JP3321046B2 - Core member for electromagnetic solenoid and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a core member for an electromagnetic solenoid and a method for manufacturing the same, and more particularly, to a core member for an electromagnetic solenoid having a plurality of magnetic plates superposed in an involute shape and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, for example, Japanese Patent Application Laid-Open No. 8-28816
As disclosed in No. 4, a core member for an electromagnetic solenoid including a plurality of magnetic plates superposed in an involute shape is known. An insulating layer is formed on the surface of the plurality of magnetic plates provided in the conventional core member. According to such a configuration, it is possible to suppress an eddy current caused by a change in the magnetic flux density flowing through the core member, and to impart high responsiveness to the electromagnetic solenoid.

In the above-mentioned conventional manufacturing process of a core member, first, a plurality of magnetic plates curved into a predetermined shape are superposed in the circumferential direction. Next, the magnetic plate group is inserted into a cylinder whose inner shape is formed into a tapered shape. The inner diameter of the cylinder is
It is gradually reduced from the side where the magnetic plate group is inserted toward the other side. The magnetic plate group inserted into the cylinder is pressed until it passes through the cylinder and escapes from the other side. During this time, a stress is applied to the group of magnetic plates in the diameter reducing direction, and as a result, each magnetic plate is formed into an involute shape.

A ring member is on standby at the end of the cylinder. The ring member is formed so that its inside diameter is the same as the inside diameter of the cylinder. The magnetic plate group that has escaped from the cylinder is inserted inside the ring member. The ring member prevents the shape of the magnetic plate group from being lost after the ring member escapes from the cylinder. The magnetic plate group is conveyed while being surrounded by the ring member. Thereafter, a welding step of welding the adjacent magnetic plates, an annealing step of releasing the stress remaining on the magnetic plates, and the like are performed to manufacture the core member. According to the above manufacturing method, a plurality of magnetic plates can be maintained in close contact with each other in the core member manufacturing process, and a core member having a high space factor can be manufactured.

[0005]

However, in the above-mentioned conventional manufacturing method, in order to properly maintain the shape of the magnetic plate group after escape from the cylinder by using the ring member, the inner diameter of the ring member must be accurately adjusted. It is necessary to arrange the ring member at the end of the cylinder so that it matches the inside diameter of the cylinder and that the center of the ring member exactly matches the center of the cylinder.

In other words, in the above-mentioned conventional manufacturing method, if the inner diameter of the ring member does not match the inner diameter of the cylinder, or if the center of the ring member does not match the center of the cylinder, escape from the cylinder. In the process of inserting the magnetic plate group into the ring member, the shape of the magnetic plate group may be broken, or the tight contact between the magnetic plates may be loosened. In this regard, the above-described conventional manufacturing method is not always an optimal method for securing the productivity of the core member.

The present invention has been made in view of the above points, and it is a first object of the present invention to provide a method of manufacturing an electromagnetic solenoid core member capable of manufacturing an electromagnetic solenoid core member with high productivity. The purpose of. Another object of the present invention is to provide a core member for an electromagnetic solenoid that can be manufactured with high productivity.

[0008]

The first object of the present invention is to provide a method for manufacturing a core member for an electromagnetic solenoid having a plurality of magnetic plates superposed in an involute shape as described in claim 1. Multiple magnetic plates
Achieved by a method for manufacturing a core member for an electromagnetic solenoid, comprising: a magnetic plate arranging step of arranging them inside a cup so that they overlap in the circumferential direction; and a diameter reducing step of reducing the diameter of the cup after the magnetic plate arranging step. Is done.

In the present invention, the core member is manufactured by stacking a plurality of magnetic plates in an involute shape so that they are in close contact with each other. In the manufacturing process of the core member, the plurality of magnetic plates are formed into an involute shape by being compressed together with the cup in the diameter reducing direction. In this case, the plurality of magnetic plates can be maintained in close contact with each other after the diameter reduction step without taking any special measures.

A first object of the present invention is to provide a method of manufacturing a core member for an electromagnetic solenoid according to the first aspect of the present invention, wherein the step of arranging the magnetic plates is performed at a central portion of the plurality of magnetic plates. This is achieved by a method of manufacturing a core member for an electromagnetic solenoid having a core material arranging step of arranging a core material.
In the present invention, a core material is arranged at the center of the plurality of magnetic plates before they are compressed in the diameter reducing direction. In this case, the plurality of magnetic plates adhere to the core material by being compressed in the diameter reducing direction. When a plurality of magnetic plates come into close contact with the core material, high accuracy is given to the center position of the core member.

A first object of the present invention is to provide a method for manufacturing a core member for an electromagnetic solenoid according to the second aspect, wherein the core material has a larger linear expansion coefficient than the magnetic plate. While having, after the diameter reducing step,
This is achieved by a method of manufacturing a core member for an electromagnetic solenoid, in which an annealing step for releasing the residual stress of the core material is performed.

In the present invention, the annealing step is performed by heating the cup, the magnetic plate and the core. When these are heated, the core material expands more thermally than the magnetic plate. Therefore, during the execution of the annealing step, the magnetic plate is compressed from the inside in the radially expanding direction by the core material. When the magnetic plate is compressed from the inside in the radially expanding direction, the space factor of the plurality of magnetic plates is further improved.

A first object of the present invention is to provide a method of manufacturing a core member for an electromagnetic solenoid according to the second aspect, wherein the cup has a smaller linear expansion coefficient than the magnetic plate. This is achieved by a method of manufacturing a core member for an electromagnetic solenoid, wherein an annealing step for releasing the residual stress of the core material is performed after the diameter reducing step.

