JP2010144541A - Method for manufacturing engine intake control device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily and quickly join a first case half body and a second case half body which form a control case to each other without using a seal member or a plurality of fastening members. <P>SOLUTION: This method for manufacturing an engine intake control device performs: a step of molding the first case half body 25a with a first female lower mold 55 and a first male upper mold 56 and at that time forming a connection groove 47 along the periphery of the first case half body on the divided surface P2 of the first case half body 25a; a step of molding the second case half body 25b by a second female upper mold 57 and a second male lower mold 58 and at that time forming a connection groove 48 along the periphery of the second case half body on the divided surface P2 of the second case half body 25b; and a step of overlapping the divided surfaces P2 of the first and second case half bodies 25a, 25b with the first female lower mold 55 holding the first case half body 25a with an opening/closing control mechanism A set by closing a second female upper mold 57 holding the second half body 25b, and filling bonding resin 49 into the connection grooves 47, 48 to join the first and second case half bodies 25a, 25b to each other. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention includes a throttle body that has an intake passage and supports a valve shaft of a throttle valve that opens and closes the intake passage, a control case made of synthetic resin continuously provided on one side of the throttle body, and the control case And an opening / closing control mechanism for controlling the opening / closing of the throttle valve. The opening / closing control mechanism is an electric motor, a reduction gear mechanism for reducing the rotation of the electric motor and transmitting it to the valve shaft, and an opening of the throttle valve. The present invention relates to a method for manufacturing an engine intake control device, which includes a throttle sensor for detecting the degree, and is divided so that the control case can be joined to a first case half and a first case half at a predetermined dividing surface.

Such an intake control device is already known as disclosed in Patent Document 1 below.
JP 2008-232056 A

  In the conventional intake control device for such an engine, when the first case half and the second case half constituting the control case are joined, a seal member is interposed between the split surfaces of both case halves, Since both case halves were connected by a plurality of fastening members such as bolts, the number of parts and assembly man-hours were large, and this was an obstacle to cost reduction.

  The present invention has been made in view of such circumstances, and the first case half and the second case half constituting the control case are simply and quickly joined without using a seal member or a plurality of fastening members. It is an object of the present invention to provide a method of manufacturing an intake control device for an engine that can reduce costs.

  In order to achieve the above object, the present invention comprises a throttle body that has an intake passage and supports a valve shaft of a throttle valve that opens and closes the intake passage, and a synthetic resin continuously provided on one side of the throttle body. And an open / close control mechanism that is housed in the control case and controls the opening and closing of the throttle valve. The open / close control mechanism decelerates the rotation of the electric motor and the electric motor and transmits it to the valve shaft. An intake control device for an engine, comprising a reduction gear mechanism and a throttle sensor for detecting an opening of a throttle valve, wherein the control case is divided so as to be joined to the first case half and the first case half on a predetermined dividing surface The first case half is formed by a first female lower mold and a first male upper mold that can be opened and closed with each other, and at that time, the periphery of the first case half is formed on the dividing surface of the first case half. And a second step of opening the first female lower die and the first upper die while leaving the first case half in the first female lower die after the first step. And a third step of setting the open / close control mechanism on the first case half left in the first female lower mold, and a second female upper mold and a second male lower mold that can be opened and closed. A fourth step of forming a connecting groove along the peripheral edge of the dividing surface of the second case half, and the second case half after the fourth step. The fifth step of opening the second female upper die and the second male lower die while remaining in the upper die, and the second female lower die holding the first case half with the opening / closing control mechanism set therein, By closing the second female upper mold holding the case half, the split surfaces of the first and second case half are overlapped, and the connecting groove is filled with a binding resin. To perform a sixth step of joining the first and second case halves to each other to the first feature.

