Abstract:
The invention relates to a hydrostatic actuator, having a master cylinder including a housing and a piston, which is axially mountable in the housing and which pressurizes a pressure chamber filled with pressure medium, a planetary rolling-contact gear system that converts a rotary drive into an axial motion and that has a sleeve, a gear-driven spindle, and planetary rolling elements that roll therebetween, and an electric motor that drives the planetary rolling-contact gear system and that has a stator rigidly connected to a housing and a rotor that can be rotated relative to the stator. In order to optimize the installation space, the pressure chamber is annular and the planetary rolling-contact gear system is arranged radially within the pressure chamber.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is filed under 35 U.S.C. §120 and §365(c) as a continuation of International Patent Application No. PCT/DE2010/001185 filed Oct. 7, 2010, which application claims priority from German Patent Application No. 10 2009 051 245.4 filed Oct. 29, 2009, which applications are incorporated herein by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention broadly relates to a hydrostatic actuator with a master cylinder that includes a housing and a piston that is axially displaceable in the housing and applies pressure to a pressure chamber filled with a pressure fluid, with a planetary rolling-contact gear system converting a rotary drive into an axial movement and including a sleeve, a gear spindle and planetary rolling bodies rolling off therebetween, and with an electric motor, including a stator, that is fixed to the housing and a rotor that is rotatable relative to the stator. 
       BACKGROUND OF THE INVENTION 
       [0003]    A hydrostatic actuator of this type is known from German Patent No. 197 00 935 A1. In accordance with this document, a piston of a master cylinder is driven by an electric motor and the rotary movement of the electric motor is converted into an axial movement by a gearing mechanism in the form of a worm drive. The piston is driven by an eccentric pin arranged on the worm gear. 
         [0004]    In addition, European Patent No. 0 320 621 A1 discloses a planetary rolling-contact gear system that includes a threaded spindle, a sleeve arranged coaxially with the threaded spindle, and planetary gears rolling off between the two. The planetary gearing mechanism is driven to rotate by an electric motor and converts a fast rotary movement into a slower axial movement. 
         [0005]    Thus, there is a long-felt need for a hydrostatic actuator that is preferably used in a motor vehicle and has an increased efficiency, reduced required installation space, and increased operating pressure of the master cylinder. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    An object of the invention is attained by a hydrostatic actuator having a master cylinder with a housing and with a piston that is axially movable in the housing and applies pressure to a pressure chamber that is filled with a pressure fluid, a planetary rolling-contact gear system converting a rotary drive into an axial movement and including a sleeve, a gear spindle, and planetary rolling bodies rolling off therebetween, as well as an electric motor driving the planetary rolling-contact gear system and including a stator that is fixed to the housing and a rotor that is rotatable relative to the stator, where the pressure chamber is annularly shaped and the planetary rolling-contact gear system is arranged radially inside the pressure chamber. The result is a design that is axially shortened. Alternatively, the planetary rolling-contact gear system may be arranged in the rotor of the electric motor. Compared to this alternative arrangement, an advantage of the arrangement of the planetary rolling-contact gear system radially inside the pressure chamber, as suggested herein, is that this arrangement provides a hydrostatic actuator with a small diameter. The reason for this is that the alternative nestled arrangement, including the rotor and the planetary rolling-contact gear system, requires more installation space than the nestled arrangement of the planetary rolling-contact gear system and the master cylinder, as suggested herein, for example, if the sleeve of the planetary rolling-contact gear system essentially corresponds to the stroke of the piston. 
         [0007]    Moreover, the electric motor and the planetary rolling-contact gear system are preferably arranged coaxially and at a distance from each other. Thus, the diameter of the electric motor can be adapted to be the same as or smaller than the diameter of the master cylinder. If the sleeve is arranged radially inside the annular pressure chamber, the interior space available to the rotor may be small, and with a predetermined diameter, the electric motor may be comparatively powerful. Since the surface portion of the pressure chamber arranged radially on the outside of the housing of the master cylinder is only slightly smaller compared to a total surface with only a small surface portion that is radially on the inside, the installation space located radially inside the pressure chamber may be used for the sleeve. 
         [0008]    The hydrostatic actuator is suitable for use as a master controlled by a control unit to provide a pre-determinable pressure via a pressure port in the pressure chamber and via a pressure line to a slave for axial displacement of components such as a slave cylinder of an opened or closed friction clutch arranged, for instance, between a combustion engine and a gearing mechanism in the drive train of a motor vehicle, a selector shaft or selector roller arranged in a gearing mechanism to shift gears, a brake cylinder for operating brakes, and the like. 
