JP2006156710A5 - - Google Patents

Description

Bobbinless coil and method for manufacturing bobbinless coil

The present invention includes a bobbin-less coil wound wire without using a bobbin, and to a method for producing it.

A coil used for an electromagnetic actuator or a motor is generally wound around an insulator called a bobbin. A bobbinless coil that eliminates this bobbin is known from Patent Document 1 below. This bobbin-less coil is formed by winding a conductive wire with a tape with an adhesive layer in a spiral shape into a cylindrical shape, and then fixing the shape of the coil body with adhesive tape at several locations in the circumferential direction. is doing.
Japanese Patent Laid-Open No. 10-172823

  By the way, the above-described conventional device has a problem that the shape of the coil body is likely to be inaccurate because there is no bobbin serving as a guide when winding the conducting wire. In addition, since the conductive wires are bonded over the entire length, not only a large amount of tape with an adhesive layer is required, but there is a problem that a lot of man-hours are required for winding the tape with the adhesive layer.

  The present invention has been made in view of the above circumstances, and an object thereof is to manufacture a bobbinless coil with the minimum number of parts and the minimum number of man-hours.

  In order to achieve the above object, according to the first aspect of the present invention, the first step of winding a conducting wire around a cylindrical bobbin jig into a coil shape, and the conducting wire wound around the bobbin jig are made plastic. A bobbinless coil manufacturing method is proposed, which includes a second step of forming a bobbinless coil by compressing in a radial direction to a region and a third step of separating a bobbin jig from the bobbinless coil. .

  According to a second aspect of the present invention, in addition to the configuration of the first aspect, in the second step, the conductive wire wound around the bobbin jig is compressed in the axial direction. A manufacturing method is proposed.

  According to the third aspect of the present invention, in addition to the configuration of the first or second aspect, the wire before compression is a round wire having a circular cross section, and the gap between the adjacent wires in the second step. A method of manufacturing a bobbinless coil is proposed in which the conducting wire is plastically deformed until the wire disappears.

According to a fourth aspect of the present invention, there is proposed a bobbinless coil in which a conducting wire is wound without using a bobbin and the conducting wire is compressed to a plastic region. .

According to the invention described in claim 5, in addition to the configuration of claim 4, the conducting wire is a round wire having a circular cross section, and is plastically deformed into a polygonal cross section by compression after winding, and the adjacent wires A bobbinless coil is proposed in which the gaps between the conductors have disappeared.

  According to the first aspect of the present invention, the bobbinless coil is separated from the bobbinless coil after forming the bobbinless coil by radially compressing the conducting wire wound in the coil shape on the cylindrical bobbin jig to the plastic region. Therefore, the bobbin and tape with adhesive layer can be eliminated to reduce the number of parts and cost, and the unwinding of the conductor can be prevented, and the inner diameter of the bobbinless coil can be reduced by the amount of the elimination of the bobbin, and the resistance and inductance can be reduced. The current response can be improved by reducing the current.

  According to the configuration of the second aspect, when the conducting wire wound in the coil shape is compressed in the radial direction, the conducting wire can be further plastically deformed to further stabilize the coil shape by compressing the conducting wire in the radial direction. it can.

  According to the configuration of the third aspect of the present invention, since a conducting wire made of a round wire having a circular cross section is wound around a bobbin jig and then compressed to a plastic region to eliminate the gap between adjacent conducting wires, the space factor of the bobbinless coil The coil shape can be further stabilized by increasing the frictional force between the conducting wires that are in contact with each other.

According to the configuration of claim 4, since the lead wire of the bobbinless coil is compressed to the plastic region, the bobbin and the tape with the adhesive layer can be abolished, and the unwinding of the lead wire can be prevented while reducing the number of parts and the cost. In addition, the inner diameter of the bobbinless coil can be reduced by the amount corresponding to the elimination of the bobbin, and the current response can be improved by reducing the resistance and inductance.

According to the configuration of claim 5, a winding wire having a circular cross section is compressed after being wound to be plastically deformed into a polygonal cross section, and the gap between adjacent conductive wires is eliminated. As a result, the coil shape can be further stabilized by increasing the frictional force between the conducting wires in contact with each other.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below based on examples of the present invention shown in the accompanying drawings.

