JP3133944B2 - Current sensor device and method of assembling current sensor device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a current sensor device and a method for assembling the current sensor device, which are suitable for use in measuring instruments such as speedometers and tachometers provided in vehicles such as ordinary cars and buses.

[0002]

2. Description of the Related Art At present, measuring instruments such as speedometers and tachometers for vehicles are driven mainly based on a current value detected by a current sensor device. Conventionally, as one of such current sensor devices,
A Hall element type current sensor device in which a Hall element is provided in a magnetic field generated by a current, and the Hall element detects the magnetic flux density of the magnetic field as a so-called Hall voltage, thereby indirectly detecting a current value proportional to the magnetic flux density. It has been known.

[0003] This Hall element type current sensor device comprises:
As shown in FIG. 11, a substantially annular bobbin 100 and a rectangular cylinder provided in a shape to be sandwiched between annular portions 100a of the bobbin 100 along a direction orthogonal to the radial direction of the bobbin 100. As shown in the top view of FIG. 12 (a) and the side view of FIG. 12 (b), the Hall element holding portion 101, the Hall element provided in the Hall element hole 101a of the Hall element holding portion 101 The Hall element holding part 10
1 and a copper wire 102 wound along the annular portion 100a in a direction perpendicular to the radial direction of the bobbin 100.

[0004] As shown in FIG. 13, the bobbin 100 has a plate-shaped core having a substantially C-shaped upper surface in an upper half 103 having a substantially cylindrical shape having a bottom and a lower half 104 having a substantially cylindrical shape having a bottom. The core 105 is formed by stacking a plurality of cores 105a.

The upper half 103 has an upper half 10
The cylindrical portion 106 having an outer diameter smaller than the outer diameter of the upper half 103 is provided so as to be coaxial with the central axis of the outer diameter of the upper half 103. The height of the peripheral wall 106 a of the cylindrical portion 106 is the same as the height of the peripheral wall 103 a of the upper half 103. Also, the inner peripheral wall of the upper half 103 and the cylindrical portion 106
The width of the concave portion formed between the outer peripheral wall and the outer peripheral wall is substantially the same as the width of the plate-shaped core 105.
Approximately half of the laminated plate-shaped core 105 is accommodated. In addition, the upper half 103 is provided with a holding portion upper half 101b that forms a half of the rectangular Hall element holding portion 101. The holding portion upper half 101b has the same length in the longitudinal direction as the width of the upper half 103, and the height is approximately twice the height of the upper half 103. It is provided in a shape protruding from the upper surface of the upper half 103.

Next, the lower half 104 has the same structure as the upper half 103, and the cylindrical portion 107 having an outer diameter smaller than the outer diameter of the lower half 104 is provided at the center of the outer diameter of the lower half 104. It is provided so as to be coaxial with the axis. The height of the peripheral wall 107a of the cylindrical portion 107 is the same as the height of the peripheral wall 104a of the lower half 104. Further, the width of the concave portion formed between the inner peripheral wall of the lower half 104 and the outer peripheral wall of the cylindrical portion 107 is substantially the same as the width of the plate-shaped core 105, and the concave portion is formed by the concave portion. The other half of the plate-shaped core 105 is accommodated. In addition, the lower half 104 is provided with a holding unit lower half 101c that forms the remaining half of the rectangular Hall element holding unit 101. The holding portion lower half 101c has a length in the longitudinal direction that is the same as the width of the lower half 104, and the height is approximately twice the height of the lower half 104. It is provided so as to protrude from the bottom surface of the half 104.

Next, the upper surface of the core 105 housed in the bobbin 103 is "substantially C-shaped" as shown in FIG.
A plurality of sheets are laminated so that the gaps 105b of the plate-like core 105a are aligned, and about 3 to 4 places are fixed with an adhesive as shown by oblique lines in FIG. The number of stacked plate-like cores 105a is such that the height of the core 105 formed by this is slightly lower than the sum of the height of the recess of the upper half 103 and the height of the recess of the lower half 104. It has been adjusted to be. Also,
The diameter of the hole 105c of each plate core 105a is the same as the diameter of the cylindrical portion 106 provided in each of the halves 103 and 104.
The width of each gap 105b of each plate core 105a is slightly larger than the length of the Hall element holding portion 101 in the short direction. When the core 105 is housed in the bobbin 100, the gap 105b causes the Hall element holder 1
01 is held in such a form as to hold it.

[0008] Such an upper half 103 and a lower half 10
When the bobbin 100 is formed by the core 4 and the core 105, first, a predetermined number of plate-like cores 105 are stacked so that the gaps 105b are aligned, and a predetermined portion is fixed with an adhesive as shown by oblique lines in FIG. Thereafter, the adhesive is dried to form the core 105.

Next, the core 105 is housed in the lower half 104 in such a manner that the holding portion lower half 101c is sandwiched by the gap portion 105b. Next, the upper half 10 is inserted into the gap 105b of the core 105 housed in the lower half 104.
The upper half 103 and the lower half 104 are abutted so as to insert the upper half 101b of the third holding portion. Then, the butted upper half 103 and lower half 104 are fixed with an adhesive, and the adhesive is dried.

As a result, as shown in FIG. 14A, a rectangular cylindrical Hall element holding portion 101 is formed in a part of the annular portion 100a.
The bobbin 100 is formed so as to sandwich the bobbin.
A left sectional view of the bobbin 100 cut along the line AB in FIG. 14A is as shown in FIG. From this figure, each of the halves 103, 1
It can be seen that the core 105 is housed in each of the recesses 04 and a hole 101 a for inserting a Hall element is formed inside the Hall element holding part 101.

Next, a copper wire 10 is attached to such a bobbin 100.
When the wire 2 is wound, the winding rod 105 wound with the copper wire 102 is repeatedly passed through the inner hole 100b of the bobbin 100 as shown by an arrow in the drawing as shown in FIG. The copper wire 102 wound around the winding rod 105 is wound along the annular portion 100a of the bobbin 100. As a result, as described with reference to FIGS. 12A and 12B, the copper wire 102 is wound around the portion excluding the Hall element holding portion 101 to form a current sensor device.

