EP1029335B1 - Starting switch with mobile core comprising a directly mounted closure cup - Google Patents

Description

The invention relates to an electromagnetic actuator of a launcher of a motor vehicle starter, also called starter contactor.

The invention relates more particularly to a contactor of a thermal engine starter, in particular a vehicle automobile, of the type comprising an annular coil, which surrounds a cylindrical magnetic core mounted to slide axially in a bore of the spool, of the type in which a rear section mobile core protrudes axially outside the fixed coil, of the type in which an external spring of the mobile magnetic core is in axial support against a collar external radial reported from the back segment of the nucleus mobile magnet and the coil body, of the type in which the movable magnetic core has an inner bore which opens at its rear end and allows the passage of a hitch pin whose rear end is linked to a lever actuation of the starter pinion, which is recalled elastically towards the front of the bore by an internal spring mounted axially compressed between a front surface shoulder of the coupling rod and a shoulder surface back of the mobile magnetic core, and which is likely to to bear on a bottom before the bore to be driven in translation by the mobile magnetic core of the starter.

In known manner, the magnetic field created by the electrical conductor wrapped around the body of the coil of a contactor follows field lines that are substantially axially inside the coil and which have the shape of loops closing on themselves outside the coil.

According to a known design, the mobile magnetic core is usually a piece of soft iron that, whatever its axial position in the bore of the coil, ensures the continuity of passage of the magnetic flux between the carcass and the mobile magnetic core. Thus, the field lines close again on themselves in the immediate vicinity of the coil, which can increase the efficiency of the electromagnet and reduce the electrical power consumed by it.

Conventionally, the mobile magnetic core is made by bar turning because it presents complex shapes such as a rear shoulder surface of the core bore magnetic mobile, interior and forming support for the spring internal of the coupling rod, or such as a front surface, arranged at the bottom of the bore of the movable magnetic core, and for receiving a front plate closing the core bore mobile magnet after assembly of the components in the bore.

This type of manufacturing makes this piece expensive in the part of a mass production.

According to a known conception, it has already been proposed to bring back to the back side of the mobile magnetic core a cup with an outer collar reported so to simplify the shapes of the mobile magnetic core. This design, though it partly simplifies the magnetic core mobile, does not allow to achieve the surface of the rear shoulder of the bore of the mobile magnetic core and the front surface for receiving the closure plate according to a process other than bar turning, and the manufacture of mobile magnetic core remains expensive, the collar external being not a form feasible by bar turning and before preferably being a patch.

"EP-A-0 643 411" discloses an engine starter switch thermal equation corresponding to the preamble of independent claim 1.

To simplify the forms of the mobile magnetic core, and allow the use of another manufacturing process, less expensive, such as extrusion, the invention proposes a core movable magnet having a rear shoulder surface of the bore of the simplified mobile magnetic core, and a simplified closure of the bottom of the bore.

For this purpose, the invention proposes a contactor for thermal engine starter, in particular of a motor vehicle, of the type having an annular coil, which surrounds a core cylindrical magnet mounted to slide axially in a bore of the coil, of the type in which a rear section of the mobile magnetic core protrudes axially outside of the fixed coil, of the type in which an external return spring mobile magnetic core is in axial support against a external radial flange reported from the rear section of the mobile magnetic core, of the type in which the magnetic core mobile has an internal bore which opens at the end rear which is arranged in front of the collar and which allows the passage of a coupling rod, whose rear end is linked to an actuating lever of the starter pinion, which is resiliently biased forward of the bore by a spring internal mounted compressed axially against a front surface shoulder of the coupling rod and a shoulder surface rear of the mobile magnetic core, and whose front end is likely to bear on a bottom before the bore to be driven in translation by the magnetic core movable starter, characterized in that the front bottom of the bore is made integrally with the core body mobile magnet, and that a cup reported to the rear end of the mobile magnetic core has the rear shoulder surface of the bore of the magnetic core mobile and the outer collar.

