WO2016120279A1 - Controller for a motor vehicle brake system - Google Patents

Abstract

The invention relates to a controller (1) for a motor vehicle brake system, comprising - at least one hydraulic unit (2) and an electronic control unit (3), - at least one valve coil module (4) for actuating an electromagnetically actuatable hydraulic valve, - and at least one circuit board (5) for receiving electronic components. The circuit board (5) is connected to a valve coil (4.3) contained in the valve coil module (4) in an electrically conductive manner by means of at least one contact means (7). The controller is characterized in that the valve coil module (4) is connected to the hydraulic unit (2) in a fixed manner, and an elastic mechanical attachment of the electric contact of the valve coil (4.3) is provided.

Description

description

Control device for a motor vehicle brake system The invention relates to a control device for a motor vehicle brake system according to the preamble of claim 1.

EP 0705747 Al describes an electro-hydraulic control ^¬ unit for a braking system, are mounted in the valve spool by means of valve spool mounting elements on a to be mounted to the housing support plate, centrally arranged to the valve ^¬ coil assembly elements snap-in hooks are snapped into openings provided on the support plate. In this solution, however, disadvantageous is the largely rigid mechanical connection between the support plate and valve coils. In order to counteract manufacturing tolerances and thermal expansion improved, the valve coils are mounted according to EP 0 520 047 Bl means arranged on a spring-mounted support plate elastic brackets, whereby an axial and radial displacement of the valve coils is possible.

In DE 197 43 842 AI a valve control device for receiving a plurality of valve coils is described, which overcomes the disadvantages of a rigid mechanical connection and the separate support plate for the valve coils. For this purpose, the coil wires in an elastic encapsulation embedded bent portions, whereby the ends of the coil wires are directly taktiert kon ^¬ with the circuit board. Comparable valve coil modules are described in DE 295 08 389 Ul. Using rigid contact pins, which have no resilient elements, in the arrangement described in US 5,845,672, to avoid air gaps and compensation of tolerances and reduction of mechanical stress on the circuit board, a mechanical elasticity by a movably arranged arrangement of the bobbin with the Valve coil based on the Spulenjoch a valve coil module realized, wherein for generating a bias in a hydraulic unit facing part of the valve coil module, a spring between the bobbin and the Coil yoke is provided. The disadvantage here is the increased complexity of the valve coil module and that there is no delimitation to avoid contamination of the circuit board from the side of the hydraulic unit.

For example, as also shown in EP 2703241 AI control unit, the coils for providing a resilient contact, for example by means of press fit contacts are ^¬ bent-over pins (with the coil wire is welded) is electrically connected to the printed circuit board. The coils are thereby fixed in the housing of the electronic control unit with suspensions and a spring plate, below the coil provides the necessary life over contact force from coil to valve plate. Thus, mechanical stress on the circuit board can be reduced. The coil assembly is done with the help of press tools, which press the contact pins into the circuit board. A disadvantage to the Leis ^¬ processing capacity of the coils, in particular distance ^¬ knob, required for mounting punches within the coil yoke, the coils suspension or holders and one or more elastic member for pressing the spool of the valve plate (bearing surface of the hydraulic unit acting to close the Mag ^¬ netkreises). Furthermore, complex assembly equipment with workpiece carriers for pressing in coils and PCB are needed. A housing of the electronic control unit is susceptible to contamination in the production due to the required large openings for mounting the coil. The handling and transport of the valve coil modules are due to the sometimes very delicate components correspondingly complex.

Due to the increase in the number of functional modules in the motor vehicle, there is a need to reduce the space requirements and the weight of already integrated systems bezie ^¬ tion to use for more powerful systems to further improve the safety of the vehicle occupants. Among other things, the robustness against environmental influences, such as vibrations and temperature fluctuations, and the range of functions must be increased. In addition, the importance of comfort is growing the vehicle occupants, in particular the prevention of the generation, for the vehicle occupants unpleasant disturbances concerns. Brake control units have to meet these diverse requirements and withstand the enormous cost pressure.

Object of the present invention is therefore to provide a control device for a motor vehicle brake system of the type mentioned, which allows at least constant performance and robustness to environmental influences, a reduction in space requirements and yet inexpensive to produce.

This object is achieved by the control device according to the invention according to claim 1.

