ES2286145T3 - HOUSING CONTACTOR FOR AN AUTOMATIC VEHICLE STARTING AND A START UP PROVIDED BY A CONTACTOR LIKE THAT. - Google Patents

Abstract

1- Contactor for a motor vehicle start, of the type comprising a housing (1) of material that allows a magnetic flux passage and comprising a perforated bottom for the passage of a mobile magnetic core (3), a projection for the support of a fixed core (2) and a cylindrical portion of axial orientation, called crimping portion, which extends, in the opposite direction to the bottom, axially beyond the projection for crimping a cover (6) characterized by the the fact that the housing (1) is made of three pieces, namely a first piece (12) of transverse orientation, called bottom, which constitutes the perforated bottom, an external tube (13) of axial orientation presenting the crimping portion ( 13 ¿) and an internal tube (14) of axial orientation housed inside the external tube (13) and by the fact that the external tube (13) is fixed to the bottom (12) and extends, in the opposite direction to the background (12), protruding axia lmente with respect to the inner tube (14) that has the projection (14 ¿).

Description

Contactor with housing for starting automatic vehicle and a starter provided with a contactor like that.

The invention concerns a contactor with housing for an automatic vehicle start and a start equipped with A contactor like that.

As you know a contactor for starting of motor vehicle, comprises a mobile contact capable of being shifted in translation between a resting position, in which the contact is in support on a fixed conductor element attached to a polar mass of the vehicle, and an active position, in which the mobile contact establishes the electrical connection between a terminal power input and a motor power terminal electric starter. In the active position the motor shaft electric drag in rotation a Bendix provided with a pinion, which gear with a starter crown, connected in rotation to the engine thermal of the vehicle, to start the aforementioned engine. The input and output terminals are supported by a block of hollow shaped support that forms a cover made of material insulating. A contactor like that is described in the document "EP-A-0 768695".

The contactor comprises a winding with at least a winding to send the movement of a mobile core of the contactor, displacement that results in a part, causing the engine power at the end of the run electric starter and, on the other hand, causing, via a pivoting fork attached to the mobile core and meshing with the Bendix, shifting the starter pinion to engage With the toothed crown starter.

Figure 1 represents a contactor like that. In this figure for simplicity have been referenced only the main elements that belong to the state of the art. From this mode this contactor comprises a housing 1 of material magnetic, classically made of solid or sintered sweet iron. This housing visible only in figure 2 forms a cylindrical housing 1 tightly closed by the cover 6. The annular winding 4 that presents one or two windings is mounted in this accommodation 1, which, in combination with the cover 6, protects the inside of the contactor of external aggressions and guarantees a return to the mass. The annular winding 4, when it is traveled by a current of excitation, causes an axial magnetic flux in the contactor, in particular thanks to a polar mass 2 that forms a fixed core and that it is mounted on one of the axial ends of the winding 4. The winding 4 is then capable of causing displacement axial of the moving core 3 of magnetic material in the same way as the fixed core 2.

The mobile core 3 is thus capable of sliding between a back rest position in which it protrudes axially through a first axial end of the contactor housing, and an active advanced position in which, under the effect of the magnetic field induced by the winding, it is received almost completely inside the coil
binado 4.

The first axial end is constituted by the bottom 1a perforated in its central part of the housing 1, which it comprises a tubular part 1b of axial orientation that joins the outer periphery of the transverse orientation bottom 1a.

A helical compression spring requests elastically the mobile core towards its resting position by taking support on the external rear face of the bottom 1a oriented so contrary to winding 4. This bottom 1a serves equally, thanks to its central opening, as a support for a supported guide tube also by the winding support 4. The guide tube has by its inner periphery a firm contact with the outer periphery of the mobile core 3 cylindrical. This core is provided centrally from a blind hole to accommodate a rod of actuation and of a spring tooth against tooth that acts between the moving core 3 and a protruding rod head of the mobile core to support an articulation shaft for the Starter fork geared with the Bendix of the latter.

The housing 1 is closed at its second end axial opposite its bottom by the cover 6.

The support block 6 comprises an annular skirt cylindrical, which allows its centering and fixing to the second open end of the housing 1, and a transverse bottom that closes axially the contactor.

Advantageously, the support is made of plastic material.
co.