  The present invention also includes a throttle body that has an intake passage and supports a valve shaft of a throttle valve that opens and closes the intake passage, a control case made of a synthetic resin continuously provided on one side of the throttle body, And an opening / closing control mechanism housed in a control case for controlling opening / closing of the throttle valve. The opening / closing control mechanism includes an electric motor, a reduction gear mechanism for reducing the rotation of the electric motor and transmitting the rotation to the valve shaft, and a throttle valve. The throttle body and the control case are integrated with the first and second case halves on a dividing plane that includes or is parallel to the axis of the valve shaft. In manufacturing an intake control device for an engine, which is divided into a first divided block and a second divided block made of synthetic resin, the first can be opened and closed with each other. The first step of forming the first divided block by the lower die and the first upper die, and forming a connecting groove along the peripheral edge on the dividing surface of the first divided block, After the step, the first divided block is left in the first female lower die, the second step of opening the first female lower die and the first upper upper die, and the first divided block left in the first female lower die. The second divided block is formed by a third step of setting the opening / closing control mechanism, and a second female upper die and a second male lower die that can be opened and closed, and at that time, on the dividing surface of the second divided block, A fourth step of forming a connecting groove along the peripheral edge, and a fifth step after the fourth step, leaving the second divided block in the second female upper die and opening the second female upper die and the second male lower die. Holding the second divided block with respect to the first female lower mold holding the first divided block on which the opening and closing control mechanism is set. Closing the second female upper mold overlaps the divided surfaces of the first and second divided blocks, fills the connecting groove with a bonding resin, and joins the first and second divided blocks to each other. The second feature is to perform the six steps.

  The present invention further includes a throttle body that has an intake passage and supports a valve shaft of a throttle valve that opens and closes the intake passage, a control case made of a synthetic resin continuously provided on one side of the throttle body, And an opening / closing control mechanism housed in a control case for controlling opening / closing of the throttle valve. The opening / closing control mechanism includes an electric motor, a reduction gear mechanism for reducing the rotation of the electric motor and transmitting the rotation to the valve shaft, and a throttle valve. A throttle sensor for detecting the degree of opening of the control case, and the control case is divided so as to be connectable to the first case half and the first case half at a predetermined dividing surface, and the valve between the throttle body and the control case is provided. A first female lower mold and a first male upper mold that can be opened and closed with each other in manufacturing an intake control device for an engine divided so as to be joined by a second dividing surface orthogonal to the shaft A first step of forming the first case half, and forming a connecting groove along the peripheral edge on the dividing surface of the first case half, and the first case after the first step. A second step of opening the first female lower mold and the first male upper mold while leaving the half body in the first female lower mold; and the opening / closing control mechanism in the first case half remaining in the first female lower mold. Forming the second case half by a third step of setting the second upper and lower female molds and a second male lower mold that can be opened and closed. And a fifth step of opening the second female upper die and the second male lower die while leaving the second case half in the second female upper die after the fourth step. And by closing the second upper female mold holding the second case half against the first lower female mold holding the first case half set with the opening / closing control mechanism. And a sixth step of constructing the control case by superimposing the dividing surfaces of the second case halves, filling the connecting grooves with a bonding resin, and joining the first and second case halves together. And a seventh step of superimposing the throttle body on the control case on the second dividing surface and coupling the throttle body with a fastening member. In addition, the said fastening member respond | corresponds to the volt | bolt 53 in the Example of this invention mentioned later.

  Furthermore, in addition to any of the first to third features, the present invention provides the opening / closing control mechanism in at least one of the first and second case halves in the first step and / or the fourth step. A protrusion that can contact the outer peripheral surface of the component is formed, and in the sixth step, the second female upper mold is closed with respect to the first female lower mold, and the divided surfaces of the first and second case halves are overlapped. In this case, the projection is in contact with the component and elastically deformed.

  Furthermore, in addition to any one of the first to fourth features, the present invention provides a common upper mold formed by juxtaposing the first male upper mold and the second female upper mold, and the first female lower mold. The first step and the fourth step are simultaneously executed using the die and the common lower die formed by arranging the second male lower die in parallel, and the second step and the fifth step are simultaneously executed. This is the fifth feature.

  According to the first feature of the present invention, the first and second case halves are joined to each other by the bonding resin filled in the connecting groove by overlapping the dividing surfaces of the first and second case halves, For the joining, it is not necessary to use a sealing member or a fastening member such as a bolt, so that not only can the number of parts and the number of processes be reduced, the cost can be reduced, but also the first and second divided blocks. The seal between can be ensured.

  Moreover, there is no wasteful process of taking out the first and second case halves from the respective molds, the first female lower mold and the second female upper mold during the manufacture, and both case halves can be joined. In addition to being able to efficiently manufacture the intake control device, it is possible to prevent distortion of both case halves and contribute to improving the quality of the intake control device.

  According to the second feature of the present invention, the throttle body and the control case are integrally formed with the first and second case halves, respectively, on a dividing surface including or parallel to the axis of the valve shaft. The first divided block is divided into a first divided block and a second divided block made of a synthetic resin, respectively molded, and the first and second divided blocks are overlapped with the divided resin and filled in the connecting grooves to form the first. Since the second divided blocks are joined to each other, the number of parts and the number of assembling steps of the intake control device can be further reduced while achieving the same effect as the first feature.