In the present invention, the annealing step is performed by heating the cup, the magnetic plate and the core. When they are heated, the cup exhibits a small thermal expansion compared to the magnetic plate. Therefore, during the execution of the annealing step, the magnetic plate is compressed by the cup from the outside in the diameter reducing direction. When the magnetic plate is compressed from the outside in the diameter reducing direction, the space factor of the plurality of magnetic plates is further improved.

A first object of the present invention is to provide a method of manufacturing a core member for an electromagnetic solenoid according to the first aspect of the present invention, wherein the step of reducing the diameter comprises forming the inner shape into a tapered shape. This is achieved by a method of manufacturing a core member for an electromagnetic solenoid, comprising a forming die passing step of reducing the diameter of the cup by passing through a die.

In the present invention, the cup passes through the inside of the mold. The inside of the mold is formed in a tapered shape. For this reason, the cup is compressed in the diameter reducing direction while passing through the inside of the mold. The first object is claim 6
As described in the above, in the method of manufacturing a core member for an electromagnetic solenoid according to claim 5, wherein the mold passing step,
A forward passing step of passing the cup from a forward direction through a mold having an inner diameter tapered, and a reverse passing step of passing the cup from a reverse direction through a mold having an inner diameter tapered. This is achieved by a method for manufacturing a core member for an electromagnetic solenoid, comprising:

In the present invention, when the cup passes through the mold, an axial stress acts on the cup and the magnetic plate together with a stress in the radially reduced direction. Therefore, when the cup passes through the mold, the cup and the magnetic plate undergo axial deformation. As in the present invention, when the cup is passed through the mold from both the forward direction and the reverse direction, deformation of the cup and the magnetic plate in the axial direction is suppressed.

A first object of the present invention is to provide a method for manufacturing a core member for an electromagnetic solenoid according to the fifth aspect of the present invention, wherein the inner diameter of the cup after the step of reducing the diameter is provided at the bottom of the cup. And a contact bottom forming step of forming a contact bottom having a diameter smaller than that of the magnetic plate. In the magnetic plate disposing step, the plurality of magnetic plates are arranged such that their ends contact the contact bottom. This is achieved by a method for manufacturing a core member for an electromagnetic solenoid.

In the present invention, in the process of reducing the diameter of the cup, the boundary between the bottom surface and the side surface of the cup is deformed into an arc shape. Therefore, when the plurality of magnetic plates are in direct contact with the bottom surface of the cup, the plurality of magnetic plates are displaced in the axial direction in the process of reducing the diameter of the cup. As in the present invention, when the contact bottom is formed at the bottom of the cup, the magnetic plate does not shift in the axial direction even if the boundary between the bottom surface and the side surface of the cup is deformed into an arc shape. In the present invention, the contact bottom includes both a contact bottom configured separately from the cup and a contact bottom configured using the bottom surface of the cup.

According to a first object of the present invention, in the method of manufacturing a core member for an electromagnetic solenoid according to the first aspect of the present invention, after the diameter reducing step, the end of the cup is attached to a mounting plate. This is achieved by a method of manufacturing a core member for an electromagnetic solenoid in which a finishing step of welding is performed. In the present invention, a mounting plate is welded to the end of the cup. The mounting plate is used when fixing the electromagnetic solenoid core member at a predetermined position. According to the present invention, the cup can be used without removing it.

According to a first object of the present invention, there is provided a method of manufacturing a core member for an electromagnetic solenoid according to the first aspect, wherein a cup removing step of removing the cup after the diameter reducing step is performed. This is achieved by a method of manufacturing a core member for an electromagnetic solenoid that is performed. In the present invention,
When the diameter reducing step is completed, the cup surrounding the magnetic plate is removed. According to the present invention, a plurality of magnetic plates are in close contact with each other, and a core member for an electromagnetic solenoid without a cup is easily manufactured.

According to a first object of the present invention, in the method of manufacturing a core member for an electromagnetic solenoid according to the first aspect, the residual stress of the core is released after the step of reducing the diameter. The annealing process for
This is achieved by a method of manufacturing a core member for an electromagnetic solenoid, wherein a bobbin groove forming step of forming a bobbin groove in the plurality of magnetic bodies is performed after the annealing step.

In the present invention, bobbin grooves are formed in the plurality of magnetic bodies. The electromagnetic solenoid core member is used in a state where the coil is housed in the bobbin groove. When the bobbin groove is provided before the diameter reducing step or the annealing step, the stress applied to the magnetic plate during the execution of the diameter reducing step is concentrated around the bobbin groove, and during the execution of the annealing step, the stress around the bobbin groove is increased. Is greatly deformed to release stress. Therefore, under such circumstances, the magnetic plate cannot be formed properly. When the bobbin groove is formed after the annealing step as in the present invention, the magnetic plate is formed into an appropriate shape, and the bobbin groove is given high accuracy.

A second object of the present invention is to provide a magnetic recording medium, comprising: a plurality of magnetic plates stacked in an involute shape; and a cup for holding the plurality of magnetic plates so that they are closely adhered in a circumferential direction. And a core member for an electromagnetic solenoid. In the present invention, the plurality of magnetic plates are held in close contact by the cup. In this case, the plurality of magnetic plates can be easily held in close contact.

According to a second aspect of the present invention, there is provided a core member for an electromagnetic solenoid according to the eleventh aspect, wherein the cup is made of a non-magnetic material. Achieved. In the present invention, the cup surrounding the magnetic plate is made of a non-magnetic material. When a plurality of electromagnetic solenoids are used, core members of adjacent electromagnetic solenoids may be arranged close to each other. As in the present invention, when the magnetic plate is surrounded by a cup made of a non-magnetic material, under such circumstances, it is possible to prevent the magnetic flux from being transferred between adjacent electromagnetic solenoid core members. it can.