[0012]

However, in such a conventional current sensor device, since the bobbin 100 has an annular shape, the copper wire 1 is inserted into the inner hole 100b of the bobbin 100.
No. 02 has a problem that a complicated work process of repeatedly passing the wound winding rod 105 and winding the copper wire 102 on the bobbin 100 is required, and it takes time to assemble the current sensor device. This has hindered mass production.

Further, since the bobbin 100 has an annular shape, the plate core 1 for forming the core 105 is inevitably formed.
05a also needs to be annular. For this reason, the annular plate-shaped core 105a is die-cut from the original plate (ferrite plate) from which the plate-shaped core 105a is die-cut. There was a problem that some members were wasted.

As described above, the conventional current sensor device requires a complicated winding process and a long time for the assembling process, and also has many wasteful parts in the original plate from which the plate-shaped core 105a is die-cut. The cost was high.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and can simplify the assembling process to enable mass production. An object of the present invention is to provide a current sensor device and a method for assembling the current sensor device, which can prevent the occurrence of the current sensor device and reduce the cost.

[0016]

A current sensor device according to the present invention is a current sensor device for detecting the amount of current of an object using a Hall element, wherein one bobbin having a predetermined shape is provided in order to solve the above-mentioned problem. A plurality of bobbin pieces, each having a shape divided into a plurality of pieces by a line in a direction orthogonal to the center axis of the bobbin, and each having a connection unit for establishing an electrical connection with each other, While being wound around the plurality of cores to be stored and the bobbin pieces,
One end or both ends is provided with a winding winding connected to the connection means. The bobbin pieces on which the winding coils are wound are formed by connecting the bobbin pieces via the connection means provided on the respective bobbin pieces.

The method of assembling the current sensor device is as follows.
In the method of assembling a current sensor device that detects the amount of current of an object using a Hall element, in order to solve the above-described problem, one bobbin having a predetermined shape is defined by a line in a direction orthogonal to the center axis of the bobbin. A plurality of cores are respectively housed in a plurality of bobbin pieces each having a shape divided into a plurality, and each having connection means for establishing electrical connection with each other, and a winding winding is wound around each of the bobbin pieces. While wearing
One or both ends of the winding winding are connected to the connection means. The bobbin pieces on which the winding coils are wound are formed by connecting the bobbin pieces via the connection means provided on the respective bobbin pieces.

In such a current sensor device and a method of assembling the current sensor device, a winding winding is wound for each of the above-mentioned bobbin pieces, and thereafter, each of the bobbin pieces is electrically connected via the above-mentioned connecting means. I do. Thereby, the assembly of the current sensor device can be facilitated through the liberalization of the winding process.

Further, since the plate-shaped core is cut out from the original plate of the core in accordance with the shape of each bobbin piece, when a substantially ring-shaped core is cut out, there is no waste of material at the center of the core. Can be prevented from occurring. That is, it is possible to adjust the take-up position so that members in the central portion are not wasted. Therefore, the material yield can be improved, and the cost of the current sensor device can be reduced.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of a current sensor device and a method for assembling the current sensor device according to the present invention will be described below in detail with reference to the drawings.

First Embodiment << Structure >> In a current sensor device and a method of assembling the current sensor device according to the present invention, as shown in FIG. 1, a Hall element is provided in a magnetic field generated by an electric current, By detecting the magnetic flux density of a magnetic field as a so-called Hall voltage by an element, the present invention can be applied to a Hall element type current sensor device that indirectly detects a current value proportional to the magnetic flux density.

The current sensor device according to the first embodiment abuts a substantially semi-annular first bobbin piece 1 and a substantially semi-annular second bobbin piece 2. It has a substantially annular bobbin formed.

The first bobbin piece 1 includes a first upper half 3 having a semi-bottomed cylindrical shape, a first lower half 4 also having a semi-bottomed cylindrical shape, and the upper half 3 and the lower half 4. The core 5 is formed by stacking a plurality of storable semi-annular plate-shaped cores 5a. Further, the second bobbin piece 2 includes a second upper half 6 having a semi-bottomed cylindrical shape,
A second lower half 7 also having a semi-bottomed cylindrical shape, and a core 8 formed by laminating a plurality of semi-annular plate-like cores 8a that can be accommodated by the upper half 6 and the lower half 7. Have been.

The first lower half 4 and the second lower half 7 are formed so as to form a cylindrical portion coaxial with the center axis of the outer diameter formed when they are connected to each other. A first semi-cylindrical portion 9 and a second semi-cylindrical portion 10 each having a semi-cylindrical shape are provided. A recess formed between the outer peripheral wall 9a of the first semi-cylindrical part 9 and the inner peripheral wall 4a of the first lower half 4 forms a core storage gap 11 for laminating and storing the plate-like cores 5a. It has become. Further, a recess formed between the outer peripheral wall 10a of the second semi-cylindrical portion 10 and the inner peripheral wall 7a of the first lower half 7 forms a core housing gap for stacking and storing the plate-shaped cores 8a. The section 12.

Next, the first lower half 4 is provided with a first connecting portion so as to protrude from one end of the first semi-cylindrical portion 9 through one end of the lower half 4 in a radial direction. 13 are provided. At a substantially intermediate position of the first connection portion 13, a first connection hole 13a for fitting with a first connection pin 14a described below is provided. In addition, the second
The lower half 7 is provided with a second connecting portion 14 projecting from one end of the second semi-cylindrical portion 10 through one end of the lower half 7 in the radial direction. This second
The first connection hole 13a is provided at a substantially intermediate position of the connection portion 14 of the first embodiment.
A first connection pin 14a that fits with the first connection pin 14a is provided.

