JP2008267966A - Magnet unit and accelerator pedal apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve low costs, heighten the degree of freedom of a magnet shape, improve resistance etc. to external magnetic forces when a magnet is jointed to an armature or a stator. <P>SOLUTION: In the case of joining the magnet 120 to the armature 110 in a magnetic unit including the magnet 120 to be fixed to the armature 110 and either a stator 130 or a stator 140, the armature 110 is made of a plurality of laminates 111 and 112 in a sheet shape formed in such a layered state as to define a recession part 110b. The magnet 120 is joined in such a way that its part may be embedded in the recession part 110b. Since the magnet 120 in a state held in the recession part of the plurality of laminates is thereby fixed, it is possible to reduce costs in comparison with the case of its fixation in a recession part formed in a one-piece body, heighten the degree of design freedom, and easily fix even a magnet having a complicated contour. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a magnet unit including a magnet that generates a magnetic force in a magnetic circuit and an accelerator pedal device using the magnet unit, and in particular, an armature (mover), a stator (stator), an armature or a magnet fixed to the stator. The present invention relates to an accelerator pedal device including a magnet unit including the magnetic position sensor including the magnet unit.

Conventionally, as a method of fixing a magnet for a sensor, a shaft for rotatably supporting a rotor core, a retaining ring inserted into the shaft, an annular magnet, a press fit into the inner periphery of the magnet, and an integral fit on the shaft There is known a unit that includes a combined collar, a ball bearing that abuts on an end surface of the collar, and the like, and a magnet is sandwiched and fixed between a retaining ring and the collar (for example, see Patent Document 1).
However, in this fixing method, since a part of the collar is press-fitted into the inner circumference of the magnet, there is a risk that the magnet will be damaged if the tightening allowance (fitting allowance) due to press-fitting is too large. It is difficult to form (mold) integrally, and can be applied to a magnet formed in advance as a sintered product. Therefore, it is difficult to make magnets, collars and the like correspond to complicated shapes, and it is necessary to manage the dimensions with high accuracy, resulting in an increase in cost as a whole and poor productivity.

As another fixing method, a magnetic rotation sensor including a core, a magnet, a yoke, a lead terminal, a bobbin, etc., in which a magnet, a coil, a terminal, etc. are integrally molded (molded) with a synthetic resin material (for example, a patent) (Refer to Document 2). Also equipped with a rotating shaft of the armature, a resin part fixed to the rotating shaft to support the commutator and defining an annular groove, a magnet for the sensor, etc., and the magnet is integrated with the annular groove of the resin part. What was shape | molded automatically is known (for example, refer patent document 3).
However, in these fixing methods, since the magnet is integrally molded with resin, a resin molding process is required in the manufacturing process, and when directly supporting with resin, positioning of the magnet is not easy, and further, resin There is a risk that the magnet may fall off due to deterioration over time.

Further, as another fixing method, a rotor yoke having a double cylindrical shape, a magnet for a sensor, a magnet for a field, a magnet cover, and the like are provided. 2. Description of the Related Art A field magnet is internally fitted on an inner peripheral surface, and a magnet cover is fitted to a rotor yoke so as to hold down both magnets (see, for example, Patent Document 4).
However, in this fixing method, since the magnet is press-fitted into the rotor yoke by external fitting and internal fitting, there is a possibility that the magnet may be damaged if the tightening allowance (fitting allowance) due to press-fitting is too large. It is difficult to integrally mold the magnet, and it can be applied to a magnet formed in advance as a sintered product. Therefore, it is difficult to make magnets, rotor yokes and the like correspond to complicated shapes, and it is necessary to manage the dimensions with high accuracy, resulting in high costs and poor productivity as a whole. In addition, a dedicated magnet cover is required, which complicates the assembly process and increases costs.

On the other hand, as an accelerator pedal device applied to an electronically controlled throttle system (drive-by-wire system) in an engine mounted on an automobile or the like, a pedal arm integrally having an accelerator pedal and supported swingably with respect to a housing A swing support shaft that swingably supports the pedal arm, a return spring that returns the pedal arm to the rest position, a position sensor that is disposed around the swing support shaft and detects the angular position of the pedal arm, and the like. A sensor that detects the amount of depression (angular position) of an accelerator pedal (pedal arm) by a sensor and controls engine output based on the detection signal is known (for example, see Patent Document 5).
This position sensor is formed by an arcuate armature that rotates integrally with the pedal arm, an arcuate magnet fixed to the armature, two stators fixed to the housing, and a hall element. Therefore, since the relative displacement between the armature and the magnet and the stator will affect the output signal, it can be positioned and assembled with high accuracy in order to control the accelerator opening with high accuracy. Required.
However, since this armature is formed as an integral part and the magnet is simply joined to the circular arc surface, it is not easy to position both of them, and it is affected by disturbance (magnetic force from other). It is necessary to take measures such as a shield plate to prevent it.

Japanese Patent Laid-Open No. 10-322976 Japanese Patent Application Laid-Open No. 06-102054 Japanese Patent Laid-Open No. 11-308812 JP 2002-199660 A JP 2004-155375 A

  The present invention has been made in view of the above circumstances, and its purpose is to simplify the structure, reduce weight, reduce costs, improve design flexibility, improve assembly workability, and produce. Can improve the performance, prevent the influence of disturbance magnetic force (improve external magnetic force resistance), improve the accuracy of the sensor, and can detect the angular position of the accelerator pedal (pedal arm) with high accuracy A magnet unit and an accelerator pedal device using the magnet unit are provided.

