Electric linear motion actuator and electric disk brake system

A disk brake system includes a disk, brake pads, and a linear motion actuator including an electric motor, a rotary shaft coupled to the motor through a reduction gear mechanism, planetary rollers formed with helical grooves in their outer surfaces, and an outer ring member having a helical rib engaged in the helical grooves. The outer ring is coupled to one of the brake pads. When the rotary shaft is rotated by the motor, the outer ring member is moved axially through the planetary rollers, and the brake pads are pressed against the disk. The linear motion actuator further includes a locking mechanism including engaging holes formed in an intermediate gear of the reduction gear mechanism at equal intervals, a locking pin, and a linear solenoid for moving the locking pin until the pin engages in one of the engaging holes, thus locking the motor.

TECHNICAL FIELD

This invention relates to an electric linear motion actuator for linearly driving a driven member such as brake pads, and an electric disk brake system including this electric linear motion actuator.

BACKGROUND ART

An electric linear motion actuator of this type includes a motion convertor mechanism which converts the rotary motion of the rotor shaft of an electric motor to a linear motion of an axially movable driven member.

Known motion convertor mechanisms used in this type of electric linear motion actuators include a ball-screw mechanism and a ball-ramp mechanism. These motion convertor mechanisms can increase power to some extent but cannot increase power to such an extent as required in an electric disk brake system.

Thus in an electric linear motion actuator using one of the above-mentioned motion convertor mechanisms, a reduction mechanism such as a planetary gear mechanism is additionally provided to increase driving force. Such a separate reduction mechanism adds to the complexity and the size of the electric linear motion actuator.

The applicant of the present invention has already proposed in JP 2010-65777A and JP 2010-90959A electric linear motion actuators which are free of this problem, and which can sufficiently increase power without the need for a separate reduction mechanism and thus can be used in an electric disk brake system, of which the linear motion stroke is relatively small.

The electric linear motion actuator disclosed in either of JP 2010-65777A and JP 2010-90959A includes a rotary shaft rotated by an electric motor, an axially movably supported outer ring member, and planetary rollers mounted between the rotary shaft and the outer ring member. A helical rib is formed on the radially inner surface of the outer ring member which is engaged in helical grooves or circumferential grooves formed on the radially outer surfaces of the respective planetary rollers. Thus when the rotary shaft rotates, the planetary rollers revolve around the rotary shaft while rotating about their respective axes due to contact friction between the planetary rollers and the rotary shaft, and simultaneously, the outer ring member is moved in the axial direction.

If the electric linear motion actuator disclosed either JP 2010-65777A or JP 2010-90959A is used in an electric disk brake system, such a disk brake system has the function as the service brake only, i.e. the brake which can only control the braking force according to the force applied to the brake pedal by a driver. In order to keep the vehicle parked in position, it is necessary to keep the electric motor energized while the vehicle is being parked, which is a huge waste of electric energy.

JP 2006-183809A proposes an electric brake system which includes a parking brake locking mechanism which, when actuated, is adapted to stop rotation of the rotor of the electric motor in the brake releasing direction. This almost completely eliminates the disadvantages of the above-mentioned disk brake system.

While the electric brake system disclosed in JP 2006-183809A has the parking brake locking mechanism, since this locking mechanism is mounted around the rotor, the brake system tends to be large in diameter, so that the brake system could interfere with a wheel when mounted on a vehicle.

Also, since the parking brake locking mechanism is mounted around the rotor, it adds to the weight of the electric motor, resulting in a weight imbalance of the entire brake system, which could detrimentally influence how the brake pads are pressed against the brake disk during braking, thus destabilizing the braking operation. This could cause brake squeak.

In the electric brake system disclosed in JP 2006-183809A, various components of the parking brake locking mechanism, such as a pivot arm with a claw, a solenoid for pivoting the pivot arm and a torsion return spring for the pivot arm, are formed into a module so that these components can be easily mounted on the brake system. A rigid protective cover is necessary to protect this module against e.g. flying stones while the vehicle is traveling.

SUMMARY OF THE INVENTION

An object of the invention is to provide an electric linear motion actuator which includes a locking mechanism capable of selectively locking and unlocking the rotation of the rotor shaft of the electric motor and which is small in size and well balanced in weight distribution, and an electric disk brake system including this electric linear motion actuator.