• la collerette extérieure est agencée à l'extrémité arrière de la coupelle, et la surface d'épaulement de l'alésage du noyau magnétique mobile constitue un fond avant de la coupelle, percé pour le passage de la tige d'attelage, et qui est en butée axialement vers l'avant contre la face d'extrémité arrière du corps du noyau ;
• le diamètre extérieur du corps de la coupelle est sensiblement égal au diamètre du corps du noyau magnétique mobile, de manière que la coupelle prolonge axialement vers l'arrière le corps du noyau magnétique mobile ;
• le fond avant de la coupelle est soudé à l'extrémité arrière du corps du noyau magnétique mobile ;
• la coupelle comporte au moins deux bras qui s'étendent axialement vers l'avant au delà du fond avant de la coupelle et en regard de la périphérie du noyau magnétique mobile ;
• les bras comportent à leurs extrémités avant des coudes qui sont rabattus radialement vers l'axe du noyau magnétique mobile ;
• les bras sont découpés dans le fond avant de la coupelle, et sont repliés à angle droit ;
• la coupelle est sertie sur le noyau magnétique mobile par un écrasement axial du matériau de l'extrémité arrière du corps du noyau magnétique mobile, qui forme un bourrelet périphérique agencé axialement entre l'extrémité arrière du corps du noyau magnétique mobile et les coudes des bras, de manière à immobiliser axialement les bras ;
• les coudes des bras sont emboítés radialement dans une gorge formée dans la périphérie du corps du noyau magnétique mobile ;
• la coupelle est sertie sur le noyau magnétique mobile par un écrasement axial du matériau de la périphérie du noyau magnétique mobile, qui provoque, radialement et vers l'extérieur, un reflux de matière dans des trous qui sont agencés en regard dans les bras ;

According to other features of the invention:

• the outer flange is arranged at the rear end of the cup, and the shoulder surface of the bore of the movable magnetic core constitutes a front bottom of the cup, pierced for the passage of the coupling rod, and which is abutting axially forwardly against the rear end face of the core body;
• the outer diameter of the body of the cup is substantially equal to the diameter of the body of the movable magnetic core, so that the cup extends axially rearwardly the body of the movable magnetic core;
• the front bottom of the cup is welded to the rear end of the body of the movable magnetic core;
• the cup comprises at least two arms which extend axially forwardly beyond the front bottom of the cup and facing the periphery of the movable magnetic core;
• the arms have at their front ends elbows which are folded radially towards the axis of the movable magnetic core;
• the arms are cut in the front bottom of the cup, and are bent at right angles;
• the cup is crimped on the movable magnetic core by an axial crushing of the material of the rear end of the body of the movable magnetic core, which forms a peripheral bead arranged axially between the rear end of the body of the movable magnetic core and the elbows of the arms , so as to immobilize the arms axially;
• the bends of the arms are fitted radially into a groove formed in the periphery of the body of the movable magnetic core;
• the cup is crimped on the movable magnetic core by axial compression of the material of the periphery of the movable magnetic core, which causes, radially and outwardly, a material reflux in holes which are arranged facing in the arms;

• la figure 1 est une vue en coupe axiale d'un démarreur comportant un contacteur selon l'état de la technique ;
• la figure 2 est une vue en coupe axiale d'un noyau magnétique mobile sur lequel est soudée une coupelle selon un premier mode de réalisation de l'invention ;
• la figure 3 est une vue en coupe axiale d'un noyau magnétique mobile sur lequel est sertie une coupelle selon un deuxième mode de réalisation de l'invention ;
• la figure 4 est une vue d'après la figure 3 représentant, selon une vue axiale arrière, une coupelle selon le deuxième mode de réalisation de l'invention ;
• la figure 5 est une vue en coupe axiale de la coupelle de la figure 4 ;
• la figure 6 est une vue en coupe axiale d'un noyau magnétique mobile sur lequel est emboítée une coupelle selon un troisième mode de réalisation de l'invention ;
• la figure 7 est une vue en coupe selon la ligne 7-7 de la figure 9 d'un noyau magnétique mobile sur lequel est sertie une coupelle selon un quatrième mode de réalisation de l'invention ;
• la figure 8 est un détail F8 de la figure 7 représentant la fixation des bras de la coupelle sur le noyau magnétique mobile ;
• la figure 9 est une vue selon la ligne 9-9 de la figure 10 représentant en une vue axiale arrière de la coupelle représentée à la figure 7 ; et
• la figure 10 est une vue en coupe axiale, selon la ligne 10-10 de la figure 9, de la coupelle représentée à la figure 7.