         [0009]    In one embodiment, the housing of the master cylinder and the housing of the electric motor may be of one-piece construction, for instance, made of aluminum or other light metal or alloy thereof in a casting process such as die casting, or of plastic in an injection molding process. Due to the one-piece construction of the housings, the number of parts is reduced and the stability of the two housings with the piston supported on the housing between the master cylinder and the electric motor is increased when the pressure chamber is pressurized. 
         [0010]    In this context, it is preferable that a pressure fluid reservoir is integrated into the hydrostatic actuator without increasing the required installation space to any significant extent. The reservoir may contain a pressure fluid supply that may be exchanged in the relaxed state of the piston when a loss of pressure fluid occurs in the hydraulic system between the master cylinder, pressure line and slave cylinder, or when temperature fluctuations occur between the pressure chamber and the reservoir. For instance, with a predetermined diameter of the electric motor, the diameter of the master cylinder may be matched with the diameter of the electric motor, the reservoir being provided in an annular space radially outside the pressure chamber. In this context, the annular space may be intersected by a hollow cylinder that is located along the axis of rotation and may include a connection to a separate and/or further reservoir for instance in the case of an unfavorable inclination of the hydrostatic actuator upon its installation in a motor vehicle or a bellows to equalize pressure with the environment in order to even out pressure differences between the reservoir, and thus, the pressure chamber in the unpressurized state and the environment. 
         [0011]    In another embodiment with the sleeve of the planetary rolling-contact gear system axially spaced apart from the electric motor, the sleeve may be fixed to the housing so as to be fixed against rotation and axially displaceable and the piston may be driven by the sleeve. The sleeve may be arranged longitudinally in the housing and connected to the piston to be rotationally fixed. As a consequence, the gear spindle, which requires a considerable amount of installation space in the axial direction, is driven by the electric motor and remains axially fixed in position so that it may, for instance, be extended over the entire axial installation space and may be supported and axially fixed on both end faces of the hydrostatic actuator. The length of the hydrostatic actuator may be adapted to the threaded spindle without stroke. The stroke of the sleeve is identical with the stroke of the piston, which means that the axial displacement of the sleeve does not increase the required axial installation space. Thus, the present invention provides a space-saving hydrostatic actuator. 
         [0012]    In order to be able to design the electric motor as an electronically commutated motor on the one hand and to monitor the rotary movement of the gear spindle on the other hand, a sensor device is provided in the hydrostatic actuator to at least sense a rotary movement of the gear spindle. The sensor device may include Hall effect sensors that detect an analogous angle or increment sensors that detect the number of magnetic pulses over an angle of rotation of the gear spindle and determine the angle from the number of detected magnetic pulses. Suitable measures may be taken to calibrate the incremental sensors to a defined reference point such as the angular difference, for example, a stop that is detected by the control device may be provided. The Hall effect sensors are formed by a sensor part that is preferably fixed to the housing to provide better wiring options, and by one or more sensing magnets that are arranged on the movable component. In this way, sufficient angular resolutions of the angle of rotation of the gear spindle are possible in accordance with the number of sensing magnets distributed along the circumference of the gear spindle, i.e., of magnet segments formed thereof generating magnetic pulses. 
         [0013]    For reasons of the electric or electronic susceptibility, it is preferable that at least one sensor for detecting operating data of the hydrostatic actuator is arranged on a circuit board of the local electronics. The circuit board may be arranged directly in an optimum position of the sensor or, if there is no such space available in this region, a non-electronic variable to detect the signal such as a mechanical or intrinsic physical variable may be fed to the region of the positioned circuit board. 
         [0014]    As an alternative or in addition to the detection of the angle of rotation of the gear spindle, the detection of the stoke of the sleeve or piston by means of a Hall effect sensor is preferable. For this purpose, a suitable sensor may be provided directly in the region between the housing and piston or sleeve, with the wires leading to a local electronics for signal conversion potentially provided in the housing, or leading out of the housing. If the local electronics is remote in particular due to a lack of installation space, for example, for reasons of lower electromagnetic susceptibility of such a sensor, it is preferable for the sensor to be arranged close to or on the local electronics and for the movement of the piston or sleeve to be transmitted to the sensor by means of a rod. Potential slip of the planetary rolling-contact gear system may be determined and compensated for in particular from sensed signals of the angle of rotation of the gear spindle and from the axial displacement of the piston. 
