JP3429874B2 - Electromagnetic coil and method of manufacturing electromagnetic coil - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic coil and a method for manufacturing the electromagnetic coil, and more particularly to an electromagnetic coil used in an environment such as an automobile where the heat change is large and vibration is applied, and the manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, a coil wire wound around a bobbin of an electromagnetic coil is connected to an electromagnetic coil terminal at the start end and the end thereof by soldering or welding. This soldering will be described with reference to FIG. This work is performed by previously winding the coil electric wire 150 around the connection terminal 120, first applying flux to this, and then applying solder 180.

Next, the connection of the coil electric wire by welding is shown in FIG.
This will be described with reference to (B) and (C). First, the coil electric wire 150 is positioned in the U-shaped connection terminal 122, and a force is applied in the F-F direction in the figure to deform the connection terminal 122, thereby deforming the coil electric wire 150.
Then, the coil electric wire 150 and the connection terminal 122 were connected by spot welding at point GG in FIG. 7C.

[0004]

However, in the connection using the solder, when the hot solder is placed on the cold connection terminal 120, the solder scatters and fine solder balls scatter around, and this solder is generated during the operation of the electromagnetic coil. In some cases, the contact part of the ball bites into the ball, resulting in defective operation, or when the ball adheres to the insulating part and causes a short circuit in the circuit. Similarly, when soldering, the flux made of an insulating material volatilizes, but this may adhere to the conductive portion and cause conduction failure. For this reason, when the connection is made with solder, it is indispensable to perform cleaning to remove the solder and the flux, which causes a rise in manufacturing cost.

On the other hand, when the connection is made by welding,
Although cleaning is unnecessary, there is a problem that the coil electric wire is easily cut. This will be described with reference to FIGS. 7 (D) and (E). 7D is a view taken in the direction of arrow H in FIG. 7C, and FIG. 7E is an enlarged view of the part viewed from the I side in FIG. 7D. As shown in FIG. 7 (E), when the coil electric wire 150 is sandwiched between the connection terminals 122, the cross section changes abruptly at the end 150a of the coil electric wire. For this reason, when the electromagnetic coil is used in a place where there is a lot of vibration such as an automobile, or in a place where heat change is large and tension is applied due to thermal contraction, the coil wire 1 at the end 150a is used.
50 was easy to cut.

When connecting by this welding,
As shown in FIG. 7B and described above, the coil electric wire 150 is positioned in the U-shaped connection terminal 122 and then sandwiched between the connection terminals 122, but this positioning is difficult. It was That is, after the bobbin around which the coil electric wire is wound is attached to the base of the electromagnetic coil, the unfixed coil electric wire starting end and end are chucked with a brush or the like, and this is positioned in the connection terminal 122. Workability was low.

Further, in order to prevent the coil electric wire from being cut due to the tension applied thereto, the present inventor prevents the stress concentration on the welded portion by providing the unwelded portion Z wound around the pin 60, and further the connection terminal. We devised to make the coil electric wire connected to slack. However, in the case of soldering, the method of providing the unwelded portion Z wound around the pin 60 is difficult because the solder and the flux rise to the Z portion.

The present invention has been made in order to solve the above-mentioned problems, and its object is to make a wire break even when used in a place where the manufacturing cost is low and the temperature change is large and the vibration is large. An object of the present invention is to provide an electromagnetic coil and a method of manufacturing the electromagnetic coil, in which

[0009]

In order to achieve the above object, the bobbin 3 has flange portions 30a and 30b at both ends.
0, the coil electric wire 50, the pin 60 having the cylindrical portion 60b, and the clamp member 20a connected to the electromagnetic coil terminal 20A, the electromagnetic coil of the present invention winds the coil electric wire 50 around the bobbin 30, The pin 60 is erected on the flange portion 30a of the bobbin 30, and the starting end 50a or the end 50b of the coil electric wire 50 is wound around the cylindrical portion 60b of the erected pin 60, and the coil electric wire 50 is wound. The coil wire 50 by clamping the pin 60 to the clamp member 20a and performing welding.
And the electromagnetic coil terminal 20A connected to the clamp member 20a are connected. Further, in a preferred embodiment of the present invention, an unwelded portion of the coil electric wire 50 wound around the pin 60 is provided, and a portion wound around the pin 60 and a portion wound around the bobbin 30. The coil electric wires 50c and 50d passed between and are loosened.