The invention relates to a control device for a motor vehicle brake system, comprising at least one hydraulic unit and an electronic control unit, at least one valve coil module for controlling an electromagnetic

operable hydraulic valve and at least one printed circuit board for receiving electronic components, the printed circuit board by means of at least one contact means electrically connected to a valve spool by the valve spool valve connected, wherein the control unit further characterized in that the valve spool module is fixedly connected to the hydraulic unit and an elastic mechanical connection of the electrical contacting of the valve coil is present. Preferably, there is a technical joining connection.

The fixed connection of the valve coil module with the hydraulic unit forms according to the invention preferably the only mechanically rigid attachment, wherein the elastic mechanical connection of the electrical contact, in addition to the joining technical connection with the hydraulic unit, preferably forms the only further mechanical attachment. Since a space ^¬ taken by the valve coil modules according to the invention is reduced in comparison with known electro-hydraulic control units, a reduction of the space requirement can be realized by the inventive electro-hydraulic control unit in an advantageous manner. In addition, the performance of the coils can be improved in terms of space requirements, as in a same space of a housing now more windings can be placed on the coil.

Optionally, a separate cooling device of a power control unit could thereby be omitted. The number of

Components and the related number of manufacturing steps and their complexity are advantageously ^¬ legally reduced, which has a positive effect on costs and weight, as for example, carried out to form a holder, complex and therefore expensive

Overmolding of the valve coil modules and a frequently used elastic element for pressing the modules against the base of the valve dome is eliminated, which also means that no or at least lower loads act on the coil chamber wall and therefore a lower material thickness is sufficient for this. Since the valve coil modules are not arranged to move relative to each other due to the joining technology Ver ^¬ bond with the hydraulic unit, can be dispensed with a separation of the valve coil modules, for example by arranged between these housing walls. A ^¬ Ver simplification of the structural design of the valve coil modules is also possible, which enables effective production as well as a reduction in the burden of handling and transport of the Ventilspu ^¬ lenmodule. The robustness of the electronic

Control unit against contamination from production can also be increased. According to the prior art, in the case of a valve coil suspension, which provides latching hooks which engage in the coil yoke of the valve coil yoke, frequently a chamfer on an outer edge on one of the circuit board has been provided. _n

5 facing end of the coil yoke of the valve coil module pre ^¬ see so snap hooks are not rubbed off. This chamfer and the associated additional process step are also not necessary because there is no mechanical suspension of the valve coil modules in this sense. By eliminating the chamfer, more space can also be provided for coil turns.

The valve coil module is connected according to a particularly preferred development of the invention fixed with a valve dome comprised by the hydraulic unit. Preferably, a spool ^¬ lenjoch encompassed by the valve spool module is connected by joining technology to a valve dome encompassed by the hydraulic unit. In this case, a base of the valve dome is understood as encompassed by the valve dome, wherein the Spulenj och is preferably connected to the base of the valve dome. The coil yoke is preferably connected by means of a press fit with the valve dome. According to an advantageous embodiment of the invention, a Spulenkammerwandung for delimiting a region in which the at least one valve spool module is located, and a region in which the circuit board is located, seen before ^¬ , wherein the Spulenkammerwandung comprises at least one wall element, at least having an opening for the implementation of ^¬ at least one contact means. The Spulenkammerwandung is thus almost completely closed ge ^¬ , whereby the range of electro-hydraulic

Control unit, in which the valve coil modules located, and the area of the electronic control unit with the circuit board in an advantageous manner delimited from each other, which in particular the electronics is protected against contamination from the hydraulic unit. The wall element preferably has a dome-shaped Aus ^¬ shaping for receiving a printed circuit board facing the end of a valve dome of the hydraulic unit. According to a particularly preferred embodiment of the invention, the valve coil module comprises at least one connection element for electrically contacting the at least one contact means with the valve coil, wherein the connection element is electrically conductively connected to the Ven ^¬ tilspule and with respect to the valve coil module and / or the bobbin movable to ^¬ ordered. The mechanical connection of the contact means to the connection element is preferably configured substantially immovable. The contact means is in particular rigid out ^¬ .