  1 to 7 show an embodiment of the present invention. FIG. 1 is a longitudinal sectional view of an active vibration isolating support device, FIG. 2 is an enlarged view of a part 2 in FIG. 1, and FIG. 4 is a sectional view taken along line 4-4 of FIG. 3, FIG. 5 is an enlarged view of a portion 5A and 5B of FIG. 3, FIG. 6 is a longitudinal sectional view of the completed coil assembly, and FIG. It is a flowchart to explain.

  As shown in FIGS. 1 and 2, an active anti-vibration support device M (active control mount) used for elastically supporting an automobile engine on a body frame is substantially axisymmetric with respect to an axis L. A substantially cup-shaped actuator case having an open upper surface between a flange portion 11a at the lower end of the substantially cylindrical upper housing 11 and a flange portion 12a at the upper end of the generally cylindrical lower housing 12. The outer peripheral flange portion 13a, the outer peripheral portion of the annular first elastic body support ring 14, and the outer peripheral portion of the annular second elastic body support ring 15 are overlapped and joined by caulking. At this time, the annular first floating rubber 16 is interposed between the flange portion 12a of the lower housing 12 and the flange portion 13a of the actuator case 13, and the upper portion of the actuator case 13 and the inner surface of the second elastic body support member 15 By interposing the annular second floating rubber 17 therebetween, the actuator case 13 is floatingly supported so as to be movable relative to the upper housing 11 and the lower housing 12.

  The lower end and the upper end of the first elastic body 19 formed of thick rubber are joined to the first elastic body support ring 14 and the first elastic body support boss 18 disposed on the axis L by vulcanization adhesion. Is done. A diaphragm support boss 20 is fixed to the upper surface of the first elastic body support boss 18 with bolts 21, and the outer peripheral portion of the diaphragm 22 joined to the diaphragm support boss 20 by vulcanization adhesion is added to the upper housing 11. Joined by sulfur adhesion. An engine mounting portion 20a integrally formed on the upper surface of the diaphragm support boss 20 is fixed to an engine (not shown). Further, the vehicle body mounting portion 12b at the lower end of the lower housing 12 is fixed to a vehicle body frame (not shown).

  A flange portion 23a at the lower end of the stopper member 23 is coupled to the flange portion 11b at the upper end of the upper housing 11 by bolts 24 ... and nuts 25 ..., and a diaphragm support boss 20 is attached to a stopper rubber 26 attached to the upper inner surface of the stopper member 23. The engine mounting portion 20a that protrudes from the upper surface of the upper and lower surfaces faces each other so as to be able to come into contact therewith. When a large load is input to the active vibration isolating support device M, the engine mounting portion 20a abuts against the stopper rubber 26, thereby suppressing excessive displacement of the engine.

  The outer peripheral portion of the second elastic body 27 formed of a film-like rubber is joined to the second elastic body support ring 15 by vulcanization adhesion, and the movable member 28 is added so as to be embedded in the central portion of the second elastic body 27. Joined by sulfur adhesion. A disk-shaped partition wall member 29 is fixed between the upper surface of the second elastic body support ring 15 and the outer periphery of the first elastic body 19, and the first partition partitioned by the partition wall member 29 and the first elastic body 19. The liquid chamber 30 and the second liquid chamber 31 partitioned by the partition member 29 and the second elastic body 27 communicate with each other through a communication hole 29 a formed at the center of the partition member 29.

  An annular communication path 32 is formed between the first elastic body support ring 14 and the upper housing 11, and one end of the communication path 32 communicates with the first liquid chamber 30 through the communication hole 33. The other end communicates with the third liquid chamber 35 defined by the first elastic body 19 and the diaphragm 22 through the communication hole 34.

  Next, the structure of the actuator 41 that drives the movable member 28 will be described.

  The fixed core 42, the coil assembly 43, and the yoke 44 are sequentially attached to the inside of the actuator case 13 from the bottom to the top. The coil assembly 43 includes a bobbinless coil 46 disposed between the fixed core 42 and the yoke 44, and a coil cover 47 that covers the outer periphery of the bobbinless coil 46. The coil cover 47 is integrally formed with a connector 48 that extends through the openings 13b and 12c formed in the actuator case 13 and the lower housing 12 and extends to the outside.