[0026]

FIG. 1 is a sectional view of an electromagnetic solenoid 10 according to an embodiment of the present invention. Electromagnetic solenoid 1
0 is provided with a valve body 12 used as an intake valve or an exhaust valve of an internal combustion engine. The valve body 12 is integrally provided with a valve shaft 14. An armature 16 is fixed to the valve shaft 14.

On the upper and lower sides of the armature 14, core members 18,
20 are provided. The core members 18 and 20 include cups 22 and 24, magnetic plate groups 26 and 28, core members 30 and 32, and mounting plates 34 and 36. Cup 2
2, 24, core members 30, 32, and mounting plate 34,
36 is made of a non-magnetic material. Core member 18,
20 is fixed at a predetermined position via mounting plates 34 and 36.

The magnetic plate groups 26 and 28 are provided with annular bobbin grooves 38 and 40, respectively. The coils 42 and 44 are housed in the bobbin grooves 38 and 40, respectively. Coils 42 and 44
Generates a magnetic flux that circulates around the inner and outer circumferences when supplied with an exciting current. The magnetic flux generated by the coil 42 is
The liquid flows back through the magnetic plate group 26 and the armature 16.
The magnetic flux generated by the coil 44 returns through the magnetic plate group 28 and the armature 16.

When a magnetic flux circulating through the magnetic plate group 26 and the armature 16 is generated, an attractive force is generated between the core member 18 and the armature 16. Similarly, the magnetic plate group 28
When the magnetic flux that flows back through the armature 16 is generated, an attractive force is generated between the core member 20 and the armature 16. For this reason, according to the electromagnetic solenoid 10, the excitation current is supplied to the coils 42 and 44, so that the armature 1 is supplied.
6 can be displaced toward the core member 18 and the core member 20, that is, the valve element 12 can be reciprocated.

FIG. 2 shows the core member 18 taken along the line II-II shown in FIG.
The figure represented by the arrow is shown. Hereinafter, the configuration of the core member 18 will be described with reference to FIG. It should be noted that the core member 20 does not differ from the core member 18 in the configuration. Therefore, in the following description, only the configuration of the core member 18 will be described. As shown in FIG. 2, the magnetic plate group 26 includes a plurality of magnetic plates 46. The magnetic plate 46 includes the core 30.
It is arranged around the center. The magnetic plate 46 is formed in an involute shape so that adjacent ones are in close contact with each other over the entire surface. An insulating layer is formed on the surface of the magnetic plate 46. Therefore, neither the current nor the magnetic flux is transferred between the adjacent magnetic plates 46.

When the density of the magnetic flux flowing through the magnetic plate group 26 changes, an eddy current is generated by electromagnetic induction in a direction that impedes the change. Like the core member 18, the magnetic plate group 26
Is constituted by a plurality of magnetic plates 46 insulated from each other, the above-mentioned eddy current can be eliminated at an early stage. In order to give the electromagnetic solenoid 10 excellent responsiveness,
It is desirable that the eddy current generated in the magnetic plate group 26 disappears at an early stage. For this reason, according to the core member 18, excellent responsiveness can be given to the electromagnetic solenoid 10.

A plurality of magnetic plates 46 constituting the magnetic plate group 26
If the axial displacement occurs, the adhesion between the core member 18 and the armature 16 changes. When the adhesion between the core member 18 and the armature 16 changes, the magnitude of the electromagnetic force acting between the core member 18 and the armature 16 changes. Therefore, in order to generate a stable electromagnetic force between them, it is necessary to prevent the core magnetic plate 46 from being displaced in the axial direction.

During the operation of the electromagnetic solenoid 10, the armature 16 repeatedly contacts the core member 18. In such a situation, in order to prevent the plurality of magnetic plates 26 from shifting in the axial direction, the plurality of magnetic plates 26
That is, it is effective to make the ratio of the cross-sectional area of the magnetic plate 26 to the cross-sectional area of the magnetic plate group 46 (hereinafter, referred to as a space factor) a high value.

The present embodiment is characterized in that the core members 18 and 20 having a high space factor are manufactured by a simple method. The core members 18, 20 are manufactured in a similar manner. Hereinafter, a method of manufacturing the core member 18 will be described as a typical example thereof with reference to FIGS. FIG. 3 is a flowchart illustrating a series of steps performed during the manufacturing process of the core member 18. In the manufacturing process of the core member 18, first, the operation of Step 100 is performed.

In step 100, an operation of setting the components of the core member 18 in a predetermined positional relationship is performed.
4 and 5 show an exploded view of the components of the core member 18 set in a predetermined positional relationship in step 100 and a cross-sectional view of the components set in a predetermined positional relationship.

As shown in FIG. 4 and FIG.
In 00, the disk 48 is disposed inside the cup 22, and a plurality of magnetic plates 46 and the core 30 are disposed above the disk 48. The plurality of magnetic plates 46 and the core member 30 are disposed such that their end surfaces abut on the upper surface of the disk 48. At the stage when this step 100 is executed, the magnetic plate 4
6 is formed in a predetermined curved shape so that it can be formed into an involute shape by being compressed in the diameter reducing direction. Further, at the stage when the present step 100 is executed, the cup 22 has a bottom surface portion 50 and a side surface portion 52. At this stage, the bottom surface 50 of the cup 22 has a larger diameter than the diameter of the core member 18.

A through hole 54 is formed in the center of the core member 30. The disk 48 has a fitting portion 56 that fits into the through hole 54. Core material 30 and disk 48
When the fitting portion 56 is fitted into the through hole 54, the core material 3
0 is provided to be perpendicular to the disk 48. The diameter of the disk 48 is set to a value slightly smaller than the diameter of the core member 18. Therefore, this step 1
At the stage when 00 is executed, a predetermined clearance is secured between the boundary 53 between the bottom surface 50 and the side surface 52 and the end of the disk 48.

