CN101323161B - 内燃机中的空气流量调节阀所用的设有磁体的轴的制造方法 - Google Patents

内燃机中的空气流量调节阀所用的设有磁体的轴的制造方法 Download PDF

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CN101323161B
CN101323161B CN2008101099127A CN200810109912A CN101323161B CN 101323161 B CN101323161 B CN 101323161B CN 2008101099127 A CN2008101099127 A CN 2008101099127A CN 200810109912 A CN200810109912 A CN 200810109912A CN 101323161 B CN101323161 B CN 101323161B
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马尔切洛·科里
乔治·西尼奥雷利
罗伯托·皮乔蒂
纳扎里奥·贝拉托
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    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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Abstract

本发明涉及一种内燃机中的空气流量调节阀(1)所用的设有磁体(24)的轴(6)的制造方法，该方法包括以下步骤：布置第一模具(26)，该第一模具凹形地仿现出轴(6)的形状并决定用于所述磁体(24)的座(28)的构造；将熔融的塑性材料注射到所述模具(26)内，从而通过注射成型而形成设有用于所述磁体(24)的座(28)的轴(6)；布置环绕用于所述磁体(24)的所述座(28)的第二模具(27)；以及将熔融的磁性聚合物注射到所述第二模具(27)内，从而通过注射成型而形成所述磁体(24)。