  Here, a manufacturing method of the coil assembly 43 will be described.

  As shown in FIGS. 3 and 4, a bobbin jig 64 is prepared by dividing a cylinder into a plurality of (four in the embodiment) compression members 64a in the circumferential direction. The diameter of the bobbin jig 64 can be enlarged or reduced by the compression members 64a... Being connected to a drive source (not shown) and moving in the radial direction. Annular support plates 63 and 63 are disposed at both ends of the bobbin jig 64 in the direction of the axis L, and these support plates 63 and 63 are connected to a drive source (not shown) to be in the direction of the axis L (approaching each other). Direction).

  First, as shown in FIG. 3A, a conducting wire 65 made of a round wire having a circular cross section is wound into a coil shape with the outer peripheral surface of the bobbin jig 64 and the opposing surfaces of the support plates 63 and 63 as guides. Subsequently, as shown in FIGS. 3B and 4, the compression members 64 a... Of the bobbin jig 64 are moved outward in the radial direction and compressed until the lead wire 65 is plastically deformed. Since the conducting wire 65 is wound with a predetermined tension, even when a radially outward load is applied from the bobbin jig 64, the outside diameter of the conducting wire 65 wound in a coil shape almost increases. Absent.

  Subsequently, as shown in FIG. 3C, the support plates 63 and 63 are moved in the direction of the axis L so as to approach each other, thereby further compressing the conducting wire 65. In addition, if the process of FIG.3 (B) and the process of FIG.3 (C) are performed simultaneously, the conducting wire 65 can be compressed further efficiently. Subsequently, as shown in FIG. 3D, the bobbin less coil 46 is completed by removing the reduced bobbin jig 64 from the center of the conductive wire 65 wound in the coil shape. In this bobbinless coil 46, since the conductive wire 65 is compressed to the plastic region, the coil shape is maintained even if the load from the bobbin jig 64 and the support plates 63 and 63 disappears.

  The bobbinless coil 46 thus completed is inserted into a mold together with support plates 63 and 63 sandwiching both ends in the direction of the axis L, and a coil cover 47 made of synthetic resin is integrally molded around the periphery, so that FIG. The coil assembly 43 including the bobbinless coil 46, the support plates 63 and 63, and the coil cover 47 as shown in FIG. When the coil cover 47 is molded, the connector 48 is integrally formed there.

  1 and 2, the seal member 49 is disposed between the upper surface of the coil cover 47 and the lower surface of the yoke 44, and the seal member 50 is disposed between the lower surface of the bobbinless coil 46 and the upper surface of the fixed core 42. Is done. These seal members 49 and 50 can prevent water and dust from entering the internal space 61 of the actuator 41 from the openings 13 b and 12 c formed in the actuator case 13 and the lower housing 12.

  A thin cylindrical bearing member 51 is fitted to the inner peripheral surface of the cylindrical portion 44a of the yoke 44 so as to be vertically slidable. An upper flange 51a bent radially inward is formed at the upper end of the bearing member 51. A lower flange 51b that is bent radially outward is formed at the lower end. A set spring 52 is disposed in a compressed state between the lower flange 51b and the lower end of the cylindrical portion 44a of the yoke 44. The elastic force of the set spring 52 causes the lower flange 51b to be fixed to the fixed core 42 via the elastic body 53. The bearing member 51 is supported by the yoke 44 by being pressed against the upper surface of the yoke 44.

  A substantially cylindrical movable core 54 is fitted to the inner peripheral surface of the bearing member 51 so as to be slidable up and down. A rod 55 extending downward from the center of the movable member 28 penetrates the center of the movable core 54 loosely, and a nut 56 is fastened to the lower end thereof. A set spring 58 in a compressed state is disposed between a spring seat 57 provided on the upper surface of the movable core 54 and the lower surface of the movable member 28, and the movable core 54 is pressed against the nut 56 by the elastic force of the set spring 58. Fixed. In this state, the lower surface of the movable core 54 and the upper surface of the fixed core 42 face each other via the conical air gap g. The rod 55 and the nut 56 are loosely fitted into an opening 42 a formed at the center of the fixed core 42, and the opening 42 a is closed by a plug 60 through a seal member 59.