As shown in FIG. 3, when the operation shown in step 100, that is, the operation of setting the components of the core member 18 is completed, the operation in step 102 is performed next. In step 102, the component set in the state shown in FIG. 5 (hereinafter, referred to as a processing target 58) is subjected to forward diameter reduction processing.

FIG. 6 is a sectional view of a diameter reducing device 60 and a processing object 58 used for diameter reduction in the forward direction. The diameter reducing device 60 includes a base block 62. A support shaft 64 is inserted into the base block 62. Support shaft 64
Is urged upward by a spring 66 in FIG. The support shaft 64 can be displaced in its axial direction while receiving the urging force of the spring 66.

The diameter reducing device 60 includes a molding die 68 and a pressing shaft 70. The molding die 68 is fixed to the base block 62. On the other hand, the pressing shaft 70 is
2 supported. Therefore, the molding die 68 and the pressing shaft 70
And the relative position is accurately determined. In the diameter reducing device 60, the relative positions of the molding die 68 and the pressing die 70 are set such that their central axes coincide with each other.

A depression 72 is provided at the center of the pressing shaft 70. The processing object 58 is set in the diameter reducing device 60 so that the core material 30 fits into the concave portion 72. After the processing target 58 is set as described above, the diameter reducing device 60 presses the processing target 58 downward using the pressing shaft 70 toward the lower side of the molding die 68. The pressing of the processing target 58 is continued until the processing target 58 escapes below the molding die 68.

A tapered portion 74 is formed on the inner wall of the molding die 68. The tapered portion 74 is formed such that the inner diameter of the mold 68 gradually decreases from above to below. The upper end of the tapered portion 74 is provided with a larger diameter than the initial value of the diameter of the cup 22. On the other hand, the lower end of the tapered portion 74 has a smaller diameter than the initial value of the diameter of the cup 22. Therefore, the processing target 58 is
The processing object 58 is compressed in the diameter reducing direction while passing through the forming die 68.

As shown in FIG. 6, according to the diameter reduction in the forward direction, the bottom surface 50 advances inside the molding die 68 prior to the side surface 52. At this time, an axial stress (upward stress in FIG. 6) acts on the boundary portion 53 of the cup 22 together with the stress in the radially reduced direction. When the above-described stress acts on the cup 22, the cup 22 is deformed in the radially reduced direction together with the magnetic plate 46 housed therein. At this time, the cup 22
Is deformed into an arc shape. Therefore, the magnetic plate 46
Is in contact with the boundary 53, the magnetic plate 46 is displaced in the axial direction with the execution of the diameter reduction processing in the forward direction.

In this embodiment, as described above, the disc 48 is disposed on the bottom surface 50 of the cup 22. Therefore, the position of the magnetic plate 46 in the axial direction is set at the boundary 5 of the cup 22.
It is regulated by a disc 48 instead of 3. In this embodiment, a predetermined gap is formed between the boundary 53 and the disk 48. Therefore, even if the boundary portion 53 is deformed in an arc shape, the relative position between the bottom surface 50 and the disk 48, that is, the relative position between the bottom surface 50 and the magnetic plate 46 does not change. Therefore, according to the present embodiment, the diameter of the cup 22 and the magnetic plate 46 can be reduced without significantly displacing the individual magnetic plates 46 in the axial direction by performing the forward diameter reduction processing.

The diameter reduction in the forward direction is performed in a state where the core material 30 is fitted in the concave portion 72. For this reason, the diameter reduction in the forward direction is performed in a state in which the center axis of the processing object 58 and the center axis of the pressing shaft 72 coincide with each other, that is, the state in which the central axis of the processing object 58 and the center axis of the molding die 68 match. Done in Further, in the present embodiment, the core member 30 extends perpendicular to the disk 48. For this reason, the diameter reduction processing in the forward direction is performed in a state where the core material 30 is perpendicular to the end faces of all the magnetic plates 46 (end faces abutting on the discs 48). Therefore, according to the diameter reduction in the forward direction, the core 30 is perpendicular to the end face of the magnetic plate group 26 while the center axis of the processing object 58 and the center axis of the core 30 are accurately aligned. Cup 22 while extended
In addition, the diameter of the magnetic plate group 26 can be reduced.

As shown in FIG. 3, upon completion of the forward diameter reduction in step 102, the operation in step 102 is performed. In step 102, reverse diameter reduction processing is performed. FIG. 7 is a sectional view of a diameter reducing device 80 and a processing target 58 used for reverse diameter reduction. The diameter reducing device 80 includes a base block 82. A support shaft 84 is inserted into the base block 82. Support shaft 8
At the center of 4, a concave portion 86 that fits with the core member 30 is formed. The support shaft 84 is urged upward by a spring 88 in FIG. The support shaft 84 can be displaced in its axial direction while receiving the urging force of the spring 88.

The diameter reducing device 80 includes a molding die 90. The mold 90 is fixed to the base block 82. Therefore, the relative position between the molding die 90 and the support shaft 84 is accurately determined. In the diameter reducing device 80, the forming die 9
The relative positions of 0 and the support shaft 84 are set such that their central axes coincide with each other. The diameter reducing device 80 also includes a pressing shaft 92. The pressing shaft 92 is supported by the base block 82. The diameter reducing device 80 includes the support shaft 8.
4 with the core material 30 fitted in the recess 86, the pressing shaft 9
The workpiece 58 is pressed downward of the mold 90 by using 2. The pressing of the processing target 58 is continued until the processing target 58 escapes below the molding die 90.