The terminals are fundamentally diametrically opposed at the bottom of deck 6, over and over part of the axis of axial symmetry of the contactor.

The terminals each comprise a head of contact arranged inside the contactor, against the bottom cross section of the support block 6, and a threaded joint bolt in part and extending axially across the transverse bottom so that it flows to the outside of the contactor.

The first terminal is ready to be connected to the positive terminal (not shown) of a battery vehicle accumulators via a normally operated switch by the contact key or by any other means. The second terminal is ready to receive a power cable (no represented) of the electric starter motor.

The support block 6 is fixed, by tight crimping, to the second end of the housing 1. For this purpose, this housing 1 has at its second end, constituted by the free end of its tubular part 1b, a transverse projection 1c for the support of the core fixed 2, a cylindrical centering portion of the fixed core 2 and a cylindrical portion 1d of small thickness, called crimping portion, intended for crimping the cover 6. More precisely the end of the portion 1d bends inwards in contact with an external conical-shaped portion of the cover 6 for tightening the fixed core 2 between the projection 1c and the free end of the cover 6. The axially oriented portion 1d extends axially, in the opposite direction to the bottom 1a, beyond the
outgoing 1c.

A mobile contact 5, formed by a plate, is liable to be displaced axially inside the space delimited by the annular wall and the bottom of the cover 6, between a back rest position in which it is in support of the fixed core 2 and an active forward position in which the mobile contact 5 is simultaneously supporting on the heads of the terminals so that it establishes between these two terminals an electrical connection that allows the starter motor to be powered with electric current that comes from the battery of accumulators vehicle.

The axial displacement of the mobile contact 5 is commanded by a control rod, which is axially guided, and whose displacements are sent by the mobile core 3.

In known manner, the mobile contact 5 is mounted sliding on the control rod.

The control rod drags the moving contact from its resting position to its active position through a contact spring that is supported on one side on a projection of the control rod and on the other side on the face transverse rear of the mobile contact 5.

A recovery spring allows you to bring again the control rod and the mobile contact 5 to the position of repose.

The recovery spring is in support in the bottom of a cylindrical housing arranged in the center of the bottom transverse of cover 6 and axially request a washer metallic (not visible) that is in support on a second projection of the control rod and on the front transverse face of the mobile contact, which cooperates on the other hand with the terminals.

In one embodiment the mobile contact contact in rest position with fixed core 2 advantageously provided with protrusions for this purpose.

It is interesting to use electronic circuits of control of the feeding of the winding of the contactor. Those electronic circuits allow perfect control of displacement of the moving core of the contactor. In this way the contactor is here electronic and comprises a circuit board printed that comprises electronic components and that extends in a transverse plane and axially between the fixed core 2 and a transverse wall that belongs to a dividing wall of tightness as described in EP A 0 751 545 and the application FR 99 09977 deposited on 07/30/1999. Advantageously, the partition wall is made by molding material plastic thus allowing an assembly with effort in the cover 6 advantageously made of the same material. The tightness is obtained thanks to the deformation of the material.

In this way, the control rod, which joins the mobile magnetic core 3 with mobile contact 5, through guided axially a tubular axial cylinder of the dividing wall of tightness

The axial cylinder has a diameter staggered and features a front and rear section as described in application FR 99 09977.

The rear axial annular section is intended for be received inside the inside diameter of the fixed core with which cooperates tightly.

A metal connection can be introduced into the waterproof partition wall. The metal connection guarantees contact electrical between the fixed core 2 and the mobile contact 5 when it is in rest position.

This connection comprises a tab that protrudes axially towards the front of the dividing wall and that is folded radially so that it extends along of the front transverse face of the dividing wall for guarantee electrical contact with mobile contact 5 when this The last one is in the rest position. This tab is solidarity with a washer-shaped support axially traversed by the section axial rear ring of the partition wall cylinder. The support guarantees electrical contact with the fixed core 2. With this purpose the cylinder comprises a hole for the passage of the tongue. This hole is formed in the protrusion made thanks to the change in diameter between the rear and front sections of the dividing wall cylinder. For more details will be reported to the aforementioned application FR 99 09977.

The mobile contact in idle position is therefore according to the embodiments in contact or with the fixed core, in particular when a card is not provided electronics inside the contactor, or with a wall sealing division directly or indirectly by means of a piece in electrical contact with the fixed core.