As will be described later, the first connection hole 13a
And the first connection pin 14a are connected to the first and second bobbin pieces 1 and 2, respectively, to form a single bobbin. 2 is a connector terminal for electrical connection.

Next, the end of the first lower half 4 opposite to the first connection portion 13 and the end of the second lower half 7 opposite to the second connection portion 14 are: The third and fourth connection portions 15 and 16 are respectively connected by heat welding. In the vicinity of the connection portions 15 and 16, partition members 15a and 16a are provided so as to partition the core storage gap portions 11 and 12, respectively. Therefore, when the lower halves 4 and 7 are connected, the partition members 15
While the a and 16a face each other, a substantially rectangular gap is formed on the upper surface. The gap serves as a hall element housing for housing the hall element.

Next, the first and second upper halves 3, 6
Has a semi-cylindrical semi-cylindrical portion at the center thereof, substantially in the same manner as the corresponding lower halves 4 and 7, respectively. The laminated plate-shaped core 5a or plate-shaped core 8a is accommodated in a core accommodating gap formed as a recess formed between the cores.

The first upper half 3 is provided with a fifth connecting portion 17 protruding in a radial direction of the upper half 4. At a middle position, a second connection hole 17a is provided for fitting with the second connection pin 18a. Further, the second upper half 6 is provided with a sixth connecting portion 18 so as to protrude in a radial direction of the upper half 6.
The second connection hole 17a is located at a substantially intermediate position of the connection portion 18 of the second embodiment.
A second connection pin 18a that fits with the first connection pin 18a is provided.

The second connection hole 17a and the second connection pin 18a are provided in the first connection hole provided for electrically connecting the first and second bobbin pieces 1 and 2. 13
Unlike the first connection pin 14a and the first connection pin 14a, the first connection pin 14a serves as a connection portion for mechanically connecting the bobbin pieces 1 and 2 to each other.

The end of the first upper half 3 opposite to the fifth connecting portion 17 and the end of the second upper half 6 opposite to the sixth connecting portion 18 are respectively Seventh and eighth connection portions 19 and 20 connected by heat welding are provided. A partition member is also provided in the vicinity of each of the connection portions 19 and 20 so as to partition each of the core housing gaps. Further, each of the connecting portions 19 and 20 has an upper surface of “substantially U-shape” and “substantially inverted U-shape”, respectively. A hole for inserting a Hall element 20c (see FIG. 3B) for leading to the Hall element housing is formed.

<< Assembling Step >> Next, an assembling step of the current sensor device according to the first embodiment having such a configuration will be described. The assembling process of this current sensor device is roughly divided into a bobbin piece assembling step of storing the plate-shaped cores 5a and 8a to assemble the first and second bobbin pieces 1 and 2, and the bobbin pieces 1 and 2 thus assembled. 2 is a winding step of performing a winding process, and a connection step of connecting the bobbin pieces 1 and 2 that have been subjected to the winding process and housing a Hall element.

<Assembly step of bobbin pieces> First, in the above-described bobbin piece assembling step, a plurality of semi-annular plate-like cores 5a and 8a are arranged and laminated as shown in FIG. The cores 5 and 8 are formed by performing an adhesive treatment at several places as indicated by oblique lines. Each plate core 5
a and 8a are stacked when the first upper half 3 and the first lower half 4 are combined to form the first bobbin piece 1, and when the second upper half 6 and the second lower half are combined. When the second bobbin piece 2 is formed by combining the first and second bobbin pieces 7 with each other, the number of laminated cores 5 and 8 in each of the bobbin pieces 1 and 2 is such that the cores 5 and 8 are accommodated without rattling. The thickness and the like of each of the plate-shaped cores 5a and 8a are set so that the magnetic characteristics of the cores 5 and 8 formed by laminating a plurality of the cores have predetermined magnetic characteristics suitable for the current sensor device. Of course.

Next, each of the cores 5, 8 thus formed is
Are respectively stored in the respective core storage gaps 11 and 12 of the first and second lower halves 4. At this time, the cores 5 and 8 are accommodated in the core accommodating gaps 11 and 12 without gaps, respectively, but are accommodated such that about half of the total height is exposed.

Next, the core 5 of the first lower half 4 in which the core 5 is housed so that about half of the total height is exposed.
The lower half 4 and the upper half 3 are butted in such a manner as to cover the core accommodating gap of the first upper half 3 from above, and a heat welding process is performed along the abutted surface, as shown in FIG. A first bobbin piece 1 having a semi-annular shape is formed as shown in FIG. Similarly, the core storage gap of the second upper half 6 is covered from above the core 8 of the second lower half 7 in which the core 8 is stored so as to expose about half of the total height. The lower half 7 and the upper half 6 are abutted in such a manner, and a heat welding process is performed along the abutted surface to form the second bobbin piece 2 having a semi-annular shape as shown in FIG. I do. This completes the bobbin piece assembling process.

<Winding Step> Next, a winding step of performing a winding process on each of the bobbin pieces 1 and 2 assembled as described above is performed. In this step, as shown in FIG. 3A, the copper wires 20a and 20b are separately wound around the bobbin pieces 1 and 2, respectively. The copper wires 20a, 20a
0b can be easily performed without being restricted.

That is, if the bobbin has an annular shape as in the prior art, the winding rod 11 on which the copper wire 102 is wound is inserted into the hole 100b of the bobbin as described with reference to FIG.
It is necessary to wind the copper wire 102 around the bobbin by repeatedly passing 0, which limits the winding operation of the copper wire. Since the bobbin of the current sensor device according to the present invention has a semi-annular shape obtained by dividing an annular bobbin into two equal parts, there is no such a hole 100b, and the winding of the copper wire is not restricted to this. Equipment. For this reason, the winding rod 110 can be dispensed with, and equipment for automatically winding the copper wires 20a, 20b can be freely designed in terms of equipment, for example, to increase the winding operation. Degree can be compensated.