The inner wall of the mold 90 is formed with a tapered portion 94. The tapered portion 94 is formed such that the inner diameter of the mold 90 gradually decreases from above to below. The upper end of the tapered portion 94 is provided with a larger diameter than the diameter of the processing target 58 that has completed the diameter reduction processing in the forward direction. On the other hand, the lower end of the tapered portion 74 is provided with a diameter equal to the diameter to be provided to the cup 22 in the core member 18. For this reason, the processing target 58 is reduced in diameter in the process of passing through the forming die 68 to a diameter to be given to the cup 22 of the core member 18.

As shown in FIG. 7, according to the reverse diameter reduction processing, the side surface 52 advances inside the mold 90 before the bottom surface 50. At this time, a downward force input from the pressing shaft 92 acts near the center of the magnetic plate 46. On the other hand, an upward force input from the side surface 52 of the cup 22 acts near the outer periphery of the magnetic plate 46. Therefore, according to the reverse diameter reduction processing, stress is applied to the individual magnetic plates 46 to deform them in the axial direction.

A stress is applied to the magnetic plate 46 to deform each magnetic plate 46 in the axial direction even during the above-described forward diameter reduction processing. These stresses, that is, the stress generated during the execution of the forward diameter reduction processing and the stress generated during the execution of the reverse diameter reduction processing, act on the magnetic plate 46 in opposite directions. Therefore, when the reverse diameter reduction processing is executed after the forward direction diameter reduction processing is performed, the axial deformation generated in the magnetic plate 46 due to the forward direction diameter reduction processing is performed in the reverse direction diameter reduction processing. Can be offset. Therefore, according to the manufacturing method of this embodiment, the deformation of the magnetic plate 46 in the axial direction can be suppressed to an extremely small amount.

The reverse diameter reduction processing is performed in a state where the core material 30 is fitted in the recess 86. For this reason, the reverse diameter reduction processing is performed in a state where the center axis of the processing object 58 and the center axis of the support shaft 84 coincide with each other, that is, in a state where the center axis of the processing object 58 and the center axis of the molding die 90 match. Done in Therefore,
According to the reverse diameter reduction processing, the diameter of the cup 22 and the magnetic plate group 26 can be reduced while the center axis of the processing target 58 and the center axis of the core material 30 are accurately aligned.

When the forward diameter reduction processing and the reverse diameter reduction processing described above are performed, the magnetic plate 46 is formed into an involute shape, and a state where the adjacent magnetic plates 46 are in close contact with each other over the entire surface is formed. After the above processing is performed,
The cup 22 prevents the magnetic plate 46 from being deformed in the diameter expanding direction. For this reason, in the manufacturing method of the present embodiment, after the above-described processing is performed, the state in which the magnetic plates 46 are in close contact with each other can be maintained without taking any special measures.

As shown in FIG. 3, when the reverse diameter reduction processing shown in step 104 is completed, the operation in step 106 is performed next. In step 106, the processing target 58
Annealing is performed. At the stage when the forward diameter reduction processing and the reverse diameter reduction processing are completed, stress remains in the magnetic plate 46. In the annealing step 58, processing for heating and cooling the processing target 58 with a predetermined profile is performed. When the annealing step is performed, the structure of the magnetic plate 46 changes, and the stress remaining on the magnetic plate 46 can be released.

FIG. 8A is a cross-sectional view of a processing object 58 at a stage where an annealing step is performed. FIG. 8B
Shows a sectional view of the processing target 58 after the end of the annealing step. In this embodiment, the core 30 is made of a material having a larger linear expansion coefficient than the magnetic plate 46. on the other hand,
The cup 22 is made of a material having a smaller linear expansion coefficient than the magnetic plate 46.

Therefore, during the execution of the annealing step,
When the magnetic material 8 is heated, the magnetic plate 46 is compressed in the radially expanding direction from the center side thereof by the core material 30 expanding greatly, and the magnetic plate 46 expands greatly compared to the cup 22. Thus, they are compressed in the diameter reducing direction from outside. When the above-described compressive force acts on the magnetic plate 46, the space factor of the magnetic plate 46 is further improved.

The annealing step is performed to change the structure of the magnetic plate 46 to release the stress remaining on the magnetic plate 46. At this time, similarly to the magnetic plate 46, the core 30 and the cup 22 also change their structures. In the present embodiment, the conditions of the annealing step and the like are determined such that a structural change that expands the diameter of the core material 30 occurs, and a structural change that does not significantly change the diameter of the cup 22 occurs.

Therefore, as shown in FIGS. 8A and 8B, when the annealing step is completed, the magnetic plate 46
The compressed state in the radial direction is maintained as compared to before the annealing step is performed. Therefore, according to the manufacturing method of the present embodiment, by executing the annealing step, it is possible to obtain a higher space factor than the space factor obtained by the compression working in the forward and reverse directions.

As shown in FIG. 3, when the annealing step shown in step 106 is completed, the process in step 108 is executed. In step 108, machining is performed on the processing target 58. In this step 108, specifically,
From the processing object 58 to the bottom surface 50 of the cup 22 and the disk 48
, The unnecessary portion of the side surface 52 of the cup 22 and the unnecessary portion of the core material 30 are removed on the upper surface side of the processing object 58, and the bobbin groove 38 is provided in the magnetic plate group 26.

In order to realize the core member 18, it is essential to provide the magnetic plate group 26 with the bobbin groove 38. The bobbin groove 38 can be formed, for example, by punching out a portion corresponding to the bobbin groove 38 at the time of pressing the individual magnetic plates 46. However, if a notch corresponding to a bobbin groove is formed in the magnetic plate 46,
The strength of the peripheral portion of the notch is lower than the strength of the other portions. For this reason, when diameter reduction processing in the forward direction and the reverse direction is performed in a state where the notch portion is formed, a situation occurs in which deformation concentrates around the notch portion. Further, if the annealing step is performed in a state where the notch is formed, stress is intensively released around the notch, and it is difficult to maintain an appropriate involute shape.

