CN103026428B - 电磁致动器 - Google Patents

电磁致动器 Download PDF

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CN103026428B
CN103026428B CN201180036589.5A CN201180036589A CN103026428B CN 103026428 B CN103026428 B CN 103026428B CN 201180036589 A CN201180036589 A CN 201180036589A CN 103026428 B CN103026428 B CN 103026428B
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D·迈尔
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Robert Bosch GmbH
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    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
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    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0614—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of electromagnets or fixed armature
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    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0625—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures
    • F02M51/0664—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding
    • F02M51/0685—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding the armature and the valve being allowed to move relatively to each other or not being attached to each other
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    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
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    • F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
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    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
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    • H01F7/08—Electromagnets; Actuators including electromagnets with armatures
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    • H01—ELECTRIC ELEMENTS
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    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
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    • H—ELECTRICITY
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    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00—Magnets
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Abstract

电磁致动器包括一极芯（2），其中，所述极芯（2）具有至少一个磁性区域（3）和至少一个非磁性区域（4），所述非磁性区域（4）提供所述磁性区域（3）的磁分离，所述极芯（2）被构造为一体式的部件，并且所述极芯（2）的磁性区域（3）和非磁性区域（4）材料锁合地借助双组分金属粉末注射成型方法连接。

Description

电磁致动器
技术领域
本发明涉及一种用于燃料喷射阀的电磁致动器以及一种用于制造电磁致动器的极芯的方法。
背景技术
现有技术的燃料喷射阀基本上被构造为具有线圈和电磁致动器的电磁转换阀，电磁致动器的极芯由多个具有铁素体磁性材料的扇形构成，这些扇形相对彼此通过一个表面层电绝缘。一个这种电磁转换阀例如由DE 19639 117 A1公开。通过薄的表面层和极芯的轮廓在运行中在磁场建立和减小时导致涡流损失以及由此导致燃料喷射阀的开关时间或者说动态性的减小。此外组合而成的极芯在多个工艺步骤中的制造非常费劲。
发明内容
按照本发明的具有权利要求1的特征的电磁致动器相对于此具有优点，即在这里提供一种电磁致动器，它具有一个有效地减小涡流的磁回路并且由此能够实现明显缩短的阀开关时间。这按照本发明通过以下方式实现，即电磁致动器包括一极芯，该极芯被构造为具有至少一个磁性区域和至少一个非磁性区域的一体式的部件。非磁性区域在这里能够实现磁分离，其中，在磁性区域和非磁性区域之间存在借助双组分金属粉末注射成型方法的材料锁合的连接。因此，电磁致动器的一体式的极芯的制造可以在一个过程步骤中以小的节拍时间和单件成本通过简单的方式作为批量生产零件实现。
