EP2181451B1 - Method and arrangement for winding a winding wire onto a winding body, and associated magnet assembly for a solenoid valve - Google Patents

Description

State of the art

The invention relates to a method for winding a winding wire on a winding body according to the preamble of independent claim 1, an arrangement for winding a winding wire on a winding body and an associated magnetic assembly for a solenoid valve.

In modern brake systems and in driver assistance systems, which include, for example, an anti-lock braking system (ABS), a traction control system (ASR system) or an electronic stability program system (ESP system), solenoid valves are used for pressure modulation. In a coarser subdivision, these solenoid valves consist of a valve cartridge, which is caulked in a fluid assembly, and a magnet assembly whose location is usually located in an associated control unit. The magnet assembly is driven to generate a corresponding magnetic field with electrical control signals, the magnet assembly comprises a wound on a winding support wire winding with a predetermined number of turns, a cover and a housing shell. The cover is pressed as Eisenkreisbauteil in the housing shell to close the iron circle of the magnet assembly.

Known from the WO 01/73799 A1 is an electrical coil intended for use in solenoid valves, for example. A bobbin of this coil has on its end flange on a holder for coil wire. On the holder two intersecting slots of different depths are formed, wherein at the bottom of the slot with lesser depth of the coil wire rests, while in the slot of greater depth an insulation displacement contact for electrical contacting of the coil wire is added. The slot of lesser depth has a width in the region of its bottom which is smaller than the diameter of the coil wire, whereby the coil wire is clamped in the slot of the holder.

Since the electrical connection dome is designed as a plastic injection molded part, it is difficult to comply with the required tolerance for the slot width by injection molding. In addition, process influences after injection molding, such as shrinkage and water absorption, for the component dimension usually can not be considered. Thus, the winding wire, for example, due to a too weak pressure in the wire receiving slot during the cutting process on the winding machine, or in the subsequent assembly processes, such as bulk material, transport, etc. and in the handling of the wound bobbin from the wire receiving slot slip back. If the clamping is too strong, the winding wire, for example, can not completely rest in the area of a wire support and break upwards. This can lead to an incorrect positioning of the winding wire, in which the contacting area is no longer given to the cutting blade, or may be outside the contacting zone in the region of the cutting knife eye. In addition, it can come by a possible, too strong pushing back of the winding wire to a contact between the winding wire and the housing shell of the magnet assembly. This can lead to a shearing through the insulation of the winding wire by vibrations that occur at field loads, thereby leading to a short circuit and thus to a failure of the magnet assembly.

Disclosure of the invention

The inventive method for winding a winding wire on a winding body with the features of independent claim 1 has the advantage that a threaded into a first wire receiving slot of a first terminal dome winding wire is placed on a first wire support, which is arranged after the first wire receiving slot, said Winding wire is deformed and held before the winding process so that the diameter of the winding wire is increased at a lying on the first wire support area in the direction of the width of the first wire receiving slot and slipping back of the winding wire start is prevented in the first wire receiving slot. By holding and forming the winding wire prevents the winding wire beginning during the winding process ... or slips back during subsequent assembly processes and / or during handling of the wound bobbin in the first wire receiving slot of the first electrical connection dome. As a result, the process reliability is advantageously increased, wherein the clamping dimension of the wire receiving slot in the electrical connection dome is no longer critical to safety.

The arrangement according to the invention for winding a winding wire onto a winding body, wherein a winding wire beginning is threaded into a first wire receiving slot of a first connecting dome of the winding body, comprises a holding embossing tool which is designed to be wound on the winding body during a winding process, through which a vorgebare number of winding wire windings is to hold the winding wire beginning threaded into the first wire receiving slot with a holding surface on a first wire support disposed after the first wire receiving slot and reshape the winding wire at a portion resting on the first wire support such that the diameter of the winding wire in this region is in Direction of the width of the first wire receiving slot is increased to prevent slipping back of the winding wire start in the first wire receiving slot.