  The electronic control unit U, to which a crank pulse sensor Sa for detecting a crank pulse output with the rotation of the crankshaft of the engine is connected, controls energization to the actuator 41 of the active vibration isolation support device M. The engine crank pulse is output 24 times per revolution of the crankshaft, that is, once every 15 ° of the crank angle.

  Next, the operation of the embodiment of the present invention having the above configuration will be described.

  When low-frequency engine shake vibration is generated while the vehicle is running, the first elastic body 19 is deformed by a load input from the engine via the diaphragm support boss 20 and the first elastic body support boss 18, and the first liquid When the volume of the chamber 30 changes, the liquid goes back and forth between the first liquid chamber 30 and the third liquid chamber 35 connected via the communication path 32. When the volume of the first liquid chamber 30 is enlarged / reduced, the volume of the third liquid chamber 35 is reduced / expanded accordingly, but the volume change of the third liquid chamber 35 is absorbed by the elastic deformation of the diaphragm 22. At this time, the shape and size of the communication path 32 and the spring constant of the first elastic body 19 are set so as to exhibit a low spring constant and a high damping force in the frequency region of the engine shake vibration. The vibration transmitted to can be effectively reduced.

  In the frequency region of the engine shake vibration, the actuator 41 is kept in an inoperative state.

  When vibration having a higher frequency than the engine shake vibration, that is, vibration during idling or vibration during cylinder deactivation caused by rotation of the crankshaft of the engine occurs, the first liquid chamber 30 and the third liquid chamber 35 are connected. Since the liquid in the communication path 32 is in a stick state and cannot exhibit the anti-vibration function, the actuator 41 is driven to exhibit the anti-vibration function.

  The electronic control unit U controls the energization to the bobbinless coil 46 based on the signal from the crank pulse sensor Sa in order to operate the actuator 41 of the active vibration isolating support device M to exhibit the vibration isolating function.

That is, in the flowchart of FIG. 7, first, in step S1, a crank pulse output from the crank pulse sensor Sa every 15 ° of crank angle is read, and in step S2, the read crank pulse is used as a reference crank pulse (specific cylinder). And the time interval of the crank pulse is calculated. In the next step S3, the crank angular velocity ω is calculated by dividing the crank angle of 15 ° by the time interval of the crank pulse, and in step S4, the crank angular velocity ω is time-differentiated to calculate the crank angular acceleration dω / dt. In the following step S5, the torque Tq around the engine crankshaft is set as I, and the moment of inertia around the engine crankshaft is set as I.
Tq = I × dω / dt
Calculate by This torque Tq is zero assuming that the crankshaft is rotating at a constant angular velocity ω, but in the expansion stroke, the angular velocity ω increases due to acceleration of the piston, and in the compression stroke, the angular velocity ω decreases due to deceleration of the piston. Since the crank angular acceleration dω / dt is generated, a torque Tq proportional to the crank angular acceleration dω / dt is generated.

  In the subsequent step S6, the maximum value and the minimum value of the temporally adjacent torque are determined, and in step S7, the active vibration isolation support device M that supports the engine as a deviation between the maximum value and the minimum value of the torque, that is, the amount of torque fluctuation. The amplitude at the position of is calculated. In step S8, the duty waveform and timing (phase) of the current applied to the bobbinless coil 46 of the actuator 41 are determined.

  Accordingly, when the engine moves downward with respect to the vehicle body frame and the first elastic body 19 is deformed downward to reduce the volume of the first liquid chamber 30, the bobbinless coil 46 of the actuator 41 is synchronized with the timing. , The movable core 54 moves downward toward the fixed core 42 by the suction force generated in the air gap g, and is pulled by the movable member 28 connected to the movable core 54 via the rod 55 to generate the second elasticity. The body 27 is deformed downward. As a result, since the volume of the second liquid chamber 31 increases, the liquid in the first liquid chamber 30 compressed by the load from the engine passes through the communication hole 29a of the partition wall member 29 and flows into the second liquid chamber 31. The load transmitted from the engine to the vehicle body frame can be reduced.