A magnet unit of the present invention is a magnet unit including a magnet fixed to one of an armature and a stator, and one of the armature and the stator is a thin plate formed so as to define a recess in a stacked state. The magnet includes a plurality of laminated plates, and the magnet is joined so that a part of the magnet is buried in the recess.
According to this configuration, in order to fix the magnet to the armature or the stator, a plurality of laminated plates are used, and a part of the magnet is buried (sandwiched) in a recess defined in a state where the laminated plates are laminated. Using different types of laminates, recesses can be easily formed, reducing costs, increasing design freedom, and creating complex contours compared to machining recesses into a single unit. (For example, a pre-molded sintered product or an integrally molded product) can be easily fixed.

In the magnet unit configured as described above, a configuration in which the plurality of laminated plates are formed of a magnetic material that forms a magnetic path can be employed.
According to this configuration, since the plurality of laminated plates form a magnetic path through which the magnetic flux emitted from the magnet passes, the laminated plate can be applied as a part of the magnetic circuit, and the desired leakage flux can be suppressed. The magnetic flux flow can be obtained.

In the magnet unit configured as described above, in the stacking direction, the plurality of stacked plates are a pair of outer plates formed so as to sandwich the magnet, and a concave notch that is stacked inside the pair of outer plates to define a recess. A configuration including a plurality of intermediate plates having portions can be employed.
According to this configuration, in the case of a sintered product in which the magnet is formed in advance, in a state where a plurality of intermediate plates are laminated on one outer plate, the magnet is fitted into the recesses defined by the respective concave notches, By laminating the other outer plate from the outside and sandwiching the magnet, the magnet can be fixed to the laminated plate, and when the magnet is integrally formed on the laminated plate, a pair of outer plates and a plurality of intermediate plates A plate can be laminated in advance, and a magnet can be formed integrally with the concave portion of the laminated plate. Further, the magnets having various shapes and sizes can be fixed by appropriately adjusting the thicknesses of the outer plate and the intermediate plate and by appropriately adjusting the number of intermediate plates.

In the magnet unit configured as described above, the plurality of intermediate plates have a positioning notch formed subsequent to the concave notch for positioning the magnet, and the magnet is fitted into the positioning notch. A configuration having protrusions can be employed.
According to this configuration, by inserting the magnetic projection into the positioning notch, it is possible to more reliably prevent the magnet from falling out of the concave portion, and the magnet can be highly accurate with respect to the predetermined position of the laminated plate. Can be positioned.

In the magnet unit having the above-described configuration, it is possible to adopt a configuration in which the pair of outer plates are formed in the same shape, and the plurality of intermediate plates are formed in the same shape.
According to this configuration, since the outer plate and the intermediate plate can be formed by punching a thin plate-like metal plate, productivity improvement, cost reduction, and the like can be achieved.

In the magnet unit having the above-described configuration, the plurality of laminated plates are formed in a substantially annular shape and are formed so as to define a recess on the inner peripheral surface thereof, and the magnet is an outer arc that is joined to the recess on the radially outer side. A circle having a predetermined thickness in the radial direction to define a surface, both side surfaces joined to the recesses in the stacking direction, both end surfaces joined to the recesses in the circumferential direction, and an inner arc surface exposed toward the radially inner side A configuration formed in an arc shape can be adopted.
According to this configuration, when the arc-shaped magnet is joined to the concave portions of the plurality of laminated plates, the outer arc surface of the magnet is joined to the bottom surface of the concave portion, and the both side surfaces of the magnet are sandwiched by the laminated plates laminated on the outside. Then, both end surfaces of the magnet are joined to the inner wall surface of the recess in the circumferential direction, and the magnet is reliably positioned and fixed at a predetermined position. In particular, it is possible to reliably prevent the magnet from falling off radially inward by forming both end surfaces of the magnet and the inner wall surfaces of the recesses joined thereto so as to form a predetermined central angle.
In addition, the magnetic force that affects the outside can be blocked by forming the magnet so that it is covered with a laminated plate, except for the inner arc surface of the magnet that faces other parts that form part of the magnetic circuit. The external magnetic resistance can be improved.

In the magnet unit configured as described above, a configuration in which the plurality of laminated plates are fixed to each other by concave and convex fitting can be employed.
According to this configuration, when a plurality of laminated plates are laminated and assembled, they are simply fitted to each other so that the assembling work is simple, which contributes to an improvement in productivity.

In the magnet unit having the above-described configuration, the magnet can adopt a configuration that is formed by a molding method in which a plurality of laminated plates are laminated and molded integrally with the laminated plate.
According to this configuration, by forming the magnet integrally with the concave portions of the plurality of laminated plates, the magnet can be accurately positioned and fixed at a predetermined position in a more closely contacted state. Even a magnet having a complicated shape can be easily formed.

