CN109121428B - Electromagnetic clutch and method of manufacturing the same - Google Patents
Electromagnetic clutch and method of manufacturing the same Download PDFInfo
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- CN109121428B CN109121428B CN201780001873.6A CN201780001873A CN109121428B CN 109121428 B CN109121428 B CN 109121428B CN 201780001873 A CN201780001873 A CN 201780001873A CN 109121428 B CN109121428 B CN 109121428B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 238000004804 winding Methods 0.000 claims abstract description 275
- 230000005389 magnetism Effects 0.000 abstract description 7
- 229910052782 aluminium Inorganic materials 0.000 description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 238000010586 diagram Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000001746 injection moulding Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000005284 excitation Effects 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 238000004378 air conditioning Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D27/00—Magnetically- or electrically- actuated clutches; Control or electric circuits therefor
- F16D27/10—Magnetically- or electrically- actuated clutches; Control or electric circuits therefor with an electromagnet not rotating with a clutching member, i.e. without collecting rings
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Mechanical Engineering (AREA)
- Electromagnets (AREA)
Abstract
An electromagnetic clutch and a method of manufacturing the same are provided, which have a structure in which a winding wire is wound around a bobbin in a tight and orderly state. An electromagnetic clutch (10) is provided with a rotor (11), an armature (12) disposed above the rotor (11), and a magnetism generating unit (20) built in the armature (12). The magnetism generation unit (20) is provided with a bobbin (21), a winding wire wound around the bobbin (21), and a ring (22) that houses the bobbin (21). The bobbin (21) has a cylindrical body (30), a first flange section (31), a second flange section (32), a notch (33) formed in the first flange section (31), and a non-circular convex section (34) that protrudes radially outward from one end of the outer surface of the cylindrical body (30).
Description
Technical Field
The present invention relates to an electromagnetic clutch and a method of manufacturing the same, and more particularly, to an electromagnetic clutch in which a winding wire is wound around a bobbin in order, and a method of manufacturing the same.
Background
The electromagnetic clutch is a mechanical mechanism disposed between an air-conditioning compressor and a power source such as an engine, and mechanically and intermittently connects the compressor and the power source. This type of electromagnetic clutch mainly includes a rotor having a built-in coil, an armature disposed on a side of the rotor, and a hub connecting a drive shaft and an armature plate.
When power is transmitted from the power source to the compressor, power is supplied to a coil formed of a winding wire wound around a bobbin to generate magnetic force, and the armature is attracted to the side surface of the rotor by the magnetic force. Thereby, the armature and the rotor are drivingly coupled via the hub, and the engine operates the compressor of the air conditioner.
On the other hand, if the power supply to the coil is stopped, the magnetic force disappears, the armature moves away from the rotor side surface, and the armature is separated from the drive of the rotor. Thereby, the compressor of the air conditioner is stopped.
In a coil built in an electromagnetic clutch, a winding wire needs to be tightly wound with respect to a bobbin in order to achieve miniaturization. For example, patent document 1 describes an invention for winding a winding group around a bobbin in a satisfactory manner. To describe a structure for the winding wire described in patent document 1, first, a wire portion is formed at an end portion of a cylindrical portion of a bobbin, and a spiral groove for guiding a metal wire is further formed on a surface of the cylindrical portion. According to the invention described in patent document 1, since the wire portions support the metal wire of the second layer in an externally attached state, the metal wire can be stably wound, and misalignment and scattering can be prevented.
Documents of the prior art
Patent document
Patent document 1: japanese unexamined patent publication No. 2013-16695
Disclosure of Invention
Technical problem to be solved by the invention
However, in the invention described in patent document 1, the wire portions for defining the position of the winding wire are in contact with only the metal wire of the second layer. Therefore, the coil portions do not define the position of the winding wire of the first layer, and when the position of the winding wire of the first layer is shifted from the designed position, the positions of the winding wires wound around the second layer outside the winding wire of the first layer are also shifted, and scattering may occur.
Further, since the diameters of the winding wires have a certain degree of tolerance, in the case where the thin portion of the wire forms the first layer of the winding wire, the second layer of the winding wire falls between the winding wires and between the winding wire and the side wall of the bobbin, and there is a problem that the winding wires are scattered and cannot be tightly wound.
In addition, in a general coil used for an electromagnetic clutch, a copper wire is used as a winding wire. Here, if an aluminum wire is used as the winding wire for the purpose of weight reduction and cost reduction of the clutch, a strong tensile stress cannot be applied when the aluminum wire is wound, and therefore the above problem still remains.
The present invention has been made in view of the above circumstances, and an object thereof is to provide an electromagnetic clutch having a structure in which a winding wire is wound around a bobbin in a tight and neat state, and a method of manufacturing the electromagnetic clutch.