Next, when the winding of the copper wires 20a and 20b on the bobbin pieces 1 and 2 is completed as described above, the above-described winding on the first bobbin piece 1 is performed as shown by oblique lines in FIG. Copper wire 2
0a is soldered to the first connection hole 13 provided in the first connection portion 13, and one end of the copper wire 20b wound around the second bobbin piece 2 is connected to the second connection hole. Soldering is performed on the first connection pins 14 provided on the portion 14. Thus, the winding step of performing the winding process on each bobbin piece is completed.

In the first connection holes 13a and the first connection pins 14a, a holding member for holding the copper wires 20a, 20b in place at the portions where the copper wires 20a, 20b are to be soldered is used. And the soldering may be omitted.

<Connection Step> Next, when such a winding step is completed, a connection step of connecting the above-described bobbin pieces 1 and 2 is performed. In this step, as shown in FIG. 2, the first and second connection holes 13a and 17a of the first bobbin piece 1 and the first and second connection pins 14a and 18a of the second bobbin piece 2 are formed.
And the third and seventh bobbin pieces 1 of the first bobbin piece 1.
Connection portions 15 and 19 and the fourth and eighth connection portions of the second bobbin piece 2.
And the connecting portions 16 and 20 of the above. Then, heat welding is performed along the abutting portions of the third and seventh connection portions 15 and 19 of the first bobbin piece 1 and the fourth and eighth connection portions 16 and 20 of the second bobbin piece 2. The process is performed to form a substantially annular current sensor device.

As described above, the first connection hole 13a provided on the first bobbin piece 1 side and the first connection pin 14a provided on the second bobbin piece 2 side are formed by the connector. Terminal. Therefore, the first connection hole 13
a and the copper wire 20b wound around the first bobbin piece 2 and the copper wire 20b wound around the second bobbin piece 2 via the first connection pin 14a, with electrical characteristics. Electrical connection can be made without adverse effects.

Next, by connecting the respective bobbin pieces 1 and 2 on which the copper wires 20a and 20b are wound as shown in FIG.
(B) As shown in FIG.
Connection portions 15 and 19 and the fourth and eighth connection portions of the second bobbin piece 2.
A hole 20c for directly inserting a Hall element is formed at a portion where the Hall elements are abutted against the connection parts 16 and 20. For this reason, the hall element is housed in the hall element housing through the hall element insertion hole 20c, and the connection process is completed, whereby the current sensor device is completed.

<< Effects of the First Embodiment >> As is clear from the above description, the current sensor device according to the first embodiment of the present invention comprises the semi-annular bobbin pieces 1 and 2 respectively. By separately assembling and winding and connecting the bobbin pieces 1 and 2, the assembling process of the current sensor device can be simplified through simplification of the copper wire winding process. Therefore, the productivity of the current sensor device can be improved, and the cost of the current sensor device can be reduced.

Further, as shown in FIG. 9, the upper surface of the plate-like core 105a provided in the conventional current sensor device has a "substantially C-shape". Naturally, from a rectangular base plate (ferrite base plate) having a length substantially the same as the diameter of the core 105a and a length in the longitudinal direction being five times the diameter of the plate-like core 105a, five sheets are naturally formed. Although only the plate-shaped core 105a can be removed, the plate-shaped core 5a (8a) provided in the current sensor device according to the first embodiment has a substantially semi-annular shape. 11 from the same size original plate as shown
The plate-like cores 5a and 8a (corresponding to five half of the plate-like core 105a) can be removed. For this reason, the raw materials (original plates) of the plate-like cores 5a and 8a can be effectively used, and the above-mentioned low cost can be realized also from this point.

[Modification of First Embodiment] Next, the first upper half 3 and the first lower half 4, the second upper half 6 and the second lower half 7, and the first The third and seventh connection portions 15 and 19 of the bobbin piece 1 and the fourth and eighth connection portions 16 and 20 of the second bobbin piece 2 are thermally welded, respectively. By adopting a modified example described below, these heat weldings can be omitted completely.

That is, the first upper half 3 and the second
Each of the upper halves 6 is provided with one or more fitting pins, and the first lower half 4 and the second lower half 7 are provided.
Is provided with a fitting hole for fitting with the fitting pin, and the two are connected through the fitting pin and the fitting hole. Similarly, one or more fitting pins are provided at the third and seventh connection portions 15 and 19 of the first bobbin piece 1, respectively, and the fourth and eighth connection pins of the second bobbin piece 2 are provided. The connecting portions 16 and 20 are provided with fitting holes for fitting with the fitting pins, and the connection between the two is achieved through the fitting pins and the fitting holes.

At this time, the diameter of the fitting hole is set to a diameter that can be firmly fitted to the connection pin, or the tip of the connection pin is formed in a hook needle shape having a “return” in a direction opposite to the insertion direction. After assembling, a stable assembling state can be realized by adopting a configuration in which the connection pins are prevented from falling off by “returning”.

As described above, the connection between the first upper half 3 and the first lower half 4 and the connection between the second upper half 6 and the second lower half 7 through the fitting pins and the fitting holes. By making the connection, all the heat welding steps in the current sensor device can be omitted, and the assembling steps can be further simplified.

Further, since the bobbin assembled as described above is subjected to a winding process to form a current sensor device,
The falling off can be prevented by the tightening force of the winding process. For this reason, precision is not required for the design of the fitting holes and the connection pins, and the productivity of the current sensor device can be more remarkably improved from the viewpoint of easy design. .

[Second Embodiment] << Configuration >> Next, a description will be given of a current sensor device according to a second embodiment of the present invention. As shown in FIG. 5, the current sensor device according to the second embodiment includes first and second lids 2 formed by dividing an annular plate-shaped member into two equal parts in the radial direction.
1 and 22; first and second storage sections 24 and 25 formed by dividing a bottomed cylindrical member into two equal parts in the radial direction; and substantially semi-annular sections in the storage sections 24 and 25, respectively. Plate core 23
and a core 23 formed by stacking and storing a plurality of sheets a each.