The accelerator pedal device of the present invention includes a pedal arm having an accelerator pedal, a housing that supports the pedal arm so as to be swingable around a predetermined swing axis between a rest position and a maximum depression position, and the pedal arm in the rest position. An accelerator pedal device including a return spring that exerts a return biasing force and a magnetic position sensor that detects an angular position of the pedal arm, wherein the pedal arm has a cylindrical portion centering on a swing axis, and The housing has a fitting portion that allows the cylindrical portion to be slidably fitted around the swing axis, and a protruding portion that is arranged in a non-contact manner inside the cylindrical portion. An annular armature fitted and fixed to the magnet, a magnet joined to the armature, a stator fixed together with the protrusion to form a magnetic path, and a sensor element for detecting magnetic flux. The cha includes a plurality of thin laminated plates formed so as to define a concave portion on an inner peripheral surface thereof in a laminated state, and the magnet is bonded so that a part of the magnet is buried in the concave portion. It has a configuration.
According to this configuration, the cylindrical portion of the pedal arm is a fitting portion of the housing (for example, a convex fitting portion that fits to the inner peripheral surface of the cylindrical portion, a concave fitting portion that fits to the outer peripheral surface of the cylindrical portion). The ring armature is fixed to the cylindrical portion of the pedal arm, the stator and the sensor element are fixed to the protruding portion of the housing, and the cylindrical portion of the pedal arm is relatively relative to the protruding portion of the housing. By rotating, the angular position of the accelerator pedal (pedal arm) is detected.
Here, in order to fix the magnet to the armature, a plurality of laminated plates are used, and a part of the magnet is buried (sandwiched) in a recess defined in a state where a plurality of laminated plates are laminated. By using a plate, the recess can be easily formed. Compared to machining the recess into an integrated product, the cost is reduced, the degree of freedom of design is increased, and a magnet having a complicated contour (for example, pre-molded) Can be easily fixed.

In the accelerator pedal device having the above-described configuration, a configuration in which the plurality of laminated plates are formed of a magnetic material that forms a magnetic path can be employed.
According to this configuration, since the plurality of laminated plates form a magnetic path through which the magnetic flux emitted from the magnet passes, the laminated plate can be applied as a part of the magnetic circuit, and the desired leakage flux can be suppressed. The magnetic flux flow can be obtained.

In the accelerator pedal device having the above-described configuration, the plurality of laminated plates are, in the lamination direction, a pair of outer plates formed so as to sandwich the magnet, and a concave cut that is laminated inside the pair of outer plates to define a recess. A configuration including a plurality of intermediate plates having notches can be employed.
According to this configuration, in the case of a sintered product in which the magnet is formed in advance, in a state where a plurality of intermediate plates are laminated on one outer plate, the magnet is fitted into the recesses defined by the respective concave notches, By laminating the other outer plate from the outside and sandwiching the magnet, the magnet can be fixed to the laminated plate. Also, when the magnet is integrally formed, a pair of outer plates and a plurality of intermediate plates are preliminarily formed. The magnets can be formed integrally with the concave portions of the laminated plates. Further, the magnets having various shapes and sizes can be fixed by appropriately adjusting the thicknesses of the outer plate and the intermediate plate and by appropriately adjusting the number of intermediate plates.

In the accelerator pedal device having the above-described configuration, it is possible to adopt a configuration in which the pair of outer plates are formed in the same shape, and the plurality of intermediate plates are formed in the same shape.
According to this configuration, since the outer plate and the intermediate plate can be formed by punching a thin plate-like metal plate, productivity improvement, cost reduction, and the like can be achieved.

In the accelerator pedal device configured as described above, the magnet includes an outer circular arc surface joined to the recess in the radially outer side, both side surfaces joined to the recess in the stacking direction, both end surfaces joined to the recess in the circumferential direction, and a diameter. In order to define an inner arc surface that is exposed inward in the direction and faces the protruding portion in a non-contact manner, a configuration that is formed in an arc shape having a predetermined thickness in the radial direction can be employed.
According to this configuration, when the arc-shaped magnet is joined to the concave portions of the plurality of laminated plates, the outer arc surface of the magnet is joined to the bottom surface of the concave portion, and the both side surfaces of the magnet are sandwiched by the laminated plates laminated on the outside. Then, both end surfaces of the magnet are joined to the inner wall surface of the recess in the circumferential direction, and the magnet is reliably positioned and fixed at a predetermined position. In particular, it is possible to reliably prevent the magnet from falling off radially inward by forming both end surfaces of the magnet and the inner wall surfaces of the recesses joined thereto so as to form a predetermined central angle.
In addition, by blocking the magnetic force exerted from the outside by forming the magnet so that it is covered with a laminated plate except for the inner arc surface of the magnet facing the other parts that form part of the magnetic circuit. The external magnetic resistance can be improved. Therefore, even when an operator (car driver) operating the accelerator pedal wears a blood flow promoting magnet on the ankle or calf, the influence of the magnetic force can be suppressed or prevented. The sensor accuracy of the type position sensor can be improved.

In the accelerator pedal device having the above-described configuration, the plurality of intermediate plates have a positioning notch formed subsequent to the concave notch for positioning the magnet, and the magnet is fitted into the positioning notch. It is possible to adopt a configuration having protrusions.
According to this configuration, by inserting the magnetic projection into the positioning notch, it is possible to more reliably prevent the magnet from falling out of the concave portion, and the magnet can be highly accurate with respect to the predetermined position of the laminated plate. Positioning can be performed, and the sensor accuracy of the magnetic position sensor can be improved.

In the accelerator pedal device having the above-described configuration, it is possible to adopt a configuration in which the plurality of laminated plates are fixed to each other by concave-convex fitting.
According to this configuration, when a plurality of laminated plates are laminated and assembled, they are simply fitted to each other so that the assembling work is simple, which contributes to an improvement in productivity.

In the accelerator pedal device having the above-described configuration, the magnet can adopt a configuration formed by a molding method in which a plurality of laminated plates are laminated and molded integrally with the laminated plate.
According to this configuration, by forming the magnet integrally with the concave portions of the plurality of laminated plates, the magnet can be accurately positioned and fixed at a predetermined position in a more closely contacted state. Even a magnet having a complicated shape can be easily formed.