The solenoid assembly of the invention for a solenoid valve comprises a bobbin having a first electrical terminal dome with a first wire receiving slot into which a winding wire beginning is threaded, and a second electrical terminal dome with a second wire receiving slot into which a winding wire end is threaded. The first connection dome and the second connection dome are designed, for example, as a plastic injection-molded part and each have a wire support, which are arranged after the first wire-receiving slot or after the second wire-receiving slot. The winding wire is reshaped at a region resting on the first wire support area and at a region resting on the second wire support so that the diameter of the winding wire in these regions is increased in the direction of the width of the wire receiving slots, in order to prevent the winding wire from slipping back into the first wire receiving slot and to prevent the winding wire end from slipping back into the second wire receiving slot. Due to the plastic deformation of the winding wire slipping back of the winding wire start or the winding wire end is advantageously prevented in the corresponding wire receiving slot, so that the winding wire start or the winding wire end in the handling of the wound winding body and during normal use the magnet assembly are held in the corresponding wire receiving slots of the electrical connection dome and an optimal electrical connection can be made to a corresponding control device to generate a desired magnetic field with the magnet assembly.

The measures and refinements recited in the dependent claims are advantageous improvements of the independent claim 1 method for winding a winding wire on a winding body, the arrangement specified in the independent claim 6 for winding a winding wire on a winding body and the magnetic assembly specified in the independent claim 12 possible.

It is particularly advantageous that the wound into the second wire receiving slot winding wire end is placed on a second wire support, which is arranged after the second wire receiving slot, wherein the winding wire is transformed and cut after the winding process so that the diameter of the winding wire at one on the second wire support lying area is increased in the direction of the width of the second wire receiving slot and slipping back of the winding wire end is prevented in the second wire receiving slot. The forming of the winding wire prevents the winding wire end from slipping back into the second wire receiving slot of the second electrical connection dome after the cutting process or during subsequent assembly processes and / or during the handling of the wound winding body. As a result, the process reliability is advantageously increased, wherein the clamping dimension of the wire receiving slot in the electrical connection dome is no longer critical to safety.

In an embodiment of the arrangement according to the invention, a cutting embossing tool is provided, which is designed to cut a wound after the winding process in a second wire receiving slot and arranged on a second after the second wire receiving slot wire support resting wire end, and the winding wire on a resting on the second wire support area so order that the diameter of the winding wire is increased in this area in the width direction of the second wire receiving slot to prevent the winding wire end slipping back into the second wire receiving slot. To reshape the area of the threaded winding wire resting on the first wire support, this has Holding embossing tool, for example, a first embossing nose, which presses the winding wire in a first recess in the first wire support. Furthermore, the cutting embossing tool has a second embossing nose, which presses the region of the threaded winding wire resting on the second wire support for forming into a second depression in the second wire support. The recesses in the wire supports are designed, for example, as notches, which each have an embossing edge, which are arranged directly behind the respective wire receiving slot and buckle the winding wire. The indented depressions, the retaining embossing tool, the cutting embossing tool and the embossing edges are designed so that the shapes of the winding wire start and the winding wire end remain substantially unchanged. Characterized a drahtrestfreies winding is ensured in an advantageous manner, ie the remaining in the wire guide of the winding winding wire end is not kinked and can thus be used for the next winding process as a winding wire beginning of the next winding carrier. Due to the plastic deformations of the winding wire in the region of the recesses and by the buckling of the winding wire on the embossing edges on the one hand slipping back into the corresponding wire receiving slot is avoided and on the other hand, the winding wire is less deformed in its cross section, so that the test for winding wire presence and winding wire spacing in a test window a subsequent camera inspection easier and caused by reduced winding wire cross-sections pseudo errors in the camera inspection can be avoided. In addition, can be reduced by the invention of the Committee in the manufacture of the magnetic assemblies.

Advantageous embodiments of the invention described below are shown in the drawings. In the drawings, like reference numerals designate components that perform the same or analog functions.