In order to achieve this object, the present invention provides an electric linear motion actuator comprising an electric motor having a rotor shaft, a reduction gear mechanism including an output gear having a center axis for reducing a rotation of the rotor shaft of the electric motor and outputting the thus reduced rotation at the output gear, a slide member movable in a direction of the center axis of the output gear, a rotation-to-linear-motion converting mechanism for converting a rotary motion of the output gear of the reduction gear mechanism to a linear motion and transmitting the linear motion to the slide member, and a locking mechanism capable of selectively rotationally locking and unlocking the rotor shaft of the electric motor, wherein the locking mechanism comprises a plurality of engaging portions provided on one side of one of a plurality of gears forming the reduction gear mechanism so as to be arranged in a circumferential direction of the one of the plurality of gears, a locking pin movable toward and away from the engaging portions and configured to be brought into engagement with any one of the engaging portions when moved toward the engaging portions, thereby locking the gears of the reduction gear mechanism, and a pin driving actuator for moving the locking pin between an advanced position and a retracted position, the pin driving actuator being mounted between the electric motor and a housing in which the slide member and the rotation-to-linear-motion-converting mechanism are mounted.

The present invention also provides a disk brake system comprising brake pads, a brake disk, and an electric linear motion actuator for linearly driving one of the brake pads, thereby pressing the brake pads against the brake disk, and imparting a braking force to the brake disk, wherein the electric linear motion actuator is the electric linear motion actuator according to the present invention, and wherein the one of the brake pads is coupled to the slide member of the electric linear motion actuator.

In this electric disk brake system, when the electric motor of the electric linear motion actuator is activated, the rotation of the rotor shaft of the electric motor is reduced by the reduction gear mechanism and outputted from the output gear. The rotation of the output gear is then converted to a linear motion by the rotation-to-linear-motion converting mechanism, and transmitted to the slide member. The slide member is thus advanced, pressing the brake pad coupled to the slide member against the brake disk, thus applying a braking force to the brake disk.

When parking the vehicle equipped with this brake system, with the brake pads pressed against the brake disk in the above manner such that a braking force necessary to keep the vehicle parked is applied to the brake disk, the locking pin is advanced by the pin driving actuator until the locking pin is engaged in one of the engaging portions, thus locking the gears. With the gears locked in position, the electric motor is deactivated, thereby saving electric energy during parking.

With the locking pin engaged in one of the engaging portions, i.e. with the rotor shaft of the electric motor locked in position, torque is applied to the respective gears forming the reduction gear mechanism that tends to release the brake, due to the reaction force from the brake disk. This torque acts on the portions of the locking pin and one of the engaging portions that are in engagement with each other. This torque is large at the output gear and decreases gradually toward the input gear.

Thus, if the locking mechanism, including the locking pin and the engaging portions, is located close to the output gear, relatively large torque acts on the engaged portions of the locking pin and one of the engaging portions. If the engaged portions are not sufficient in strength, such large torque could cause deformation of the engaged portions. One way to prevent such deformation would be to increase the rigidity and thus the strength of the engaged portions. But this solution increases the weight of the electric linear motion actuator.

To avoid this problem, the engaging portions are preferably provided on one side of a gear other than the output gear. More preferably, the engaging portions are provided on a gear located close to an input gear mounted on the rotor shaft of the electric motor.

The engaging portions may be engaging holes extending through the one of the plurality of gears, or may be radial grooves formed on the one side of the one of the plurality of gears. Since the engaging portions are circumferentially spaced from each other, when the locking pin is advanced toward the gear by the pin driving actuator, the locking pin may not be aligned with and thus cannot engage any of the engaging portions. In such a case, with the locking pin advanced, the electric motor is driven to rotate the gear in the braking direction until the locking pin aligns with and engages in one of the engaging portions.