         [0015]    Alternatively or redundantly, the effect of the piston on the pressure chamber may be detected by sensing the pressure in the pressure chamber by means of a pressure sensor. To be able to determine the pressure directly by means of a pressure sensor arranged on a circuit board belonging to a local electronics and removed in space from the pressure chamber, a connecting bore that extends as far as the local electronics may be provided on the pressure chamber in the housing, for example, in a one-piece housing of the master cylinder and the electric motor. In terms of the invention, the local electronics may be provided on the side of the housing of the electric motor that faces away from the master cylinder, or in a non-required free space of the housing(s) of the hydrostatic actuator. The local electronics may be arranged in the region of or inside a cover that closes off the housing of the electric motor towards the outside once the electric motor and the components that are mounted from this side have been installed. A plug-in connection to the control device may be provided in the cover or in the housing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which: 
           [0017]      FIG. 1  illustrates the hydrostatic actuator of the invention; 
           [0018]      FIG. 2  is an elevational view of the hydrostatic actuator shown in  FIG. 1 ; 
           [0019]      FIG. 3  is a cross-sectional view taken along line A-A of the hydrostatic actuator shown in  FIG. 2 ; 
           [0020]      FIG. 4  is a cross-sectional view taken along line B-B of the hydrostatic actuator shown in  FIG. 2 ; and, 
           [0021]      FIG. 5  is a cross-sectional view taken along line C-C oldie hydrostatic actuator shown in  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspects. 
         [0023]    Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and, as such, may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims. 
         [0024]    Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described. 
         [0025]      FIG. 1  is a three-dimensional view of the hydrostatic actuator including one-piece housing  3  formed by the housing of electric motor  2  and the housing of the master cylinder, and housing portion  4  including reservoir dome  5  that is closed by covering cap  6 , which has pressure compensation opening  7 . Installation opening  12 , which is closed by further covering cap  11 , is used to install components and to test the functioning, for example, of the sensors of hydrostatic actuator  1 . 
         [0026]    Mounting  8  to fix hydrostatic actuator  1  to a component that is fixed to a frame, for instance, a firewall of a motor vehicle is provided on housing  3 . In addition, pressure port  9  of pressure line  10  that provides a connection to a non-illustrated slave cylinder is fixed to housing  3 , for instance, as a quick-acting coupling. Pressure port  9  is connected to the pressure chamber of the master cylinder. On the inside of the housing portion, there is a bearing to receive the gear spindle. On the outside, the housing portion is reinforced by reinforcement ribs  13 . In one embodiment, housing portion  4  may be made of light metal such as aluminum and alloys thereof or of plastic, for instance, in a die casting or injection molding process. 
         [0027]      FIG. 2  is an elevational view of the hydrostatic actuator of  FIG. 1 , including housing portion  4  with reservoir dome  5  and installation opening  12  as well as mounting  8  fixed to housing  3  (shown in  FIG. 1 ) and pressure port  9 . Section lines A-A, B-B, and C-C represent the cut surfaces of the sectional views of the hydrostatic actuator illustrated in  FIGS. 3 ,  4 , and  5 . 
         [0028]      FIG. 3  is a cross-sectional view of hydrostatic actuator  1  taken along section line A-A of  FIG. 2 , showing one-piece housing  3  formed by housing  14  of electric motor  2  and housing  15  of master cylinder  16 , and housing portion  4  that is fixed to housing  3 , for example, by screwing, pressing or welding. 
         [0029]    Stator  17  of the electric motor is received radially inside on centering sleeve  18 , which acts to center and support gear spindle  19  by means of the integrally formed axial bearing dome  20 . Stator  17  is axially locked between bearing disc  21  and centering sleeve  18  and fixed against rotation in centering sleeve  18 . Centering sleeve  18  axially fixes bearing disc  21  to stop  22  of housing  3  and is axially fixed itself by means of stop disc  23  and cover  24  that is connected, for instance, screwed to housing  3 . 