  According to the third aspect of the present invention, the first and second case halves are joined to each other by the bonding resin filled in the connecting groove by overlapping the dividing surfaces of the first and second case halves, After obtaining the control case, the throttle body is coupled to the control case by the fastening member, so that the same effect as the first feature can be achieved, and the throttle body can be connected regardless of the control case made of synthetic resin. It can be configured with freely selected materials, and can meet the required characteristics of various engines.

  According to the fourth aspect of the present invention, the first or second case that contacts the outer peripheral surface of the component of the opening / closing control mechanism using the mold closing force between the first female lower mold and the second female upper mold. Since the protrusions of the half are elastically deformed, the deformation repulsive force of the protrusions can hold the component parts without play between the first and second case halves, thereby reducing the number of holding members for the component parts. be able to.

  According to the fifth feature of the present invention, the manufacturing time of the intake air control device can be shortened by simultaneously executing the first step and the fourth step, and the second step and the fifth step.

  Embodiments of the present invention will be described below on the basis of preferred embodiments of the present invention shown in the accompanying drawings.

  1 is a cross-sectional view of an intake control device for an engine manufactured by the manufacturing method according to the first embodiment of the present invention, FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1, and FIG. 3 is 3-3 of FIG. 4 is a sectional view taken along line 4-4 of FIG. 1, FIG. 5 is a sectional view taken along line 5-5 of FIG. 1, FIG. 6 is a schematic diagram of a default mechanism of a throttle valve in the intake device, and FIG. FIG. 8 is a perspective view of a first divided block in the intake control device, FIG. 9 is a perspective view of a second divided block in the intake control device, and FIG. 10 is a perspective view of the second divided block in the intake control device. FIG. 11 is an explanatory diagram of the manufacturing process of the intake control device, FIG. 11 is an explanatory diagram of the manufacturing process in the middle stage, FIG. 12 is an explanatory diagram of the manufacturing process in the latter stage, and FIG. 13 is a diagram illustrating the manufacturing method according to the first embodiment. FIG. 14 is a process explanatory diagram of a main part of the manufacturing method according to the second embodiment, and FIG. It is an exploded perspective view of the intake control device of an engine produced by the process.

  First, the configuration of the intake control device for an engine according to the first embodiment of the present invention will be described. 1 and 2, an engine intake control device D includes a cylindrical throttle body 1 connected to an intake system of an engine mounted on a vehicle such as a motorcycle or an automobile. The throttle body 1 has an intake passage 2 connected to the intake port of the engine on the inside, and a throttle valve 3 that opens and closes the intake passage 2 is attached to the throttle body 1. The throttle valve 3 has a valve shaft 3 a that is rotatably supported via bearing bushes 4 and ball bearings 5 on both left and right side walls of the throttle body 1 across the intake passage 2.

  A plug body 6 that covers the outer end of the left end portion of the valve shaft 3 a is fitted to the left side wall of the throttle body 1. The right end portion of the valve shaft 3 a protrudes outward from the right side wall of the throttle body 1, and an electric motor 8 for opening and closing the throttle valve 3 is connected to the protruding end portion via a reduction gear mechanism 9. The

  The reduction gear mechanism 9 includes a primary drive gear 11 fixed to the output shaft 10 of the electric motor 8, a primary driven gear 12 that is rotatably supported by the intermediate shaft 15 and meshes with the primary drive gear 11. A secondary drive gear 13 formed integrally with one side of the secondary driven gear 12, and a sector type secondary driven gear 14 fixed to the right end of the valve shaft 3a and meshing with the secondary drive gear 13. The rotation of the output shaft 10 of the electric motor 8 is decelerated in two steps and transmitted to the valve shaft 3a so that the throttle valve 3 can be opened and closed. Each gear of the reduction gear mechanism 9 is a spur gear, and the valve shaft 3a, the output shaft 10 and the intermediate shaft 15 are parallel to each other on a first plane P1 (see FIG. 2) whose axis is orthogonal to the axis of the intake passage 2. It is arranged to line up.

  The secondary driven gear 14 includes a mounting plate 14a that is molded on the inner peripheral side thereof, and this mounting plate 14a is fitted to a joint nut 39 that is screwed to the right end of the valve shaft 3a. Thus, the secondary driven gear 14 is fixed to the valve shaft 3a. The secondary driven gear 14 is connected to a closing spring 17 made of a torsion coil spring that urges the secondary driven gear 14 in the closing direction of the throttle valve 3. In the schematic view of FIG. 6, the closing spring 17 is displayed as a coil spring for easy understanding.