Technical solution for solving technical problem
An electromagnetic clutch according to the present invention includes: a rotor; an armature disposed on an axial side of the rotor and attracted to a side surface of the rotor by a magnetic field; a magnetic generating unit that generates the magnetic field by excitation, the magnetic field causing the armature to be attracted to the rotor; the magnetic generating unit includes a bobbin having a cylindrical or substantially cylindrical barrel portion, a first flange portion extending in a wall shape from one axial end side of the barrel portion to the outside in the radial direction, a second flange portion extending in a wall shape from the other axial end side of the barrel portion to the outside in the radial direction, a notch formed in the first flange portion, and a projecting portion of an incomplete ring shape projecting the one end of the outer surface of the barrel portion to the outside in the radial direction, the projecting portion having a forward side end portion and a reverse side end portion in the winding direction of the winding wire, and a winding wire wound around the bobbin, and the forward side end portion being disposed on the forward side apart from the notch.
In the electromagnetic clutch according to the present invention, the axial width of the convex portion is half or substantially half of the diameter of the winding wire, and the winding wire disposed on the other side of the winding wire of the first layer is in contact with the second flange portion.
In the electromagnetic clutch according to the present invention, a receiving convex portion that abuts the winding wire of the first layer is formed on the outer peripheral surface of the cylindrical portion of the bobbin along the winding direction, and an inclination angle of the receiving convex portion from the outer peripheral surface of the cylindrical portion is 45 degrees or more and 60 degrees or less.
The present invention is a method of manufacturing an electromagnetic clutch having a step of forming a magnetic generating unit by winding a winding wire around a bobbin, the electromagnetic clutch including a cylindrical or substantially cylindrical bobbin, a first flange portion extending in a wall shape from an axial end side of one side of the bobbin to an outer side in a radial direction, a second flange portion extending in a wall shape from an axial end side of the other side of the bobbin to an outer side in a radial direction, a notch formed in the first flange portion, and a projecting portion of an incomplete ring shape projecting radially outward from an end of one side of an outer surface of the bobbin, the projecting portion having a forward side end portion and a reverse side end portion in a winding direction of the winding wire, the forward side end portion of the projecting portion being disposed on a forward side apart from the notch, when the winding wire is wound around the bobbin, the winding wire wound around the bobbin from the slit is wound around the barrel portion of the bobbin while being in contact with the convex portion.
In the method of manufacturing an electromagnetic clutch according to the present invention, when the winding wire is wound around the cylindrical portion, the winding wire is supplied to the rotating bobbin through a nozzle, and when a direction perpendicular to a tangential direction of a winding start portion of the cylindrical portion where the winding wire starts to be wound around the cylindrical portion and a direction away from the bobbin is a first direction and a direction opposite to the first direction is a second direction, the nozzle is disposed on the second direction side of the winding start portion of the cylindrical portion of the bobbin where the winding wire starts to be wound.
In the method of manufacturing the electromagnetic clutch according to the present invention, the nozzle is disposed on the second direction side with respect to the cylindrical portion of the bobbin on which the winding wire starts to be wound, and is disposed on the first direction side with respect to the center of the cylindrical portion.
ADVANTAGEOUS EFFECTS OF INVENTION
An electromagnetic clutch according to the present invention includes: a rotor; an armature disposed on an axial side of the rotor and attracted to a side surface of the rotor by a magnetic field; a magnetic generating unit that generates the magnetic field by excitation, the magnetic field causing the armature to be attracted to the rotor; the magnetic generating unit includes a bobbin having a cylindrical or substantially cylindrical barrel portion, a first flange portion extending in a wall shape from one axial end side of the barrel portion to the outside in the radial direction, a second flange portion extending in a wall shape from the other axial end side of the barrel portion to the outside in the radial direction, a notch formed in the first flange portion, and a projecting portion of an incomplete ring shape projecting the one end of the outer surface of the barrel portion to the outside in the radial direction, the projecting portion having a forward side end portion and a reverse side end portion in the winding direction of the winding wire, and a winding wire wound around the bobbin, and the forward side end portion being disposed on the forward side apart from the notch. Therefore, in the present invention, the number of windings of the winding wire can be secured to be constant or more by winding the winding wire neatly around the bobbin, and the bobbin can be miniaturized, but in the initial stage of winding the winding wire around the bobbin, the position of the winding wire wound into the bobbin from the notch of the first flange portion can be effectively arranged at a predetermined position by the convex portion, and the winding wire of the first layer can be accurately wound around the solenoid. Further, by separating the forward side end portion of the convex portion from the notch, the degree of bending of the portion where the winding wire starts to be wound can be relaxed. Therefore, by winding the winding wire after the second layer is wound on the upper layer of the winding wire of the first layer which is accurately wound as designed, the winding wires of all the layers can be accurately wound as designed.
In the electromagnetic clutch according to the present invention, the axial width of the convex portion is half or substantially half of the diameter of the winding wire, and the winding wire disposed on the other side of the winding wire of the first layer is in contact with the second flange portion. Therefore, the winding wires of the second layer can be easily wound between the winding wires of the first layer, and the winding wires after the second layer can be accurately wound.