The control unit expediently has a housing enclosing at least the one or more valve coil modules and the printed circuit board (s). The bobbin wall and / or the at least one wall element are preferably integrally connected to the housing. Thus, the housing and the coil chamber wall and / or the at least one wall element can advantageously be produced in a common process step, such as an injection molding process. Changes to existing hydraulic unit or in particular the valve domes are not necessary for the realization.

The valve coil module is preferably mechanically fixed by means of a press fit to the valve dome or the base of the valve dome.

Due to the largely free orientation possibility of the valve coil modules with regard to their contact means further optimizations in the design of the layout of the circuit board can be made. For example, grouped press-in zones can be provided for introducing the press-fit contacts of the contact means on the printed circuit board, whereby an improved packing density of the valve coil modules can also be achieved ^

is.

In addition to the advantages mentioned so far, the controller according to the invention also provides a particularly simple assembly method for the production, which has the steps:

1. electrically contacting contact means with a printed circuit board,

 2. Inserting the circuit board in a housing one

 electronic control unit of the control device, wherein the contact means are passed through openings provided for this purpose a Spulenkammerwandung,

3. Application and technical joining of valve ^¬ coil modules on valve domes of a hydraulic unit of the controller and

4. Assembly of the hydraulic unit with the electronic control unit, wherein the contact means are contacted with An ^{¬ closing} elements of the valve ^{coil modules} .

Steps 1, 2 and 3 are interchangeable in order, with step 4 representing the final assembly (wedding) of the electronic control unit and hydraulic unit. Preferably, the contact means on at least one of the printed circuit board facing end Einpresskontakte for pressing in contacting openings of the circuit board, so that the electrical contacting of the contact means with the circuit board can be made in accordance with step 1 by pressing the press-fit. Due to the comparatively simple geometry of the contact means for contacting the valve coils and the overall less complex structure of the valve ^¬ spulanordnung the assembly process can be automated in a simpler manner, which is preferably done using an image processing system.

Further preferred embodiments will become apparent from the following description of exemplary embodiments with reference to figures. In a schematic diagram show:

Fig. 1 in fragmentary exploded views of a

 Embodiment of the electrohydraulic control unit according to the invention,

2 is a further limited to some components, a partial representation of the embodiment of the electro-hydraulic control unit,

Fig. 3 shows an embodiment of the valve coil module according to the

 Invention,

Fig. 4 bobbin of the valve coil module and detail representation in particular of the connection elements of

Valve coil modules,

5 shows an exemplary embodiment of the contact pins of the Ven ^¬ tilspulenmodule with exemplary dimensions,

6 shows an exemplary coil wall of the housing of the electronic control unit, wherein this can be provided as a separate part to be mounted or is made in one piece with the housing,

7 is a sectional view of an embodiment of the electronic control unit with assembled valve coil module, and FIG. 8 is an exemplary sequence of the invention

 Method for mounting the valve coil modules in the electronic control unit.

To provide a brief and simple description of the embodiments, like elements are given the same reference numerals.

The partial images a) and b) of Fig.l show an explosion Representing an embodiment of the electro-hydraulic control unit 1 (HECU) according to the invention in different perspectives, wherein only hydraulic unit 2 with valve dome 2.1, valve coil module 4, circuit board 5, contact pins 7 and a wall element 6.1 a Spulenkammer- wall, which preferably integrally with the housing of the electronic Control unit is connected, are shown. Valve coil module 4 is pushed in the assembled state by means of Ven ^¬ tildomaufnahmeöffnung 4.2 on valve dome 2.1 of the hydraulic unit 2, as shown in Fig. 2, whereby the corresponding valve dome 2.1 associated electromagnetic hydraulic valve by driving the valve coils of the valve coil module 4 is actuated. The contact pins 7 are preferably executed without resilient elements or curved course - rigid and straight - and have at least on the, the circuit board side facing, press-fit. The valve coil module 4 comprises connecting elements 4.5 for contacting the contact pins 7 in such a way that an electrically conductive connection of the printed circuit board to the valve coil can be realized in order to control the valve coil.