  1, 2, and 6, the secondary driven gear 14 is integrally formed with a stopper arm 18, and an idle stopper bolt 19 that receives the stopper arm 18 and restricts the idle opening of the throttle valve 3 is provided. The throttle body 1 is adjustably attached. A default lever 20 is rotatably supported on the valve shaft 3 a adjacent to the secondary driven gear 14. The secondary driven gear 14 is integrally formed with a contact arm 21 that contacts the default lever 20 and forcibly rotates the default lever 20 when the secondary driven gear 14 rotates to the closing side of the throttle valve 3. The lever 20 is connected to an opening spring 22 made of a coil spring that urges the lever 20 in the opening direction of the throttle valve 3 and is stronger than the closing spring 17. In FIG. 6, the opening spring 22 is displayed as a coil spring for easy understanding. When the default lever 20 is rotated in the opening direction of the throttle valve 3 by the biasing force of the opening spring 22, the default lever 20 drives the throttle valve 3 in the opening direction via the contact arm 21, that is, the secondary driven gear 14. At this time, a default stopper bolt 23 for receiving the default lever 20 and stopping the opening of the throttle valve 3 from the idle opening at a predetermined limp opening is attached to the throttle body 1 in an adjustable manner. Therefore, when the electric motor 8 is not energized during the operation of the engine, the default lever 20 is received by the default stopper bolt 23 by the biasing force of the opening spring 22 and the secondary driven by the biasing force of the closing spring 17. When the contact arm 21 of the gear 14 contacts the default lever 20, the throttle valve 3 is held at the default opening. This makes it possible to supply the engine with an intake air amount that enables the vehicle to travel at a low speed to the maintenance shop. The fixed ends of the closing spring 17 and the opening spring 22 surround the valve shaft 3a and are locked to a first case half 25a of a control case 25 described later. Thus, the default mechanism 24 is constituted by the default lever 20, the contact arm 21, the closing spring 17, the default lever 20, the opening spring 22 and the default stopper bolt 23. Further, the electric motor 8, the reduction gear mechanism 9 and the wiring board 35 described later constitute an opening / closing control mechanism A.

  In FIGS. 1 and 2 again, the throttle body 1 is provided with a control case 25 that houses the opening / closing control mechanism A, and the throttle body 1 and the control case 25 constitute a throttle body / case combination 34. . A throttle sensor 16 that detects the opening degree of the throttle valve 3 is provided between the control case 25 and the secondary driven gear 14. The throttle sensor 16 is supported by a synthetic resin cylindrical magnet holder 30 integrally coupled to the joint nut 39, a magnet 16a (rotor) embedded in the magnet holder 30, and a control case 25. The hall element 16b (stator) is embedded in the wiring board 35 made of synthetic resin and is opposed to the magnet 16a. The opening degree of the throttle valve 3 is taken out from the hall element 16b as an electric signal. It has become. The wiring board 35 includes a first wiring portion 35a that supports the Hall element 16b, a second wiring portion 35b that is disposed inside the first driven gear 12 so as to surround a half circumference of the first drive gear 11, and a first driven gear. The wiring assembly 35c integrally connects the first and second wiring portions 35a and 35b so as to straddle the gear 12, and the first wiring portion 35a is embedded with a conductive wire connected to the hall element 16b. The second wiring portion 35b is formed with a pair of connectors 37, 37 to which the pair of energization terminals 36, 36 of the electric motor 8 are connected, and a conductive wire connected therewith is embedded. A plurality of power supply terminals 38, 38... Connected to all the conductive wires are embedded and held. At that time, the power supply terminals 38,... Protrude from the end face of the dowel 40 having a rectangular cross section formed at one end portion of the wiring assembly portion 35c and are arranged in an orderly manner. The control case 25 has a support wall 41 to which the dowel 40 is fitted, and a square tubular coupler 42 that protrudes outward from the support wall 41 and accommodates the protruding end portions of the power supply terminals 38, 38. Are formed integrally with the control case 25.

  As shown in FIGS. 2, 3, and 7 to 9, the throttle body / case combination 34 is formed from the first plane P <b> 1 in which the axis lines of the valve shaft 3 a, the output shaft 10, and the intermediate shaft 15 are arranged. A second plane P2 (see FIG. 2) slightly offset in parallel to the downstream side of 2 is divided into two as a dividing plane P2. Hereinafter, one half of the upstream of the intake passage 2 divided into two is called a first divided block 34a, and the other half of the downstream of the intake passage 2 is called a second divided block 34b. One half is called the first case half 25a, and the other half of the control case 25 on the second divided block 34b side is called the second case half 25b.