In the electromagnetic clutch according to the present invention, a receiving convex portion that abuts the winding wire of the first layer is formed on the outer peripheral surface of the cylindrical portion of the bobbin along the winding direction, and an inclination angle of the receiving convex portion from the outer peripheral surface of the cylindrical portion is 45 degrees or more and 60 degrees or less. Therefore, the receiving convex portion can be brought into contact with the surface of the winding wire of the first layer, thereby winding the winding wire of the first layer at a predetermined portion. Further, by setting the inclination angle of the housing convex portion to 45 degrees or more, the housing convex portion can receive the pressure applied when winding the winding wire of the second layer, and the winding wire of the second layer can be prevented from coming off from the predetermined position. Further, by setting the inclination angle of the housing convex portion to 60 degrees or less, it is possible to ensure good releasability between the molding die and the bobbin when the bobbin is molded by injection molding.
The present invention is a method of manufacturing an electromagnetic clutch having a step of forming a magnetic generating unit by winding a winding wire around a bobbin, the electromagnetic clutch including a cylindrical or substantially cylindrical bobbin, a first flange portion extending in a wall shape from an axial end side of one side of the bobbin to an outer side in a radial direction, a second flange portion extending in a wall shape from an axial end side of the other side of the bobbin to an outer side in a radial direction, a notch formed in the first flange portion, and a projecting portion of an incomplete ring shape projecting radially outward from an end of one side of an outer surface of the bobbin, the projecting portion having a forward side end portion and a reverse side end portion in a winding direction of the winding wire, the forward side end portion of the projecting portion being disposed on a forward side apart from the notch, when the winding wire is wound around the bobbin, the winding wire wound around the bobbin from the slit is wound around the barrel portion of the bobbin while being in contact with the convex portion. Therefore, the position of the winding wire wound into the bobbin from the notch of the first flange portion is effectively arranged at the predetermined position by the convex portion, and the winding wire of the first layer can be accurately wound around the solenoid. Therefore, by winding the winding wire after the second layer is wound on the upper layer of the winding wire of the first layer which is accurately wound as designed, the winding wires of all the layers can be accurately wound as designed.
In the method of manufacturing an electromagnetic clutch according to the present invention, when the winding wire is wound around the cylindrical portion, the winding wire is supplied to the rotating bobbin through a nozzle, and when a direction perpendicular to a tangential direction of a winding start portion of the cylindrical portion where the winding wire starts to be wound around the cylindrical portion and a direction away from the bobbin is a first direction and a direction opposite to the first direction is a second direction, the nozzle is disposed on the second direction side of the winding start portion of the cylindrical portion of the bobbin where the winding wire starts to be wound. Therefore, the winding wire can be stroked by the nozzle when the winding wire is discharged from the nozzle, and the winding wire can be supplied to a predetermined portion of the bobbin body by the pressing force applied to the winding wire at the time of stroking.
In the method of manufacturing the electromagnetic clutch according to the present invention, the nozzle is disposed on the second direction side with respect to the cylindrical portion of the bobbin on which the winding wire starts to be wound, and is disposed on the first direction side with respect to the center of the cylindrical portion. Therefore, by appropriately straightening the winding wire with the nozzle, excessive deformation of the winding wire due to the straightening can be suppressed, and the winding wire can be prevented from being misaligned due to the deformation.
Drawings
Fig. 1 is a sectional view showing an electromagnetic clutch according to an embodiment of the present invention.
Fig. 2 is an exploded perspective view showing a magnetism generating unit constituting an electromagnetic clutch according to an embodiment of the present invention.
Fig. 3 is a view showing an electromagnetic clutch according to an embodiment of the present invention, where (a) is a perspective view showing the entire bobbin, and (B) is an enlarged perspective view showing a main part thereof.
Fig. 4 is a diagram showing an electromagnetic clutch according to an embodiment of the present invention, where (a) is a cross-sectional view of a bobbin around which a winding wire is wound, and (B) is a schematic diagram showing a structure in which the winding wire is wound around the bobbin.
Fig. 5 is a diagram showing an electromagnetic clutch according to an embodiment of the present invention, where (a) is an enlarged view showing a structure in which a winding wire is wound around a bobbin, and (B) is an enlarged view showing a comparative example.
Fig. 6 is a diagram showing an electromagnetic clutch according to an embodiment of the present invention, and is an enlarged view showing a structure in which a winding wire is wound around a bobbin.
Fig. 7 is a diagram illustrating a method of manufacturing an electromagnetic clutch according to an embodiment of the present invention, where (a) is a side view illustrating a process of winding a winding wire around a bobbin, and (B) is a diagram illustrating a shape of a nozzle and the like.
Detailed Description
Hereinafter, the electromagnetic clutch 10 and the method of manufacturing the same according to the present embodiment will be described with reference to the drawings. In the following description, the same reference numerals are given to the same portions, and overlapping description is omitted. In the following description, the respective directions of up, down, left, and right are used, but the left and right are left and right in the case of facing the winding direction, the upper side is the outer side in the radial direction of the bobbin 21, and the lower side is the inner side in the radial direction of the bobbin 21.
A schematic structure of the electromagnetic clutch 10 of the present embodiment will be described with reference to a cross-sectional view of fig. 1. The electromagnetic clutch 10 mainly includes a rotor 11, an armature 12 disposed above the rotor 11, and a magnetic generating unit 20 (coil) incorporated in the armature 12.