FIG. 3 shows an embodiment of the valve coil module according to the invention. Coil yoke 4.4 is executed, for example, two ^¬ part and includes a cylindrical part (shown in phantom) and a cover plate. The cover plate has an omission for the implementation of the connection elements 4.5 and a corresponding shape of bobbin 4.1, in which the connection elements 4.5 are inserted or engaged ^¬ . The cylindrical coil 4.3, by means of which the magnetic field for switching the electromagnetic hydraulic valve can be constructed, is wound onto bobbin 4.1. For electrical insulation, the connection elements 4.5 are enclosed by corresponding formations of bobbin 4.1. Extensive representations of different perspectives of the area of the connection elements 4.5 and of the bobbins 4.1 of a further embodiment of valve coil module 4 are shown in the partial illustrations a), b) and c) of FIG. On the representation of the cylindrical part of Spulenjoch 4.4 was omitted in Fig. 4 a). The connecting elements 4.5 are, as already shown for the embodiment of Figures 2 and 3, configured with a substantially square cross section, wherein the ends of the coil wire are electrically conductively connected to the likewise conductive connection elements 4.5. According to the embodiment of Figures 4 a) and b) are the connection elements 4.5 - in contrast to the previously shown embodiments - not completely enclosed by the formations of the bobbin 4.1, but mechanically fixed by means of mutually directed latching hooks. The connection elements 4.5 of a valve coil module 4 can also be arranged in a deviating manner, for example on opposite sides of the circuit board 5 facing the end of the valve ^¬ coil module 4.

5 shows an embodiment of a contact pin 7 with press-in contact, on which in the assembled state of the Lei ^¬ terplatte 5 facing the end, with exemplary dimensions. To illustrate the exemplary relative dimensions hatched also an exemplary section of circuit board 5 is shown in cross section.

A wall element 6.1 of a coil chamber wall already shown in FIG. 1 is shown again in a separate form in FIG. The wall element 6.1 can as separately on

Spulenkammerwandung be arranged to be mounted or mounted component or already produced in one piece together with the entire housing or parts thereof, which offers a cost-effective solution especially when using plastic as a housing material. In the assembled state of Ven ^¬ tilspulenmodul 4, the contact pins 7 are passed through the provided in Wan ^¬ training element 6.1 openings 6.2 and the dome-shaped configuration 6.3 receives the printed circuit board 5 facing the end of a valve dome 2.1.

7 shows a sectional view of one embodiment of the electronic control unit with mounted Ventilspu ^¬ lenmodul 4. This illustration shows in particular how the contact pins 7 (only a single shown), starting from the pressed into the circuit board 5 press-fit, passed through the openings 6.2 of wall element 6.1 and are plugged into the connection elements 4.5 of the valve coil module 4. Wall element 6.1 is provided according to this example as a materially connected part of housing 6 of the electronic control unit of the electro-hydraulic control unit 1. It is also shown how the recording of the circuit board 5 facing the end of the valve dome 2.1 can be realized by the dome-shaped configuration 6.3. As already described, valve coil module 4 is pushed in the installed state via valve dome receiving opening 4.2 on valve dome 2.1 of the hydraulic unit 2. For mechanical fixation of valve spool module 4, the Spulenjoch 4.4 according to the preferred embodiment of FIG. 7, at one of the hydraulic unit 2 facing the end of valve ^¬ coil module 4 and valve dome 2.1, by means of press fit with the valve dome 2.1 - in particular a base of the valve dome - mechanically connected , One possibility for the mechanical fixation or support of the mechanical fixation of

Printed circuit board 5 within the housing 6 is shown in the form of preferably also cohesively connected to housing 6 latching hook 6.4. The electrical contacting of the valve coil modules 4 to the printed circuit board 5 can be realized in various ways, the mechanical connection of the electrical contacting is designed according to the invention elastic.

Preferred realizations of the connection according to the invention is shown in the embodiments of Figures 1 to 8, according to which the electrically conductive connection elements 4.5 configured as sockets and locked in a designated shaping of bobbin 4.1, the ends of the coil wire of the valve coil 4.3 with the respective connection element 4.5 are mechanically connected, for example by means of ultrasonic welding or soldering. The contact pins 7, which are rigid in accordance with these embodiments, can be pressed, for example by means of press-fit contacts (not shown). placed) in press-fit sockets of the connection elements 4.5 pressed and thus mechanically and electrically connected to these. The shaping and locking allows the connection elements 4.5 or press-fit translatory movements preferably in all spatial directions, wherein the coil wire is designed to be carried. Thus, the movement of the connecting elements 4.5 compensating element (offset compensation) of the coil wire. The contact point of contact pin 7 to An ^¬ closing element 4.5 can be carried out accordingly immobile (rigid), whereby fretting corrosion can be avoided. Particularly in the case of press-fit contacts for contacting with the connection elements 4.5, the connection elements 4.5 can also be mechanically fixed to the valve coil module 4 or bobbin 4.1.