Therefore, in order to secure a high space factor by making the magnetic plate 46 into an appropriate involute shape, the method of forming the notch at the stage of press working is not always optimal. On the other hand, according to the procedure of forming the bobbin grooves 38 in the magnetic plate group 26 after the completion of the annealing process in the forward and reverse directions as in the present embodiment, the involute of the magnetic plate 46 is reduced. Without losing the shape, that is, without losing the space factor of the magnetic plate 46, the bobbin groove 38
Can be formed.

Further, by forming the bobbin groove 38 after performing necessary processing on the magnetic plate group 26 as in the present embodiment, the size of the bobbin groove 38 can be accurately matched with the size of the coil 42, In addition, the side surface of the bobbin groove 38 can be a smooth surface with no irregularities. Exciting current is coil 4
2, the coil 42 generates heat. The coil 42 dissipates the heat through the magnetic plate group 26.

Accordingly, in order to avoid overheating of the coil 42, it is desirable that the thermal resistance between the coil 42 and the magnetic plate group 26 be as small as possible. The thermal resistance between the coil 42 and the magnetic plate group 26 decreases as the two are in close contact. Coil 42
To make the magnetic plate group 26 closely contact with the
Is suitable for the size of the coil 42, and the inner wall of the bobbin groove 38 is preferably smooth.

As described above, according to the manufacturing method of this embodiment, the bobbin groove 38 can be formed while satisfying these two requirements. Therefore, according to the manufacturing method of the present embodiment, it is possible to manufacture the core member 18 having a high space factor of the magnetic plate 46 and capable of providing the coil 42 with excellent heat dissipation. As shown in FIG.
When the annealing step shown in FIG.
Is performed.

In step 110, the mounting plate 34
Is performed. The core member 18 is completed by performing the operation of step 110. FIG. 10 is a cross-sectional view of the core member 18 in a completed state by performing the operation of Step 110 described above. The processing object 58 and the mounting plate 34 are fixed by fitting the end of the core 30 to the mounting plate 34 and welding the end of the cup 22 to the mounting plate 34.

According to the above-described manufacturing method, the core member 18 can be completed while the cup 22 surrounding the magnetic plate group 26 is mounted. When the magnetic plate group 26 is surrounded by the cup 22, it is possible to maintain the adjacent magnetic plates 46 in a close contact state without welding or the like. When the adjacent magnetic plates 46 are in close contact with each other, the magnetic plate group 26 is unlikely to lose its shape. For this reason, according to the manufacturing method of the present embodiment, the core member 18 that does not easily lose its shape can be manufactured with high productivity.

In the above embodiment, the core member 18 is completed without removing the side surface 52 of the cup 22. However, the cup 22 is removed, and the outer periphery of the magnetic plate group 26 is welded in a ring shape. This may prevent the magnetic plate 46 from being loosened. Further, in the above embodiment, the magnetic plate 46 is compressed using the diameter expansion of the core material 30 accompanying the execution of the annealing step, but the method of compressing the magnetic plate 46 is not limited to this. not,
For example, after the annealing step, the core 30 may be removed and a core having a larger diameter may be pressed into the magnetic plate 46 to further compress it.

In the above embodiment, the step 100 corresponds to the “magnetic plate arranging step” of the first aspect.
The steps 102 and 104 correspond to the “diameter reduction step” of the first embodiment, respectively, and the core material 30 is set inside the cup 22 at the step 100 by the “second step”. A core material arranging step ”is realized.

In the above embodiment, the step 106 corresponds to the “annealing step” according to the third, fourth, and tenth aspects. Processing object 58 is mold 6
By passing through 8, 90, the "mold passing step" according to claim 5 is realized.

In the above-described embodiment, the step 102 is the "forward passage step" according to the sixth aspect.
In addition, the step 104 corresponds to the “reverse passage step” of the above-described claim 6, and the disk 48 is arranged inside the cup 22 in the step 100. A contact bottom forming step ”is realized.

In the above embodiment, the step 110 corresponds to the “finishing step” of the eighth aspect, and the operation of removing the cup 22 from the magnetic plate group 48 after the annealing step is performed. Thus, the “cup removing step” according to the ninth aspect is realized, and the “bobbin groove forming step” according to the tenth aspect is realized by forming a bobbin groove in the step.

Next, a second embodiment of the method of manufacturing the core member 18 will be described with reference to FIG. In this embodiment, the core member 18 is manufactured by executing a series of steps shown in FIG. FIG. 11 shows the state of the processing target 112 after the component setting step shown in step 100 is completed. In FIG. 11, the same components as those shown in FIGS. 1 to 10 are denoted by the same reference numerals, and description thereof will be omitted.

The processing object 112 has a cup 114. The cup 114 has a contact bottom 116 on the bottom surface. In the present embodiment, the magnetic plate 46 is set inside the cup 22 such that its end abuts on the abutment bottom 116. The contact bottom 116 has a diameter slightly smaller than the diameter to be provided to the cup 114 of the core member 18 in a completed state, similarly to the disk 48 in the first embodiment. Therefore, according to the contact bottom 116, the processing target 1
It is possible to prevent the magnetic plate 46 from being displaced in the axial direction during the process of reducing the diameter of the magnetic plate 46 in the forward and reverse directions.

In this embodiment, steps 102 to 10
In steps 6 and 110, the same processing as in the first embodiment is performed. In step 108, machining for removing the contact bottom 116 is performed together with the bobbin groove 38 and the like. According to the above-described manufacturing method, the core member 18 having a high space factor can be easily manufactured without using the disk 48.