  According to the magnet unit configured as described above, it is possible to simplify the structure, reduce the weight, reduce the cost, improve the degree of design freedom, improve the assembly workability, improve the productivity, and prevent the influence of disturbance magnetic force (external resistance) Improvement of magnetic properties), improvement of sensor accuracy, etc. can be achieved. In addition, by applying such a magnet unit, it is possible to prevent the influence of disturbance magnetic force while achieving cost reduction, productivity improvement, design freedom improvement, etc., and the angular position of the accelerator pedal (pedal arm) It is possible to obtain an accelerator pedal device that can detect the above with high accuracy.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
1 to 8 show an embodiment of an accelerator pedal device provided with a magnet unit according to the present invention. FIG. 1 is a side view of the device, FIG. 2 is a side view showing the inside of the device, and FIG. Is a sectional view showing the inside of the apparatus, FIG. 4 is a plan view and a sectional view showing a magnetic position sensor including a magnet unit, FIG. 5 is a perspective view showing a magnet unit and a magnet, and FIG. 6 is a section showing a magnet unit and a magnet. FIG. 7 is a plan view showing a plurality of laminated plates included in the magnet unit, and FIG. 8 is a cross-sectional view showing a state before the plurality of laminated plates are laminated.

As shown in FIGS. 1 to 3, the accelerator pedal device includes a housing main body 10 and a housing cover 20 as a housing fixed to a vehicle body M such as an automobile, and an accelerator pedal 30a (housing main body 10 and housing cover). 20), a pedal arm 30 supported so as to be swingable about a predetermined swing axis L defined by 20), a return spring 40 for returning the pedal arm 30 to a rest position, and a stepping force (pedal load) to generate hysteresis. A hysteresis generating mechanism 50 including a first slider 51, a second slider 52, and a return spring 53, a magnetic position sensor 100 that detects the rotational angle position of the pedal arm 30, and the like are provided.
Here, the magnetic position sensor 100 includes an annular armature 110, a pair of magnets 120 joined to the armature 110, stators 130 and 140, a sensor element 150 that detects (changes in) magnetic flux, and the like.

  The housing body 10 is entirely formed of a resin material, and as shown in FIGS. 1 to 3, a convex fitting that is slidably fitted (internally fitted) to a cylindrical portion 31 of a pedal arm 30 described later. The joint portion 11, the thrust receiving portion 12 that supports the cylindrical portion 31 in the direction of the swing axis L, the concave portion 13 that accommodates the return spring 40, the concave portion 14 that accommodates the hysteresis generating mechanism 50, and the pause that stops the pedal arm 30 at the pause position. The stopper 15, the fully open stopper 16 that stops the pedal arm 30 at the fully open position (maximum depression position), the flange portion 17 for fixing to the vehicle body M and the like, the connecting portion 18 for connecting the housing cover 20, and the like are provided.

The housing cover 20 is entirely formed of a resin material, and as shown in FIGS. 1 to 3, a concave fitting portion that slidably fits (externally fits) a cylindrical portion 32 of a pedal arm 30 described later. 21, for connecting the thrust receiving portion 22 that supports the cylindrical portion 32 in the direction of the swing axis L, the protruding portion 23 that is formed coaxially inside the concave fitting portion 21, and the wiring of the magnetic position sensor 100 described later. Connector 24, a coupling portion 25 for coupling to the housing body 10, and the like.
As shown in FIG. 3, the protruding portion 23 is formed in a columnar shape centering on the swing axis L of the pedal arm 30, and a part of the magnetic position sensor 100 (the stators 130 and 140, and the sensor element) is formed therein. 150) is buried (fixed). And the protrusion part 23 is arrange | positioned by the non-contact in the inner side area | region of the cylindrical part 32 of the pedal arm 30 mentioned later.

The pedal arm 30 is entirely formed of a resin material, and as shown in FIGS. 1 to 3, the pedal arm 30 is formed in a cylindrical shape centered on the swing axis L in a state assembled to the housing (10, 20). Cylindrical portions 31, 32, an accelerator pedal 30 a formed at the lower end extending downward from the cylindrical portions 31, 32, an upper end extending upward from the cylindrical portions 31, 32, and abutting on the stop stopper 15 in a detachable manner. An upper end portion 36 that removably engages with the contact portion 35 and the first slider 51 of the hysteresis generating mechanism 50, a seat portion 37 that receives the end portion of the return spring 40, and a fully open stopper 16 of the housing body 10 that removably contacts. A contact portion 38 and an inner peripheral surface 39 for fitting and fixing the annular armature 110 are provided.
As shown in FIG. 3, the cylindrical portion 31 is formed to be slidably fitted (externally fitted) around the swing axis L with respect to the convex fitting portion 11 of the housing body 10.
As shown in FIG. 3, the cylindrical portion 32 is formed so as to be slidably fitted (internally fitted) around the swing axis L with respect to the concave fitting portion 21 of the housing cover 20.
The inner peripheral surface 39 is formed so that the armature 110 to which the magnet 120 is bonded is fitted (inserted) and fixed while being positioned at a predetermined angular position.

  As shown in FIG. 2, the return spring 40 is a compression type coil spring formed of spring steel or the like, and is arranged in a compressed state in the concave portion 13 of the housing body 10, and is attached to the seat portion 37 of the pedal arm 30. The parts are brought into contact with each other to generate a biasing force that returns the pedal arm 30 to the rest position.