In order to achieve the above object, in the method for manufacturing an electromagnetic coil of the present invention, the flange portions 30a, 30 are provided at both ends.
b, the step of winding the coil electric wire 50 around the bobbin 30 in which the hole portion 30c is formed at a predetermined position of the flange portion 30a, and the cylindrical portion 60b is formed in the hole portion 30c of the flange portion 30a of the bobbin 30. A step of erecting the pin 60 having the step, a step of winding the starting end 50a and the terminal end 50b of the coil electric wire 50 around the cylindrical portion 60b of the erecting pin 60 so as to provide an unwelded portion Z, and the bobbin 30.
Is attached to the base 70 of the electromagnetic coil to position the pin 60 at a position where the clamp member 20a attached to the base 70 at a predetermined position can clamp the pin 60, and the pin 60 is connected to the electromagnetic coil terminal 20A. The step of clamping with the clamp member 20a is performed, and the coil 60 and the electromagnetic coil terminal 20A connected to the clamp member 20a are welded between the pin 60 around which the coil electric wire 50 is wound and the clamp member 20a. And a step of connecting and. Further, in a preferred aspect of the present invention, in the step of standing the pin 60 in the hole 30c of the flange portion 30a of the bobbin 30, the pin 60 is set up so as to be further insertable into the hole 30c, Standing pin 6
After the step of winding the starting end 50a and the terminating end 50b of the coil electric wire 50 around 0, the pin 60 is attached to the hole portion 30.
By inserting further into c, the coil electric wires 50c and 50d provided between the portion wound around the pin 60 and the portion wound around the bobbin 30 are loosened. It is characterized by having steps.

[0011]

In the electromagnetic coil constructed as described above, the starting end 50a or the terminating end 50b of the coil electric wire 50 is wound around the cylindrical portion 60b of the pin 60, and the pin 60 is clamped by the clamping member 2
It is clamped at 0a and then welded. When the pin 60 is clamped by the clamp member 20a, the coil electric wire 50 is crushed. However, since the coil electric wire 50 is crushed along the cylindrical portion 60b of the pin 60, the cross section of the coil electric wire 50 changes gently at this portion. become. Therefore, even if vibration and heat contraction are applied to the crushed portion of the coil electric wire 50, the coil electric wire 50 is not easily broken. Further, in the preferred embodiment of the present invention, the coil electric wire 50 wound around the pin 60 is used.
The unwelded portion Z is further provided, and since the coil electric wires 50c and 50d passed between the portion wound around the pin 60 and the portion wound around the bobbin 30 are loosened, The crushed portion of the coil wire 50 is no longer subjected to tension due to vibration and heat contraction,
The disconnection of can be eliminated.

In the conventional method for manufacturing an electromagnetic coil, the starting end 50a and the terminating end 50b of the coil wire 50 are clamped by the clamp member 2.
0a is clamped, then clamped, and then welding is performed. Therefore, the starting end 50a and the terminating end 50b of the coil wire 50 are
It was difficult to lock the clamp member 20a to the clamp member 20a (positioning work). On the other hand, in the method of manufacturing the electromagnetic coil configured as described above, the starting end 50a and the terminating end 50b of the coil electric wire 50 are wound around the pin 60 that is erected in the hole 30c provided at the predetermined position of the bobbin 30. Turn, bobbin 30
Is attached to the base 70 to attach the pin 60 to the base 70 at a predetermined position.
It can be positioned at a clampable position of 0a. That is, since the starting end 50a and the terminating end 50b of the coil wire 50 can be positioned without being locked, workability is improved. Also,
In the preferred embodiment of the present invention, the hole 30c of the bobbin 30.
The pin 60 is erected so that it can be inserted further. Then, the start end 50a of the coil electric wire 50 is attached to the upright pin 60.
After winding the end 50b and the end 50b, the pin 60 is inserted into the hole 30c.
By further inserting the coil electric wires 50c and 50d between the portion wound around the pin 60 and the portion wound around the bobbin 30, it is easy to give slack. You can do it. Also, the coil wire 50 is attached to the pin 60.
It is made easy to secure the unwelded part Z by fixing.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. 1 shows an electromagnetic coil for an automobile according to an embodiment of the present invention, FIG. 1 (A) shows a side surface, and FIG. 1 (B) shows a bottom surface. On the base 70, the D terminal 20D to which the contact 58 of the electromagnetic coil is attached, the C terminal 20C connected to the yoke 40, the A terminal 20A connected to the start end (coil electric wire) 50a of the coil 52, and the end side. B terminal 20B connected to the coil electric wire (not shown) of FIG. The bobbin 30 mounted and fixed on the base 70 is formed with a pair of flange portions 30a and 30b, and a coil 52 formed by winding a coil electric wire between the flange portions 30a and 30b. It is arranged.
A pair of pins (only one of which is shown in the figure) 60 is erected downwardly below the one flange portion 30a, and a start end (coil electric wire) 50 of the coil 52 is provided on the pin 60.
a is wound. The pin 60 is connected to the A terminal 20.
It is welded to the connection terminal 20a of A. As a result, the starting end (coil electric wire) 50a of the coil 52 and the A terminal 2
Connection with 0A is being made. Similarly, the coil 52
The coil electric wire (not shown), which is the end of the cable, is connected to the B terminal 20B.

