JP2002317696A - Manufacturing method for control device consolidated with engine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a control device at a low cost without complicating die casting even if a structure of a bus bar circuit to be embedded complicated. SOLUTION: An intermediate molding 50 is formed having a bus bar accommodating groove 50a, and the bus bar circuit body 8 is accommodated in the groove 50a, and then a device body is integrally molded to the intermediate molding 50 so that the bus bar circuit 8 is embedded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an engine-integrated control device provided integrally with an engine.

[0002]

2. Description of the Related Art A conventional engine-integrated control device 100 of this type is disclosed in Japanese Unexamined Patent Publication No.
There is one disclosed in Japanese Patent Publication No. 317556. As shown in FIGS. 13 and 14, a wiring portion (branch circuit portion) embedded along the wall surface of the cylinder head cover 101 is provided.
102, a plurality of contacts 103 connected to the terminals of the wiring portion 102, and a plurality of connector fitting portions 104 provided around the plurality of contacts 103 approaching each other as one block. ing. The wiring section (branch circuit section) 102 and the plurality of contacts 103 are connected by some means. Then, a connector (not shown) connected to an electronic component, an engine control unit, or the like is fitted into each connector fitting portion 104.

According to the engine-integrated control device 100, the wiring portion 102 is routed on the cylinder head cover 101, and the contact 1
Since the connector 03 and the connector fitting portion 104 can be freely arranged, there is an advantage that the amount of wire harness routed around the engine can be extremely reduced.

Incidentally, the production of such a resin cylinder head cover 101 in which the wiring portion 102 is embedded is generally performed by insert molding.

[0005]

However, in the insert molding, it is necessary to position the wiring portion 102, which is a member inserted inside the mold, at a predetermined position with a positioning pin or the like. Therefore, as the number of circuits formed by the wiring portion 102 embedded in the cylinder head cover 101 increases, the die casting becomes complicated in insert molding,
There is a problem that the manufacturing cost increases.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an engine-integrated control device which can be manufactured at low cost without complicating die casting even if an embedded circuit is complicated. It is an object of the present invention to provide a method for producing the same.

[0007]

According to a first aspect of the present invention, there is provided an intermediate molded body provided with a bus bar accommodating groove for accommodating a bus bar circuit body for forming a desired circuit pattern, and thereafter, the intermediate molded body is formed. The bus bar circuit body is accommodated in the bus bar accommodating groove, and thereafter the bus bar circuit body is embedded in the intermediate molded body accommodating the bus bar circuit body, thereby integrally molding the device body. And

In this manufacturing method of the engine-integrated control device, the bus bar circuit body is positioned in the mold by being housed in the bus bar housing groove of the intermediate molded body. The casting does not become complicated.

According to a second aspect of the present invention, there is provided a method of manufacturing an engine-integrated control device according to the first aspect, wherein the busbar circuit body has a plurality of branch circuits formed therein and connected to electrical components. The contact is formed integrally with the terminal.

In the method of manufacturing the engine-integrated control device, in addition to the operation of the first aspect, the bus bar circuit body integrally forms a plurality of contacts by using the branch circuit portion and its terminals.

[0011] The invention of claim 3 is claim 1 or claim 2.
The method of manufacturing an engine-integrated control device according to claim 1, wherein a connector connected to an electrical component is fitted, and a connector fitting portion in which the plurality of contacts are arranged is provided on the device body. And

According to this method of manufacturing an engine-integrated control device, in addition to the effects of the first and second aspects of the present invention, the electrical component is connected by fitting the connector on the electrical component side into the connector fitting portion of the device body. it can.

According to a fourth aspect of the present invention, there is provided a method of manufacturing an engine-integrated control device according to any one of the first to third aspects, wherein the device main body is a cylinder head cover for closing an upper opening of the engine. Features.

In this method of manufacturing the engine-integrated control device, in addition to the effects of the first to third aspects of the present invention, there is no need to provide a member for providing the bus bar circuit body separately from the cylinder head cover.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings.