As a result of the foregoing the thicknesses the bottom 1a and the tubular part 1b of the housing 1 remain determined according to the flow passage needs magnetic. In practice to avoid too large consumption of current and a volume of copper too important at the level of winding 4, it is necessary not to saturate the circuit too much magnetic, therefore having a passage section for the magnetic flux large enough.

The bottom 1a thus has a thickness relatively important of the order of 3 to 6 mm. The thickness of the tubular part 1b is weaker since the flow passage section magnetic is spread along one more circumference big. This thickness is of the order of 2 to 4 mm. These thicknesses correspond to a fabrication of the housing by drawing deep of a sheet.

The 1d crimping portion normally has a thickness from 0.4 mm to 1 mm; internally comprising the portion tubular 1b three different diameters for in particular the formation of the projection 1c thanks to a change in diameter.

The housing 1 is made in a first stage by drawing, then in a second operation is the object of machining finishing operations and finally suffers in a third stage a surface treatment to perform a corrosion protection and give this case a good look visible from the outside in particular when the boot is mounted in a vehicle

The machining finishing operations are necessary because, on the one hand, an adjustment of the housing length, and on the other hand, the internal stepping of the diameter of the tubular part 1b for the formation of the projection 1c and the crimping portion 1d.

The surface treatment must be good electricity conductor since the outer face of the bottom 1a (the rear face) is used for the return to the mass of the winding 4, which performs a mobile contact retention function after closing of this one when the electric motor of the starter turns, and in the case of an electronic contactor return to the circuit ground electronic. To make memory it will be noted that the fund 1a serves for fixing the contactor on the starter housing.

These three stages need strong investments, in particular as regards the drawing operation deep and are rarely carried out in the same geographical place taking into account in particular their differences.

It is therefore an objective of the invention to carry out The housing more simply and economically.

According to the invention a contactor equipped with a Magnetic material housing of the type indicated above is characterized by the fact that the housing is made in three pieces namely a first cross-orientation piece, called bottom, which forms the perforated bottom, an orientation tube axial presenting the crimping portion and an inner tube of axial orientation housed inside the outer tube and by the fact that the outer tube is fixed to the bottom and extends, in opposite direction to the bottom, protruding axially with respect to the inner tube that has the projection.

Advantageously the inner tube is in contact with the bottom and with the outer tube.

Thanks to the invention each of the elementary components only need simple means of production  and inexpensive.

The material cost is reduced with respect to an embodiment by deep drawing of a sheet, which needs special metallurgical characteristics of the sheet.

With respect to a solution to obtain the Extrusion housing investments are reduced.

In addition you can easily increase the thickness From the bottom.

The outer tube advantageously receives previously the surface treatment operation. The tube internal is protected and does not need a surface treatment since it is surrounded by the longer outer tube. This tube internal is housed fixed in the outer tube advantageously by pressure adjustment.

The fund does not need to receive a treatment of aesthetic surface since it is less visible than the outer tube aesthetic fact, particularly from the point of view of color and of appearance, thanks to its surface treatment that suits also for corrosion resistance. This treatment of external tube surface need not take into account a good electricity conduction carried out by the inner tube protected, so that there is a greater number of elections in which concerns the surface treatment of the outer tube.

In addition, since the bottom is in contact with the starter housing, which supports the electric motor and the contactor, a bottom surface treatment is not necessary since the risk of corrosion is weak due to the fact that the starter housing is Made of aluminum alloy. In the case where the starter is subjected to a more aggressive environment from the point of view of corrosion and / or protection is imposed, the nature of the treatment that best suits without worrying about
esthetic.

Of course the thickness of the inner tube increased with the thickness of the outer tube is chosen to be corresponds to the thickness of the tubular part of figure 2 and the thickness of the outer tube corresponds to the thickness of the portion of setting of figure 2.

This outer tube, thinner than the tube internal, cut to the desired length to have the length desired in the crimping zone.

This provision facilitates standardization of the internal tube since the contactor can be electronic or not that influences the length of the roof and the portion of setting. The outer tube is therefore an adaptation piece for this length variation and protrudes more or less from the inner tube to vary the length of the crimping portion according to the applications, which allows to reduce the number of pieces of reference to be stored.