The electromagnetic clutch 10 is mounted between a compressor of an air conditioner (not shown) that cools and heats the vehicle interior and a power source (not shown) such as an engine, for example, and has a function of driving and intermittently connecting the compressor and the power source. While power is supplied from a control device (not shown) to the winding wire 38 (not shown) of the magnetic generating unit 20, the electromagnetic clutch 10 drivingly connects the compressor and the power source, thereby operating the air conditioner. On the other hand, if the power supply from the control device, not shown, is stopped, the compressor and the power source are driven separately, and the air conditioner is stopped.
The rotor 11 is formed in a substantially annular shape, and is formed as a single body with a pulley that transmits power from a power source via a belt, not shown. The rotor 11 incorporates a magnetism generating unit 20.
The armature 12 is disposed to face the upper side surface of the rotor 11, and is composed of a plurality of annular armature plates. During the period in which the power is not supplied to the magnet generating unit 20 built in the rotor 11, the armature 12 is separated from the upper side surface of the rotor 11 without rotating. On the other hand, while the magnetic generator 20 of the rotor 11 is energized, the armature 12 is attracted to the upper side surface of the rotor 11 by the magnetic field and rotates together with the rotor 11.
A hub 18 is disposed near the center of the armature 12, and the hub 18 is drivingly connected to a compressor, not shown, disposed below the rotor 11 via a drive shaft, not shown.
As will be described later, in the electromagnetic clutch 10 of the present embodiment, the magnet generating unit 20 is arranged with the winding wire 38 aligned, so that the magnet generating unit 20 can generate a large magnetic force with a small volume, and the armature 12 can be attracted to the rotor 11. Therefore, the electromagnetic clutch 10 can be efficiently operated, and the electric energy required for the operation of the electromagnetic clutch 10 can be reduced.
The structure of the magnetic generating unit 20 will be described with reference to fig. 2. The magnetism generating unit 20 includes a bobbin 21, a winding wire 38 wound around the bobbin 21 and not shown here, a ring 22 housing the bobbin 21, and a connector 23 connecting the winding wire 38 wound around the bobbin 21 to the outside. The lower surface of the ring 22 is covered with a cover made of a steel plate, not shown here.
The bobbin 21 is made of an injection-molded resin material, and is a member for winding a not-shown winding wire 38 into a predetermined shape. A plurality of projections are formed on the outer side surface of the bobbin 21 to fix a fuse or the like, not shown.
The ring 22 is formed of a steel plate formed in a substantially annular shape, and has an internal space capable of accommodating the bobbin 21, and an opening for inserting the bobbin 21 in the upper surface.
The connector 23 is fixed to the lower surface of the bobbin 21, and is connected to both ends of the winding wire 38, not shown. The lower end of the connector 23 is led out downward through an opening, not shown, formed in the lower surface of the ring 22.
The inner space of the ring 22 in which the bobbin 21 is housed is filled with a resin not shown here. Thus, the bobbin 21, the winding wire 38, the ring 22, and the connector 23, which are not shown, are integrated into a module, and are built into the rotor 11 shown in fig. 1 in this state.
The structure of the winding pipe 21 will be described with reference to fig. 3. Fig. 3(a) is a perspective view showing the entire bobbin 21, and fig. 3(B) is an enlarged perspective view showing a main part of the bobbin 21. In fig. 3(B), the winding direction, which is the direction in which the winding wire 38 is wound, is indicated by an arrow.
Referring to fig. 3 a, the bobbin 21 includes a cylindrical or substantially cylindrical barrel portion 30 having a central axis in the vertical direction, a first flange portion 31 extending in a wall shape from an axial end side of one side (upper side in this case) of the barrel portion 30 to the outside in the radial direction, a second flange portion 32 extending in a wall shape from an axial end side of the other side (lower side in this case) of the barrel portion 30 to the outside in the radial direction, a notch 33 formed in the first flange portion 31, and a projecting portion 34 in an incomplete ring shape projecting radially outward from an end portion of one side (upper side in this case) of the outer surface of the barrel portion 30. The barrel portion 30, the first flange portion 31, and the second flange portion 32 constituting the bobbin 21 are formed of synthetic resin integrally molded by injection molding using a molding die. A winding wire 38, not shown here, is wound around the inner space surrounded by the outer side surface of the barrel portion 30, the inner side surface of the first flange portion 31, and the inner side surface of the second flange portion 32.
The housing convex portion 37 is formed by projecting the outer side surface of the barrel portion 30 outward in the radial direction along the circumferential direction. The receiving convex portion 37 is in contact with the winding wire 38 in the first row from the radially inner side, and is used for neatly winding the winding wire 38 in the first row into a predetermined shape. The shape and the like of the housing projection 37 will be described later with reference to fig. 6.
A specific structure of the bobbin 21 will be described with reference to fig. 3 (B). First, the notch 33 is formed by partially cutting the first flange portion 31. The notch 33 is formed from the radially outer end to the radially inner end of the first flange 31. The width of the slit 33 in the circumferential direction is a length that allows one end of the winding wire 38 to be led out from the bobbin 21 to the outside, and further a length that allows the other end of the winding wire 38 to be led into the bobbin 21 from the outside.