1 to 9 show an embodiment of an engine to which an engine-integrated control device manufactured by the manufacturing method of the present invention is applied, FIG. 1 is a perspective view of the engine viewed from an intake side, and FIG. FIG. 3 is a perspective view of the engine seen from the exhaust side, FIG. 3 is a cylinder head cover seen from the intake side, and a perspective view clearly showing through a bus bar circuit body, and FIG. 4 is a cylinder head cover seen from the exhaust side. FIGS. 5 to 7 are partially cutaway cross-sectional views of the cylinder head cover viewed from the exhaust side, while FIGS. FIG. 8B is a perspective view showing a state before contact between the contact and the contact on the cylinder head cover side, and FIG. 8B shows a contact state between the contact on the engine control unit side and the contact on the cylinder head cover side. Perspective view, FIG. 9 is a sectional view showing a mounted state of the ignition coil ignitor.

As shown in FIGS. 1 and 2, an intake pipe 2 and an exhaust pipe 3 are connected to the engine main body 1, and air sucked from the intake pipe 2 is supplied to a cylinder chamber (not shown) in the engine main body 1. ), And exhaust gas generated by combustion in a cylinder chamber (not shown) is exhausted from an exhaust pipe 3. On the upper surface of the engine body 1, a cylinder head cover 4, which is the apparatus body of the engine integrated control device A, is provided with bolts 5.
The opening at the top of the engine is closed by the cylinder head cover 4.

As shown in detail in FIGS. 3 to 7, the cylinder head cover 4 is formed of a heat-resistant insulating material, and includes a baffle plate 6 and an upper cover portion 7 arranged at a predetermined interval on the baffle plate 6. And a two-layer structure. A busbar circuit body 8 is buried in the upper cover part 7, and the busbar circuit body 8 uses a branch circuit part 9 which is a wiring part of an engine control circuit and a terminal part forming the branch circuit part 9. It is composed of a plurality of integrally formed contacts 10a to 10g. The plurality of contacts 10a to 10g are arranged close to each other to form a contact group. In this embodiment, the plurality of contacts 10a are a group of contacts for the engine control unit 20, the plurality of contacts 10b are a group of contacts for the water temperature detection sensor,
The plurality of contacts 10c are a contact group for a camshaft phase detection sensor, the two contacts 10d and 10e are two contact groups for an oxygen amount detection sensor, and the plurality of contacts 10f are valves 36 for controlling valve timing. And a plurality of contacts 10g at four locations are provided with an ignition coil integrated igniter 4.
0 constitutes four contact groups.

Four ignition coil integrated igniters 40
The first to sixth connector fitting portions 12a to 12f are provided around the other contacts 10a to 10f, respectively, except for the contact 10g.
12 f is provided integrally with the cylinder head cover 4. The contacts 10a to 10f arranged in the first to sixth connector fitting portions 12a to 12f are exposed so as to protrude from the surface of the cylinder head cover 4. or,
Contact point 10g of four ignition coil integrated igniters 40
Are respectively arranged on the end faces of the ignition coil attachment port 13,
It is exposed from the cylinder head cover 4 along the end face.

Engine control unit 20 which is an electrical component
Are bolts 21 (FIG. 2) on the upper surface of the cylinder head cover 4.
Shown). The engine control unit 20 has an engine control circuit unit (not shown) mounted thereon, and is used to input outputs of various sensors and the like and output control signals to the engine control circuit unit (not shown). Are provided at three locations. The two connectors 22 and 23 are provided on the side surface of the engine control unit 20.
And the connector 28 of the harness 27 led to the injector 26 and the like are fitted respectively. Another connector (not shown) is provided on the bottom surface of the engine control unit 20, and this connector (not shown) is fitted to the first connector fitting portion 12 a of the cylinder head cover 4. More specifically, as shown in FIGS. 8A and 8B, the plurality of contacts 10a on the cylinder head cover 4 side have a plate-like shape standing upright, and the engine control unit 20
The plurality of contacts 29 on the side have a holding plate shape having a gap 29a upward from the center of the lower end surface, and the contact 10a on the cylinder head cover 4 side is inserted into the gap 29a of the contact 29 on the engine control unit 20 side. As a result, the two contacts 10a and 29 are electrically connected to each other.