Description

内燃机中的空气流量调节阀所用的设有磁体的轴的制造方法
技术领域
本发明涉及一种内燃机中的空气流量调节阀所用的设有磁体的轴。
本发明可有利地应用于蝶阀轴，以下在说明书中清楚地参照蝶阀轴而不因此丧失其一般性。
背景技术
在使用汽油的内燃机中要使用布置在进气歧管上游并对供应至缸体内的空气流量进行调节的蝶阀。公知的蝶阀具有阀体，在该阀体内具有与蝶阀板接合的阀座，蝶阀板锁在旋转轴上从而在结合至轴本身的电动马达的作用下借助于齿轮传动装置在打开位置和闭合位置之间转动。
适于检测上述轴的(即蝶阀板的)角位置的位置传感器连接至蝶阀板支承轴的一端，从而使控制单元可对电动马达进行反馈控制。在现代蝶阀中，位置传感器是非接触式传感器，并包括定子和配合到蝶阀板支承轴一端上的转子，该定子在使用中面向转子从而检测转子自身的角位置。通常，电动马达、齿轮传动装置和位置传感器容纳在阀体容纳腔室内，该容纳腔室由通常支承位置传感器的定子的可卸下的盖关闭。
在磁性类型的位置传感器的情况下，转子包括通常为圆形的磁体，该磁体固定到蝶阀板支承轴的一个端部上。当前，构成位置传感器转子的这样的磁体通过胶合或通过共同成型而固定到蝶阀板支承轴的一个端部上；然而，这样的制造方法具有相对较高的生产成本。
发明内容
本发明的目的是提供一种内燃机中的空气流量调节阀所用的磁体，其制造方法没有上述缺点，具体而言该方法能容易且节约成本地实施。
根据本发明，提供一种内燃机中的空气流量调节阀所用的设有磁体的轴的制造方法，该方法包括以下步骤：
布置第一模具，该第一模具凹形地仿现出轴的形状并决定用于所述磁体的座的构造；
将熔融的塑性材料注射到所述模具内，从而通过注射成型而形成设有用于所述磁体的座的轴；
布置环绕用于所述磁体的所述座的第二模具；以及
将熔融的磁性聚合物注射到所述第二模具内，从而通过注射成型而形成所述磁体。
附图说明
以下将参照附图描述本发明，这些附图示出了本发明实施方式的非限定性实施例，其中：
图1为内燃机所用的蝶阀的前视示意图，其中为了清楚起见而移除了一些部件；
图2为根据本发明的制造方法目的制成的图1中的蝶阀轴的轴的局部剖视侧视图；
图3为图2中的轴的立体示意性剖视图；并且
图4为图2中的轴的制造步骤的立体示意图。
具体实施方式
图1中，附图标记1整体上表示内燃机(未示出)所用的蝶阀。蝶阀1包括容纳电动马达3的阀体2，而且阀体内设有与蝶阀板5(图2所示)接合的阀座4，该蝶阀板可在电动马达3的作用下在阀座4的打开位置和闭合位置之间移位。具体而言，蝶阀板5被锁在具有纵向旋转轴线7的轴6上，并且闭合位置在电动马达3的作用下借助于齿轮传动装置8而与轴6本身机械地结合。
电动马达3具有筒体9，其在基部处由金属板10限定，金属板10设有一对通孔(未示出)，为电动马达3提供电力的两根电线11穿过这对通孔；在每根电线11和板10中的对应孔(未示出)之间设有对应的绝缘衬套12。板10的主要功能是使得可将电动马达3固定到阀体2上；为此目的，板10具有三个穿孔径向附属部(appendix)13，相应的紧固螺钉14穿过这些附属部至阀体2。
电动马达3具有轴15，该轴终止于齿轮16，齿轮16通过介于齿轮16和与轴6成一体的端部齿轮18之间的惰齿轮17而机械地连接到轴6。齿轮17具有结合至齿轮16的第一组齿19以及结合至端部齿轮18的第二组齿20；第一组齿19的直径与第二组齿20的直径不同，从而齿轮17决定了非单一传动比。端部齿轮18由与轴6成一体的完整筒形中央体21限定，并设有圆形的冠部22，该冠部22具有一系列与齿轮17结合的齿。整个齿轮传动装置8(即，齿轮16、齿轮17以及端部齿轮18)通常由塑性材料形成。
如图1和图2所示，蝶阀1包括位置传感器23，其结合至轴6并适于检测蝶阀板5的角位置。位置传感器23为非接触式磁性传感器，其包括与轴6成一体的磁体24以及布置成面向磁体24并用于读取磁体24的角位置的读取装置25。具体而言，磁体24呈圆形，并至少部分嵌在端部齿轮18的完整筒形中央体21内。如附图所示，磁体24部分地嵌入在端部齿轮18的筒形中央体21内，即：磁体24的基壁可见，从而没有被筒形中央体21覆盖；根据不同的实施方式(未示出)，磁体24完全嵌入在端部齿轮18的筒形中央体21内，即：磁体24完全隐藏在筒形中央体21内部。
如图4所示，轴6和端部齿轮18由塑性材料(科技聚合物)一起注射而成；因此，轴6和端部齿轮18是一体的，即由相同材料无缝形成。轴6和端部齿轮18的制造可设想采用第一模具26，其凹形地仿现出轴6的形状和端部齿轮18的形状，将熔融的塑性材料注入到其中以形成轴6和端部齿轮18。第一模具26成形为限定端部齿轮18中的圆形座或空腔28，该圆形座或空腔28用于以后容纳位置传感器23的磁体24。
接着，将轴6和端部齿轮18(或仅仅是端部齿轮18)至少部分地插入第二模具27，该第二模具27凹形地仿现出位置传感器23的磁体24的形状，将熔融的磁性聚合物(例如，钕聚合物)注入到其中以形成磁体24。显然，第二型腔27包围(环绕)用于容纳位置传感器23的磁体24的圆形座或空腔28。所述磁性聚合物包括小的磁性金属材料颗粒(粉末)以及塑料结合母体；为了注射磁性聚合物，使塑料结合母体熔化，同时使小的磁性金属材料颗粒(粉末)保持为固态并悬浮在熔化了的塑料母体中。
根据一优选实施方式，从关于纵向旋转轴线7对称布置并定位在用于磁体24的座28外周上的至少两个不同注射点径向地(即，垂直于纵向旋转轴线7)进行用于形成磁体24的熔融磁性聚合物注射，从而通过迫使塑性材料流流入磁体24的容积内而优化塑性材料流接缝线的位置。换言之，将熔融的磁性聚合物从至少两个不同的注射点沿着径向方向注入，以形成磁体24；注入点的数量至少等于两个，通常在两个和四个之间。通过利用从若干不同的注射点径向注入熔融的磁性聚合物，可将磁体24的接缝线布置在磁体24内部，从而磁体24本身是特别均质的；由于注入的材料具有相当高的均质性，所以磁体24在磁化后产生的磁场磁通线是均匀的，从而位置传感器23的读数非常精确。
最后，通过将磁体24布置在适当取向的场中并改变磁场的强度而使磁体24进行磁滞循环从而使磁体24磁化。通常，磁体24是在注入磁体24本身之后磁化的；可选的是，磁体24能在注入过程中磁化，例如通过设置具有在使用中电流通过其中的线圈的第二模具27。
根据一可能的实施方式，两个模具26和27具有共同部分29(即，用于两个模具26和27的部分)以及两个相应的特征部分30和31(即，每个模具26和27的特有部分)。换言之，第一模具26包括共同部分29和特有的特征部分30，而第二模具27包括共同部分29以及特有的特征部分31。
换言之，轴6、端部齿轮18以及磁体24是通过两步注射而制成的，或者说是通过形成轴6和端部齿轮18的塑性材料以及形成磁体24的磁性聚合物的顺序注射而制成的。
在上述制造方法中，首先与端部齿轮18一起制成轴6，而磁体24稍后制成；根据一不同的实施方式，可首先制成磁体24稍后制成端部齿轮18。
上述轴6、端部齿轮18和磁体24的制造方法特别有利，这是因为其使得可抑制制造时间和成本，同时可获得高度一体性的部件以及相当高的制造精度(特别是在磁体24相对于轴6的定位方面)。具体而言，对制造时间和成本的抑制是通过以下事实而实现的，即：轴6、端部齿轮18和磁体24的上述制造方法可简单且完全地自动化。
显然，上述制造方法可用来制造用于内燃机所用的任何类型的空气流量调节阀的轴-磁性转子组件；例如，这样的制造方法可用于制造用于内燃机的进气歧管的涡旋系统或翻转系统的扼流阀的轴-磁性转子组件。