The side projecting portion 24 is formed by projecting the outer side surface of the first flange portion 31 axially outward at a position across the notch 33. The connector 23 shown in fig. 1 is fitted to the side protruding portion 24, and thereby the connector 23 is fixed to a predetermined position of the bobbin 21.
The convex portion 34 is formed at a portion where the outer side surface of the barrel portion 30 is continuous with the inner side surface of the first flange portion 31. As described later, the convex portion 34 has a rectangular or substantially rectangular cross section and is formed in an incomplete annular shape. The convex portion 34 has a forward end 35 disposed in a forward direction with respect to the winding direction and a reverse end 36 disposed in a reverse direction with respect to the winding direction. In the following description, the winding direction is simply referred to as the forward direction, and the winding direction is simply referred to as the reverse direction. The width of the convex portion 34 in the axial direction of the bobbin 21 is, for example, half or substantially half of the winding wire 38 to be wound.
In the present embodiment, the forward end 35 of the convex portion 34 is located at a position separated to the reverse side from the forward end of the notch 33. In this way, the winding wire can smoothly abut against the convex portion 34. Specifically, if the positive end of the slit 33 is aligned with the convex portion 34 in the circumferential direction, the winding wire introduced into the bobbin 21 from the slit 33 may be greatly bent at the portion where the convex portion 34 is formed in the winding process, and the bending may prevent the winding wire from being aligned. In the present embodiment, the forward end 35 of the convex portion 34 is disposed so as to be spaced further forward than the forward end of the notch 33. As shown in fig. 4(B), the winding wire 38 introduced into the bobbin 21 through the slit 33 is gently bent in the normal direction and then comes into contact with the side surface of the convex portion 34, and can be aligned as described later.
The length L5 between the forward side end 35 of the convex portion 34 and the forward side end 35 of the notch 33 is, for example, 0.5mm to 2.0 mm.
By setting L5 to 0.5mm or more, the degree of bending of the winding wire 38 at the portion wound into the bobbin 21 from the slit 33 and in contact with the side surface of the convex portion 34 can be reduced, and smooth and orderly winding can be performed. Further, by setting L5 to 2.0mm or less, the length of the convex portion 34 can be ensured to be long, and by bringing the inner side surface of the convex portion 34 into contact with the winding wire 38, the effect of defining the position of the winding wire 38 can be enhanced.
In the present embodiment, the end 36 of the convex portion 34 on the opposite side is located at the same position in the circumferential direction as the end on the opposite side of the notch 33. In this way, the length of the portion in which the convex portion 34 is formed can be secured in the circumferential direction of the barrel portion 30, and the effect of arranging the winding wires in order can be enhanced by forming the convex portion 34.
As described above, the housing convex portion 37 is formed on the outer side surface of the barrel portion 30 in the winding direction. The receiving protrusion 37 extends parallel to the winding direction. Further, a non-formed portion 39 is defined on the outer surface of the cylindrical body portion 30 in the peripheral portion of the notch 33, and the non-formed portion 39 is a smooth surface on which the receiving convex portion 37 is not formed. Since the housing convex portions 37 are not formed in the non-formation portion 39, when winding the winding wire around the bobbin 21, the winding wire 38 is wound around the non-formation portion 39 from the reverse end portion of one housing convex portion 37 to the forward end portion of the other housing convex portion 37 adjacent to the one housing convex portion 37.
Referring to fig. 4, a structure in which the winding wire 38 is wound around the bobbin 21 will be described. Fig. 4(a) is a sectional view showing a structure in which the winding wire 38 is wound around the bobbin 21, and fig. 4(B) is a schematic view of the structure in which the winding wire 38 is wound as viewed from the outside in the radial direction.
Referring to fig. 4(a), in the present embodiment, the winding wire 38 is wound around the bobbin 21 in order. In detail, the winding wire method of winding the same number of winding wires 38 in multiple layers is generally called the same number of windings, but the winding wire method of the present embodiment adjusts the position of the winding wire in the first layer based on the same number of windings. The first layer of the winding wire 38 is wound from the right end to the left end, the second layer is wound from the left end to the right end opposite to the first layer, odd-numbered layers among the following layers are wound to the left, and even-numbered layers are wound to the right.
As described above, the cylindrical portion 30 and the first flange portion 31 are formed with the convex portion 34 having a rectangular cross-sectional shape. The left side surface of the convex portion 34 is in contact with the right end of the winding wire 38A wound first in the rightmost direction of the first layer. As described above, the width of the convex portion 34 is half or substantially half of the diameter of the winding wire 38. Then, the left side surface of the convex portion 34 is brought into contact with the right end of the winding wire 38A wound first in the rightmost direction in the first layer, whereby the winding wire 38C wound leftmost in the first layer is arranged at a predetermined position, and the left end of the winding wire 38C is brought into contact with the inner side surface of the second flange portion 32. This has the advantage that the winding wire 38 of the second layer can be arranged at a predetermined position as described later. The convex portion 34 is not in contact with the winding wire 38 wound on the second layer.