Brief description of the drawings

• Fig. 1 shows a schematic sectional view of a magnet assembly for a solenoid valve.
• Fig. 2a shows a plan view of a winding body for the magnetic assembly according to Fig. 1 ,
• Fig. 2b and 2c each show a detail Fig. 2a ,
• Fig. 3a shows a schematic side view of an unwound bobbin for the magnet assembly according to Fig. 1 ,
• Fig. 3b shows a schematic side view of a wound bobbin for the magnet assembly according to Fig. 1 ,
• Fig. 4 shows a schematic sectional view of a first terminal dome for the magnetic assembly according to Fig. 1 before a winding process.
• Fig. 5a shows a perspective view of a retaining embossing tool for the winding of a winding body of the magnetic assembly according to Fig. 1 ,
• Fig. 5b shows a schematic side view of the holding embossing tool according to Fig. 5a ,
• Fig. 6 shows a schematic sectional view of a second terminal dome for the magnetic assembly according to Fig. 1 after a winding process.
• Fig. 7a shows a perspective view of a cutting embossing tool for the winding of a winding body of the magnet assembly according to Fig. 1 ,
• Fig. 7b shows a schematic side view of the cutting embossing tool according to Fig. 7a ,

Embodiments of the invention

How out Fig. 1 to 3b 1, a solenoid assembly 1 for a solenoid valve comprises a winding body 3, which has a first electrical connection dome 10 with a first wire receiving slot 12 designed as an insulation displacement connection 13 into which a winding wire beginning 4.1 is threaded, and a second electrical connection dome 20 with an insulation displacement connection 23 second wire receiving slot 22, in which a winding wire end 4.2 is threaded. An iron circle of the magnet assembly 1 is formed by a housing jacket 2 and a cover disk 5 pressed into the housing jacket 2. The electrical connection domes 10, 20 are designed for example as plastic injection molded parts. How farther Fig. 2a to 2c apparent , the first electrical connection dome 10 and the second electrical connection dome 20 each have a wire support 11, 21 with a recess 11.2, 21.2.

How out Fig. 3a it can be seen, the winding wire beginning 4.1 is threaded into the first wire receiving slot 12 of the first terminal dome 10 before a winding process by which a vorgebare number of winding wire windings are wound onto the winding body 3. How out Fig. 3 can be seen, the winding wire end 4.2 is threaded and cut after the winding process in the second wire receiving slot 22 of the second terminal dome 20.

How out Fig. 4 can be seen, is the threaded into the first wire receiving slot 12 winding wire beginning 4.1 before the winding process and during the winding process on a first wire support 11 which is disposed after the first wire receiving slot 12, and is held by a holding surface 32 of a Halteprägewerkzeugs 30. As well as out Fig. 5a and 5b is visible, the Halteprägewerkzeugs 30 includes the support surface 32 and the embossing nose 31. The winding wire 4 is pressed by an embossing nose 31 of the Halteprägewerkzeugs 30 via a embossing edge 11.1 into the recess 11.2, that the winding wire 4 in the region of the embossing edge 11.1 a bend down and is reshaped so that the diameter of the winding wire 4 in the region of the first recess 11.2 has an enlarged in the direction of the width of the first wire receiving slot 12 diameter, whereby a slipping back of the winding wire 4.1 is prevented in the first wire receiving slot 12. The clamping of the winding wire 4 in the first electrical connection dome 10 must, in addition to the clamping forces of the winding wire 4, absorb and retain the tensile forces during the winding process. This is facilitated by the inventive deformation of the winding wire 4. In addition, the winding wire beginning 4.1 is less deformed in comparison to the conventional winding method in its cross-section, since the hold-down force of the holding surface 32 in the region of the winding wire beginning 4.1 by the forming process of the winding wire 4 in the recess 11.2 can be reduced, and a slipping back of the winding wire 4 in the wire receiving slot 12 can still be prevented. The holding embossing tool 30 therefore carries out with the winding wire 4 a holding function, a plastic forming function and a buckling function. How out Fig. 4 It can also be seen that the diameter A of the winding wire remains unchanged in the region of the winding wire beginning 4.1 and is reduced in the region of the depression 11.2 by the bending and forming process to a remaining diameter B which is for example 2/3 of the original one Diameter A corresponds. The depth C of the groove 11.2, which is designed as a notch, corresponds approximately to half the original diameter A of the winding wire 4.