从属权利要求示出本发明的优选扩展构型。
优选地，所述极芯具有至少两个磁性区域和至少两个非磁性区域，这些磁性区域和非磁性区域在所述极芯的圆周方向上交替地布置，其中，所述磁性区域由此非磁性区域相对彼此分离，并且，所述极芯的磁性区域和非磁性区域材料锁合地借助双组分金属粉末注射成型方法连接。
优选地，极芯的非磁性区域的两个侧面相对彼此平行，由此该电磁致动器达到特别高的动态性。非磁性区域的宽度在这里选择为这么大，使得实现相邻的磁性区域的电分离。非磁性区域的扇形面积明显小于磁性区域的扇形面积，优选以因子4至6、尤其是以因子5小于磁性区域的扇形面积。
还优选该极芯具有一个径向向外延伸的法兰。按照另一种优选的设计方案，在法兰中设置一个用于电接触的引线。由此能够完全在阀壳体的内部中实现短的电缆引线，这保证电磁致动器的运行可靠的电接触。另外能够在一个制造步骤中借助双组分-金属粉末-注射成型方法同时也制造线圈壳体。
优选极芯具有一个在轴向方向上延伸的线圈壳体，从而线圈在径向方向上设置在线圈壳体和极芯之间。由此实现电磁致动器的紧凑的结构形式，该紧凑的结构形式有助于减小整个燃料喷射阀的结构体积。
还优选的是，极芯的轴向延伸尺寸小于线圈壳体的轴向延伸尺寸。由此以简单且成本低廉的方式将极芯的面向喷射侧的端部固定在阀壳体上，而极芯的背对喷射侧的端部支撑在阀壳体的内部中。由此能够以少量的装配步骤实现快速的制造。
按照另一种优选的设计方案，该极芯具有一个中心的贯穿开口。由此保证对一个设置在其中的阀针连同复位弹簧和套筒的运行可靠的导向。
优选地，极芯具有偶数数量的磁性区域、尤其是四个磁性区域和偶数数量的非磁性区域、尤其是四个非磁性区域。还优选该极芯具有对称结构。由此通过少量的磁性区域和非磁性区域就已经实现在电磁致动器的运行中在磁场变化时的涡流损失的剧烈减小。此外该极芯由此具有一个简单的且可成本低廉地制造的结构形式。
本发明还涉及一种用于制造用于电磁致动器的一体式的极芯的方法，包括以下步骤：提供磁性和非磁性材料，和借助双组分金属粉末注射成型方法制造所述极芯的非磁性区域和磁性区域，以便建立非磁性区域和磁性区域之间的材料锁合的连接。通过按照本发明的方法能够以高的可重复性进行一体式的极芯的制造，从而提供一种电磁致动器，它显著地减小了燃料喷射阀的开关时间，由此在例如机动车中使用时必须喷射到燃烧室中的燃料量明显更少。通过减少的喷射量改善了发动机的空转性能。这导致发动机的排气性能明显改善。另外该方法也可极其经济地用于制造不同大小的复杂部件。
附图说明
下面参照附图详细描述本发明的实施例。在附图中：
图1示出按照本发明的第一优选实施例的具有电磁致动器的燃料喷射阀的示意性剖视图；
图2示出沿着图1的燃料喷射阀的平面A-A的剖视图；
图3示出按照本发明的第二优选实施例的极芯的剖视图；和
图4示出沿着图3的极芯的平面B-B的剖视图。
具体实施方式
在下面参考图1和2详细地描述一种根据本发明的第一优选实施例的电磁致动器以及一种用于制造电磁致动器的极芯的方法。
图1示出一种根据本发明的第一实施例的用于控制流体的燃料喷射阀10的示意性剖视图。该燃料喷射阀10包括一个阀壳体11，在该阀壳体的内部设有一个向内打开的阀针12，该阀针带有一个设置在其上的复位元件14和一个压块15。另外设有一个电磁致动器1，它包括一个固定在阀针12上的磁衔铁13以及一个极芯2和一个线圈8，该线圈与中心轴线X同轴地在一个线圈壳体7中在径向方向上设置在线圈壳体7和极芯2之间。极芯2具有一个贯穿开口9，带有复位元件14和压块15的阀针12在该贯穿开口中导向。极芯2还具有一个径向向外延伸的法兰5，在该法兰中构造一个用于线圈8的电接触的引线6。如图1还可看到，极芯2的轴向延伸尺寸构造得大于线圈壳体7的轴向延伸尺寸。极芯2的面向喷射侧的端部在线圈8和磁衔铁13之间从线圈壳体7伸出来并且在外侧上固定在阀壳体1上。在操作燃料喷射阀1时，阀针12在中心轴线X的方向上向着极芯2运动并且在关断时通过复位元件14重新回到初始位置中。
极芯2具有两个在图1的视图中可见的非磁性区域4以及在它的面向和背对喷射侧的端部上具有磁性区域3。如由示出一个沿着图1的平面A-A的剖视图的图2可见，在第一实施例中设有四个非磁性区域4，这些非磁性区域以90°的角度距离设置在极芯2上并且使四个磁性区域3相互磁分开。非磁性区域4通过各两个相互平行的侧面4a、4b和各一个凸拱地构成的外端面和一个凹拱地构成的内端面限界。在这里，外端面的凸拱曲率相应于极芯2的外直径并且内端面的凹拱曲率对应于贯穿开口9的外直径。磁性和非磁性区域3、4的数量可以与所示的第一实施例不同地按照所希望的电磁致动器的功能相应地改变，但是至少存在或设有两个非磁性区域。
电磁致动器1的磁性2的制造优选通过双组分-金属粉末-注射成形方法进行。在这里变换地可以首先注射成型由非磁性材料制成的非磁性区域4然后注射成型由磁性材料制成的磁性区域3或者以相反的顺序注射成型并且在一个制造步骤中时间高效且成本高效地材料锁合地相互连接。通过该方法的非常好的可重复性可实现电磁致动器1的极芯2的磁值的小发散。
通过按照本发明的制造方法能够特别经济地在一个唯一的加工工艺中制造一个用于按照本发明的电磁致动器1的、也具有复杂轮廓的一体的极芯2，这一点不能通过传统的制造方法实现。还能够实现线圈壳体7的构件集成，由此能够在制造中节省连接工艺和与此相关的检查步骤。按照可达到的减小的涡流损失尤其是明显改善在高压喷射阀中所希望和要求的动态特性，这有助于显著改善发动机的燃料消耗和排放特性。
在下面在参考图3和4的情况下详细描述根据本发明的第二优选实施例的电磁致动器。相同的或功能相同的部件在这里标有与在第一实施例中相同的附图标记。
与之前描述的第一实施例不同，第二实施例具有一个没有集成的线圈壳体7的极芯2（图3），它同样构造有四个磁性区域3和四个非磁性区域4，它们以90°的角度距离相对彼此交替地设置，如其在图4中所示的对图3的平面B-B的剖视图中可见那样。端侧的轴向端部31、32在这里如在图1中所示的第一实施例那样分别具有一个完全环绕的磁性区域3。