In the arrangement in which the engaging portions are the engaging holes, the engaging holes may each be formed with a locking surface provided at one circumferential end of the engaging hole and configured such that when the locking pin engages the locking surface, the locking surface prevents the one of the plurality of gears from rotating in the brake releasing direction (i.e. the direction in which the slide member moves backward), and a tapered surface provided at the other circumferential end of the engaging hole and configured such that when the one of the plurality of gears tends to rotate in the braking direction (i.e. the direction in which the slide member is advanced), the locking pin is allowed to separate from the engaging hole while sliding along the tapered surface. With this arrangement, the gear can be smoothly rotated in the braking direction, thus making it possible to apply a pressing force to the brake disk which is necessary to keep the vehicle parked in position.

In the arrangement in which the engaging portions are the radial grooves, the radial grooves are preferably each formed with a locking surface provided at one circumferential side of the radial groove and configured such that when the locking pin engages the locking surface, the locking surface prevents the one of the plurality of gears from rotating in the brake releasing direction (direction in which the slide member moves backward), and a tapered surface provided at the other circumferential side of the radial groove and configured such that when the one of the plurality of gears tends to rotate in the braking direction (direction in which the slide member is advanced), the locking pin is allowed to separate from the radial groove while sliding along the tapered surface. With this arrangement, the gear can be smoothly rotated in the braking direction, thus making it possible to apply a pressing force to the brake disk which is necessary to keep the vehicle parked in position.

In either of the above two arrangements, the locking mechanism preferably further includes an elastic member biasing the locking pin toward the one of the plurality of gears so that the locking pin can be reliably engaged in one of the engaging portions.

By using a linear solenoid as the pin-driving actuator, it is possible to reduce the size of the electric linear motion actuator according to the present invention.

The rotation-to-linear-motion converting mechanism may comprise a rotary shaft supporting the output gear of the reduction gear mechanism, the above-described slide member, which is in the form of an outer ring member slidably supported by the housing so as to be coaxial with the rotary shaft, a carrier rotatable about the rotary shaft, and planetary rollers rotatably supported by the carrier between the radially outer surface of the rotary shaft and the radially inner surface of the outer ring member, wherein a helical groove or circumferential grooves are formed on the radially outer surface of each of the planetary rollers, wherein a helical rib is formed on the radially inner surface of the outer ring member which is engaged in the helical grooves or circumferential grooves of the planetary rollers, whereby the outer ring member as the slide member is moved in the direction of the center axis of the output gear when the planetary rollers rotate due to contact friction between the rotary shaft and the planetary rollers.

Alternatively, the rotation-to-linear-motion converting mechanism may comprise a rotary shaft supporting the output gear of the reduction gear mechanism and formed with a helical rib on the radially outer surface of the rotary shaft, the above-mentioned housing, which is a cylindrical member located coaxial with the rotary shaft, and the above-mentioned slide member, which is in the form of a plurality of planetary rollers mounted between the radially inner surface of the housing and the radially outer surface of the rotary shaft and each formed with circumferential grooves on the radially outer surface of the planetary roller with the same pitch as the helical rib of the rotary shaft, the helical rib being engaged in the circumferential grooves, whereby the rotation-to-linear-motion converting mechanism converts the rotary motion of the rotary shaft to a linear motion of the planetary rollers, as the slide member, due to engagement between the circumferential grooves and the helical rib.

In the electric linear motion actuator according to the present invention, it is possible to lock the rotor shaft of the electric motor by actuating the pin-driving actuator to advance the locking pin until it is engaged in one of the engaging portions formed on one side of one of the gears of the reduction gear mechanism, thereby stopping the rotation of the gears. This makes it possible to lock the slide member after axially moving the slide member to any desired position. By using this electric linear motion actuator in an electric disk brake system, while the vehicle is being parked, it is possible to keep the brake pads pressed against the brake disk with a necessary force without the need to keep the electric motor energized.

Since the locking pin is movable toward and away from the engaging portions formed on one side of the gear, and the pin-driving actuator for moving the locking pin toward and away from the engaging portions is mounted between the electric motor and the housing in which the slide member and the rotation-to-linear-motion converting mechanism are mounted, the electric motor and the housing have smaller diameters, so that the entire electric linear motion actuator is sufficiently small in size.

Since the pin-driving actuator is mounted between the electric motor and the housing in which the slide member is mounted, good weight balance is maintained, which stabilizes braking operation. Since the pin-driving actuator is protected by the electric motor and the housing too, its protective cover may be a simple one.