  The throttle valve 3 and the opening / closing control mechanism A are set in the first divided block 34a.

  That is, the valve shaft 3a of the throttle valve 3 is engaged with the first recess 31a that opens on the dividing surface P2 of the first dividing block 34a, and the bearing bush 4 and the ball bearing 5 are opened on the dividing surface P2. 2 and third recesses 31b and 31c, respectively. A rectangular positioning flange 28 is formed at one end of the casing of the electric motor 8 on the output shaft 10 side, and the positioning flange 28 opens on the dividing surface P2 of the first and second case halves 25a and 25b, respectively. A plate that fits into the positioning grooves 29a and 29b and presses the electric motor 8 toward the positioning grooves 29a and 29b between the other end surface of the casing of the electric motor 8 and the inner wall of the first divided block 34a facing the casing. A spring 32 is interposed. As a result, the positioning flange 28 of the electric motor 8 is pressed and brought into contact with the inner wall of the positioning grooves 29a and 29b on the output shaft 10 side, thereby restraining the movement in the axial direction.

  Both end portions of the intermediate shaft 15 are engaged with a pair of concave portions 33, 33 that open on the dividing surface P2 of the first divided block 34a. Further, a plurality of mounting bosses 51, 51... (See FIG. 7) are formed on the wiring board 35. These mounting bosses 51, 51... Are fixed to the first case half 25a by screws 52 (see FIG. 4). Fixed in position.

  A plurality of rib-shaped protrusions 44a and 44b are formed on the surfaces of the first and second divided blocks 34a and 34b facing the outer peripheral surface of the electric motor 8, and the divided surface P2 of the first and second divided blocks 34a and 34b. When the two are overlapped, the electric motor 8 is elastically held between the divided blocks 34a and 34b by the elastic deformation of the projections 44a and 44b.

  Endless connecting grooves 47 and 48 are formed along the peripheral edges of the throttle body 1 and the control case 25 on the divided surface P2 of the first and second divided blocks 34a and 34b, and the divided surface P2 of both the divided blocks 34a and 34b. The divided blocks 34a and 34b are joined to each other by the joining resin 49 filled in the connecting grooves 47 and 48. Reference numerals 47 a and 48 a are gates for filling the connecting grooves 47 and 48 with the bonding resin 49.

  Next, a method for manufacturing the intake control device D will be described with reference to FIGS.

  First, the first divided block 34a made of synthetic resin is formed by the first female lower die 55 and the first upper upper die 56 that can be opened and closed in the first step (a) shown in FIG. An endless connecting groove 47 along the periphery of the throttle body 1 and the control case 25 is simultaneously formed on the dividing surface P2 of 34a.

  Next, in the second step (b), both molds 55 and 56 are opened so that the first divided block 34a remains in the first female lower mold 55. Next, the throttle valve 3 and the opening / closing control mechanism A are set in the first divided block 34a remaining in the first female lower die 55 in the third step (c) as described above.

  Next, the second divided block 34b made of synthetic resin is formed by the second female upper mold 57 and the second male lower mold 58 that can be opened and closed in the fourth step (d) shown in FIG. An endless connecting groove 48 along the periphery of the throttle body 1 and the control case 25 is simultaneously formed on the dividing surface P2 of the block 34b. After the molding, in a fifth step (e), both molds 57 and 58 are opened so that the second divided block 34b remains in the second female upper mold 57.

  Then, in the sixth step (f) shown in FIG. 12, the first and second divided blocks 34a are closed by closing the second female upper mold 57 to which the second divided blocks 34b are attached to the first female lower mold 55. , 34b are overlapped. As a result, the projections 44a and 44b of the first and second divided blocks 34a and 34b are appropriately crushed by the outer peripheral surface of the electric motor 8, and the repulsive force causes the electric motor 8 to be elastic between the divided blocks 34a and 34b. The valve shaft 3a and the intermediate shaft 15 are also held between the divided blocks 34a and 34b.

  In this state, the bonding resin 49 is injected from the nozzle N to the gates 47a and 48a to fill the connecting grooves 47 and 48 on the dividing surface P2 of the first and second divided blocks 34a and 34b. The bonding resin 49 has a higher melting point than the first and second divided blocks 34a and 34b. Therefore, when the connecting grooves 47 and 48 are filled, they are fused with the peripheral walls of the connecting grooves 47 and 48, By solidifying, the first and second divided blocks 34a and 34b can be joined to each other, and a good holding state of the electric motor 8 and the like by both the divided blocks 34a and 34b can be ensured.

