and/or the actual wear level of the brake pads 11 and/or the brake disc 9. Furthermore, the brake assembly 100, or the actuator 1, comprises a control unit 35 for electronically triggering the lash adjustment step. The control unit 35 may be connected to the sensor unit such that in case the sensor unit detects an undesired wear level and/or an undesired clearance value, the control unit 35 of the actuator 1 initiates the adjusting step. Thus, the lash adjustment step is only initiated when necessary. Unnecessary adjustment is prevented.

To initiate the clearance adjustment step, preferably to start the clearance adjustment step, the brake pad 11 or the output shaft 2 is moved further in the reverse direction R beyond the rest position of the brake pad 11, so that a negative stroke is performed. The clearance adjustment step is therefore only initiated when the brake pad 11 has performed such a negative stroke that it moves beyond the rest position in the reverse direction R. The magnitude or distance in the reverse direction R relative to the rest position will be determined so that during normal operation of the brake assembly 100, or during dynamic braking operation, the brake pad 11 does not reach the reference position shown in fig. 3. As shown in fig. 3, in case an energy absorbing and/or storing unit 33 is provided, the actuator 1 actuates the output shaft 2 such that the brake pad 11 reaches its reference position, the actuator 1 having to overcome the energy absorbing and/or storing unit force applied to the output shaft 2 oriented in the forward direction F, i.e. against the direction of movement of the brake pad 11 or the output shaft 2. Exemplarily, the energy absorption and/or storage unit 33 comprises a spring member 4 and an activation plate 5, the coupling member 6 being fixedly attached to the activation plate 5, and the output shaft 2 abutting the activation plate 5 in the rest position, such that, in order to reach the predetermined reference position, the spring member 4 generates a spring force upon its deformation, which deformation is caused by the axial movement of the output shaft 2 in the reverse direction R beyond the rest position.

In particular in wheel brake applications, where such an energy absorption and/or storage unit 33 is necessary to prevent damage to the wheel brake assembly 100 components, the idle position is not suitable for initiating the clearance adjustment step, since during dynamic braking operation of the brake assembly 100, the actuator 1 or the output shaft 2 returns to a slightly different axial direction after each braking operation, depending on the dynamics and force of the respective brake application. It is therefore an advantage of the present invention that a further reference position is defined which triggers or initiates the gap adjustment step.

As shown in fig. 3, the reference position is offset beyond the rest position in the reverse direction R and is defined by a predetermined activation force generated by the actuator 1 in order to bring the brake pad 11 or the output shaft 2 into the reference position. As shown in fig. 3, in the reference position, the axial distance between the brake pad 11 and the brake disc 9 is greater than the axial clearance distance in the rest position. After reaching the reference position, the actuator force is released and the brake pads 11 and the output shaft 2 return to a predetermined rest position, respectively, which is then used for the clearance adjustment step. The axial clearance distance s and/or the actual wear level of the brake pads 11 and/or the brake disc 9 is measured by a sensor unit (not shown) and transmitted to the control unit 35 of the actuator 1 in order to adjust the axial clearance distance s. Via the sensor unit and the control unit 35, measurements can be continuously performed and evaluated in order to decide when to perform the gap adjustment step. Advantageously, the gap adjustment step is only activated or triggered when required. The decision is made based on predetermined axial clearance distance thresholds and wear level thresholds for brake pads 9 and/or brake rotor 11.

The features disclosed in the above description, in the drawings and in the claims may be essential for the invention to be implemented individually as well as in any combination in its different embodiments.

List of reference signs

1 actuator

2 output shaft

3 end stop

4 spring component

5 actuating plate

6 connecting component

7 rod

9 brake disc

11 brake pad

13-bar arrangement

15 end of the tube

17 mounting piece

19. 21 end of the tube

23 bar

25. 27 end of

29 gap adjuster

31 through hole

33 energy absorption and/or storage unit

35 control unit

100 brake assembly

F forward direction

R reverse direction

s axial gap distance.