According to an alternative embodiment (not shown), the electric connection of cylindrical coil 4.3 instead of contact pins 7 by means of contact springs, which apply spring forces in the direction of the valve coil module 4 and the circuit board 5 and allow translational movements in the spatial directions. The contact springs preferably have a silver or copper coating to allow a low-current current transport. The holding device for the spring is preferably formed integrally with the bobbin 4.1. One of the circuit board 5 and / or the valve coil module 4 facing the end of such a contact spring can be connected, for example by means of press-fit, soldering or welding to the circuit board 5 or appropriately ausgestaltetem connection element 4.5 of valve ^¬ coil module 4.

According to the example, the assembly of the valve coil modules takes place in the sequence described below with reference to the partial illustrations a) to c) of FIG. 8: FIG. 8 a) -pressing the contact pins 7 into the printed circuit board 5;

2. Fig. 8 b) - introducing the preferably already in the sentlichen fully assembled circuit board 5 in the housing 6 of the electronic control unit, wherein the contact pins 7 are passed through the designated openings 6.2 of the bobbin wall of the housing 6,

3. application - in particular pressing (press fit) - the valve coil module 4 and the Spulenjochs 4.4 on valve dome 2.1 of the hydraulic unit 2 and

4. Assembly of the hydraulic unit 2 with the electronic

Control unit, wherein the contact pins 7 are contacted with the An ^{¬ closing} elements 4.5 of the valve coil modules 4.

In particular, the steps 1 to 3 can be realized in the order essentially arbitrary. Particularly preferably, all steps of the assembly be carried out fully automated, in ^¬ play, by using an image processing system.

Claims

claims Control unit (1) for a motor vehicle brake system comprising at least one hydraulic unit (2) and an electro ^¬ African control unit (3),  - At least one valve coil module (4) for controlling an electromagnetically actuated hydraulic valve and - at least one printed circuit board (5) for receiving electromagnetic ^¬ tronic components, wherein the circuit board (5) by means of at least one contact means (7) included electrically conductive with a through the valve coil module (4) valve spool (4.3) is connected characterized in that the Valve coil module (4) with the hydraulic unit (2) is fixedly connected and an elastic me ^¬ chanical connection of the electrical contact of the valve coil (4.3) is present. 2. Control device (1) according to claim 1, characterized in that the valve spool module (4) is fixedly connected to a by the hydraulic unit (2) valve dome (2.1). 3. Control device (1) according to claim 1 or 2, characterized in that a through the valve coil module (4) comprises Spulenjoch (4.4) is connected by joining technology with a by the hydraulic unit (2) encompassed valve dome (2.1). Control unit (1) according to claim 3, characterized in that the coil yoke (4.4) is connected by means of a press fit with the valve dome (2.1). Control unit (1) according to at least one of the preceding claims, characterized in that a Spulenkam- merwandung to delimit a region in which the at least one valve spool module (4) is located, and a region in which the printed circuit board (5) is provided, wherein the Spulenkammerwandung comprises at least one wall element (6.1) having at least one opening (6.2) for carrying out the at least one contact pin (7). 6. Control device (1) according to claim 5, characterized in that the wall element (6.1) has a dome-shaped shape (6.3) for receiving one of the printed circuit board (5) facing the end of a valve dome (2.1) of the hydraulic unit (2). 7. Control device (1) according to one of the preceding claims, characterized in that the valve coil module (4) comprises at least one connection element (4.5) for electrically contacting the at least one contact means (7) with the valve coil (4.3), wherein the connection element (4.5 ) Is electrically conductively connected to the valve coil (4.3) and with respect to the valve coil module (4) and / or the bobbin (4.1) is arranged to be movable. 8. Control device (1) according to claim 7, characterized in that the mechanical connection of the contact means (7) to the connection element (4.5) is substantially immovable ^¬ designed. 9. Control device (1) according to one of the preceding claims, characterized in that the contact means (7) is rigid.