Referring to fig. 4B, the winding wire 38D wound first in the second layer is placed above the winding wire 38C and the winding wire 38D disposed on the leftmost side of the first layer (the winding wire 38D is shown by a broken line). As described above, in the present embodiment, since the convex portion 34 is formed in the bobbin 21, the positions of the winding wires 38B and 38C wound last in the first layer can be accurately defined, and thus the position of the winding wire 38D disposed above between the winding wire 38C and the winding wire 38D can be accurately defined. Therefore, the winding wire 38 can be wound entirely at a predetermined position, and the winding wire 38 can be tightly wound.
The effects of the present embodiment described above will be described with reference to fig. 5. Fig. 5(a) is a cross-sectional view showing a winding wire structure of the present embodiment, and fig. 5(B) is a cross-sectional view showing a winding wire structure of a comparative example.
Referring to fig. 5(a), as described above, the winding wires 38B and 38C of the first layer are arranged so as to be closely attached to the second flange portion 32 side. Therefore, the winding wire 38D, which is the first winding wire 38 of the second layer, is arranged between the winding wires 38B and 38C. Here, even in a winding apparatus that performs precise operation, since the mechanical mechanism and operation generally include a certain tolerance, it is considered that the position at which the winding wire 38D of the second layer is wound is shifted in the left-right direction by a large or small amount. In this embodiment, the winding wire 38D of the second layer may be disposed between the winding wire 38B and the winding wire 38C, and therefore the allowable displacement length of the center position P12 of the winding wire 38D in the left-right direction can be set between the center position P11 of the winding wire 38B and the center position P12 of the winding wire 38C. The distance L2 between the center position P11 of the winding wire 38B and the center position P10 of the winding wire 38C is sufficiently large and on the same level as the diameter of the winding wire 38B or the like. That is, the winding wire 38D is allowed to be shifted leftward to the position shown by the broken line and rightward to the position indicated by the dashed line. Therefore, even if the position at which the winding wire 38D is wound is shifted by a large or small amount, the winding wire 38D can be prevented from being separated from between the winding wire 38B and the winding wire 38C.
Referring to fig. 5(B), a comparative example will be described. When the winding wire 38C disposed at the left end of the first layer is separated from the second flange portion 32 and wound, the winding wire 38D wound at the left end of the second layer is disposed between the winding wire 38C and the second flange portion 32 in the left-right direction. Referring to fig. 4(a), the winding wire 38A is continuously wound while being directly brought into close contact with the first flange portion 31 without forming the convex portion 34 at the end portion on the first flange portion 31 side. In this case, the allowable length of allowing the winding wire 38D to be displaced becomes a short length L3 from the center position P10 of the winding wire 38C to the center position P12 of the winding wire 38D. L3 is on the same level as the radius of the winding wire 38C. Therefore, in the case of this comparative example, when the position at which the winding wire 38D is wound is shifted (for example, when the winding wire 38D is shifted to the portion indicated by the broken line), the winding wire 38D is separated from between the winding wire 38C and the second flange portion 32.
Referring to fig. 6, a receiving protrusion 37 is formed on the outer side surface of the barrel portion 30 of the bobbin 21 along the circumferential direction thereof. The receiving protrusion 37 is formed corresponding to each winding wire 38 and has a triangular cross section. Here, three receiving convex portions 37 are shown, and the winding wires 38E, 38F of the first row are received between these receiving convex portions 37. Lower portions of the left and right sides of the winding wires 38E and 38F are in contact with the inclined surfaces of the receiving protrusions 37. A winding wire 38G in the second row is wound above and between the winding wire 38E and the winding wire 38F.
The housing convex portion 37 is formed to protrude outward in a triangular shape from the surface of the cylindrical body portion 30, and the inclination angle θ of the inclined surface of the housing convex portion 37 from the surface of the cylindrical body portion 30 is, for example, 45 degrees or more and 60 degrees or less.
By setting the inclination angle θ of the inclined surface of the receiving convex portion 37 to 45 degrees or more, the winding wire 38G of the second row can be stably supported by the receiving convex portion 37. Specifically, when the point at which the load of the winding wire 38E in the first row acts on the receiving projection 37 is P20 and the point at which the load of the winding wire 38F in the second row acts on the receiving projection 37 is P21, P21 can be positioned closer to the distal end of the receiving projection 37 than P20. When a triangular region having the winding wires 38F, 38E, and 38G as the end portions is defined (the triangular region is indicated by a chain line in the drawing), P21 can be arranged inside the triangular region than P20, and thus the winding wire 38G in the second row can be stably supported on the inclined surface of the receiving protrusion 37 via the winding wires 38F and 38E.
Further, by setting the inclination angle θ of the inclined surface of the receiving convex portion 37 to 60 degrees or less, the bobbin 21 having the receiving convex portion 37 can be made to have good releasability from the forming die when injection molding the bobbin 21.
A method of manufacturing the electromagnetic clutch having the structure shown in fig. 1 will be described with reference to fig. 7. Here, a process of winding the winding wire 38 around the bobbin 21 is shown, fig. 7(a) is a side view showing the winding process, and fig. 7(B) is a view showing a structure of the nozzle 40 used for winding.