         [0030]    Rotor  25 , which is arranged radially inside stator  17 , is received radially inside on bearing sleeve  26  to be axially fixed and centered thereon. Bearing sleeve  26  is received for rotation in an axially fixed manner by means of bearing disc  21 . For this purpose, axial bearings  27 , for example needle bearings, are arranged on both sides of bearing disc  21 . Axial bearings  27  form a bearing seat with annular rim  28  of bearing sleeve  26 , on the one hand, and with rotor  25  that is axially fixed on bearing sleeve  26  by means of securing disc  29 , on the other hand. Bearing sleeve  26  is connected to gear spindle  19  to be fixed against rotation relative to the latter, for instance, shrink-fitted so that axial centering of bearing sleeve  26 , and thus, of rotor  25  is achieved by means of radial bearing  30  via centering sleeve  18  on housing  3  and axial support of gear spindle  19  on the housing is achieved via bearing disc  21 . Gear spindle  19  is additionally supported by radial bearing  31  in bearing dome  32  of housing portion  4 . 
         [0031]    Planetary rolling-contact gear system  33  formed by gear spindle  19 , sleeve  34 , and planetary rolling bodies  35  rolling off therebetween is arranged to be axially spaced apart from electric motor  2 . To convert the rotary movement of threaded spindle  19 , which is driven to rotate by rotor  25 , into an axial movement of sleeve  34 , the planetary rolling bodies have toothing  36 , which meshes with coarse toothing  37  of sleeve  34 , and with fine-pitch thread  38 , which meshes with exterior thread  39  of the gear sleeve. 
         [0032]    Master cylinder  40  is arranged radially outside planetary rolling-contact gear system  33  and includes piston  41 , which is moved in the axial direction by sleeve  34 , and pressure chamber  42 , which is equipped with pressure port  9  (shown in  FIG. 1 ). Piston  41  and pressure chamber  42  are arranged annularly around sleeve  34 . Pressure chamber  42  is sealed by grooved ring seals  43 ,  44  arranged between piston  41  and housing  15 . Further grooved ring seal  45  seals piston  41  towards the interior of housing portion  4 . Spacer ring  46  is provided between two grooved ring seals  43 ,  44 . Housing portion  4  is sealed towards housing  15  by means of annular seal  47 . 
         [0033]    In one embodiment, master cylinder  40  is shown in the fully operated condition, i.e., piston  41  is moved towards electric motor  2  to build up pressure and is thus in a position that corresponds to the extended position of piston  41 . Thus, a circuit of forces is created outside the electric motor and operation essentially free of axial forces can be achieved. The axial force exerted by planetary rolling-contact gear system  33  to move piston  41  is supported by bearing disc  21  on housing  3 . The pressure exerted by the piston  41  onto the pressure chamber  42  is likewise introduced into housing  3  so that a short low-elasticity circuit of forces is formed. 
         [0034]    To prevent the sleeve from rotating as a result of drag and friction torques, sleeve  34  is received and guided in housing  15  in a manner to be fixed against rotation. For this purpose, longitudinal guide  48  is provided between sleeve  34  and housing  15 . Longitudinal guide  48  may be formed by one or more longitudinal grooves that are distributed in the circumferential direction and into which complementary longitudinal springs engage in the radial direction. To improve in particular the tribologic behavior of grooved ring seals  43 ,  44 , the longitudinal guide may be slightly helical. For instance, it may have a small angular proportion of a few degrees in the circumferential direction. 
         [0035]    Stator  17 , rotor  25 , and planetary rolling-contact gear system  33  may form an assembly unit that is inserted into housing  3  from one side. Subsequently, the housing may be closed on this side by means of cover  24 . Master cylinder  40  is installed from the other side, with piston  41  being connected to the sleeve at least in an axially fixed manner, for instance caulked, locked, or suspended therein. 
         [0036]      FIG. 4  is a cross-sectional view of hydrostatic actuator  1  taken along line B-B in  FIG. 2 . This view illustrates the arrangement of reservoir  49  for the operation of the hydraulic system into which hydrostatic actuator  1  is integrated due to pressure chamber  42 . Reservoir  49  extends radially outside pressure chamber  42  in housing portion  4  and is delimited by spacer ring  46 . A volume exchange between reservoir  49  and pressure chamber  42  occurs with piston  41  (shown here in the Fully operated condition) in the resting position. In the resting position, piston  41  is moved radially towards bearing dome  32  far enough for it to pass grooved ring seal  43 . Thus, reservoir  49  is connected to pressure chamber  42  by means of one or more channels  50  provided in spacer ring  46 . Compensation grooves  51  may be provided in piston  41  to improve control of the transition between closed and open connection. 