Above the bobbin 30, a substantially L-shaped yoke 40 is attached, and a core 80 fixed by caulking is attached to the yoke 40 inserted into the through hole 30e of the bobbin. , On the top of the yoke 40,
One end of the doglegged spring plate 42 is fixed, and the coil 5 is attached to the other end of the spring plate 42.
A swing plate 46 that is swung by the excitation of 2 is fixed, and a contact 48 that abuts the contact 58 is attached to the lower end.

The electromagnetic coil having the above-mentioned structure is provided with the A terminal 20.
By energizing between the A and B terminals 20B, the coil 52 is excited and the swing plate 46 is attracted to the core 80 in opposition to the repulsive force of the spring plate 42,
The contact 48 attached to the lower end of the spring plate 42 is
It contacts the contact 58 on the D terminal 20D side. This gives C
The terminal 20C and the D terminal 20D are switched to be conductive. On the other hand, when the energization between the A terminal 20A and the B terminal 20B is released, the excitation of the coil 52 is stopped,
The contact 48 is D terminal 20D due to the repulsive force of the spring plate 42.
It is separated from the side contact 58. As a result, the C terminal 20C
The connection between the D terminal and the D terminal 20D is disconnected.

Next, a method of manufacturing the electromagnetic coil shown in FIG. 1 will be described with reference to FIGS. 2A shows the side surface of the bobbin 30, FIG. 2B shows the front surface of the bobbin 30, and FIG. 2C shows the side surface of the pin 60. A through hole 30 for inserting the core 80 is provided in the center of the bobbin 30.
e is drilled. And one flange portion 30a
Holes 30c, 30c for inserting the pair of pins 60, 60 are provided at the lower end of the. Further, lower end key-shaped lock portions 30d for attaching the bobbin 30 to the base 70 are formed on both sides of the other flange portion 30b. FIG. 2C is an enlarged view of the pin 60 shown in FIG. The pin 60 includes a prismatic portion 60a having an upper cross section formed in a square shape and a cylindrical portion 60b having a lower cross section formed in a circular shape. Here, the attachment of the pin 60 to the holes 30c, 30c of the bobbin 30 is performed by the pin 6
This is performed by temporarily press-fitting the prismatic portion 60a on the upper side of 0 at a predetermined pressure, and as shown in FIG.

Next, FIG. 3A showing the front of the bobbin 30.
As described above, the coil wire 50 is wound around the bobbin 30 to form the coil 52. The start end (coil electric wire) 50a of the coil is wound around the pin 60 to be engaged, and the end end (coil electric wire) 50b of the coil is wound around the pin 60 to be engaged. The coil electric wire 50d passed between the starting end 50a of the coil wound around the pin 60 and the coil 52 is in a state in which tension is applied when the starting end 50a is wound around the pin 60. Similarly, pin 6
The coil electric wire 50c passed between the end 50b wound around 0 and the coil 52 is also in a tensioned state.

Then, as shown in FIG.
Is further press-fitted to the deep end of the hole 30c (main press-fitting). As a result, the coil electric wire 50d passed between the start end 50a and the coil 52 and the coil electric wire 50c passed between the end end 50b and the coil 52 are loosened.

Thereafter, the oscillating plate 46 described above with reference to FIG.
A spring plate 42 to which a contact 48 and a contact 48 are attached is joined to the top of the yoke 40, and the yoke 40 is attached to the bobbin 3.
Assemble on top of 0.

On the other hand, the A terminal 20A, the B terminal 20B, the C terminal 20C, and the D terminal 20D are attached to the base 70 in parallel with the assembling of the yoke 40 and the like on the bobbin 30. FIG. 4A is a plan view of the A terminal 20A, and
FIG. 4B is a side view. The A terminal 20A is formed by bending a flat plate into a clamp shape, and includes a vertical leg portion 20d serving as a terminal of an electromagnetic coil, a horizontal portion 20c formed horizontally, and a vertical portion 20b formed vertically. Become. A coil electric wire 50 is provided at the right end of the vertical portion 20b.
A connecting terminal 20a bent into a U shape for clamping is formed, and a holding portion 20e for holding a coil electric wire of a resistor 72 described later is formed at the lower end of the vertical portion 20b.