The bottom surfaces of the first and second lids 21 and 22 are formed along the semi-annular shape of each of the lids 21 and 22 as shown in FIG. Bottom plates 26 and 27 are respectively provided on the outer peripheral side and the inner peripheral side so as to form predetermined steps. The predetermined step formed on the inner peripheral side of each of the lids 21 and 22 is a step along the outer periphery of the semi-cylindrical parts 28 and 29 provided in the storage parts 24 and 25. The predetermined step formed on the outer peripheral side of each of the lids 21 and 22 is
Is a step along the inner periphery of.

Two leaf springs 30 are provided on the bottom plates 26 and 27 provided on the lids 21 and 22, respectively. Each of the leaf springs 30 is formed of a durable rectangular plate-shaped member such as steel, and is provided to have a predetermined angle with respect to each of the bottom plates 26 and 27. It is bent so as to be substantially parallel to the bottom plates 26 and 27 from the middle part to the tip part (the end opposite to the installation end). As will be described later, the portion from the intermediate portion to the tip portion of each leaf spring 30 is formed when the first and second lid portions 21 and 22 and the first and second storage portions 24 and 25 abut against each other. The storage sections 24, 25
A pressing portion 30a which comes into contact with the plate-shaped core 23a stored therein and presses and fixes the plate-shaped core 23a by the elastic force of the plate spring 30.

Further, both ends of each of the lids 21 and 22 are connected to connecting portions 21a, 21b,
22a and 22b. Of these, the connecting part 21
Each of b and 22b is a flat surface, but the upper surface of the connecting portion 21a is “substantially U-shaped”, and the upper surface of the connecting portion 22a is “substantially inverted U-shaped”. Then, when the connection portions 21a and 22a are connected by butt,
A rectangular top hole element insertion hole 31 penetrating from the top surface to the bottom surface of the lids 21 and 22 is formed. And each of such lid parts 21 and 22
Are the connecting portions 21a, 21b, 2 provided at the respective ends.
A substantially annular lid portion is formed by heat-welding the 2a and 22b so as to abut each other.

Next, the first and second storage sections 24, 25
Has a semi-bottomed cylindrical shape as described above, and when the storage portions 24 and 25 are connected to each other, a storage portion having a bottomed cylindrical shape is configured. When the storage portions 24 and 25 are formed by connecting the storage portions 24 and 25 to each other to form a storage portion, a cylindrical portion coaxial with the central axis of the storage portion is formed. like,
A semi-cylindrical half-cylindrical portion 28, 2
9.

A recess formed between the outer peripheral wall 28a of the semi-cylindrical portion 28 and the inner peripheral wall 24c of the first storage portion 24
A core storage gap portion 34 for stacking and storing the plate-like cores 23a is formed between the outer peripheral wall 29a of the semi-cylindrical portion 29 and the inner peripheral wall 25c of the second storage portion 25. The recessed portion serves as a core storage gap portion 35 for stacking and storing the plate-like cores 23a.

The substantially annular lid formed by connecting the lids 21 and 22 has an outer shape substantially formed by connecting the housings 24 and 25. The outer shape of the bottom cylindrical storage portion is substantially the same, and the inner diameter of the lid portion is substantially the same as the outer shape of the substantially cylindrical cylindrical portion of the substantially bottomed cylindrical storage portion. .

Next, a connection portion 24a is provided in the first storage portion 24 so as to protrude from one end of the semi-cylindrical portion 28 in the opposite radial direction through one end of the storage portion 24. . At a substantially intermediate position of the connection portion 24a, a connection hole 32 for fitting with a connection pin 33 described below is provided. Further, the second storage portion 25 is provided with a connection portion 25 a so as to protrude from one end of the semi-cylindrical portion 29 through one end of the storage portion 25 in the opposite radial direction. The connection hole 32 is provided at a substantially intermediate position of the connection portion 25a.
A connection pin 33 that fits with the connection pin 33 is provided.

As will be described later, the connection holes 32 and the connection pins 33 are used to connect two separately formed bobbin pieces to form one bobbin. It is a connector terminal for electrically connecting the pieces.

Next, the other ends of the storage sections 24 and 25 are
The connection portions 24b and 25b are connected by heat welding. In the vicinity of the connection portions 24b and 25b, partition members 36 and 37 are provided so as to partition the core storage gap portions 34 and 35. Therefore, when the storage sections 24 and 25 are connected, the partition members 3
A gap having a rectangular shape on the upper surface is formed during the opposition between 6, 6 and 37. The size of the gap is determined by connecting the lids 21 and 22 to each connection 21a,
It has the same size as the hole element insertion hole 31 formed between the holes 22a.

In other words, each of the partition members 36, 3
7 is a connecting portion 21a, 22a of each of the lids 21 and 22.
Each connecting portion 2 is formed so as to form a continuous space portion of the same size from the hole element insertion hole 31 formed by
4b and 25b. The gap element accommodates a Hall element inserted through the Hall element insertion hole 31.

Next, each of the plate-like cores 23a has a substantially semi-annular shape such that the plate-like cores 23a are accommodated in the core accommodating gaps 34 and 35 of the accommodating portions 24 and 25 without any gap. The cores 23 are formed by being stacked and stored in the core storage gap portions 34 and 35, respectively. The number of layers of the plate-shaped core 23a in the core storage gaps 34 and 35 is such that the lids 21 and 22 can be assembled to the storages 24 and 25 in which the plate-shaped core 23a is stacked and stored, and , A leaf spring 3 provided on each of the lids 21 and 22
The number of laminations is such that the plate-like cores 23a stored in the respective storage portions 24 and 25 are pressed without looseness by the elastic force of zero.