Other features and advantages of the invention will appear on reading the detailed description which follows for the understanding of which reference will be made to the appended drawings in which:

• Figure 1 is an axial sectional view of a starter comprising a contactor according to the state of the art;
• Figure 2 is an axial sectional view of a movable magnetic core on which is welded a cup according to a first embodiment of the invention;
• Figure 3 is an axial sectional view of a movable magnetic core on which is crimped a cup according to a second embodiment of the invention;
• Figure 4 is a view from Figure 3 showing, in a rear axial view, a cup according to the second embodiment of the invention;
• Figure 5 is an axial sectional view of the cup of Figure 4;
• Figure 6 is an axial sectional view of a movable magnetic core on which is fitted a cup according to a third embodiment of the invention;
• Figure 7 is a sectional view along the line 7-7 of Figure 9 of a movable magnetic core on which is crimped a cup according to a fourth embodiment of the invention;
• Figure 8 is a detail F8 of Figure 7 showing the attachment of the arms of the cup on the movable magnetic core;
• Figure 9 is a view along the line 9-9 of Figure 10 showing a rear axial view of the cup shown in Figure 7; and
• FIG. 10 is an axial sectional view, along line 10-10 of FIG. 9, of the cup shown in FIG. 7.

In the description that follows, figures of identical reference designates identical or similar functions.

FIG. 1 shows a starter 10 intended to equipping a motor vehicle combustion engine (no represent). The starter 10 is constituted essentially by a housing 12 inside which is arranged a pinion of launcher 14 which is slidably mounted on one end of a shaft 16. The shaft 16 is rotated by an electric motor 18 of the starter 10.

The sliding movements of the starter pinion 14 are caused by a lever or fork 20 which pivots to inside the housing 12 around a horizontal geometric axis XX.

The lower free end 22 of the control lever 20 acts on a driver 24 of the starter gear 14 while its upper free end 25 is connected to a coupling rod 26 belonging to an electromagnetic contactor 30, which is arranged at the top of the starter 10.

According to a known design, the contactor 30 comprises a mobile magnetic core 32 whose movements are controlled by a coil 34 along a horizontal axis Y-Y perpendicular to the X-X pivoting axis of the lever 20.

The mobile magnetic core 32 is a general piece of hollow cylindrical cylindrical shape which is guided in sliding by its external cylindrical surface and the internal bore 36 receives the coupling rod 26 and a spring helical compression 38.

The rear end 40 of the spring 38 bears against a rear shoulder surface 42 of the bore 36 of the core movable magnet 32, and the front end 44 of the spring 38 bears against a shoulder surface before the stem hitch 26, which is carried by a head 46 arranged to the free front end of the coupling rod 26.

Moreover, the coupling rod 26 is capable of take support, through his head 46, on a background before 48 consisting of a closing disk of the bore 36 in plate shape, which is set in a cylindrical housing 50 mobile magnetic core 32, the coupling rod 26 being capable of being translated in translation along the Y-Y axis and backward by the mobile magnetic core 32 when the actuation or release of the electromagnet which is composed of the movable magnetic core 32 and the coil 34.

According to the state of the art, the annular surface rear shoulder 42 is made integrally with the body of the mobile magnetic core 32, and the rear end 52 mobile magnetic core 32, which protrudes axially towards the rear out of the fixed coil 34, comprises a cup reported 54, which is crimped on the rear end 52 of the core mobile magnet 32, and which has at its periphery a flange 56, which extends radially outwards, and which is intended to serve as a support for an external spring 58 movable magnetic core 32 to its rear rest position illustrated in Figure 1. Indeed, the spring 58 recalls resiliently to the rear the movable magnetic core 32 into bearing between the flange 56 and the carcass 31 of the contactor 30.

FIG. 2 illustrates a first embodiment of the invention in which a new insert cup 54 is arranged at the rear end 52 of the movable magnetic core 32.

The movable magnetic core 32 differs substantially from mobile magnetic core previously described with reference to the FIG. 1, to the extent that the bore 36 of the mobile core 32 opens at the rear of the mobile magnetic core 32 and is blind in the front.

Thus, the front end 48 of the bore 36 is no longer, as previously described with reference to the state of the art, constituted by a reported disk but it is realized come from material with the body of the movable magnetic core 32.

The tubular body of the insert cup 54 is externally of a diameter substantially equal to the diameter of mobile magnetic core 32 and has at its end rear flange 56 previously described with reference to the figure 1.

The bore 36 no longer has a rear annular face internal as previously described with reference to FIG. but it opens into the free end annular face back 52 of the core 32.

The rear radial shoulder of the core bore 36 movable magnet 32 is constituted by a bottom 62 of the cup 54, including a central hole 60, of diameter greater than the diameter of the coupling rod 26, allows axial movements and vertical of the coupling rod 26 when the rear end of it moves with the 25 end of the lever actuator 20.