         [0037]    Reservoir dome  5  is connected to reservoir  49  in a non-illustrated location by means of openings, for example. Reservoir dome  5  includes bellows  52 , which is connected to reservoir  49  on one side and to the environment on the other side via pressure compensation opening  7  to even out a pressure difference between reservoir  49  and the environment. 
         [0038]    The cross-sectional view of  FIG. 4  further indicates axial extension  53  of pressure chamber  42  in housing  3 . Axial extension  53  extends as far as the end face shoulder  53   a , at which a non-illustrated local electronics is positioned. Thus, extension  53  is directly fed to a pressure sensor for detecting the operating pressure of pressure chamber  42 , and thus, of master cylinder  40 . The pressure sensor is provided on a circuit board of the local electronics and may be used without electric lines. 
         [0039]      FIG. 5  is a cross-sectional view of hydrostatic actuator  1  taken along line C-C of  FIG. 2 . This view is towards the sensor device  54 , which may be arranged on local electronics  55 , which is formed by at least electronic circuit board  56  on which the necessary electronic components are provided for controlling electric motor  2  and supplying it with energy and for processing and/or transmitting the measurement signals sensed by the sensors. Local electronics  55  includes connector  57  which may be guided through housing  3  or cover  24  and includes signal and supply lines and is connected to an external control device. Local electronics  55  is arranged and fixed between the centering sleeve  18  and the cover  24 . 
         [0040]    In one embodiment, all sensors for controlling the hydrostatic actuator are positioned in a central position on circuit board  56  without a connecting line. For this purpose, pressure sensor  58  is received on circuit board  56 . Pressure sensor  58  detects the pressure at extension  53 , such as the connecting bore of  FIG. 4 , and seals the extension. In addition, sensor  59  for sensing the angle or rotation of gear spindle  19  is arranged on circuit board  56 . Sensor  53  may be a Hall effect sensor, with associated sensing magnet  60  arranged on gear spindle  19 . To detect the axial path of piston  41 , rod  61  is connected to piston  41 , for instance, suspended or locked therein. Rod  61  is axially guided in guide  62  of housing portion  4  and is guided as far as circuit board  56 . Thus, axial path sensor  63 , which is only diagrammatically indicated here and is received on circuit board  56  and extends into clearance  65  formed in housing  3  detects the axial path of piston  41  at a spatial and axial distance thereto. Axial path sensor  63  is preferably a Hall effect sensor that detects the axial path depending on the distance of sensing magnet  64  mounted on rod  61 . Installation opening  12  closable by covering cap  11  is provided in housing portion  4  for the purpose of mounting rod  61  and testing the functioning of axial path sensor  63 . 
         [0041]    Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention. 
       LIST OF REFERENCE SYMBOLS 
       [0000]    
       
           1  hydrostatic actuator 
           2  electric motor 
           3  housing 
           4  housing portion 
           5  reservoir dome 
           6  covering cap 
           7  pressure compensation opening 
           8  mounting 
           9  pressure port 
           10  pressure line 
           11  covering cap 
           12  installation opening 
           13  reinforcement rib 
           14  housing 
           15  housing 
           16  master cylinder 
           17  stator 
           18  centering sleeve 
           19  gear spindle 
           20  bearing dome 
           21  bearing disc 
           22  stop 
           23  stop disc. 
           24  cover 
           25  rotor 
           26  bearing sleeve 
           27  axial bearing 
           28  annular rim 
           29  securing disc 
           30  radial bearing 
           31  radial bearing 
           32  bearing dome 
           33  planetary rolling-contact gear system 
           34  sleeve 
           35  planetary rolling body 
           36  toothing 
           37  toothing 
           38  fine-pitch thread 
           39  exterior thread 
           40  master cylinder 
           41  piston 
           42  pressure chamber 
           43  grooved ring seal 
           44  grooved ring seal 
           45  grooved ring seal 
           46  spacer ring 
           47  annular seal 
           48  longitudinal guide 
           49  reservoir 
           50  channel 
           51  compensation groove 
           52  bellows 
           53  extension 
           53   a  shoulder 
           54  sensor device 
           55  local electronics 
           56  circuit board 
           57  connector 
           58  pressure sensor 
           59  angle of rotation sensor 
           60  sensing magnet 
           61  rod 
           62  guide 
           63  axial path sensor 
           64  sensing magnet 
           65  clearance 
         A-A section line 
         B-B section line 
         C-C section line