As shown in FIG. 2, the hysteresis generating mechanism 50 is accommodated in the recess 14 of the housing 10, and is formed by a first slider 51, a second slider 52, and a return spring 53.
When the pedal arm 30 is depressed toward the maximum depressed position (fully opened position), the upper end 36 pushes the first slider 51 leftward in FIG. 2 against the urging force of the return spring 53, and the first slider The wedge action of the first slider 51 and the second slider 52 generates a frictional force that increases linearly as the urging force of the return spring 53 increases. On the other hand, the pedal arm 30 is moved according to the urging force of the return springs 40 and 53. When returning toward the rest position, the first slider 51 and the second slider 52 move rightward in FIG. 2 toward the original position by the biasing force of the return spring 53, and the biasing force of the return spring 53 decreases. Along with this, the frictional force due to the wedge action also weakens, and a frictional force that decreases linearly is generated. Here, since the frictional force during the return operation is smaller than the frictional force during the stepping operation, the entire pedaling force (pedal load) from the stepping operation to the returning operation can be set as a hysteresis load.

  The magnetic position sensor 100 is a non-contact magnetic sensor, and is joined to an annular armature 110 fixed to the inner peripheral surface 39 of the pedal arm 30 and a recess 110b of the armature 110 as shown in FIG. A pair of arc-shaped magnets 120, stators 130 and 140 embedded and fixed in the projecting portion 23 of the housing cover 20, two sensor elements 150 (such as Hall elements) disposed between the stators 130 and 140, etc. As other components formed, there are provided a terminal 160 embedded in the housing cover 20 and a circuit board 170 on which various electronic components are mounted.

As shown in FIGS. 4 to 8, the annular armature 110 is formed of a plurality of thin laminated plates made of a magnetic material, and has a cylindrical inner peripheral surface 110 a having a predetermined inner diameter (2R1). Two arc-shaped concave portions 110b having a central angle θ are defined at two opposing portions of the surface 110a.
That is, the armature 110 is laminated on the inner side of a pair of outer plates 111 and a pair of outer plates 111 formed so as to sandwich the magnet 120 in the stacking direction, thereby defining an inner peripheral surface 110a and a recess 110b. A pair of outer plates 111 and five intermediate plates 112 are laminated and fixed to each other by concavo-convex fitting.

As shown in FIGS. 5A, 6A, and 7A, the pair of outer plates 111 are formed in the same shape by punching a magnetic plate having a predetermined thickness D. , Respectively, are provided with a circular opening 111a, a convex 111c, a concave 111d and the like having a radius R1 defining the inner peripheral surface 110a.
As shown in FIGS. 5 (a), 6 (a), and 7 (b), the five intermediate plates 112 are formed in the same shape by punching a magnetic plate having a predetermined plate thickness D. A concave notch formed in an arcuate shape forming an inner arcuate portion 112a defining a radius of curvature R1 defining the inner peripheral surface 110a, a radius of curvature R2 defining a concave portion 110b in a stacked state, and a central angle θ. A portion 112b, a convex portion 112c, a concave portion 112d, and the like are provided.
Thus, since the pair of outer plates 111 have the same shape and the five intermediate plates 112 have the same shape, they can be easily formed by punching a thin metal plate. Thus, improvement in productivity, cost reduction, and the like can be achieved.

Here, as shown in FIG. 8, the pair of outer plates 111 and the five intermediate plates 112 are stacked and fixed so that the convex portions 111c and 112c and the concave portions 112d and 111d are fitted to each other. It has become.
The pair of outer plates 111 and the five intermediate plates 112 (armatures 110), when stacked, define two arc-shaped concave portions 110b on the inner peripheral surface 110a.
As described above, when a pair of outer plates 111 and five intermediate plates 112 are laminated to form a laminated plate, only the concave and convex portions are fitted to each other. Also contributes. The convex portions 111c and 112c and the concave portions 111d and 112d are not provided at the time when the outer plate 111 and the intermediate plate 112 are formed by punching, and are pressed so that the outer plate 111 and the intermediate plate 112 are laminated and the concave and convex portions are fitted. May be formed so that a convex portion and a concave portion are formed.

As described above, the armature 110 is formed by the five intermediate plates 112 having the pair of outer plates 111 and the concave notches 112b that define the concave portions 110b. In this case, with the five intermediate plates 112 stacked on one outer plate 111, the magnet 120 is fitted into the recess 110b defined by the five concave cutouts 112b, and the other outer plate 111 is stacked from the outside. By sandwiching the magnet 120, the magnet 120 can be fixed.
In addition, when the magnet 120 is formed by a molding method (injection molding, insert molding, or the like) that integrally molds the laminated plate, it is formed as a laminated plate in which a pair of outer plates 111 and five intermediate plates 112 are laminated and fixed in advance. And the magnet 120 can be shape | molded (molded) with respect to the recessed part 110b of this laminated board.