The water temperature detection sensor 30a and the camshaft phase detection sensor 30b, which are electrical components, are provided on the side surface of the cylinder head cover 4. The connector 31a connected to the water temperature detection sensor 30a and the connector 31b connected to the camshaft phase detection sensor 30b
The second and third connector fitting portions 12b and 12c of the cylinder head cover 4 are fitted respectively. Connectors 34 and 35 are provided at the ends of the electric wires 33 connected to the two oxygen amount detection sensors 32 as electrical components, respectively. The connectors 34 and 35 are connected to the fourth and fifth terminals of the cylinder head cover 4. They are fitted to the connector fitting parts 12d and 12e, respectively. A connector 37 connected to a valve 36 for controlling valve timing, which is an electrical component.
Is the sixth connector fitting portion 12 of the cylinder head cover 4.
f. And the connectors 31a, 31
b, 37 and the second, third and sixth connector fitting portions 12b,
The direction of engagement with 12c and 12f is substantially the same as the engine vibration direction V.

The ignition coil integrated igniter 40, which is an electric component, is fixed to the cylinder head cover 4 by bolts 42 while being inserted into the ignition coil mounting opening 41, as shown in detail in FIG. A plurality of contacts 43 for receiving the supply of the ignition current are provided on the side surface of the ignition coil integrated igniter 40, and the plurality of contacts 43 are in contact with the respective contacts 10 g of the cylinder head cover 4.

Next, a method of manufacturing the cylinder head cover 4 which is the main body of the engine-integrated control device A will be described with reference to FIG.
This will be described with reference to FIGS. 10 is a perspective view of the intermediate molded body and the busbar circuit body, FIG. 11 is a perspective view of the busbar circuit body housed in the intermediate molded body, and FIG. 12A is a perspective view of an engine head cover manufactured by double molding. 1
2 (b) is an engine head cover manufactured by double molding, and is a perspective view clearly showing through a bus bar circuit body.

First, as shown in FIG. 10, a bus bar circuit body 8 having a desired circuit pattern is formed by press working or the like, and a bus bar accommodating groove 50a for accommodating the bus bar circuit body 8 is formed on the upper surface. The molded body 50 is formed by molding using a first mold (not shown). The intermediate molded body 50 has substantially the outer diameter shape of the cylinder head cover 4 except for the upper surface side.

Next, as shown in FIG.
The busbar circuit body 8 is housed in the busbar housing groove 50a of No. 0.

Next, the intermediate molded body 50 on which the bus bar circuit body 8 is mounted is set at a predetermined position in a second mold (not shown), and the bus bar is mounted on the intermediate molded body 50 containing the bus bar circuit body 8. What is necessary is just to perform the shaping | molding which embeds the circuit body 8. FIG. Thus, the engine head cover 4 is integrally formed as shown in FIGS.

As described above, in the manufacturing method of the engine-integrated control device A, the bus bar circuit body 8 is positioned inside the second mold (not shown) by being housed in the bus bar housing groove 50a of the intermediate molded body 50. Therefore, even if the bus bar circuit body 8 is complicated, the mold casting does not become complicated. Therefore, even if the bus bar circuit body 8 to be buried becomes complicated, the mold casting does not become complicated, and the manufacturing can be performed at low cost. In particular,
In the conventional insert molding, the more complicated the structure of the circuit body, the more complicated the mold casting becomes. However, in the above-described double molding (two-color molding), the branch circuit body of the busbar circuit body 8 is used. Since the mold casting does not become complicated depending on the complexity of 9, the more complicated the circuit body, the more effective. Further, there is an advantage that the design can be easily changed and the manufacturing tact (time) can be shortened as compared with the conventional case of insert molding.

Further, the bus bar circuit body 8 has a branch circuit section 9 and a plurality of contacts 10a to 10g formed integrally using terminals thereof. There is no need for a process of connecting Therefore,
For example, the cylinder head cover 4 can be easily formed by the double molding as described above using the bus bar circuit body 8 formed by press molding. In this regard, the production is easy and the cost can be reduced.