The first embodiment and the second embodiment
In the embodiment, the bottom surfaces of the cups 22 and 114 are removed. However, the present invention is not limited to this. , 114 may be completed while leaving the bottom surface of the core member 18. As described above, according to the manufacturing methods of the first embodiment and the second embodiment,
The magnetic plate group 26 of the core member 18 can be surrounded by cups 22 and 114 made of a non-magnetic material. Less than,
The effect obtained when the magnetic plate group 26 is surrounded by a non-magnetic material will be described with reference to FIGS.

FIGS. 12 and 13 show a state in which two electromagnetic solenoids are arranged adjacent to each other. FIG.
In FIG. 13, the same components as those shown in FIG. 1 are denoted by the same reference numerals, and description thereof will be omitted. The electromagnetic solenoid 120 shown in FIG.
22. The core member 122 is made of a soft magnetic material. The coil 42 is housed in the core member 122. When an exciting current flows through the coil 42, a magnetic flux flowing back and forth between the inner and outer circumferences of the coil 42 flows through the core member 122.

As shown in FIG. 12, the two core members 122
Are disposed adjacent to each other, the magnetic flux generated by the coil 42 of one electromagnetic solenoid 120 may return through the core member 122 and the armature 16 of both electromagnetic solenoids 120. In this case, an attractive force is generated between the armature 16 and the core member 122 in the electromagnetic solenoid 120 receiving the excitation current, and
A similar attractive force is generated in the other electromagnetic solenoid 120. Therefore, when two electromagnetic solenoids 120 are disposed adjacent to each other, the operation of one electromagnetic solenoid 120 may be affected by the operation of the other electromagnetic solenoid 120.

The electromagnetic solenoid 130 shown in FIG. The core member 132 includes a magnetic portion 134 made of a soft magnetic material, and a cup 136 made of a non-magnetic material. The cup 136
A core member 132 surrounds the magnetic portion 134 except for the surface opposing the armature 16. The coil 42 is housed in the magnetic portion 134. When an exciting current flows through the coil 42, a magnetic flux circulating through the inner and outer circumferences of the coil 42 flows through the magnetic portion 134.

As shown in FIG. 13, the electromagnetic solenoid 130
According to this, when two of them are disposed adjacent to each other, the cup 136 can be interposed between two adjacent magnetic portions 134. For this reason, according to the configuration shown in FIG. 13, the magnetic flux generated by the coil 42 of one electromagnetic solenoid 130 is generated by the core member 13 of the electromagnetic solenoid 130.
Reflux only through 2 and armature 16. Therefore, according to the electromagnetic solenoid 130, even when they are arranged adjacent to each other, one of the electromagnetic solenoids 13
0 and the other electromagnetic solenoid 130 can be operated without interfering with each other.

The core member 18 manufactured by the manufacturing methods of the first and second embodiments has cups 22 and 114 made of a non-magnetic material around a group of magnetic plates 26. Therefore, according to the core members 18, when they are arranged adjacent to each other, it is possible to prevent a magnetic flux from being transferred between one core member 18 and another core member 18. Therefore, according to the core member 18 manufactured by the manufacturing method of the first embodiment and the second embodiment, when a plurality of electromagnetic solenoids 10 are arranged adjacent to each other, they are prevented from interfering with each other. can do.

[0080]

As described above, according to the first aspect of the present invention, the plurality of magnetic plates can be easily kept in close contact with each other without taking any special measures. According to the second aspect of the present invention, it is possible to manufacture a core member whose center position is set with high accuracy.

According to the third or fourth aspect of the present invention, the space factor of the plurality of magnetic plates can be easily increased by performing the annealing step. According to the invention described in claim 5, the diameter of the cup can be easily reduced. According to the sixth aspect of the invention, the deformation of the cup and the magnetic plate in the axial direction can be easily suppressed.

According to the seventh aspect of the invention, it is possible to easily prevent the magnetic plate from being deformed in the axial direction in the diameter reducing step. According to the eighth aspect of the present invention, the magnetic body can be used as it is without removing the cup for maintaining the magnetic body in a close contact state. According to the ninth aspect of the present invention, it is possible to easily manufacture a core member for an electromagnetic solenoid in which a plurality of magnetic bodies are in close contact with each other and have no cup.

According to the tenth aspect of the present invention, a plurality of magnetic plates can be formed with high precision without being affected by the bobbin groove, and a bobbin groove with high precision can be formed. According to the eleventh aspect, the plurality of magnetic plates can be easily maintained in close contact with each other.

According to the twelfth aspect of the present invention, by surrounding a plurality of magnetic plates with a non-magnetic cup, it is possible to realize an electromagnetic solenoid core member that does not leak magnetic flux to the outside.

[Brief description of the drawings]

FIG. 1 is a sectional view of an electromagnetic solenoid according to an embodiment of the present invention.

FIG. 2 shows a core member included in the electromagnetic solenoid shown in FIG.
It is the figure represented by the II-II arrow.

FIG. 3 is a flowchart of a series of steps performed in a manufacturing method according to one embodiment of the present invention.

FIG. 4 is an exploded view of a component used in the component setting step shown in FIG. 3;

5 is a cross-sectional view illustrating a configuration of a processing target after a component setting step illustrated in FIG. 3 is completed.

6 is a cross-sectional view illustrating a diameter reducing device used in the forward-direction diameter reducing processing illustrated in FIG. 3 and a configuration of a processing target to be subjected to the processing.

7 is a cross-sectional view illustrating a diameter reduction device used in the reverse diameter reduction processing illustrated in FIG. 3 and a configuration of a processing target to be processed.