The central portion of the bottom 62 of the cup 54 which extends radially inwards facing the bore 36 form the rear annular shoulder surface 42 which allows the support of the internal spring 38 of return of the coupling rod 26.

The cup 54 thus comprises alone both surfaces 56 and 42 of support of the outer springs 58 of the mobile magnetic core 32, and internal 38 of the stem coupling 26.

Advantageously, in this embodiment, the cup 54 is welded at the periphery of its bottom 62 to the periphery of the rear end 52 of the mobile magnetic core 32.

Alternatively, the bottom 62 of the cup 54 can be assembled by spot welding or glued to the rear end 52 of the movable magnetic core 32.

FIG. 3 illustrates a second embodiment in which the cup 54 is crimped at the rear end 52 of the mobile magnetic core 32.

The cup 54 has a shape generally similar to that described with reference to Figure 2. In this second mode embodiment of the invention, the tubular body of the cup 54 is of a diameter slightly greater than the outside diameter mobile magnetic core 32 and preferably comprises three arm 64, angularly distributed at regular intervals, which extend axially forward so as to be adjacent to the periphery of the movable magnetic core 32. The arms 64 comprise at their ends before elbows 68 whose function is to centering the cup 54 on the core body mobile 32.

Advantageously, the cup 54 may, for example, be made by stamping.

In a variant, the cup 54 may, at the moment of its manufacture, be formed from a cup 54 similar to that described with reference to FIG. 2, in the bottom 62 of which are cut by punching three radial tabs planes which are subsequently folded perpendicularly and along the Y-Y axial direction at the bottom 62 to form the arms 64 which extend axially forward.

At the time of assembly, the cup 54 is threaded on the rear end 52 of the movable magnetic core 32 until that the bottom 62 of the cup 64 is axially in abutment against the rear end 52 of the movable magnetic core 32. Advantageously, the rear end 52 of the magnetic core 32 constitutes an axial stop forward for the cup 54.

Moreover, the cup 54 is simultaneously maintained externally so as not to be able to deform radially outwards. A crimping tool then penetrates axially along the Y-Y axis inside the cup 54 in the spaces left free by cutting the arms 64, that can be seen more particularly in Figure 4, and crushes the end 52 of the movable magnetic core, forming axially next to the arms 64 of the cup 54 a bead 66 of mobile magnetic core material 32, which allows the axial immobilization towards the rear of the arms 64 of the cup 54 relative to the mobile magnetic core 32. The cup 54 being moreover immobilized axially towards the front through its bottom 62 pressing on the rear end 52 of the movable magnetic core 32, it is finds rigidly related to the mobile magnetic core 32.

Figure 6 illustrates a third embodiment in which the cup 54 is not crimped but fitted to force on the rear end 52 of the movable magnetic core 32. The cup 54 is substantially similar to the cup 54 described with reference to Figure 3, and is provided with three arm 64 distributed angularly at regular intervals which extend axially forward in contact with the periphery mobile core 32. The arms 64 comprise at their front end of the elbows 68 which are folded radially towards the Y-axis Y of the mobile magnetic core 32 and which are, in this embodiment, likely to be received in a throat external radial 70 made on the periphery of the magnetic core mobile 32.

In this way, and as can be seen in Figure 6, when assembling the cup 54 on the magnetic core mobile 32, the cup 54 is threaded axially on the core mobile magnet 32 by temporarily deforming to the outside the arms 64, then the elbows 68 of the arms 64 of the cup 54 penetrate the groove 70 of the magnetic core mobile 32 thus ensuring its axial immobilization, the bottom 62 of the cup 54 coming into contact with the rear end 52 mobile magnetic core 32 to complete the immobilization axial axis of the cup 54 and determine an axial position precise of the cup 54 with respect to the core 32.

Figures 7 to 10 illustrate a fourth mode of embodiment in which the cup has two axial arms diametrically opposite and which are attached to the magnetic core mobile 32.

As illustrated in FIGS. 9 and 10, the cup 54 comprises two arms 64, which extend axially towards the front and substantially in the shape of an arc in a circle transverse plane perpendicular to the Y-Y axis. The arms 64 each have two holes 71 located in this same plane transverse, and which are intended to cooperate with the body of the mobile magnetic core 32 during crimping to achieve the immobilization of the cup 54 relative to the core movable magnetic 32.

The cup 54 may for example be made by stamping and punching, the arms 64 being previously cut into the bottom 62 of the cup 54, then folded perpendicular to it so that once the cup 54 in position on the movable magnetic core 32, these extend axially forward by marrying the periphery of the mobile magnetic core 32.