The thickness and the like of each of the plate-like cores 23a are set so that the magnetic characteristics of the cores 23 formed by laminating a plurality of cores have predetermined magnetic characteristics suitable for the current sensor device. Of course. In addition, each plate-like core 23a stacked and stored in each of the storage portions 24 and 25 in this manner.
Is that one of the characteristics of the current sensor device is that the bonding is not performed with an adhesive.

<< Assembly Process >> Next, an assembly process of the current sensor device according to the second embodiment having such a configuration will be described. The assembling process of this current sensor device is roughly divided into an assembling process of assembling the two bobbin pieces while accommodating the plate-shaped core 23a, and a winding process of performing a winding process on each of the assembled bobbin pieces. It consists of a wire process and a connection process of connecting the bobbin pieces subjected to the winding process to house the Hall elements.

<Assembling process of bobbin pieces> First, as shown in FIG. 5, the bobbin piece assembling process is substantially semi-annular in the core storage gap portions 34 and 35 of the storage portions 24 and 25, respectively. Are stacked and stored. As described above, since the plate-like core 23a is shaped so as to be housed in the core accommodating gaps 34 and 35 without any gap, play in stacking and accommodating is limited to a minimum. Is done.

Next, the lids 21 and 22 are respectively assembled to the storage portions 24 and 25 from above the plate-like cores 23a are stacked and stored as described above to complete each bobbin piece. Specifically, as described with reference to FIG. 6, each of the lids 2 and 22 is provided on each bottom surface of the first and second lids 21 and 22.
Bottom plates 26 and 27 are formed along the semi-annular shape of the lids 21 and 22 on the outer and inner peripheral sides of the lids 21 and 22, respectively, so as to form predetermined steps. Predetermined steps formed on the inner peripheral side of 21 and 22 are steps along the outer peripheries of semi-cylindrical half-cylindrical portions 28 and 29 provided in the storage portions 24 and 25, respectively. A predetermined step formed on the outer peripheral side of each of the lids 21 and 22 is a step along the inner periphery of each of the storage sections 24 and 25. For this reason, in each of the core storage gap portions 34, 35 of the storage portions 24, 25, the bottom plate 26,
The lids 21 and 22 are assembled to the storage portions 24 and 25 in such a manner that the fittings 27 are fitted respectively.

Next, the lids 21 and 22 and the housings 24 and 25 are heat-welded along the contact portions of the respective parts.
Thereby, a bobbin piece obtained by assembling the first lid portion 21 to the first storage portion 24 in which the plate-shaped cores 23a are stacked and stored,
The second storage portion 25 in which the plate-shaped cores 23a are
The bobbin piece assembling step of assembling the bobbin piece with the lid portion 22 is completed. In this case, since the lids 21 and 22 and the housings 24 and 25 are heat-welded to each other, the bonding step using an adhesive and the drying step required when forming the bobbin are performed. Can be omitted.

Here, the bottom plate 2 of each of the lids 21 and 22 is provided.
Two leaf springs 30 are provided in each of 6 and 27. For this reason, each lid part 21,
By assembling the plate springs 22, each pressing portion 30a, which is a portion from the substantially middle portion to the distal end portion of each of the leaf springs 30, is connected to the upper surface portion of the plate-like core 23a, which is stacked at the top in each of the storage portions 24, 25. The respective plate-shaped cores 23a are pressed by the elastic force of the respective leaf springs 30. Thereby, each of the storage sections 24,
It can be fixed without rattling within 25. For this reason, it is possible to omit the bonding process for bonding the respective plate cores 23a with an adhesive and the drying process.

<Winding Step> Next, a winding step of performing a winding process on each of the bobbin pieces assembled as described above is performed. In this step, as shown in FIG. 7A, the copper wire 40 is wound around each of the bobbin pieces. At this time, each of the bobbin pieces has a substantially semi-annular shape as a whole. The copper wire 4
The operation for winding 0 can be easily performed without any restriction.

That is, if the bobbin has an annular shape as in the prior art, the winding rod 12 around which the copper wire 11 is wound is repeatedly passed through the hole 1a of the bobbin as described with reference to FIG. Accordingly, it is necessary to wind the copper wire 11 around a bobbin, and therefore, the operation of winding the copper wire is restricted. However, the current sensor device according to the second embodiment is not limited. Bobbin has a semi-annular shape obtained by dividing an annular bobbin into two parts, so that the hole 1
There is no such thing as "a", and the copper wire can be wound without being bound by this. For this reason, the winding rod 1
2 can be unnecessary, and the degree of freedom in the design of the device, such as enlarging the winding operation, can be compensated for the device that automatically winds the copper wire 40.

Next, when the winding of the copper wire 40 on each of the bobbin pieces is completed, one end of the copper wire 40 is soldered to the connection hole 32 or the connection pin 33 as shown by oblique lines in FIG. I do. Thus, the winding step of performing the winding process on each bobbin piece is completed.

The connection hole 32 or the connection pin 33
The copper wire 40 may be soldered with a holding member for sandwiching the copper wire 40 for connection, and the soldering may be omitted.

<Connection Step> Next, when such a winding step is completed, a connection step of connecting the bobbin pieces is performed. In this step, as shown in FIG. 7B, the connection portions 21a and 22a of the bobbin pieces are abutted, and
In the connection hole 32 provided in the connection portion 24a, the connection portion 2
The connection pin 33 provided in 5a is inserted. Then, the connection portions 21a and 22a, which are connection portions provided at ends opposite to the connection portions 24a and 25a provided with the connection holes 32 or the connection pins 33, are thermally welded to each bobbin piece. Achieve perfect bonding.

As described above, since each of the above-mentioned bobbin pieces has a semi-annular shape, a substantially annular bobbin can be formed by connecting the two.
Further, since the connection holes 32 and the connection pins 33 are connector terminals for electrically connecting one bobbin piece to the other bobbin piece, the connection holes 32 and the connection pins 33 are separately wound around the bobbin pieces, respectively. The copper wire 40 can be connected via the connection holes 32 and the connection pins 33 without adversely affecting the electrical characteristics.