8A is a cross-sectional view illustrating a configuration of a processing target before an annealing step illustrated in FIG. 3 is performed. FIG. 8 (B)
FIG. 4 is a cross-sectional view illustrating a configuration of a processing target after an annealing process illustrated in FIG. 3 is performed.

FIG. 9 is a cross-sectional view illustrating a configuration of a processing target after the machining step illustrated in FIG. 3 is performed.

FIG. 10 is a cross-sectional view illustrating a configuration of a core member in a completed state by performing the plate welding process illustrated in FIG.

11 is a cross-sectional view illustrating a structure to be processed after the component setting step illustrated in FIG. 3 is completed in the manufacturing method according to the second embodiment of the present invention.

FIG. 12 is a diagram illustrating a flow of a magnetic flux generated when a core member that is not covered with a cup is arranged adjacently.

FIG. 13 is a diagram illustrating a flow of a magnetic flux generated when a core member covered with a cup is arranged adjacently.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Electromagnetic solenoid 18,20 Core member 22,24 Cup 26,28 Magnetic plate group 30,32 Core material 34,36 Mounting plate 38,40 Bobbin groove 42,44 Coil 46 Magnetic plate 48 Disk 50 Bottom surface 52 Side surface 53 Boundary part 58 Processing object 68,90 Mold 116 Contact bottom

Continued on the front page (72) Inventor Tatsuo Iida 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Corporation (72) Inventor Hiroyuki Hattori 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Corporation (72) Invention Person Isao Matsumoto 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Co., Ltd. No. 1 Toyota Motor Corporation (72) Inventor Keiji Yoeda 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Corporation (72) Inventor Norio Ito 3-6-6 Masaki Naka-ku, Nagoya City, Aichi Prefecture No. Inside Takagi Works (72) Inventor Makoto Ito 3-6-6 Masaki, Naka-ku, Nagoya City, Aichi Prefecture Inside Takagi Works, Ltd. (72) Kanji Suzuki 3-6-Masaki, Naka-ku, Nagoya City, Aichi Prefecture No. 6 Inside Takagi Works (72) Person Shintaro Ishihara 3-6-6 Masaki, Naka-ku, Nagoya City, Aichi Prefecture Inside Takagi Seisakusho Co., Ltd. (56) References JP-A-8-288164 (JP, A) JP-A-11-67532 (JP, A) Hei 10-233311 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) H01F 7/06 H01F 41/02

Claims (12)

(57) [Claims] 1. A method for manufacturing an electromagnetic solenoid core member comprising a plurality of magnetic plates superposed in an involute shape, wherein a plurality of magnetic plates curved into a predetermined shape are placed inside a cup so that they overlap in the circumferential direction. A method for manufacturing a core member for an electromagnetic solenoid, comprising: a step of arranging a magnetic plate; and a step of reducing the diameter of the cup after the step of arranging the magnetic plate. 2. The method of manufacturing a core member for an electromagnetic solenoid according to claim 1, wherein the step of arranging the magnetic plates includes a step of arranging a core member at a center of the plurality of magnetic plates. A method of manufacturing a core member for an electromagnetic solenoid. 3. The method of manufacturing a core member for an electromagnetic solenoid according to claim 2, wherein the core material has a larger linear expansion coefficient than the magnetic plate, and after the step of reducing the diameter, A method for manufacturing a core member for an electromagnetic solenoid, wherein an annealing step for releasing residual stress of a core material is performed. 4. The method of manufacturing a core member for an electromagnetic solenoid according to claim 2, wherein the cup has a smaller linear expansion coefficient than the magnetic plate, and the core is provided after the diameter reducing step. A method for manufacturing a core member for an electromagnetic solenoid, wherein an annealing step for releasing a residual stress of a material is performed. 5. The method of manufacturing a core member for an electromagnetic solenoid according to claim 1, wherein in the diameter reducing step, the diameter of the cup is reduced by passing the inner shape into a tapered shape. A method for manufacturing a core member for an electromagnetic solenoid, comprising a passing step. 6. The method of manufacturing a core member for an electromagnetic solenoid according to claim 5, wherein the forming die passing step causes the cup to pass through a forming die having a tapered inner diameter in a forward direction. A method of manufacturing a core member for an electromagnetic solenoid, comprising: a step of passing the cup from a reverse direction through a mold having a tapered inner diameter. 7. The method for manufacturing a core member for an electromagnetic solenoid according to claim 5, wherein a contact bottom portion having a smaller diameter than the inside diameter of the cup after the diameter reducing step is formed on the bottom portion of the cup. A method of manufacturing a core member for an electromagnetic solenoid, comprising: a bottom portion forming step; wherein, in the magnetic plate arranging step, the plurality of magnetic plates are arranged so that their ends abut on the contact bottom. Method. 8. The method for manufacturing a core member for an electromagnetic solenoid according to claim 1, wherein a finishing step of welding an end of the cup to a mounting plate is performed after the diameter reducing step. A method for manufacturing a core member for a solenoid. 9. The method for manufacturing a core member for an electromagnetic solenoid according to claim 1, wherein a cup removing step of removing the cup is performed after the diameter reducing step. Production method. 10. The method for manufacturing a core member for an electromagnetic solenoid according to claim 1, wherein, after the diameter reducing step, an annealing step for releasing residual stress of the core material is performed, and A method of manufacturing a core member for an electromagnetic solenoid, wherein a bobbin groove forming step of forming a bobbin groove in the plurality of magnetic bodies is performed later. 11. A core member for an electromagnetic solenoid, comprising: a plurality of magnetic plates superimposed in an involute shape; and a cup for holding the plurality of magnetic plates so as to be closely adhered in a circumferential direction. . 12. The core member for an electromagnetic solenoid according to claim 11, wherein the cup is made of a non-magnetic material.