The inner tube reinforces the passage section of the magnetic flux and conducts electricity.

They can be put together in the same geographical place the means of production which allows to reduce costs additional transport and production management.

In addition, no operation of machining finish since the inner tube has the projection and the outer tube the crimping portion. It is not necessary any deep drawing of pieces.

Advantageously the outer tube covers at least partly the outer periphery of the bottom, which in this way may not be visible and serves as a centering element for the tube external.

This arrangement facilitates tube fixation. external to the fund since a previous centering is carried out between these pieces.

The first piece that forms the bottom consists of an embodiment simply in a washer. How variant the bottom is rectangular, square or polygonal. This becomes possible since a form can easily be given complementary to the concerned end of the outer tube or even to The whole outer tube. By easily presenting the inner tube a complementary to that of the outer tube, it is obtained as result that the section of the tubes can be circular, rectangular, polygonal or other.

Fixing the outer tube to its bottom is advantageously performed by the inside of the outer tube and thus the housing to protect this fixing and for aesthetic reasons.

In one embodiment, the bottom and outer tube, that is fixed to each other, by means of indirect heat input, in particular by laser welding or by electron beam that allows very localized heating that does not affect the outer periphery of the outer tube when performed This weld inside the housing. It is also not necessary no material contribution and a solid, waterproof fixation is obtained with a good continuity of the magnetic circuit and without weld bead protrusions.

This welding is advantageously performed from the inside of the outer tube with an oblique shot directed towards the outer periphery of the bottom.

The invention also proposes a start according to the teachings of the invention.

Other features and advantages of the invention will appear with the reading of the detailed description that comes to continuation for the understanding of which reference will be made to the figures in annex in which:

- Figure 1 represents a contactor according to the state of the art illustrated in axial section;

- Figure 2 is an axial sectional view of the housing of figure 1;

- Figure 3 is an axial sectional view of the housing according to the invention;

- Figure 4 is an enlarged view of the pointed detail of figure 3 before tube assembly internal.

The cylindrical housing of figure 3 is intended to replace the housing of figures 1 and 2. This housing, with an axis of axial symmetry A-A, allows then a magnetic flux step like that of figure 1 and comprises pieces of magnetic material each easily and economical

More precisely according to a characteristic of the invention the housing 1 is made in three pieces namely a first piece 12 of transverse orientation, called bottom, which constitutes the perforated bottom, an external orientation tube 13 axial presenting the crimping portion 13 'and an inner tube 14, axial orientation, housed inside the outer tube 13. This inner tube 14 has the projection 14 'for the fixed core 2 and it is here in contact with the bottom 12 and with the outer tube 13 of smaller thickness than the inner tube 14. The thickness of the bottom 12 and because of the first piece it is superior to that of the tubes 13, 14.

These three pieces 12, 13, 14 are here made of sheet metal with a base of mild steel. In this figure the tubes 13, 14 are of constant thickness and have a circular section.

The outer tube 13 is fixed to the bottom 12 and is extends protruding axially with respect to the inner tube 14 which has the projection 14 'and this in the opposite direction to the bottom 12 '.

The bottom 12 replaces the bottom of figure 1 and it is thus drilled here centrally for the passage of the mobile core 3. This bottom 12 has the same thickness as the bottom 1a and It consists here of a simple washer 12.

The sum of the thicknesses of the tubes 13 and 14 is equal to the thickness of the tubular part 1b of Figure 2.

The thickness of the outer tube 13 is equal to that of the 1d portion to be able to make the crimping.

The inner diameter of the inner tube 14 is equal to that of the tubular part 1b. This tube 14 is in support on the bottom 12 by its first axial end. His second axial end constitutes the projection 14 'for the axial support of the fixed core 2. The length of this tube 14 is thus determined accordingly. Here the outer tube 13 has a first end 13 ', which extends, in the opposite direction to the bottom 12, protruding axially with with respect to the projection 14 'and the tube 14 to form the portion 13' cylindrical crimping. The tube 14 is also in contact by its outer periphery with the inner periphery of the outer tube 13 and It is intended to ensure an electrical connection between the bottom 12 and the fixed core 2. The tube 14 is protected by the tube external 13 longer.