FIG. 5 shows a plan view of the base 70.
This figure shows that the A terminal 20A, the B terminal 20B, the
The state where the C terminal 20C, the D terminal 20D and the resistor 72 are attached is shown. On the right side of the base 70 in the drawing, the bobbin 30, the yoke 40, the core 80, and the C terminal 20C.
Is formed with a fitting portion 70a for fitting therein a fixed one, and key-like lock portions 30d formed on the sides of the flange portion 30b of the bobbin 30 on both side surfaces thereof.
Lock hole 70b for locking (see FIG. 2 (B))
Has been drilled. The yoke 4 described above is attached to the base 70.
0, the core 80, the bobbin 30 in which the C terminal 20C and the like are assembled is attached. For this attachment, the yoke 40 attached to the flange portion 30a of the bobbin 30 and the lower end portion of the C terminal 20C are inserted into the above-described insertion portion 70a of the base 70, and the lock portion 30d of the bobbin 30 is inserted into the lock holes 70b and 70b. This is done by locking 30d.
By attaching this bobbin 30 to the base 70,
As shown in the figure, a pin 60 (shown by a dotted line in the figure) fixed to the bobbin 30 is positioned at substantially the center of the connection terminal 20a.

After that, the starting end (coil electric wire) 50a of the coil 52 shown in FIG. 3A is welded to the connection terminal 20a of the A terminal 20A, and the end (coil electric wire) 50b.
Is welded to the connection terminal of the B terminal 20B. This welding will be described with reference to FIG. FIG. 6A shows the connection terminal 20a viewed from the side, and FIGS. 6B and 6C show the connection terminal 20a viewed from below. In the electromagnetic coil of this embodiment,
With the bobbin 30 attached as described above, the coiled wire 50 has the pin 60 wound around the connection terminal 20a.
Is positioned approximately in the center. First, a force is applied in the JJ direction shown in FIG. 6B to deform the connection terminal 20a as shown in FIG. 6C, and the pin 60 is sandwiched between the connection terminals 20a. After that, FIG.
The connection between the coil electric wire 50 and the A terminal 20A is completed by applying a spot current to the points G and G shown in (C). The assembly of the electromagnetic coil is completed through the above steps (further, other assembly steps are present, but the description thereof is omitted because it is not directly related to the gist of the present invention).

In this assembly, the bobbin 30
Of the pin 60 erected in the hole portion 30c of the flange portion 30a of the
Since the starting end 50a and the terminating end 50b of the coil 52 are wound around and the pin 60 is clamped by the connection terminal 20a and then welded, the engaging work of the starting end 50a and the terminating end 50b of the coil 52 can be easily performed. That is, when the starting end 50a and the terminating end 50b are directly connected to the connecting terminal 20a as in the conventional case, it is difficult to position the starting end 50a and the terminating end 50b of the coil 52 at the substantially central position of the connecting terminal 20a. for,
This is because in this embodiment, by mounting the bobbin 30 on the base 70, the wound pin 60 of the coil electric wire 50 can be automatically positioned at the substantially central position of the connection terminal 20a.

Further, as described above with reference to FIG. 3, in this embodiment, the pin 60 is temporarily press-fitted so that it can be further inserted into the hole 30c of the bobbin 30. And this pin 60
After winding the starting end 50a and the terminating end 50b of the coil 52, and then press-fitting further into the hole 30c, the coil electric wires 50c and 50d are passed between the starting end 50a and the terminating end 50b and the coil 52. You can easily add slack.

FIG. 3D is an enlarged view of the connection state between the connection terminal 20a and the coil electric wire 50. In this embodiment, when the pin 60 is clamped by the connection terminal 20a, the coil electric wire 50 is crushed. However, since the coil electric wire 50 is crushed along the cylindrical portion 60b of the pin 60, the crushing start portion (coil electric wire connection In the (part) 50e, the cross section changes gently. Therefore, even if vibration and heat contraction are applied to the crushing start portion 50e of the coil wire, the coil wire is not easily broken. Further, in this embodiment, the unwelded portion Z of the coil electric wire 50 wound around the pin 60 is
Since the coil electric wires 50c and 50d in the portion wound from the coil 52 to the pin 60 are provided with slack, vibration and heat contraction are applied to the crushing start portion 50e of the coil electric wire 50. Tension is not applied, and disconnection of the coil electric wire 50 can be eliminated. For this reason, the electromagnetic coil of the present embodiment is constantly subjected to vibrations during the engine and running, and even when it is used in an automobile where the temperature changes from 40 degrees below freezing to over 100 degrees and a very large tension is applied due to thermal contraction, the wire breakage occurs. High reliability can be achieved.