  Subsequently, when the engine moves upward with respect to the vehicle body frame and the first elastic body 19 is deformed upward and the volume of the first liquid chamber 30 increases, the bobbinless coil 46 of the actuator 41 is adjusted in accordance with the timing. When the demagnetization is performed, the attracting force generated in the air gap g disappears and the movable core 54 can move freely. Therefore, the second elastic body 27 deformed downward is restored upward by its own elastic restoring force. As a result, since the volume of the second liquid chamber 31 decreases, the liquid in the second liquid chamber 31 passes through the communication hole 29a of the partition wall member 29 and flows into the first liquid chamber 30, and the engine is in contact with the vehicle body frame. It can be allowed to move upward.

  In this way, by exciting and demagnetizing the bobbinless coil 46 of the actuator 41 according to the engine vibration cycle, an active damping force for preventing the engine vibration from being transmitted to the vehicle body frame is generated. Can do.

  Since the bobbinless coil 46 is formed by compressing the coil-shaped conductive wire 65 wound around the bobbin jig 64 in the radial direction and the axis L direction to the plastic region, and then the bobbin jig 64 is separated from the bobbinless coil 46. In addition, the bobbin and the tape with the adhesive layer can be eliminated to reduce the number of parts and the cost, and the unwinding of the conductor 65 can be prevented, and the inner diameter of the bobbinless coil 46 is reduced by the amount of the elimination of the bobbin, and the resistance and inductance are reduced. The current response can be improved by reducing the current.

  In addition, as shown in FIG. 5, the conductor 65 made of a round wire is compressed to a plastic region to eliminate the gap between the adjacent conductors 65, so that not only the space factor of the bobbinless coil 46 is improved, but also the mutual It is possible to further stabilize the coil shape by increasing the frictional force between the conductive wires 65 in contact with the coil.

  Although the embodiments of the present invention have been described above, various design changes can be made without departing from the scope of the present invention.

  For example, in the embodiment, the bobbinless coil 46 of the active vibration isolating support device M is illustrated, but the bobbinless coil 46 of the present invention can be applied to any other application.

  Moreover, although the conducting wire 65 wound in the coil shape is compressed in both the radial direction and the axis L direction in the embodiment, the compression in the axis L direction is not necessarily required. Further, when compressing the conductive wire 65 wound in a coil shape outward in the radial direction, the conductive wire 65 can be compressed more efficiently if the inner peripheral surface of a cylindrical fixed mold is brought into contact with the outer peripheral surface of the conductive wire 65. can do. Furthermore, the conducting wire 65 wound in a coil shape may be compressed radially inward, or may be compressed both radially inward and outward.

Longitudinal section of active vibration isolator 2 enlarged view of FIG. Explanatory drawing of manufacturing process of coil assembly Sectional view taken along line 4-4 in FIG. 3A and 5B enlarged view of FIG. Longitudinal section of the completed coil assembly Flow chart explaining operation

Explanation of symbols

46 Bobbinless coil 64 Bobbin jig 65 Conductor L Axis

Claims (5)

A first step of winding a conducting wire (65) in a coil shape around a cylindrical bobbin jig (64);
A second step of forming a bobbinless coil (46) by radially compressing the conductive wire (65) wound around the bobbin jig (64) to the plastic region;
A third step of separating the bobbin jig (64) from the bobbinless coil (46);
A bobbinless coil manufacturing method comprising:   The bobbin-less coil manufacturing method according to claim 1, wherein in the second step, the conducting wire (65) wound around the bobbin jig (64) is compressed in the direction of the axis (L).   The lead wire (65) before compression is a round wire having a circular cross section, and the lead wire (65) is plastically deformed until the gap between the adjacent lead wires (65) disappears in the second step. A method for manufacturing a bobbinless coil according to claim 1 or 2. In a bobbinless coil in which a conducting wire (65) is wound without using a bobbin,
The bobbinless coil, wherein the conducting wire (65) is compressed to a plastic region. The conductive wire (65) is a round wire having a circular cross section, and is plastically deformed into a polygonal cross section by compression after winding, and a gap between the adjacent conductive wires (65) disappears. Item 5. A bobbinless coil according to item 4.