As shown in FIGS. 4 to 6, the magnet 120 has an inner radius of curvature r1 and an outer radius of curvature r2, and has a predetermined thickness (r2-r1) in the radial direction and a stacking direction (oscillating axis direction L). Are formed in a circular arc shape having a predetermined width W.
That is, the magnet 120 has an outer arc surface 121 having a radius of curvature R2 joined to the bottom surface of the recess 110b of the armature 110 (that is, the arc edge of the concave notch 112b of the intermediate plate 112) on the outer side in the radial direction, the stacking direction Both side surfaces 122 joined to both side surfaces of the recess 110b (that is, the inner wall surface of the pair of outer plates 111) in the swing axis direction L, and inner wall surfaces of the recess 110b in the circumferential direction (that is, the concave cut of the intermediate plate 112). Both end surfaces 123 joined to the straight edge of the notch portion 112b) and an inner circular arc surface 124 that is exposed toward the inner side in the radial direction and forms a radius of curvature R1 that faces the protruding portion 23 in a non-contact manner are defined.
Here, the width W of the magnet 120 is formed to be equal to the thickness (5D) of the five intermediate plates 112. Further, the radius of curvature r2 of the outer arc surface 121 of the magnet 120 is formed to be equal to the radius of curvature R2 of the concave notch 112b of the intermediate plate 112. On the other hand, the radius of curvature r1 of the inner inner peripheral surface 124 of the magnet 120 is formed to be smaller than the radius R1 of the inner peripheral surface 110a of the armature 110.

Therefore, when the magnet 120 is a sintered product formed in advance, the outer arc surface 121 is joined to the bottom surface of the recess 110b and the both side surfaces 122 are sandwiched between the pair of outer plates 111 when joining the recess 110b of the armature 110. The both end surfaces 123 are fixed so as to be joined to the inner wall surface of the recess 110b in the circumferential direction. On the other hand, when the magnet 120 is formed integrally with the armature 110, the pair of outer plates 111 and the five intermediate plates 112 are laminated and fixed by uneven fitting to form a laminated plate, and then the lamination is performed. The plate is placed in a predetermined mold and molded, and magnetized and heat-treated (heated) is performed.
According to this, the magnet 120 can be positioned and fixed with high accuracy in the recess 110b in a more closely contacted state, and even a magnet having a complicated shape can be easily formed.
Here, in particular, since both end surfaces 123 of the magnet 120 and the inner wall surface of the recess 110b are formed so as to form a predetermined center angle θ and toward the center of the radius of curvature, the sintered product in which the magnet 120 is formed in advance is provided. In any of the molded products, the magnet 120 can be reliably prevented from falling out from the concave portion 110b inward in the radial direction.

Further, since the magnet 120 is covered with the laminated plates (the outer plate 111 and the middle and 112) except for the inner circular arc surface 124, the size of the inner peripheral surface 110a (the inner diameter size of the circular opening 111a) is appropriately set. By selecting, it is possible to block the magnetic force exerted from the outside without adopting a dedicated magnetic shielding plate or the like, and the external magnetic resistance can be improved. Therefore, even when an operator (car driver) operating the accelerator pedal 30a wears a blood flow promoting magnet or the like on the ankle or calf, the influence of the magnetic force can be suppressed or prevented. The sensor accuracy of the magnetic position sensor 100 can be improved.
Further, by appropriately adjusting the thickness D of the outer plate 111 and the intermediate plate 112 and appropriately adjusting the number of the intermediate plates 112, the magnet 120 having various shapes and sizes can be attached to the armature 110. Can be fixed.

The armature 110 to which the magnet 120 is fixed is fitted into the inner peripheral surface 39 of the pedal arm 30 so that the magnet 120 is not in contact with the outer peripheral surface of the projecting portion 23 (that is, the stator 130) at a predetermined interval. It is formed to rotate.
The stators 130 and 140 are made of a magnetic material, and define a magnetic path through which a magnetic flux generated from the magnet 120 is actively passed.
The sensor element 150 is a Hall element or the like, and outputs a voltage signal corresponding to a change in the passing magnetic flux density.
Therefore, when the pedal arm 30, that is, the armature 110 and the magnet 120 rotate, the magnetic flux density passing between the stators 130 and 140 changes, and this change is detected by the sensor element 150 and output as a voltage signal. Thereby, the magnetic position sensor 100 detects the rotational angle position of the pedal arm 30.

  As described above, in order to fix the magnet 120 to the armature 110, a plurality of laminated plates (a pair of outer plates 111 and five intermediate plates 112) are used, and the concave portions are defined in a state where the laminated plates are laminated. Since part of the magnet 120 is buried (sandwiched) in 110b, the cost is reduced, the degree of freedom in design is increased, and the magnet has a complicated contour as compared with the case where the concave portion is processed into an integrated product (bulk product). Even so, it can be easily fixed.

Next, the operation of the accelerator pedal device will be briefly described. First, when the operator (driver) is in a rest position where the accelerator pedal 30a is not depressed, the contact portion 35 is urged by the urging force of the return springs 40 and 53. Is in contact with the stop stopper 15, and the pedal arm 30 is stopped at the position indicated by the solid line in FIG.
When the operator (driver) depresses the accelerator pedal 30a from this state, the pedal arm 30 rotates counterclockwise in FIG. 1 and FIG. 2 against the urging force of the return springs 40 and 53, and has hysteresis. While increasing the resistance load (push-back load) generated by the generating mechanism 50, the generating mechanism 50 rotates to the maximum depression position (fully opened position) indicated by the two-dotted line in FIG. Stops by contacting the stopper 16.

On the other hand, when the operator (driver) relaxes the pedaling force, the pedal arm 30 causes the return spring 40 to exert a resistance load (pedal load) smaller than the resistance load (pedal load) at the time of stepping on the operator (driver). , 53 is moved toward the rest position, and the contact portion 35 of the pedal arm 30 abuts against the stop stopper 15 of the housing body 10 and stops.
As described above, when the operator (driver) operates the accelerator pedal 30a to swing the pedal arm 30 between the rest position and the maximum depressed position, the pedal arm 30 is stable without rattling. The magnetic position sensor 100 can detect (output) the angular position of the pedal arm 30 with high reproducibility with high reproducibility. it can.
In particular, even when an operator (driver) wears a blood flow promoting magnet or the like on the ankle or calf, the magnet 120 is fixed so as to be covered with a laminated plate, and the magnetic flux from the outside is applied to the sensor element 150. Is prevented from flowing directly, the influence of the magnetic force can be suppressed or prevented, and the sensor accuracy of the magnetic position sensor can be improved.