The outer tube 13 is adjusted in length to having the same axial length as that of the housing of the Figures 1, 2 and thus to present the same axial position of the free ends of the 1d, 13 'crimping portions.

This outer tube 13 is intended, by means from the inner periphery of its cylindrical portion of crimping 13 ', to serve as a centering element for the fixed core. This arrangement simplifies the housing, which thus only presents internally two diameters and does not require additional machining operations. The  length of portion 13 'is thus greater than portion 1b. By of course the external diameter of the fixed core is increased in this case.

The outer tube 13 surrounds and thus covers at least partly the bottom 12. Here the tube 13 is in contact by the inner periphery of its other axial end 13 '' with the periphery external of the bottom 12 so that the bottom 12 is hidden by tube 13, which has previously received a treatment of surface to give it an aesthetic appearance and so that resist corrosion. The possibilities of choosing this treatment in quality and cost are much larger than those of the housing of figure 2 since this treatment should not be good electricity conductor.

The fund may not receive treatment from surface as it is intended to make contact with the crankcase of the Aluminum base boot and little subject to corrosion. But nevertheless in severe weather conditions the fund may receive the surface treatment that best suits you without worry about aesthetics.

Tube 14 does not need a treatment of surface as it is housed in tube 13.

No treatment is needed after assembly of parts 12, 13, 14.

This assembly is done by fixing first place the end 13 '' of the outer tube to the bottom 12, then simply by inserting tube 14 into the tube with forced adjustment external 13 until the tube 14 stops against the bottom 12.

This forced adjustment is advantageously performed. with tightening, here a slight tightening since after the crimping of the cover 6 the tube 14 is axially threaded between the bottom and the free end of the cover 6 which helps prevent turn The tightening value therefore depends on the applications. The tube 14 is thus housed so that it is fixed in the tube 13 for that is not lost and constitute a manipulable housing and transportable before assembly of the other constituents of the contactor

Fixing the tube 13 to the bottom 12 is visible facilitated by the fact that the adjacent 13 '' end of the tube 13 at least partly covers the outer periphery of the bottom 12.

In the case where there are no problems of space availability you can slightly increase the diameter from bottom 12 and end 13 'to form a protrusion in tube 13 at the level of the diameter change between the 13 '' end and the part main of tube 13. In this case the end 13 '' can be lengthened and fold it in contact with the back face of the bottom 12 in contact by his front face with the above projection. Fixing between the pieces 12, 13 is thus carried out in an embodiment by setting. If necessary, at least one welding point is made between the rear face of the bottom 12 and the folded part of the end 13 '' to avoid any relative rotation between parts 12, 13.

In figure 3 the fixation is done from the inside of the outer tube 13 and thus of the housing at the level of the outer periphery of the front face of the bottom 12 for in particular achieve an aesthetic appearance and protect the fixation Against external aggressions. This figure does not increase the Volume occupied and tubes 13, 14 have a simple shape.

Fixing is done locally by contribution indirect heat here by a clean welding of laser type or by electron beam. The energy densities set in motion in this type of welding they are very high so that the surface treatments are destroyed in the welding zone and do not disturb the welding. The heating is very localized and does not affect the surface treatments of the rest of the piece concerned in particular of the outer periphery of the outer tube 13, which thus retains its aesthetic appearance.

The above welding is done from the inside of the outer tube 13 and thus of the housing at the level of the outer periphery of the front face of the bottom 12 and of the adjacent inner periphery of end 13 '' of tube 13 with a oblique shot according to arrow F in figure 4.

The inner tube 14 consists of a tube section or as a variant in a curved and welded or curved and joined bushing with staples. This tube serves to reinforce the passage section of the magnetic flux that also passes through the bottom 12.

The outer tube 13 also consists of a pipe section or as a variant in a curved and welded bushing or curved and attached with staples.

The contactor equipped with the housing according to the invention is mounted in the embodiment represented in a motor vehicle start.

Of course, the present invention is not limited to the described embodiments. In this way it is also possible to increase the thickness of the bottom 12, which can easily have a thickness of 1.3 to 2 times the sum of the thicknesses of the tubes 13, 14. Other fixing means for the tubes 13, 14 can be considered. For example, the tube 14 can be fixed by welding with an oblique shot on the bottom 12 in the same manner as the tube 13. In a general way it is sought to prevent the tube 14 from being lost to form a manipulable and transferable housing.
portable.