DETAILED DESCRIPTION OF THE INVENTION

The embodiment of this invention is now described with reference to the drawings.FIGS. 1 to 5(b) show an electric linear motion actuator A according to the present invention. As shown inFIG. 1, the actuator A includes a cylindrical housing1having a base plate3radially outwardly extending from a first end of the housing1, and a cover4covering the outer side surface of the base plate3and an opening of the housing1at the first end of the housing1.

An outer ring member5as a slide member is mounted in the housing1. The outer ring member5is rotationally fixed but axially movable along the radially inner surface of the housing1. As shown inFIG. 2, a helical rib6having a V-shaped section is formed on the radially inner surface of the outer ring member5.

A bearing member7is mounted in the housing1to face a first axial end of the outer ring member5. The bearing member7is a disk-shaped member having a boss7aat its center. A stopper ring8mounted to the radially inner surface of the housing1prevents the bearing member7from moving toward the cover4.

Two rolling bearings9are mounted in the boss7aof the bearing member7so as to be axially spaced from each other. The rolling bearings9rotatably support a rotary shaft10extending along the center axis of the outer ring member5.

As shown inFIG. 1, an electric motor11having a rotor shaft12is supported by the base plate3. The rotation of the rotor shaft12of the motor11is transmitted to the rotary shaft10through a reduction gear mechanism13mounted in the cover4.

A carrier14is mounted in the outer ring member5so as to be rotatable about the rotary shaft10. As shown inFIGS. 2 and 3, the carrier14includes two axially opposed disks14aand14b. The disk14ahas a plurality of circumferentially spaced apart spacer members14cextending from the radially outer portion of the side of the disk14atoward the other disk14b. The disks14aand14bare coupled together by tightening screws15threaded into the end surfaces of the respective spacer members14c.

The inner one14bof the disks14aand14b, which is located close to the bearing member7, is rotatably and axially slidably supported by a slide bearing16mounted between the disk14band the rotary shaft10.

A shaft inserting hole17(stepped hole) is formed in the center of the outer disk14a. A slide bearing18fitted in the shaft inserting hole17is rotatably supported by the rotary shaft10. A metal washer W is fitted on the rotary shaft10adjacent to the outer end surface of the slide bearing18to support thrust loads. A snap ring19is mounted to the end of the rotary shaft10to prevent separation of the washer W.

The carrier14includes a plurality of circumferentially spaced apart roller shafts20having first and second axial ends thereof supported by the respective disks14aand14b. In particular, the roller shafts20have their first and second axial ends received in elongated shaft inserting holes21formed in the respective disks14aand14bso as to be radially movable. Elastic rings22are each wrapped around the first or second axial ends of the roller shafts20, biasing the roller shafts20radially inwardly.

Planetary rollers23are mounted between the radially outer surface of the rotary shaft10and the radially inner surface of the outer ring member5, while being rotatably supported by the respective roller shafts20. The planetary rollers23are thus pressed against the radially outer surface of the rotary shaft10by the elastic rings22, which are wrapped around the respective first and second axial ends of the roller shafts20, such that the radially outer surfaces of the planetary rollers23are kept in elastic contact with the radially outer surface of the rotary shaft10. Thus, when the rotary shaft10rotates, the planetary rollers23also rotate due to contact friction between the planetary rollers and the radially outer surface of the rotary shaft10.

As shown inFIG. 2, a plurality of helical grooves24having a V-shaped section are formed in the radially outer surface of each planetary roller23at equal axial intervals and with the same pitch as the helical rib6of the outer ring member5. The helical rib6is engaged in the helical grooves24. Instead of the helical grooves24, a plurality of axially equidistantly spaced apart circumferential grooves may be formed in the radially outer surface of each planetary roller with the same pitch as the helical rib6.

As shown inFIG. 2, a washer25and a thrust bearing26are mounted between the axially opposed surfaces of the inner disk14bof the carrier14and each planetary roller23. An annular thrust plate27is mounted between the axially opposed surfaces of the carrier14and the bearing member7. A thrust bearing28is mounted between the thrust plate27and the bearing member7.