How out Fig. 6 can be seen, the wound in the second wire receiving slot 22 winding wires 4.2 after the winding on a second wire support 21 which is disposed after the second wire receiving slot 22, and is cut off by a cutting blade 42 of a cutting tool 40. As well as out Fig. 7a and 7b The winding wire 4 is pressed by the embossing nose 41 of the cutting embossing tool 40 via an embossing edge 21.1 into the recess 21.2, that the winding wire 4 in the region of the embossing edge 21.1 a bend down and is reshaped so that the diameter of the winding wire 4 in the region of the second recess 21.2 has an enlarged in the direction of the width of the first wire receiving slot 22 diameter, whereby a slipping back of the winding wire end 4.2 is prevented in the second wire receiving slot 22. Due to the inventive reformation of the winding wire 4, the winding wire 4 is held during the cutting process, wherein the cutting embossing tool 40 simultaneously performs a cutting function, a plastic forming function and a buckling function during the cutting process. By the cutting blade 42 of the cutting tool 40, the remaining in the winding machine winding wire end is not damaged or deformed during cutting. As a result, wire-free winding is ensured, which means that the remaining in the wire guide of the winding wire end is not kinked and can thus be used for the next winding process as winding wire start 4.1 of the next winding support 3. How out Fig. 6 It can also be seen that the diameter A of the winding wire remains unchanged in the region of the winding wire end 4.2 and is reduced in the region of the depression 21.2 by the bending and forming process to a remaining diameter B which, for example, corresponds to 2/3 of the original diameter A of the winding wire 4. The depth C of the second recess 11.2, which is designed as a notch, corresponds approximately to half the original diameter A of the winding wire 4. During the cutting process, the cutting blade 42 penetrates the second wire support 21 by the depth D.

The inventive arrangement for winding the winding wire 4 on a winding body 3 and the associated magnetic assembly 1 can be carried out so that winding wires 4 with different diameters according to the inventive method can be wound on the winding body 3. As a result, magnetic assemblies that generate different magnetic forces can be manufactured with the same arrangement and the same winding body. The holding embossing tool 30, the cutting embossing tool 40 and the wire receiving slots 12, 22 of the electrical connection domes 10, 20 can be performed, for example, so that several different wire diameters including insulating varnish can be processed.

The inventive forming of the winding wire advantageously prevents the winding wire from slipping back into the corresponding wire receiving slots of the electrical connection dome during the winding process, during the cutting process or during subsequent assembly processes and / or during handling of the wound winding body. As a result, the process reliability is advantageously increased, wherein the clamping dimension of the wire receiving slot in the electrical connection dome is no longer critical to safety.

Claims (15)