When assembling the cup 54 on the core movable magnet 32, the cup 54 is threaded axially on the movable magnetic core 32 until its bottom 62 is in stop on the rear end 52 of the movable magnetic core 32.

The cup 54 is retained on its outer periphery by a suitable template to prevent it from being deformed during of the crimping operation. Then a crimping tool penetrates inside the concavity of the cup 54 in the interstices left free by cutting the arms 64 and crushes the rear end 52 of the movable magnetic core 32 so that the material of the mobile magnetic core 32 is repressed radially outward and enters the holes 71 of the cup 54, immobilizing it axially towards the rear, as shown in the detail view of Figure 8.

Advantageously, the different magnetic cores movable contactor 30 thus made allow to lower significantly the production costs.

Claims (10)

1. A contactor (30) for a starter (10) of a heat engine, especially for a motor vehicle, of the type comprising an annular coil (34) which surrounds a cylindrical magnetic core (32) mounted for axial sliding movement in a bore of the coil (34) of the type in which a rear portion of the movable magnetic core (32) projects axially outside the fixed coil (34), of the type in which an external return spring (58) for the movable magnetic core is in axial engagement against an external radial flange (56) carried by the rear portion of the movable magnetic core (32), of the type in which the movable magnetic core (32) has an internal bore (36) which is open at the rear end (52), and is disposed in front of the flange (56), and which enables a coupling rod (26) to pass through, the rear end of the coupling rod being coupled to a lever (20) for operating the actuator pinion (14) which is urged elastically towards the front of the bore (36) by an internal spring (38) mounted in axial compression against a front shoulder surface of the coupling rod (26) and a rear shoulder surface (42) of the movable magnetic core (32), the front end of the coupling rod being arranged to engage on a base element (48) at the front of the bore so as to be driven in straight line movement by the movable magnetic core (32) of the starter, characterised in that the front base element (48) of the bore (36) is formed integrally with the body of the movable magnetic core (32), and in that a capping piece (54), attached to the rear end (52) of the movable magnetic core (32), includes the rear shoulder surface (42) of the bore (36) of the movable magnetic core (32) and the external flange (56).
2. A contactor (30) for a starter (10) according to Claim 1, characterised in that the external flange (56) is arranged at the rear end of the capping piece (54), and in that the shoulder surface (42) of the bore of the movable magnetic core (32) constitutes a front base element (62) of the capping piece (54), which is pierced for passage of the coupling rod (26) through it, and which is in axial forward abutment against the rear end face of the body of the core.
3. A contactor (30) for a starter (10) according to Claim 1 or Claim 2, characterised in that the external diameter of the body of the capping piece (54) is substantially equal to the diameter of the body of the movable magnetic core (32), so that the capping piece (54) constitutes an axial rearward extension of the body of the movable magnetic core (32).
4. A contactor (30) for a starter (10) according to Claim 2, characterised in that the front base (62) of the capping piece (54) is welded to the rear end (52) of the body of the movable magnetic core (32).
5. A contactor (30) for a starter (10) according to Claim 2, characterised in that the capping piece (54) has at least two arms (64) extending axially forward beyond the front base (62) of the capping piece (54) and facing the periphery of the movable magnetic core (32).
6. A contactor (30) for a starter (10) according to Claim 5, characterised in that the arms (64) include, at their front ends, bends (68) which are bent back radially towards the axis of the movable magnetic core (32).
7. A contactor (30) for a starter (10) according to Claim 5 or Claim 6, characterised in that the arms (64) are cut out in the front base (62) of the capping piece (54) and are bent back at a right angle.
8. A contactor (30) for a starter (10) according to Claim 6, characterised in that the capping piece (54) is seamed on the movable magnetic core (32) by axial upsetting of the material of the rear end (52) of the body of the movable magnetic core, so as to form a peripheral bead (66) located axially between the rear end (52) of the body of the movable magnetic core (32) and the bends (68) in the arms (64), whereby to immobilize the arms (64) axially.
9. A contactor (30) for a starter (10) according to Claim 6, characterised in that the bends (68) of the arms (64) are attached by radial insertion in a groove (70) formed in the periphery of the body of the movable magnetic core (32).
10. A contactor (30) for a starter (10) according to Claim 6, characterised in that the capping piece (54) is seamed on the movable magnetic core (32) by axial upsetting of the material of the periphery of the movable magnetic core (32), which causes radial outward flow of material into facing holes (71) which are formed in the arms (64).

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