As shown inFIG. 2, the opening of the outer ring member5at the second end thereof, which protrudes from the opening of the housing1at its second end, is closed by a seal cover29, preventing entry of foreign matter into the device.

A bellows30has one end thereof coupled to the opening of the housing1at the second end thereof, and the other end to second end of the outer ring member5, preventing entry of foreign matter into the housing1.

As shown inFIGS. 1 and 4, the reduction gear mechanism13includes first to third reduction gear trains G1to G3. The rotation of an input gear31mounted to the rotor shaft12of the electric motor is reduced in a stepwise manner by the respective first to third reduction gears G1to G3and transmitted to an output gear32mounted to the end of the rotary shaft10to rotate the rotary shaft10. The reduction gear mechanism13further includes a locking mechanism40capable of selectively locking and unlocking the rotor shaft12of the electric motor11.

As shown inFIGS. 4,5(a) and5(b), the locking mechanism40includes a plurality of engaging holes41formed in one side of an intermediate gear33of the second gear train G2, which is located on the output side of the gear train G2, so as to be arranged on a common circle at equal angular intervals, a locking pin42movable toward and away from a point on the pitch circle of the engaging holes41, and a linear solenoid43as an actuator for driving the locking pin42, whereby when the locking pin42is engaged in one of the engaging holes41, the intermediate gear33is locked.

The solenoid43is protected by a protective cover44. The protective cover44is supported by the base plate3and disposed between the housing1and the electric motor11. The protective cover44has a front plate45formed with a pin hole46in which the locking pin42is slidably received.

FIG. 9shows an electric disk brake system B in which the electric linear motion actuator A of the above-described embodiment is mounted. This brake system includes a caliper body portion50which is integrally connected to the second end of the housing1, a brake disk51provided such that its radially outer portion extends into the interior of the caliper body portion50, a fixed brake pad52, and a movable brake pad53fixedly coupled to the second end of the outer ring member5.

Now the operation of the electric disk brake system B ofFIG. 9, which includes the linear motion actuator A, is described. When the electric motor, shown inFIG. 1, is driven, the rotation of the rotor shaft12of the electric motor11is reduced in speed by the reduction gear mechanism13and transmitted to the rotary shaft10.

Since the radially outer surfaces of the plurality of planetary rollers23are kept in elastic contact with the radially outer surface of the rotary shaft10, when the rotary shaft10rotates, the planetary rollers23revolve around the rotary shaft10while rotating about their own axes due to contact friction between the planetary rollers23and the rotary shaft10.

At this time, since the helical rib6formed on the radially inner surface of the outer ring member5is engaged in the helical grooves24formed in the radially outer surfaces of the respective planetary rollers23, the outer ring member5moves in the axial direction, thus pressing the movable brake pad53, which is fixedly coupled to the outer ring member5, against the brake disk51, thus applying a braking force to the brake disk51.

While the vehicle in which this brake system is mounted is parked, with the movable brake pad53pressed against the brake disk51such that a braking force necessary to keep the vehicle parked in position is applied to the brake disk51, the linear solenoid43is activated to advance the locking pin42toward the side surface of the intermediate gear33.

If, when the locking pin42is advanced, the locking pin42is aligned with one of the plurality of engaging holes41, as shown inFIGS. 5(a) and5(b), the locking pin42is engaged in this hole41and the intermediate gear33is locked, so that the rotor shaft12of the electric motor11is also locked. Thus the electric motor11can be kept deactivated, so that no electric power is consumed during parking.

If, when the locking pin42is advanced, the locking pin42is aligned with none of the engaging holes41, the locking pin42can engage in none of the engaging holes41. In such a case, with the locking pin42kept in its advanced position, the electric motor11is driven to rotate the intermediate gear33in the direction in which a braking force increases (shown by the arrow X inFIG. 5(a)) until one of the engaging holes41aligns with the locking pin42, thereby allowing the locking pin42to be engaged in the one of the engaging holes41.

Once the locking pin42engages in one of the engaging holes41, thereby locking the intermediate gear33, as well as the rotor shaft12of the electric motor11, the reaction force from the brake disk51acts on the respective gears as torque that tends to counteract the braking force. This torque is applied to the engaging portion between the engaging hole41and the locking pin42. This torque is large at the output gear32and gradually decreases toward the input gear31.