  After the joining, in the seventh step (g), the first female lower mold 55 and the second female upper mold 57 are opened to each other, and the product, that is, the intake control device D is taken out.

  As described above, after the first divided block 34a is molded, the electric motor 8 or the like is incorporated in the first divided block 34a while the first divided block 34a is retained in the first female lower die 55. The first female lower mold 55 is closed by closing the second female upper mold 57 to which the second divided block 34b is adhered, and the first and second divided blocks 34a and 34b are brought into close contact with each other and joined to the connecting grooves 47 and 48. Since the resin 49 is filled, there is no wasteful process of taking out the first and second divided blocks 34a and 34b from the respective molds during the production, and the intake control device D can be efficiently produced. Not only that, the distortion of the first and second divided blocks 34a and 34b can be prevented and the quality of the intake control device D can be improved.

  In addition, since the first and second divided blocks 34a and 34b are joined at once by filling the connecting grooves 47 and 48 with the coupling resin 49, it is necessary to use a sealing member or a fastening member such as a bolt. Therefore, not only can the number of parts and the number of processes be reduced, the cost can be reduced, but also the seal between the first and second divided blocks 34a and 34b can be ensured.

  Further, by utilizing the mold closing force between the first female lower mold 55 and the second female upper mold 57, the protrusions 44a and 44b of the first and second divided blocks 34b that contact the outer peripheral surface of the electric motor 8 are compressed and deformed. Since the electric motor 8 is held without play between the first and second divided blocks 34a and 34b by the repulsive force, the number of holding members for the electric motor 8 can be reduced.

  Next, a second embodiment of the present invention shown in FIG. 13 will be described.

  The second embodiment includes a common upper mold 60 formed by juxtaposing the first male upper mold 56 and the second female upper mold 57 in the previous embodiment, the first female lower mold 55 and the second male lower mold. The first step (a) and the fourth step (d) in the previous embodiment are simultaneously performed using the common lower die 61 in which the mold 58 is arranged in parallel, and the second step in the previous embodiment is performed. Since (b) and the fifth step (e) are performed at the same time and the other configurations are the same as in the previous embodiment, the same reference numerals are given to the portions corresponding to those in the previous embodiment in FIG. Thus, duplicate explanations are omitted.

  According to the second embodiment, the manufacturing time is shortened by simultaneously executing the first step (a) and the fourth step (d), and the second step (b) and the fifth step (e). Can be achieved.

  Next, a third embodiment of the present invention shown in FIG. 14 will be described.

  In the third embodiment, the throttle body 1 and the control case 25 are divided so as to be joined by a second dividing surface P3 orthogonal to the axis A of the valve shaft 3a. The throttle body 1 is integrally formed by die casting using a material different from that of the control case 25, for example, a light metal. The control case 25 and the opening / closing control mechanism A accommodated therein have the same configuration as that of the first embodiment and are manufactured by the same method. Therefore, in FIG. 14, the parts corresponding to the first embodiment Are denoted by the same reference numerals, and redundant description is omitted.

  In the third embodiment, after manufacturing the control case 25 containing the opening / closing control mechanism A in the same manner as in the first embodiment, the throttle body 1 is superposed on the control case 25 on the second dividing surface P3. They are connected by bolts 53.

  According to the third embodiment, the throttle body 1 can be configured with freely selected materials regardless of the control case 25 made of synthetic resin, and can meet the required characteristics of various engines.

  The present invention is not limited to the above embodiment, and various design changes can be made without departing from the scope of the invention. For example, the first to seventh steps (a) to (g) can be executed by any of a rotary type and a slide type. Further, any one of the protrusions 44a and 44b that are compressed and deformed by contact with the outer peripheral surface of the electric motor 8 can be omitted. In addition, the positioning grooves 29a and 29b into which the positioning flange 28 is fitted may be provided only in one of the first and second case halves 25a and 25b.