Next, when the bobbin pieces are connected in this manner, as shown in FIG. 7B, the connection portions 21a and 22a
A hole 31 for inserting a Hall element is formed at the abutting portion of. Therefore, by inserting the Hall element into the hole 31 for inserting a Hall element, the connection step is completed, and the second step is performed.
All the assembly steps of the current sensor device according to the embodiment are completed.

<< Effects of the Second Embodiment >> As is apparent from the above description, the current sensor device according to the second embodiment of the present invention has two semicircular bobbin pieces. The first and second storage portions 24 and 25, the semi-annular plate-like core 23a that can be stored therein without any gaps, and the first and second lid portions 21 and 22 of the storage portions 24 and 25, respectively. The bobbin pieces are formed and assembled and wound, and the bobbin pieces are connected to each other by the connection holes 32 provided on one bobbin piece and the connection pins 33 provided on the other bobbin piece. The wire winding process can be simplified. In addition, the bonding step using an adhesive and the drying step, which have been conventionally required, can be completely omitted. For this reason,
Productivity can be improved through improved workability,
The cost of the current sensor device can be reduced.

Further, since the respective plate-like cores 23a accommodated in the respective accommodating portions 24 and 25 are fixed by the plate springs 30 provided in the respective cover portions 21 and 22, the respective plate-like cores 23a and 22 are fixed. The bonding step and the drying step of 23a can also be omitted, and the effects such as the improvement of the workability can be made more remarkable.

The plate cores 23a are fixed by the plate springs 30, so that the partition members 36,
Each plate-like core 23 laminated in a form aligned with 37
There is no displacement at each end of a. For this reason, when the above-mentioned bobbin pieces are connected to each other, each end of the plate-like core 23a aligned and stacked on one bobbin piece and each end of the plate-shaped core 23a aligned and stacked on the other bobbin piece. The Hall element can be disposed between the bobbins, and the magnetic characteristics of the bobbin can be improved. Further, through the improvement of the magnetic characteristics, the current detection accuracy of the current sensor device can be improved.

Further, similarly to the current sensor device according to the first embodiment, the plate core 23a provided in the current sensor device according to the second embodiment has a substantially semi-annular shape. Therefore, raw materials (original plates) can be effectively used as shown in FIG.

The lids 21 and 22 and the housings 2
4 and 25 are heat-welded, and each bobbin piece is heat-welded through the connection portions 21a and 22a.
This may be done by an adhesive (preferably a so-called instant adhesive). Thereby, when assembling the bobbin pieces and when connecting the bobbin pieces, a bonding step and a drying step are required, but also in this case, the bonding step and the drying step of the plate-shaped core 23a are omitted. Accordingly, the bobbin assembling process can be simplified.

[Modification of Second Embodiment] Next, the above description has been directed to the case where the lids 21 and 22 and the storages 24 and 25 and the bobbin pieces are thermally welded to each other. In the current sensor device, by performing the following modified example, the heat welding process in the bobbin assembling process can be omitted.

That is, in the bobbin of the current sensor device according to the modified example of the second embodiment, each lid 2
One or a plurality of connection pins are provided on the sides 1 and 22, and a fitting hole for fitting the connection pin is provided on each of the storage portions 24 and 25, and each lid 2 is inserted through the connection pin and the fitting hole.
1 and 22 and the respective storage sections 24 and 25 are assembled. Also,
One or more connection pins are provided on the connection portion 24b side of the first storage portion 24, and a fitting hole for fitting the connection pin is provided on the connection portion 25b side of the second storage portion 25. The bobbin pieces are connected to each other via the connection pins and the fitting holes.

At this time, the diameter of the fitting hole is set to a diameter that can be firmly fitted to the connection pin, or the tip of the connection pin is formed into a hook-like shape having a “return” in a direction opposite to the insertion direction. After that, the connection pins are turned back so that the connection pins can be prevented from falling off, so that each of the lid portions 21 and 2 can be prevented.
2 and each of the storage portions 24 and 25 can be stably assembled.

By connecting the lids 21 and 22 to the housings 24 and 25 via the fitting pins and the fitting holes, the heat welding process in the bobbin assembling process is completely omitted. Thus, the productivity can be improved and the cost of the current sensor device can be reduced through further improvement of the workability.

Further, since the bobbin pieces assembled as described above are subjected to a winding process, the bobbin pieces are assembled to the storage portions 24 and 25 by the tightening force of the winding process. Since the lids 21 and 22 are fixed, there is no inconvenience that the connection pin comes out of the fitting hole even if the connection pin is not formed in a hook shape. For this reason, the design of the connection pin and the fitting hole does not require much accuracy, and the productivity improvement of the current sensor device is considered to be more remarkable from the viewpoint of easy design. You can do it.

[End sentence] In the above description of each embodiment, a bobbin piece having a shape obtained by equally dividing a substantially annular shape into a plurality of pieces has been formed. Bobbin pieces may be formed and connected to form the current sensor device.

Although the plurality of divided bobbin pieces are connected to each other to form a substantially ring-shaped current sensor device, the current sensor device is formed into an elliptical ring-shaped or rectangular current sensor device. You may make it. In this case, the current sensor device is formed by connecting a plurality of bobbin pieces divided by a line in a direction perpendicular to the center axis of the elliptical ring shape or the rectangular shape.

In the above description of the second embodiment, the plate-shaped cores 2a and 23a are pressed by the plate spring 30, but this may be a member other than the plate spring, such as a spring or rubber. As described above, if the member expands and contracts in response to an external pressure, the same effect as described above can be obtained. In addition, without providing the leaf spring 30, the bottom plates 26 and 27 themselves are subjected to an insulating treatment such as rubber, cardboard, plastic, metal (iron, aluminum, etc.) having a thickness capable of pressing the plate core 23a. It is possible to obtain the same effect as the above-mentioned effect by forming the above.