Referring to fig. 7(a), in this step, the winding wire 38 discharged from the nozzle 40 is wound around the barrel portion 30 of the bobbin 21 while rotating the bobbin 21 counterclockwise on the paper surface at a predetermined speed. The nozzle 40 reciprocates in the axial direction of the bobbin 21 while discharging the winding wire 38 with respect to the bobbin 21. Here, the nozzle 40 is reciprocated in a direction vertically across the paper.
At this time, as shown in fig. 3 and 4, the winding wire 38 introduced into the bobbin 21 through the slit 33 is first wound while contacting the left side surface of the convex portion 34. This allows the winding wire 38 of the first layer to be wound around a predetermined portion.
Referring to fig. 7(B), the nozzle 40 has a cylindrical shape, and the inner diameter of the nozzle 40 is formed to be larger than the winding wire 38.
As the winding wire 38, a copper wire made of copper or an aluminum wire made of aluminum can be used. In particular, when an aluminum wire is used as the winding wire 38, since aluminum is a material that is easily deformed in comparison with copper, it is necessary to appropriately adjust the tensile strength applied to the winding wire 38 during winding. The winding wire 38 is formed of a metal wire made of copper or aluminum, and a polyester film and a slip film covering the periphery of the metal wire. The coefficient of friction of the surface of the winding wire 38 is set to 0.45 to 0.55 or less in order to ensure slidability during winding.
The relative position of the nozzle 40 and the bobbin 21 is a position at which the winding wire can be wound around a predetermined portion of the bobbin 21 and excessive deformation of the winding wire 38 can be suppressed.
Referring to fig. 7(a), a direction for specifying the relative position of the nozzle 40 and the bobbin 21 will be described. First, the winding start portion of the barrel portion 30 where the winding wire 38 starts to be wound around the bobbin 21 is P30. The direction in which a tangent line to the cylindrical body portion 30 of the bobbin 21 at P30 extends is defined as a tangent direction, and the direction perpendicular to the tangent direction and away from the bobbin 21 is defined as a first direction. And, the direction opposite to the first direction is the second direction. On the paper, the upper side is the first direction and the lower side is the second direction.
In the present embodiment, when the winding wire 38 is drawn out from the nozzle 40 and wound around the bobbin 21, the position of the nozzle 40 is located on the second direction side (lower side in the drawing) than the winding start portion P30 of the bobbin 21. As shown in fig. 7(B), the upper end of the inner wall of the nozzle 40 presses the upper end portion of the winding wire 38 downward, and the winding wire 38 is supplied to the bobbin 21, whereby the winding wire 38 can be wound around a predetermined portion of the barrel portion 30.
More preferably, the position of the nozzle 40 at the time of winding is located on the second direction side (lower side in the drawing) than the winding start portion P30 of the bobbin 21, and is located on the first direction side (upper side in the drawing) than the center position P20 of the cylindrical body portion 30 of the bobbin 21. In this way, the pressing force applied to the winding wire 38 by the upper end of the inner wall of the nozzle 40 can be appropriately controlled, and the upper end portion of the winding wire 38 that is discharged can be prevented from being excessively deformed. In particular, in the case of using an aluminum wire as the winding wire 38, since the aluminum wire is a material that is easily deformed and has a high possibility of being scattered due to the deformation, such a risk can be eliminated by optimizing the vertical position of the bobbin 21 in this way.
When winding the winding wire 38 around the bobbin portion 30 of the bobbin 21, the winding wire 38 is supplied to the bobbin portion 30 while moving the nozzle 40 in the axial direction of the bobbin portion 30. In the present embodiment, the nozzle 40 does not precede the position where the winding wire 38 is wound around the barrel portion 30 in the axial direction. In the present embodiment, the nozzle 40 passes through the bobbin 30 at a position later than the winding wire 38 is wound around the bobbin 30 in the axial direction. In this way, particularly in the case where the winding wire 38 is an aluminum wire, it is possible to suppress the tensile stress applied to the winding wire 38 from becoming excessive, and to favorably realize the orderly winding of the winding wire 38.
After the above-described steps are completed, as shown in fig. 2, the bobbin 21 around which the winding wire 38 is wound is accommodated in the ring 22, the winding wire 38 is connected to the connector 23, and the resin is filled to form the magnetism generating unit 20. Referring to fig. 1, the electromagnetic clutch 10 is manufactured by assembling the magnetism generating unit 20, the rotor 11, and the armature 12 to each other.
The embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments.
Description of the reference numerals
10 an electromagnetic clutch; 11 a rotor; 12 an armature; 18 a hub; 20 a magnetic generating unit; 21 a bobbin; 22 rings; 23 a connector; 24 lateral protrusions; 30 a barrel part; 31 a first flange portion; 32 a second flange portion; 33, cutting; 34 convex parts; 35 a forward side end; 36 a reverse side end; 37 receiving the projection; 38. 38A, 38B, 38C, 38D, 38E, 38F, 38G winding wire; 39 a non-formation portion; 40 nozzles.