1 is a cross-sectional view of an intake control device for an engine manufactured by a manufacturing method according to a first embodiment of the present invention. FIG. 2 is a sectional view taken along line 2-2 in FIG. 1. FIG. 3 is a sectional view taken along line 3-3 in FIG. 1. FIG. 4 is a sectional view taken along line 4-4 of FIG. FIG. 5 is a sectional view taken along line 5-5 in FIG. The schematic diagram of the default mechanism of the throttle valve in the same intake device. The perspective view of the electric motor and wiring board in the same intake control device. The perspective view of the 1st division | segmentation block in the same intake control apparatus. The perspective view of the 2nd division | segmentation block in the same intake control apparatus. BRIEF DESCRIPTION OF THE DRAWINGS FIG. The manufacturing middle process explanatory drawing. The manufacturing latter process explanatory drawing. Explanatory drawing of the principal part of the manufacturing method which concerns on 2nd Example of this invention. The disassembled perspective view of the intake control apparatus of the engine manufactured by the manufacturing method which concerns on 3rd Example of this invention.

Explanation of symbols

A ... Opening / closing control mechanism D ... Intake control devices (a) to (g) ... 1st to 7th steps 1 ... Throttle body 2 ... Intake passage 3 ... Throttle valve 3a ... Valve shaft 8 ... Electric motor 9 ... Reduction gear mechanism 16 ... Throttle sensor 25 ... Control case 25a ... First case half 25b ... Second case Half body 34 ··· Throttle body · Case assembly 34a ·· First divided block 34b ·· Second divided block 44a, 44b ··· Protrusions 47, 48 ··· Connecting groove 49 ··· Resin 53 ·· ..Fastening members (bolts)
55 ... first female lower mold 55 ... first male upper mold 56 ... second female upper mold 57 ... second male lower mold 60 ... common upper mold 61 ... common lower mold

Claims (5)