In the embodiment, since the plurality of engaging holes41are formed in the side surface of the intermediate gear33of the second reduction gear train G2, which is on the output side of the gear train G2, torque applied to the engaging portion between the engaging hole41and the locking pin42is relatively small, so that this engaging portion is never damaged.

But to more positively prevent damage to the engaging portion, the engaging holes41are preferably formed in an intermediate gear located as close to the input gear31as possible, with the locking pin42provided at a position corresponding to the engaging holes41.

In the embodiment ofFIG. 1, since the linear solenoid43of the locking mechanism40for driving the locking pin is provided between housing1and the electric motor11, the diameters of the housing1and the electric motor11are both relatively small, so that the entire electric linear motion actuator A is also compact in size.

Also, since the linear solenoid43is mounted between the housing1and the electric motor11, the weight distribution is well balanced, so that the actuator can be operated in a stable manner. Further, since the linear solenoid43is protected by the electric motor11and the housing1, too, the protective cover44may be a simple one.

InFIG. 5, the engaging holes41serve as the pin-engaging portions. But different pin-engaging portions may be used, such as those shown inFIGS. 6(a)-8(b). The pin-engaging portions ofFIGS. 6(a) and6(b) are radial grooves61defined by a plurality of radially extending protrusions60formed on the intermediate gear33.

The pin-engaging portions ofFIGS. 7(a) and7(b) are engaging holes41as in the example ofFIGS. 5(a) and5(b). The engaging holes41each have a locking surface41aand a tapered surface41bat one and the other circumferential ends thereof, respectively, such that when the locking pin42engages the locking surface41a, the intermediate gear33is prevented from further rotating in the direction in which the brake is released, and when the intermediate gear33rotates in the direction in which the braking force increases, the locking pin42is pushed out of the engaging hole41guided by the tapered surface41b.

By providing the tapered surface41bat the other circumferential end of each engaging hole41, the intermediate gear33can be smoothly rotated in the direction in which the braking force increases, which in turn makes it possible to reliably increase the braking force applied to the brake disk51to a value necessary to keep the vehicle parked in position.

The pin-engaging portions ofFIGS. 8(a) and8(b) are radial grooves61as in the example ofFIGS. 6(a) and6(b). The radial grooves61each have a locking surface61aand a tapered surface61bat one and the other circumferential sides thereof, respectively, such that when the locking pin42engages the locking surface61a, the intermediate gear33is prevented from further rotating in the direction in which the brake is released, and when the intermediate gear33rotates in the direction in which the braking force increases, the locking pin42is pushed out of the radial groove61guided by the tapered surface61b.

By providing the tapered surface61bat the other circumferential side of each radial groove61as inFIGS. 8(a) and8(b), the intermediate gear33can be smoothly rotated in the direction in which the braking force increases, which in turn makes it possible to reliably increase the braking force applied to the brake disk51to a value necessary to keep the vehicle parked in position, in the same manner as inFIGS. 7(a) and7(b).

In the electric linear motion actuator shown inFIG. 1, in order to convert the rotary motion of the rotary shaft10to a linear motion, planetary rollers23are mounted between the radially outer surface of the rotary shaft10and the radially inner surface of the housing1, and helical grooves24or circumferential grooves are formed in the radially outer surfaces of the respective planetary rollers23so as to be brought into engagement with the helical rib6formed on the radially inner surface of the outer ring member5. But the mechanism for converting the rotary motion to a linear motion is not limited to this structure.

FIG. 10shows a different rotation-to-linear-motion converting mechanism. In this example, a helical rib70is formed on the radially outer surface of the rotary shaft10, and a plurality of circumferential grooves71are formed in the radially outer surface of each of a plurality of planetary rollers23mounted between the radially outer surface of the rotary shaft10and the radially inner surface of the housing1with the same pitch as the helical rib70, whereby when the rotary shaft10rotates, the planetary rollers23revolve around the rotary shaft10while rotating about their respective own axes by the engagement between the helical rib70and the circumferential grooves71, and simultaneously move in the axial direction, In this example, the axial force from the planetary rollers23is transmitted to the driven member through a thrust bearing72.