9 to 11 show another embodiment of the magnet unit according to the present invention. In addition, about the structure same as the above-mentioned embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted.
In this embodiment, the armature 110 is formed by a laminated plate in which a pair of outer plates 111 and five intermediate plates 112 ′ are laminated.
As shown in FIGS. 10 and 11, the intermediate plate 112 ′ includes a positioning notch 112 b ′ formed in the vicinity of both ends in the circumferential direction following the concave notch 112 b.
The magnet 120 ′ includes an outer arc surface 121, both side surfaces 122, both end surfaces 123, an inner arc surface 124, and cylindrical protrusions 125 formed in the vicinity of both end surfaces 123.
The protrusion 125 is adapted to be fitted into the positioning notch 112 ′.

  Therefore, by fitting the projection 125 of the magnet 120 ′ into the positioning notch 112 ′, it is possible to more reliably prevent the magnet 120 ′ from dropping from the recess 110b, and the laminated plate (outer plate 111, intermediate plate). 112), the magnet 120 ′ can be positioned with high accuracy, and the sensor accuracy of the magnetic position sensor 100 can be improved.

In the above-described embodiment, the case where the magnets 120 and 120 ′ are fixed to the armature 110 has been described. However, the present invention is not limited to this, and the magnet is formed so as to include a plurality of laminated plates. It is also possible to fix to.
In the above embodiment, a pair of outer plates 111 and five intermediate plates 112 are shown as a plurality of laminated plates. However, the present invention is not limited to this, and the number of intermediate plates 112 depends on the width W of the magnet 120. May be adjusted as appropriate.

In the above embodiment, the armature 110 is formed in an annular shape, and the arc-shaped magnets 120 and 120 ′ are joined to the concave portion 110b defined on the inner peripheral surface thereof. However, the present invention is not limited to this. Instead, an arc-shaped magnet may be joined to the recess defined on the outer peripheral surface of the annular armature.
In the above-described embodiment, the case where two types of laminated plates (the outer plate 111 and the intermediate plate 112 or the outer plate 111 and the intermediate plate 112 ′) are employed as the plurality of laminated plates is shown, but the present invention is not limited to this. Instead, three types of laminated plates of the outer plate 111 and the intermediate plates 112 and 112 ′ may be adopted, or four or more types of laminated plates may be adopted.

In the above embodiment, the case where a metal plate formed of a magnetic material is applied as the laminated plate (a pair of outer plates 111 and a plurality of intermediate plates 112 and 112 ') is not limited to this. Alternatively, a plurality of thin laminated plates formed of other materials can be employed.
In the above embodiment, the case where the magnet unit is applied to the magnetic position sensor 100 of the accelerator pedal device has been described. However, the present invention is not limited to this, and an armature (mover), a stator (stator), As long as it includes a magnet, it can be applied to other electronic devices and machine products.

  As described above, the magnet unit of the present invention can simplify the structure, reduce the weight, reduce the cost, improve the degree of design freedom, improve the assembly workability, improve the productivity, and prevent the influence of disturbance magnetic force. (Improved external magnetic resistance) and sensor accuracy can be achieved, so that it can be applied as a magnetic position sensor of a sensor unit, for example, an accelerator pedal device, an armature (mover), a stator ( If it is a field including a stator) and a magnet as a constituent element, it is also useful for electronic equipment and other mechanical parts.

It is a side view which shows one Embodiment of the accelerator pedal apparatus provided with the magnet unit which concerns on this invention. It is a side view which shows the internal structure of an accelerator pedal apparatus. It is sectional drawing which shows the internal structure of an accelerator pedal apparatus. BRIEF DESCRIPTION OF THE DRAWINGS The magnetic position sensor containing the magnet unit which concerns on this invention is shown, (a) The top view, (b) is sectional drawing in E1-E1 in (a). (A) is a perspective view which shows the magnet unit which concerns on this invention, (b) is a perspective view which shows the magnet which makes a part of magnet unit. (A) is a top view which shows the state which omitted some laminated boards in the armature which makes a part of magnet unit, (b) is a top view which shows the magnet contained in a magnet unit. The laminated board which forms an armature is shown, (a) is a top view which shows an outer plate, (b) is a top view which shows an intermediate | middle board. It is sectional drawing which shows the state before laminating | stacking and fixing a pair of outer plate and a some intermediate | middle board which form an armature. FIG. 5 shows another embodiment of the magnet unit according to the present invention, in which (a) is a perspective view showing the magnet unit, and (b) is a perspective view showing a magnet forming a part of the magnet unit. 9A is a plan view showing a state in which some laminated plates are omitted from the armature that forms part of the magnet unit shown in FIG. 9, and FIG. 9B is a plan view showing magnets included in the magnet unit shown in FIG. is there. FIG. 10 shows a laminated plate forming the armature of the magnet unit shown in FIG. 9, wherein (a) is a plan view showing an outer plate, and (b) is a plan view showing an intermediate plate.