1. Method for winding a winding wire (4) onto a winding body (3), a winding-wire start (4.1) being threaded into a first wire reception slot (12) of a first electrical connection dome (10), subsequently a stipulatable number of turns being wound onto the winding body (3), and after the winding operation a winding-wire end (4.2) being threaded into a second wire reception slot (22) of a second electrical connection dome (20) and being cut off, and the winding-wire start (4.1) threaded into the first wire reception slot (12) being laid onto a first wire rest (11) which is arranged after the first wire reception slot (12), characterized in that the winding wire (4), before the winding operation, is shaped and held such that the diameter of the winding wire (4) at a region lying on the first wire rest (11) is enlarged in the direction of the width of the first wire reception slot (12) and the winding-wire start (4.1) is prevented from slipping back into the first wire reception slot (12).
2. Method according to Claim 1, characterized in that the winding-wire end (4.2) threaded into the second wire reception slot (12) is laid onto a second wire rest (21) which is arranged after the second wire reception slot (22), the winding wire (4), after the winding operation, being shaped and cut off such that the diameter of the winding wire (4) at a region lying on the second wire rest (21) is enlarged in the direction of the width of the second wire reception slot (22), and the winding-wire end (4.2) is prevented from slipping back into the second wire reception slot (22).
3. Method according to Claim 1 or 2, characterized in that the shaping of the winding wire, before the winding operation, is carried out by means of a first depression (11.2) arranged in the first wire rest (11), the shaping of the winding wire, after the winding operation, being carried out by means of a second depression (21.2) arranged in the second wire rest (21).
4. Method according to Claim 3, characterized in that the depressions (11.2, 21.2) are formed in each case as a notch with an embossing edge (11.1, 21.1), into which notch the winding wire (4) is pressed in each case, the embossing edges (11.1, 21.1) being arranged directly behind the respective wire reception slot (12, 22), and the winding wire (4) being kinked and/or bent around by the embossing edges (11.1, 21.1).
5. Method according to Claim 4, characterized in that the depressions (11. 2, 21.2) formed as a notch and the embossing edges (11.1, 21.1) are designed such that the shapes of the winding-wire start (4.1) and of the winding-wire end (4.1, 4.2) remain essentially unchanged.
6. Arrangement for winding a winding wire (4) onto a winding body (3), a winding-wire start (4.1) being threaded into a first wire reception slot (12) of a first electrical connection dome (10) of the winding body (3), characterized by a holding embossing tool (30) which is designed in order, during a winding operation by means of which a stipulatable number of turns is wound onto the winding body (3), to hold the winding-wire start (4.1), threaded into the first wire reception slot (12), by means of a holding surface (32) on a first wire rest (11) which is arranged after the first wire reception slot (12), and to shape the winding wire (4) at a region lying on the first wire rest (11) such that the diameter of the winding wire (4) in this region is enlarged in the direction of the width of the first wire reception slot (12), in order to prevent the winding-wire start (4.1) from slipping back into the first wire reception slot (12).
7. Arrangement according to Claim 6, characterized by a cutting embossing tool (40) which is designed in order to cut off a winding-wire end (4.2) threaded, after the winding operation, into a second wire reception slot (12) and lying on a second wire rest (21) arranged after the second wire reception slot (22), and to shape the winding wire (4) at a region lying on the second wire rest (21) such that the diameter of the winding wire (4) in this region is enlarged in the direction of the width of the second wire reception slot (22), in order to prevent the winding-wire end (4.2) from slipping back into the second wire reception slot (22).
8. Arrangement according to Claim 6 or 7, characterized in that the holding embossing tool (30) has a first embossing nose (31) which, for shaping purposes, presses that region of the threaded-in winding wire (4) which lies on the first wire rest (11) into a first depression (11.2) in the first wire rest (11).
9. Arrangement according to one of Claims 6 to 8, characterized in that the cutting embossing tool (40) has a second embossing nose (41) which, for shaping purposes, presses that region of the threaded-in winding wire (4) which lies on the second wire rest (21) into a second depression (21.2) in the second wire rest (21).
10. Arrangement according to Claim 8 or 9, characterized in that the depressions (11.2, 21.2) are formed in each case as a notch with an embossing edge (11.1, 21.1), into which notch the winding-wire regions are pressed, the embossing edges (11.1, 21.1) being arranged directly behind the respective wire reception slot (12, 22) and kinking the winding wire (4).
11. Arrangement according to Claim 10, characterized in that the depressions (11.2, 21.2) formed as a notch, the holding embossing tool (30), the cutting embossing tool (40) and the embossing edges (11.1, 21.1) are designed such that the shapes of the winding-wire start (4.1) and of the winding-wire end (4.1, 4.2) remain essentially unchanged.
12. Magnet assembly for a solenoid valve, with a winding body (3) which has a first electrical connection dome (10) with a first wire reception slot (12), into which a winding-wire start (4.1) is threaded, and a second electrical connection dome (20) with a second wire reception slot (22), into which a winding-wire end (4.2) is threaded, characterized in that the winding wire (4) is shaped at a region arranged after the first wire reception slot (12) and lying on a first wire rest (11) and at a region arranged after the second wire reception slot (12) and lying on a second wire rest (21) such that the diameter of the winding wire (4) in these regions is enlarged in the direction of the width of the wire reception slots (12, 22), in order to prevent the winding-wire start (4.1) from slipping back into the first wire reception slot (12) and the winding-wire end (4.2) from slipping back into the second wire reception slot.
13. Magnet assembly according to Claim 12, characterized in that a first depression (11.2) with an embossing edge (11.1) is introduced into the first wire rest (11), into which depression that region of the winding wire (4) which lies on the first wire rest (11) is pressed for shaping purposes, the winding wire (4) having a kink and/or bend in the region of the embossing edge (11.1).
14. Magnet assembly according to Claim 12 or 13, characterized in that a second depression (21.2) with an embossing edge (21.1) is introduced into the second wire rest (21), into which depression that region of the winding wire (4) which lies on the second wire rest (11) is pressed for shaping purposes, the winding wire (4) having a kink and/or bend in the region of the embossing edge (21.1).
15. Magnet assembly according to Claim 13 or 14, characterized in that the embossing edges (11.1, 21.1) of the depressions (11.2, 21.2) are arranged directly behind the respective wire reception slot (12, 22).

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