Claims (2)
1. A method of manufacturing an electromagnetic clutch having a step of forming a magnetic generating unit by winding a winding wire around a bobbin,
the bobbin has a substantially cylindrical barrel portion, a first flange portion extending in a wall shape from one axial end side of the barrel portion to the outside in the radial direction, a second flange portion extending in a wall shape from the other axial end side of the barrel portion to the outside in the radial direction, a notch formed in the first flange portion, and a convex portion of an incomplete ring shape protruding from the one end side of the outer surface of the barrel portion to the outside in the radial direction,
the convex portion has a forward side end portion and a reverse side end portion along a winding direction of the winding wire, and the forward side end portion of the convex portion is disposed on a forward side apart from the slit,
when winding the winding wire around the bobbin, the winding wire wound around the bobbin from the slit is wound around the barrel portion of the bobbin while being in contact with the convex portion,
supplying the winding wire to the rotating bobbin through a nozzle while winding the winding wire on the bobbin part,
when a direction orthogonal to a tangential direction of a winding start portion in which the winding wire starts to be wound around the bobbin is a first direction, a direction separating from the bobbin is a second direction, and a direction facing the first direction is a second direction,
the nozzle is arranged on the second direction side with respect to the winding start portion of the barrel portion of the bobbin on which the winding wire starts to be wound.
2. The method of manufacturing an electromagnetic clutch according to claim 1, wherein the nozzle is disposed on the second direction side than the cylindrical portion of the bobbin on which the winding wire starts to be wound, and is disposed on the first direction side than a center of the cylindrical portion.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/JP2017/015748 WO2018193558A1 (en) | 2017-04-19 | 2017-04-19 | Electromagnetic clutch and manufacturing method therefor |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN109121428A CN109121428A (en) | 2019-01-01 |
| CN109121428B true CN109121428B (en) | 2020-04-24 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201780001873.6A Active CN109121428B (en) | 2017-04-19 | 2017-04-19 | Electromagnetic clutch and method of manufacturing the same |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPWO2018193558A1 (en) |
| CN (1) | CN109121428B (en) |
| WO (1) | WO2018193558A1 (en) |
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|---|---|---|---|---|
| JPH063764B2 (en) * | 1989-01-13 | 1994-01-12 | 日本電装株式会社 | Coil device |
| US5331729A (en) * | 1990-05-23 | 1994-07-26 | Basler Electric Company | Method for winding a toroid coil on a toroidal body |
| CN1192031A (en) * | 1997-02-19 | 1998-09-02 | 东洋电装株式会社 | Ignition coil bank-winding method |
| JP2010087439A (en) * | 2008-10-03 | 2010-04-15 | Hamanako Denso Co Ltd | Spool of coil for electromagnetic solenoid, and coil body for electromagnetic solenoid |
| JP2012015290A (en) * | 2010-06-30 | 2012-01-19 | Tdk Corp | Bobbin coil and coil component |
| JP2012036914A (en) * | 2010-08-03 | 2012-02-23 | Denso Corp | Lock sensor |
| JP2015050364A (en) * | 2013-09-03 | 2015-03-16 | 日特エンジニアリング株式会社 | Coil manufacturing device and coil manufacturing method |
| CN204614662U (en) * | 2015-05-15 | 2015-09-02 | 山东哈大电气有限公司 | Based on the dry-type air-core reactor spooling equipment of tension automatic control |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5347904B2 (en) * | 1973-09-10 | 1978-12-25 |
-
2017
- 2017-04-19 JP JP2019513145A patent/JPWO2018193558A1/en active Pending
- 2017-04-19 CN CN201780001873.6A patent/CN109121428B/en active Active
- 2017-04-19 WO PCT/JP2017/015748 patent/WO2018193558A1/en active Application Filing
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH063764B2 (en) * | 1989-01-13 | 1994-01-12 | 日本電装株式会社 | Coil device |
| US5331729A (en) * | 1990-05-23 | 1994-07-26 | Basler Electric Company | Method for winding a toroid coil on a toroidal body |
| CN1192031A (en) * | 1997-02-19 | 1998-09-02 | 东洋电装株式会社 | Ignition coil bank-winding method |
| JP2010087439A (en) * | 2008-10-03 | 2010-04-15 | Hamanako Denso Co Ltd | Spool of coil for electromagnetic solenoid, and coil body for electromagnetic solenoid |
| JP2012015290A (en) * | 2010-06-30 | 2012-01-19 | Tdk Corp | Bobbin coil and coil component |
| JP2012036914A (en) * | 2010-08-03 | 2012-02-23 | Denso Corp | Lock sensor |
| JP2015050364A (en) * | 2013-09-03 | 2015-03-16 | 日特エンジニアリング株式会社 | Coil manufacturing device and coil manufacturing method |
| CN204614662U (en) * | 2015-05-15 | 2015-09-02 | 山东哈大电气有限公司 | Based on the dry-type air-core reactor spooling equipment of tension automatic control |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2018193558A1 (en) | 2018-10-25 |
| JPWO2018193558A1 (en) | 2019-11-14 |
| CN109121428A (en) | 2019-01-01 |
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Effective date of registration: 20241010 Address after: Gunma Patentee after: ISHIKAWA ENERGY RESEARCH CO.,LTD. Country or region after: Japan Address before: Gunma Patentee before: RIVER & STREAM Co.,Ltd. Country or region before: Japan |