Explanation of symbols

L Swing axis 10 Housing body (housing)
11 Convex fitting part 12 Thrust receiving part 15 Pause stopper 16 Fully open stopper 20 Housing cover (housing)
21 concave fitting portion 23 projecting portion 30 pedal arm 30a accelerator pedal 31, 32 cylindrical portion 35 abutting portion 36 upper end portion 37 seat portion 38 abutting portion 39 inner peripheral surface 40 return spring 50 hysteresis generating mechanism 51 first slider 52 first 2 Slider 53 Return spring 100 Magnetic position sensor 110 Armature 110a Inner peripheral surface 110b Recess 111 Pair of outer plates 111a Circular opening 111c Protrusion 111d Recess 112 Intermediate plate 112a Inner circular arc 112b Recessed notch 112b 'Positioning notch Portion 112c Protrusion 112d Recess 120, 120 'Magnet 121 Outer arc surface 122 Both side surfaces 123 Both end surfaces 124 Inner arc surface 125 Protrusion 130, 140 Stator 150 Sensor element 160 Terminal 170 Circuit board

Claims (16)

A magnet unit including a magnet fixed to one of the armature and the stator,
One of the armature and the stator includes a plurality of laminated plates having a thin plate shape formed so as to define the concave portions in a laminated state,
The magnet is joined so that a part thereof is buried in the recess.
A magnet unit characterized by that. The plurality of laminated plates are formed of a magnetic material that forms a magnetic path.
The magnet unit according to claim 1. The plurality of laminated plates include a plurality of outer plates formed so as to sandwich the magnet in the stacking direction, and a plurality of concave notches that are laminated inside the pair of outer plates to define the recesses. Including intermediate plate,
The magnet unit according to claim 1 or 2, characterized in that. The plurality of intermediate plates have positioning cutout portions formed subsequent to the concave cutout portions in order to position the magnet.
The magnet has a protrusion that is fitted into the positioning notch.
The magnet unit according to claim 1, wherein the magnet unit is a magnetic unit. The pair of outer plates are formed in the same shape,
The plurality of intermediate plates are formed in the same shape,
The magnet unit according to claim 3 or 4, characterized by the above. The plurality of laminated plates are formed to have a substantially annular shape and to define the recesses on the inner peripheral surface thereof,
The magnet has an outer circular arc surface joined to the concave portion on the outer side in the radial direction, both side surfaces joined to the concave portion in the stacking direction, both end surfaces joined to the concave portion in the circumferential direction, and the inner side in the radial direction. In order to define the exposed inner arc surface, it is formed in an arc shape having a predetermined thickness in the radial direction.
The magnet unit according to claim 1, wherein the magnet unit is a magnetic unit. The plurality of laminated plates are fixed to each other by uneven fitting,
The magnet unit according to claim 1, wherein the magnet unit is a magnetic unit. The magnet is formed by a molding method in which the plurality of laminated plates are laminated integrally with the laminated plate.
The magnet unit according to claim 1, wherein the magnet unit is a magnetic unit. A pedal arm having an accelerator pedal; a housing that supports the pedal arm so as to be swingable about a predetermined swing axis between a rest position and a maximum depression position; and a return spring that exerts a biasing force to return the pedal arm to the rest position. And an accelerator pedal device comprising a magnetic position sensor for detecting the angular position of the pedal arm,
The pedal arm has a cylindrical portion centered on the swing axis,
The housing has a fitting portion that slidably fits the cylindrical portion around the swing axis, and a protruding portion that is disposed in a non-contact manner inside the cylindrical portion,
The magnetic position sensor includes an annular armature fitted and fixed to the cylindrical portion, a magnet joined to the armature, a stator and a magnetic flux that are fixed together to form the magnetic path. Including a sensor element to detect,
The armature includes a plurality of laminated plates having a thin plate shape formed so as to define a concave portion on an inner peripheral surface thereof in a laminated state,
The magnet is joined so that a part thereof is buried in the recess.
An accelerator pedal device characterized by that. The plurality of laminated plates are formed of a magnetic material that forms a magnetic path.
The accelerator pedal device according to claim 9. The plurality of laminated plates include a plurality of outer plates formed so as to sandwich the magnet in the stacking direction, and a plurality of concave notches that are laminated inside the pair of outer plates to define the recesses. Including intermediate plate,
The accelerator pedal device according to claim 9 or 10, characterized in that The pair of outer plates are formed in the same shape,
The plurality of intermediate plates are formed in the same shape,
The accelerator pedal device according to claim 11. The magnet has an outer circular arc surface joined to the concave portion on the outer side in the radial direction, both side surfaces joined to the concave portion in the stacking direction, both end surfaces joined to the concave portion in the circumferential direction, and the inner side in the radial direction. In order to define an inner circular arc surface that is exposed and is not in contact with the protruding portion, it is formed in an arc shape having a predetermined thickness in the radial direction.
The accelerator pedal device according to any one of claims 9 to 12, characterized in that: The plurality of intermediate plates have positioning cutout portions formed subsequent to the concave cutout portions in order to position the magnet.
The magnet has a protrusion that is fitted into the positioning notch.
The accelerator pedal device according to claim 9, wherein the accelerator pedal device is provided. The plurality of laminated plates are fixed to each other by uneven fitting,
The accelerator pedal device according to claim 9, wherein the accelerator pedal device is provided. The magnet is formed by a molding method in which the plurality of laminated plates are laminated integrally with the laminated plate.
The accelerator pedal device according to any one of claims 9 to 15, wherein the accelerator pedal device is provided.

Images