Further, since the busbar circuit body 8 has rigidity as a structure, dimensional accuracy can be easily obtained at the time of buried manufacturing. Further, the bus bar circuit body 8 has a manufacturing temperature (150 ° C. for FRP resin to 30 ° C. for nylon resin) at the time of burying formation.
Since no inconvenience such as deformation occurs at 0 ° C.), the degree of freedom in selecting the material of the cylinder head cover 4 is increased.

In the above embodiment, the engine control unit 20, which is an electrical component, a water temperature detection sensor 30a and a camshaft phase detection sensor 30b, an oxygen amount detection sensor 32, and a connector (not shown) connected to a valve 36 for controlling valve timing. Z), 31a, 31b, 34, 35, 37
Are fitted, and the first contact 10a to 10f are arranged.
Since the sixth to sixth connector fitting portions 12a to 12f are provided on the cylinder head cover 4, the connectors (not shown), 31a, 31b, 34, 35, and 37 on the electrical component side are connected to the connector fitting portions of the cylinder head cover 4. 12a-12f
Since the electrical components can be connected by fitting to the electronic components, the electrical components such as the engine control unit 20 can be easily connected. Further, if the ignition coil integrated type igniter 40 is attached to the ignition coil mounting opening 41, the electrical connection to the ignition coil integrated type igniter 40 is completed, so that the mounting operation of the ignition coil integrated type igniter 40 is easy.

In the above embodiment, the connectors 31a, 31b, 37 connected to the water temperature detection sensor 30a, the camshaft phase detection sensor 30b, and the valve 36 for controlling the valve timing, which are electrical components, are fitted with the second to fourth connectors. The direction of fitting with the parts 12b, 12c, and 12f is substantially the same as the vibration direction V of the engine, so that both contacts (not shown), 10b,
Since vibrations in the sliding directions act on 10c and 10f, breakage of the contacts (not shown), 10b, 10c and 10f due to engine vibration can be prevented.

In the above embodiment, since the main body of the apparatus is the cylinder head cover 4 for closing the upper opening of the engine, there is no need to provide a member for providing the bus bar circuit body 8 separately from the cylinder head cover 4. Will be reduced.

[0033]

As described above, according to the first aspect of the present invention, the intermediate molded body provided with the bus bar accommodating groove is formed, and thereafter, the bus bar circuit body is accommodated in the bus bar accommodating groove of the intermediate molded body. Thereafter, since the device main body was integrally formed by performing molding for embedding the bus bar circuit body in the intermediate molded body containing the bus bar circuit body, the bus bar circuit body is housed in the bus bar accommodating groove of the intermediate molded body. Therefore, even if the bus bar circuit body becomes complicated, the mold casting does not become complicated. Therefore, even if the bus bar circuit body to be buried becomes complicated, the mold casting does not become complicated, and the manufacturing can be performed at low cost.

According to a second aspect of the present invention, there is provided the method of manufacturing an engine-integrated control device according to the first aspect, wherein the busbar circuit body has a plurality of branch circuits formed therein and connected to electrical components. Are formed integrally with the terminal, and in addition to the effects of the invention of claim 1, a plurality of contacts are integrally formed using the branch circuit portion and the terminal by the bus bar circuit body. The step of connecting the branch circuit section and the plurality of contacts as in the conventional example is not required. Therefore, for example, the apparatus main body can be easily formed by the above-described double molding using the bus bar circuit body formed by press molding, and from this point of view, the production is easy and the cost can be reduced.

According to a third aspect of the present invention, there is provided the method for manufacturing an engine-integrated control device according to the first or second aspect, wherein the connector connected to the electrical component is fitted and the plurality of contacts are arranged. Since the connector fitting portion to be provided is provided in the device main body, in addition to the effects of the invention of claim 1 or claim 2,
If the connector on the electrical component side is fitted into the connector fitting portion of the device main body, the electrical component can be connected, so that the electrical component can be easily connected.