Claims (10)

1.电磁致动器，包括：
一极芯(2)；
其中，所述极芯(2)具有至少一个磁性区域(3)和至少一个非磁性区域(4)，
其中，所述非磁性区域(4)提供所述磁性区域(3)的磁分离，
其中，所述极芯(2)被构造为一体式的部件，并且
其中，所述极芯(2)的磁性区域(3)和非磁性区域(4)材料锁合地借助双组分金属粉末注射成型方法连接，
其特征在于，所述极芯(2)具有至少两个磁性区域(3)和至少两个非磁性区域(4)，这些磁性区域和非磁性区域在所述极芯(2)的圆周方向上交替地布置，其中，所述非磁性区域(4)提供所述磁性区域(3)的相对彼此的分离，并且，所述极芯(2)的所有的磁性区域(3)和所有的非磁性区域(4)材料锁合地借助双组分金属粉末注射成型方法连接，所述极芯(2)包括一个径向向外延伸的法兰(5)，在所述法兰(5)中设置一个用于电接触的引线(6)。
2.根据权利要求1的电磁致动器，其中，所述极芯(2)的非磁性区域(4)的两个侧面(4a，4b)相互平行地构成。
3.根据权利要求1的电磁致动器，其特征在于，所述极芯(2)具有一个在轴向方向上延伸的线圈壳体(7)，使得一个线圈(8)在径向方向上设置在所述线圈壳体(7)和所述极芯(2)之间。
4.根据权利要求3的电磁致动器，其特征在于，所述极芯(2)的轴向延伸尺寸大于所述线圈壳体(7)的轴向延伸尺寸。
5.根据以上权利要求之一的电磁致动器，其特征在于，所述极芯(2)具有一个中心的贯穿开口(9)。
6.根据权利要求1至4之一的电磁致动器，其特征在于，所述极芯(2)具有偶数数量的磁性区域和偶数数量的非磁性区域。
7.根据权利要求1至4之一的电磁致动器，其特征在于，所述极芯(2)具有对称结构。
8.根据权利要求6的电磁致动器，其特征在于，所述极芯(2)具有四个磁性区域(4)。
9.根据权利要求6的电磁致动器，其特征在于，所述极芯(2)具有四个非磁性区域(3)。
10.用于制造用于根据权利要求1至9之一的电磁致动器(1)的一体式的极芯(2)的方法，包括以下步骤：
提供磁性和非磁性材料，和
借助双组分金属粉末注射成型方法制造极芯(2)的非磁性区域(4)和磁性区域(3)，所述非磁性区域和磁性区域材料锁合地相互连接，
其中，所述极芯(2)这样构成，使得所述极芯具有至少两个磁性区域(3)和至少两个非磁性区域(4)，这些磁性区域和非磁性区域在所述极芯(2)的圆周方向上交替地布置，其中，所述非磁性区域(4)提供所述磁性区域(3)的相对彼此的分离，并且，所述极芯(2)的所有的磁性区域(3)和所有的非磁性区域(4)材料锁合地借助双组分金属粉末注射成型方法连接。
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