Finally, the description of each of the above embodiments is merely an example of the present invention. In addition, for example, three or four bobbin pieces are connected in the same manner as described above to form a substantially annular bobbin. As a matter of course, various changes can be made according to the design and the like within a range not departing from the technical idea according to the present invention.

[0089]

The current sensor device and the method for assembling the current sensor device according to the present invention can simplify the process of winding a copper wire. For this reason, the assembly process of the current sensor device can be simplified to enable mass production.

Further, it is possible to prevent a useless portion from appearing on the original plate from which the core is die-cut. Therefore, the cost of the current sensor device can be reduced.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a structure of a current sensor device according to a first embodiment of the present invention.

FIG. 2 is a perspective view showing first and second bobbin pieces constituting the current sensor device according to the first embodiment.

FIG. 3 is a diagram for explaining a connection process for each of the first and second bobbin pieces.

FIG. 4 is a view for explaining a connector terminal for electrically connecting the first and second bobbin pieces.

FIG. 5 is an exploded perspective view showing a structure of a current sensor device according to a second embodiment of the present invention.

FIG. 6 is a perspective view showing a configuration of a lid of a bobbin of the current sensor device according to the second embodiment.

FIG. 7 is a diagram for explaining an assembling process of the current sensor device according to the second embodiment.

FIG. 8 is a diagram showing a connector part of a bobbin divided into two parts of the current sensor device according to the second embodiment.

FIG. 9 is a view for explaining a step of removing a plate-like core provided in a conventional current sensor device.

FIG. 10 is a diagram for explaining a plate removing step of a plate core divided into two provided in the current sensor device according to the second embodiment.

FIG. 11 is a view for explaining a winding step of a conventional current sensor device.

FIG. 12 is a view showing the appearance of a conventional current sensor device on which a copper wire is wound.

FIG. 13 is an exploded perspective view of a bobbin constituting a conventional current sensor device.

FIG. 14 is a view showing the appearance of a bobbin constituting a conventional current sensor device.

[Explanation of symbols]

 1, 2 1st, 2nd bobbin piece 3, 6 1st, 2nd upper half 4, 7 1st, 2nd lower half 5, 8 cores 5a, 8a Plate core 11, 12 Core storage gap Part 13a First connection hole constituting a connector terminal 14a First connection pin 17a constituting a connector terminal 17a Second connection hole 18a Second connection pin 20a, 20b Copper wire 20c Hole for inserting a hole element 9a Hole for accommodating a hole element Holes 21, 22 First and second lids 23 a Plate-shaped core 24, 25 First and second storages 26, 27 Bottom plate 30 Plate-shaped spring 32 Connection hole 33 Connection pin 34, 35 Core storage gap

Claims (10)

(57) [Claims] 1. A current sensor device for detecting a current amount of an object using a Hall element, wherein a single bobbin having a predetermined shape is divided into a plurality of lines by a line in a direction orthogonal to a center axis of the bobbin. A plurality of bobbin pieces each having connection means for establishing an electrical connection with each other; a plurality of cores respectively housed in each of the bobbin pieces; and one end wound around each of the bobbin pieces. Alternatively, a winding winding having both ends connected to the connection means is provided, and the bobbin pieces wound with the winding winding are connected to each other via the connection means provided on each of the bobbin pieces. A current sensor device characterized by being formed by: 2. The method according to claim 1, wherein the plurality of bobbin pieces are each composed of an upper half and a lower half. At the time of assembly, the plurality of bobbin pieces are configured by storing the core and abutting the upper half and the lower half. The current sensor device according to claim 1, wherein: 3. The plurality of bobbin pieces include a storage part for storing the core, and a pressing part for pressing the core to the whole, a part, or a plurality of parts contacting the core stored in the storage part. 2. A pressing member is provided, and said lid is configured to press and fix the core stored in said storage portion by said pressing member by being fitted to said storage portion. The current sensor device according to claim 1. 4. A plurality of bobbin pieces each having a substantially semi-annular shape, each having said connecting means at one end thereof, and a gap for accommodating said Hall element by connecting both at the other end thereof. 4. The current sensor device according to claim 1, wherein the first and second bobbin pieces have a gap forming portion for a hall element forming the portion. 5. The current sensor device according to claim 1, wherein the core is formed by stacking a plurality of plate-shaped cores. 6. A method of assembling a current sensor device for detecting a current amount of an object using a Hall element, wherein one bobbin having a predetermined shape is divided into a plurality of lines by a line in a direction orthogonal to a center axis of the bobbin. A plurality of cores are housed in a plurality of bobbin pieces each having a shape and having connection means for electrically connecting each other, and a winding wire is wound around each of the bobbin pieces, One end or both ends of the winding winding are connected to the connection means, and the bobbin pieces on which the winding windings are wound are connected via the connection means provided on each bobbin piece. A method for assembling a current sensor device, comprising: 7. The plurality of bobbin pieces are each composed of an upper half and a lower half, and are formed by housing the core and abutting the upper half and the lower half. 7. The method for assembling the current sensor device according to 6. 8. The plurality of bobbin pieces include a storage portion for storing the core, and a pressing portion for pressing the core to the whole, a part, or a plurality of portions contacting the core stored in the storage portion. And a lid provided with a pressing member,
7. The current sensor according to claim 6, wherein the lid is fitted to the storage section so that a pressing member provided on the lid presses and fixes the core stored in the storage section. How to assemble the device. 9. A plurality of bobbin pieces each having a substantially semi-annular shape, each having said connecting means at one end, and a gap for accommodating said Hall element by connecting both at the other end. 7. The first and second bobbin pieces having a gap forming portion for a Hall element forming a portion, wherein the bobbin pieces are formed by connecting the respective bobbin pieces via the connecting means. A method for assembling the current sensor device according to claim 7. 10. The method for assembling a current sensor device according to claim 6, wherein the core is formed by stacking a plurality of plate-shaped cores.