According to a fourth aspect of the present invention, in the method of manufacturing an engine-integrated control device according to any one of the first to third aspects, the device body is a cylinder head cover for closing an upper opening of the engine. In addition to the effects of the first to third aspects of the present invention, there is no need to provide a member for providing a bus bar circuit body separately from the cylinder head cover, so that the number of parts can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of an engine according to an embodiment of the present invention, viewed from an intake side.

FIG. 2 is a perspective view of the engine, showing one embodiment of the present invention, viewed from the exhaust side.

FIG. 3 is a perspective view of the cylinder head cover viewed from the intake side and clearly showing a bus bar circuit body, showing the embodiment of the present invention.

FIG. 4 is a perspective view showing the cylinder head cover viewed from the exhaust side and clearly showing a bus bar circuit body in an embodiment of the present invention.

FIG. 5 shows one embodiment of the present invention, and is a partially cutaway sectional view of a cylinder head cover viewed from an exhaust side.

FIG. 6 shows one embodiment of the present invention, and is a partially cutaway sectional view of a cylinder head cover viewed from an exhaust side.

FIG. 7 is a partially cutaway cross-sectional view of the cylinder head cover as viewed from the exhaust side, showing one embodiment of the present invention.

8A and 8B show an embodiment of the present invention, wherein FIG. 8A is a perspective view showing a state before contact between a contact on the engine control unit side and a contact on the cylinder head cover side, and FIG. FIG. 3 is a perspective view showing a contact state between the contact and a contact on a cylinder head cover side.

FIG. 9 shows one embodiment of the present invention, and is a cross-sectional view showing a mounted state of an ignition coil integrated igniter.

FIG. 10 shows one embodiment of the present invention, and is a perspective view of an intermediate molded body and a busbar circuit body.

FIG. 11 shows an embodiment of the present invention, and is a perspective view in which a bus bar circuit body is housed in an intermediate molded body.

FIG. 12 shows an embodiment of the present invention, in which (a) is a perspective view of an engine head cover manufactured by double molding,
(B) is an engine head cover manufactured by double molding, and is a perspective view clearly showing through a bus bar circuit body.

FIG. 13 is a perspective view of a cylinder head cover to which a conventional engine-integrated control device is applied.

FIG. 14 is a sectional view taken along line AA of FIG.

[Explanation of symbols]

 Reference Signs List A Engine integrated control device 4 Cylinder head cover (device main body) 8 Bus bar circuit body 9 Branch circuit portion 10a to 10g Contact 12a to 12f Connector fitting portion 20 Engine control unit (electrical component) 30a Water temperature detection sensor (electrical component) 30b Cam Shaft phase detection sensor (electrical component) 31a, 31b, 34, 35, 37 Connector 32 Oxygen amount detection sensor (electrical component) 36 Valve for controlling valve timing (electrical component) 40 Ignition coil integrated igniter (electrical component) 50 Intermediate Molded body 50a Busbar accommodation groove

Claims (4)

[Claims] 1. An intermediate molded body having a bus bar accommodating groove for accommodating a bus bar circuit body for forming a desired circuit pattern is formed, and thereafter, a bus bar circuit body is accommodated in the bus bar accommodating groove of the intermediate molded body. A method of manufacturing an engine-integrated control device, characterized in that the main body of the engine is integrally formed by performing molding for embedding the bus bar circuit body in the intermediate molded body accommodating the bus bar circuit body. 2. The method of manufacturing an engine-integrated control device according to claim 1, wherein the bus bar circuit body has a branch circuit portion formed therein and a plurality of contacts connected to an electrical component are integrated with the terminal. A method for manufacturing an engine-integrated control device, wherein the control device is formed. 3. The method for manufacturing an engine-integrated control device according to claim 1, wherein a connector connected to an electrical component is fitted, and the plurality of contacts are arranged. Is provided in the apparatus main body, a method for manufacturing an engine-integrated control apparatus. 4. The method for manufacturing an engine-integrated control device according to claim 1, wherein the device main body is a cylinder head cover that closes an upper opening of the engine. A method for manufacturing a body control device.