In the above description, an example in which the present invention is applied to an electromagnetic coil for automobiles has been described. However, the electromagnetic coil of the present invention is used in an environment where vibration is applied or a heat change is large, for example, It goes without saying that it can also be suitably used for electromagnetic coils for other applications such as marine aircraft. Further, in the above-described embodiment, the starting end 5 of the coil 52 is
0a and the terminal end 50b are both connected to the terminal side with the pin 60 interposed, but it is also possible to connect only one of the starting end 50a and the terminal end 50b to the terminal side via the pin 60.

[0027]

As described above, in the electromagnetic coil of the present invention,
Since the cross section of the coil electric wire is connected to the terminal so that the cross section changes gently, disconnection hardly occurs and high reliability can be obtained. Further, in the method for manufacturing an electromagnetic coil of the present invention, cleaning is not required because soldering is not used, and the operation of positioning the start end and the end of the coil at the substantially central position of the connection terminal can be easily performed, so that the electromagnetic coil can be used. It is possible to manufacture at low cost.

[Brief description of drawings]

FIG. 1 shows an electromagnetic coil according to an embodiment of the present invention, FIG. 1 (A) is a side view, and FIG. 1 (B) is a bottom view.

2 shows a bobbin and a pin of the electromagnetic coil shown in FIG.
2A is a side view of the bobbin, FIG. 2B is a front view of the bobbin, and FIG. 2C is a side view of the pin.

FIG. 3 shows a state in which a coil electric wire is wound around the bobbin of FIG. 2, FIGS. 3 (A) and 3 (B) are front views, and FIG.
Is a side view.

FIG. 4 shows an A terminal, FIG. 4 (A) is a plan view, and FIG. 4 (B) is a side view.

FIG. 5 is a plan view of the base.

FIG. 6 shows a connection terminal, FIG. 6 (A) is a side view, FIGS. 6 (B) and 6 (C) are bottom views, and FIG.
Is an enlarged view.

FIG. 7 shows a connection state of a coil electric wire to a terminal of a conventional technique, FIG. 7 (A) is a side view, FIGS. 7 (B) and 7 (C) are plan views, and FIG. It is a side view, FIG.
Is an enlarged view.

[Explanation of symbols]

20a connection terminal 30 bobbins 30a Flange part 30b Flange part 50 coil electric wire 52 coils 60 pin 60b cylindrical part

─────────────────────────────────────────────────── ─── Continuation of the front page (56) References Shown 63-195707 (JP, U) Shown 63-180908 (JP, U) Shown Flat 2-35405 (JP, U) Shown 60- 78122 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01F 5/04 H01F 7/06 H01F 27/28 H01F 41/10 H01F 30/00 H01F 38/00

Claims (4)

(57) [Claims] 1. An electromagnetic coil having a bobbin having flange portions at both ends, a coil electric wire, a pin having a cylindrical portion, and a clamp member connected to an electromagnetic coil terminal, the coil electric wire being wound around the bobbin. Rotate, the pin is erected on the flange portion of the bobbin, the start or end of the coil electric wire is wound on the cylindrical portion of the erected pin, and the pin on which the coil electric wire is wound on the clamp member. An electromagnetic coil characterized in that the coil electric wire and the electromagnetic coil terminal connected to the clamp member are connected by clamping and welding. 2. The coil electric wire passed between the portion wound around the pin and the portion wound around the bobbin is loosened. Electromagnetic coil. 3. A step of winding a coil wire around a bobbin having flanges at both ends and having holes formed at predetermined positions of the flanges; and a step of forming a cylindrical portion in the holes of the flange of the bobbin. A step of arranging a pin having the pin, a step of winding the start end and the end of the coil electric wire around a cylindrical portion of the erected pin, and attaching the bobbin to a base of an electromagnetic coil to attach the pin to the base. Positioning the clamp member attached at a predetermined position in a position where it can be clamped, clamping the pin by the clamp member connected to the electromagnetic coil terminal, the pin around which the coil wire is wound, and the clamp. Connecting the coil and the electromagnetic coil terminal connected to the clamp member by welding between the member and the member. Method of manufacturing an electromagnetic coil according to claim. 4. In the step of erected a pin in the hole of the bobbin flange, the pin is erected so that it can be further inserted into the hole, and the start end of the coil wire and After the step of winding the terminal end, by inserting the pin further into the hole, the pin is passed between the portion wound around the pin and the portion wound around the bobbin. 4. The method of manufacturing an electromagnetic coil according to claim 3, further comprising a step of giving slack to the coiled electric wire.