As a variant the fixation the tube 13 is carried out by axial welding, for example by indirect heat input such as a laser or electron beam welding, at the level of the back side of bottom 12 between outer and inner peripheries respectively of the bottom 12 and the adjacent end 13 '' of the tube 13. This type of welding can be performed radially between two transverse faces respectively of bottom 12 and end adjacent 13 '' of tube 13. In this case the bottom has advantageously a plug shape with a head with a step that delimits the transverse face concerned of the bottom and a body that penetrates the tube 13 while in contact with a portion of the inner periphery of end 13 '' of which the final portion It constitutes the other transverse face. As a variant the welding radial is performed between the end portion 13 '' and the periphery external front face of bottom 12 so that the tube external 13 does not cover the bottom 12. In this variant the diameters external of the external tube 13 and the bottom 12 are the same.

Advantageously in all cases the cords Welding are continuous for good bottom tightness, good continuity of the magnetic circuit and good fixation between the pieces Welding is preferably used without metal supply to preserve the dimensions of the housing and avoid a weld bump. Type welding laser or electron beam, in a general way by contribution indirect heat, fits well for this purpose.

As a variant the inner tube 14 can present, advantageously in advance, a change in diameter to projection level 14 'for centering the fixed core 2 as in Figure 1 so that the fixed core 2 of Figure 1 is not modify When space conditions available, in particular axial, allow the outer tube 13 can cover the outer periphery of the bottom 12 and extend axially protruding with respect to the rear face of the bottom 12. The fixing between the bottom 12 and the outer tube 13 is then made by welding from inside the tube 13 with an oblique shot as in the figure 3 enter in this case the outer periphery of the rear face of the bottom 12 and the adjacent inner periphery of end 13 ''.

Claims (12)

1. Contactor for a motor vehicle start, of the type comprising a housing (1) of material that allows a magnetic flux passage and comprising a perforated bottom for the passage of a mobile magnetic core (3), a projection for the support of a fixed core (2) and a cylindrical portion of axial orientation, called crimping portion, which extends, in the opposite direction to the bottom, axially beyond the projection for crimping a cover (6) characterized by the the fact that the housing (1) is made of three pieces, namely a first piece (12) of transverse orientation, called bottom, which constitutes the perforated bottom, an external tube (13) of axial orientation presenting the crimping portion ( 13 ') and an inner tube (14) of axial orientation housed inside the outer tube (13) and by the fact that the outer tube (13) is fixed to the bottom (12) and extends, in the opposite direction to the bottom (12), protruding axial mind with respect to the inner tube (14) presenting the projection (14 '). 2. Contactor according to claim 1, characterized in that the inner tube (14) is housed so that it is fixed to the outer tube assembly (13) bottom (12). 3. Contactor according to claim 1 or 2, characterized in that the inner tube (14) is inserted tightly into the outer tube (13). 4. Contactor according to any one of the preceding claims, characterized in that the inner tube (14) is in contact with the bottom (12) and with the outer tube (13). 5. Contactor according to any one of the preceding claims, characterized in that the outer tube (13) at least partially covers the outer periphery of the bottom (12). 6. Contactor according to any one of the preceding claims, characterized in that the bottom (12) and the external tube (13) are fixed to each other by indirect heat input such as a laser or electron beam welding . 7. Contactor according to any one of the preceding claims, characterized in that the bottom (12) and the outer tube (13) are fixed to each other from inside the outer tube (13). 8. Contactor according to the preceding claim, characterized in that the fixing is carried out by laser welding or electron beam with an oblique shot directed towards the outer periphery of the bottom (12). 9. Contactor according to any one of the preceding claims, characterized in that the external tube (13) has a surface treatment against corrosion and to make it aesthetic. 10. Contactor according to any one of the preceding claims, characterized in that the outer tube (13) has a thickness smaller than the inner tube (14). 11. Contactor according to any one of the preceding claims, characterized in that the thickness of the bottom (12) is greater than that of the inner (14) and outer (13) tubes. 12. Starting a motor vehicle, characterized in that it comprises a contactor according to any one of the preceding claims.