Claims (10)

1. 一种内燃机中的空气流量调节阀(1)所用的设有磁体(24)的轴(6)的制造方法，该方法包括以下步骤：
布置第一模具(26)，该第一模具凹形地仿现出轴(6)的形状并决定用于所述磁体(24)的座(28)的构造；
将熔融的塑性材料注射到所述模具(26)内，从而通过注射成型而形成设有用于所述磁体(24)的座(28)的轴(6)；
布置环绕用于所述磁体(24)的所述座(28)的第二模具(27)；以及
将熔融的磁性聚合物注射到所述第二模具(27)内，从而通过注射成型而形成所述磁体(24)。
2. 根据权利要求1所述的方法，其中，用于形成所述磁体(24)的所述熔融的磁性聚合物的注射是从关于所述轴的纵向旋转轴线(7)对称布置的至少两个不同注射点径向进行的。
3. 根据权利要求2所述的方法，其中，所述注射点定位在用于所述磁体(24)的所述座(28)的外周上。
4. 根据权利要求2所述的方法，其中，注射点的数量在两个到四个之间。
5. 根据权利要求1所述的方法，该方法还包括以下步骤，即：通过将所述磁体(24)布置在适当取向的磁场内，并通过改变磁场强度而使得所述磁体(24)进行至少一个磁滞循环，从而使所述磁体(24)磁化。
6. 根据权利要求5所述的方法，其中，在所述熔融磁性聚合物模铸结束时使所述磁体(24)磁化。
7. 根据权利要求5所述的方法，其中，在所述熔融磁性聚合物模铸的过程中使所述磁体(24)磁化。
8. 根据权利要求1所述的方法，其中，所述轴(6)设有端部齿轮(18)，该端部齿轮由与所述轴(6)成一体的筒形中央体(21)限定并设有至少一个圆形冠部(22)，该圆形冠部具有一系列的结合齿；磁体(24)至少部分地嵌在所述端部齿轮(18)的所述筒形中央体(21)中。
9. 根据权利要求1所述的方法，其中，所述磁体(24)构成适于读取轴(6)的角位置的非接触式磁性位置传感器(23)的旋转部分。
10. 根据权利要求1所述的方法，其中，所述两个模具(26，27)具有共.部分(29)以及两个相应的特征部分(30，31)。
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