A throttle body (1) that has an intake passage (2) and supports a valve shaft (3a) of a throttle valve (3) that opens and closes the intake passage (2), and is connected to one side of the throttle body (1). A control case (25) made of synthetic resin, and an opening / closing control mechanism (A) housed in the control case (25) for controlling opening / closing of the throttle valve (3). ) Is an electric motor (8), a reduction gear mechanism (9) that decelerates the rotation of the electric motor (8) and transmits it to the valve shaft (3a), and a throttle sensor that detects the opening of the throttle valve (3) (16), and the control case (25) is divided so as to be joined to the first case half (25a) and the first case half (25a) at a predetermined dividing surface (P2). In manufacturing the equipment,
The first case half (25a) is formed by a first female lower mold (55) and a first male upper mold (56) that can be opened and closed with respect to each other. At this time, the division of the first case half (25a) is performed. A first step (a) for forming a connecting groove (47) along the periphery of the surface (P2), and after the first step (a), the first case half (25a) is formed into a first female lower mold. (55) leaving the first female lower mold (55) and the first male upper mold (56) in the second step (b), and the first case left in the first female lower mold (55) A third step (c) for setting the opening / closing control mechanism (A) on the half body (25a), and a second female upper mold (57) and a second male lower mold (58) that can be opened and closed, make the second case half. A fourth step of forming a body (25b) and forming a connecting groove (48) along the periphery of the split surface (P2) of the second case half (25b). d) and after the fourth step (d), the second case upper body (57) and the second male lower mold (58) are left leaving the second case half (25b) in the second female upper mold (57). A second case half (55) that holds the first case half (55a) holding the first case half (25a) in which the opening / closing control mechanism (A) is set. 25b) by closing the second female upper mold (57), the divided surfaces (P2) of the first and second case halves (25a, 25b) are overlapped, and the connecting grooves (47, 48) are overlapped. A sixth step (f) of filling the bonding resin (49) and bonding the first and second case halves (25a, 25b) to each other, and performing an intake control device for an engine Manufacturing method. A throttle body (1) that has an intake passage (2) and supports a valve shaft (3a) of a throttle valve (3) that opens and closes the intake passage (2), and is connected to one side of the throttle body (1). A control case (25) made of synthetic resin, and an opening / closing control mechanism (A) housed in the control case (25) for controlling opening / closing of the throttle valve (3). ) Is an electric motor (8), a reduction gear mechanism (9) that decelerates the rotation of the electric motor (8) and transmits it to the valve shaft (3a), and a throttle sensor that detects the opening of the throttle valve (3) (16), wherein the throttle body (1) and the control case (25) are divided surfaces (P2) including or parallel to the axis of the valve shaft (3a). Remove the case half (25a, 25b) Is divided into a first divided block made of synthetic resin having the, respectively integral (34a) and the second divided block (34b), when manufacturing the intake control device for an engine,
The first divided block (34a) is formed by a first female lower mold (55) and a first male upper mold (56) that can be opened and closed with respect to each other, and at that time, the divided surface of the first divided block (34a) ( In P2), a first step (a) for forming a connecting groove (47) along the periphery thereof, and after this first step (a), the first divided block (34a) is replaced with a first female lower die (55). A second step (b) for opening the first female lower mold (55) and the first male upper mold (56), and the first divided block (34a) left in the first female lower mold (55). ) To set the opening / closing control mechanism (A), and the second divided block (34b) by the second female upper mold (57) and the second male lower mold (58) that can be opened and closed. At the time of molding, a connecting groove (48) is formed along the periphery of the divided surface (P2) of the second divided block (34b). And after the fourth step (d), the second divided block (34b) is left on the second female upper die (57), and the second female upper die (57) and the second male lower The second step (e) for opening the mold (58), and the second division for the first female lower die (55) holding the first division block (34a) in which the opening / closing control mechanism (A) is set. By closing the second female upper mold (57) holding the block (34b), the divided surfaces (P2) of the first and second divided blocks (34a, 34b) are overlapped, and the connecting grooves (47, 48) And a sixth step (f) in which the first and second divided blocks (34a, 34b) are joined to each other by filling the resin for bonding (49) into the intake air control device for an engine Manufacturing method. A throttle body (1) that has an intake passage (2) and supports a valve shaft (3a) of a throttle valve (3) that opens and closes the intake passage (2), and is connected to one side of the throttle body (1). A control case (25) made of synthetic resin, and an opening / closing control mechanism (A) housed in the control case (25) for controlling opening / closing of the throttle valve (3). ) Is an electric motor (8), a reduction gear mechanism (9) that decelerates the rotation of the electric motor (8) and transmits it to the valve shaft (3a), and a throttle sensor that detects the opening of the throttle valve (3) (16), the control case (25) is divided into a first case half (25a) and a first case half (25a) at a predetermined dividing surface (P2) so as to be joinable, and the throttle body ( 1) and the control case (2) ) While is bondable divided by the second division plane perpendicular to the valve axis (3a) (P3), when manufacturing the intake control device for an engine,
The first case half (25a) is formed by a first female lower mold (55) and a first male upper mold (56) that can be opened and closed with respect to each other. At this time, the division of the first case half (25a) is performed. A first step (a) for forming a connecting groove (47) along the periphery of the surface (P2), and after the first step (a), the first case half (25a) is formed into a first female lower mold. (55) leaving the first female lower mold (55) and the first male upper mold (56) in the second step (b), and the first case left in the first female lower mold (55) A third step (c) for setting the opening / closing control mechanism (A) on the half body (25a), and a second female upper mold (57) and a second male lower mold (58) that can be opened and closed, make the second case half. A fourth step of forming a body (25b) and forming a connecting groove (48) along the periphery of the split surface (P2) of the second case half (25b). d) and after the fourth step (d), the second case upper body (57) and the second male lower mold (58) are left leaving the second case half (25b) in the second female upper mold (57). A second case half (55) that holds the first case half (55a) holding the first case half (25a) in which the opening / closing control mechanism (A) is set. 25b) by closing the second female upper mold (57), the divided surfaces (P2) of the first and second case halves (25a, 25b) are overlapped, and the connecting grooves (47, 48) are overlapped. A sixth step (f) of filling the bonding resin (49) and joining the first and second case halves (25a, 25b) to each other to form the control case (25), and its control The throttle body (1) is overlapped on the case (25) with the second dividing surface (P3), and the fastening member (53) And executes a seventh step of further coupling method for intake control device for an engine. In the manufacturing method of the engine intake control device according to any one of claims 1 to 3,
At least one of the first and second case halves (25a, 25b) in the first step (a) and / or the fourth step (d) has a component (8) of the opening / closing control mechanism (A). Protrusions (44a, 44b) that can come into contact with the outer peripheral surface are formed, and in the sixth step (f), the second female upper mold (57) is closed with respect to the first female lower mold (55), and the first and first When the split surfaces (P2) of the two case halves (25a, 25b) are overlapped, the protrusions (44a, 44b) abut against the component (8) and elastically deform, Manufacturing method of intake control device. In the manufacturing method of the engine intake control device according to any one of claims 1 to 4,
A common upper mold (60) formed by juxtaposing the first male upper mold (56) and the second female upper mold (57), the first female lower mold (55), and the second male lower mold ( 58) and a common lower mold (61) formed side by side, the first step (a) and the fourth step (d) are performed simultaneously, and the second step (b) and the second step (d) 5. A method for manufacturing an intake control device for an engine, wherein five steps (e) are performed simultaneously.

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