JPH01131332A - Manufacture of exciting device for electromagnetic clutch - Google Patents

Abstract

PURPOSE:To reduce working hours, and to lower manufacturing cost by forming an insulating coat on the surface of a coil consisted of a self-welding electric wire, and by molding an insulating resin into the space between the coil and the coil housing part so as to be fixed. CONSTITUTION:A coil 14 is housed and fixed in a ring-shaped yoke 5 consisted of a magnetic body having a coil housing part 4 of a U-shaped cross-section. On the surface of the coil 14 consisted of a self-welding electric wire, an insulating coat 16, is formed. Thereafter, the coil 14 is housed in the coil housing part 4. Next, an insulating resin 16, is molded into the space between the coil 14 and the coil housing part 4 so as to be fixed. Thus, the working hours can be reduced, and the manufacturing cost can be lowered.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of application in the FI industry) The present invention relates to a method of manufacturing an excitation device for an electromagnetic clutch used to transmit rotation of a compressor of a car air conditioner.

(Conventional Technique W) A conventional electromagnetic clutch of this type will be explained with reference to FIGS. 6 to 8. In FIG.

A rotor 1 made of a magnetic material has an annular V-groove 2 formed in a part of its outer periphery, into which a belt stretched between the rotor 1 and a drive source (not shown) engages. Inside the annular groove formed in the rotor 1, an excitation device 3 having one end fixed is arranged. As shown in the enlarged sectional view of the main part in FIG. 7, this excitation device 3 has a coil 6 in which electric wire is wound in a ring inserted into a yoke 5 having an annular coil storage part 4 with a U-shaped cross section. After that, it is molded with insulating resin 7. When this coil 6 is inserted into the coil storage section 4, insulating tape 8 is wrapped around the entire circumference of the coil 6, except for the wire tip 6a, as shown in FIG. It is wrapped around. Return to Figure 6.

The yoke 5 of the excitation device 3 is arranged to maintain constant gaps δ1 and δ2 in order to obtain an appropriate adhesion force between the yoke 5 and the rotor 1 when in operation, and to allow the rotor to rotate freely when not in operation. There is. Note that the rotor 1 described above is rotatably supported via a ball bearing 9.

An armature IO made of a magnetic material is mounted on a hub 12 mounted on a rotating shaft 11 of a rotor 1 (not shown) at positions facing each other in the axial direction of the rotor 1. and an air gap g.

The operation of the electromagnetic clutch configured as above will be explained 6. Due to the magnetic attraction force of the magnetic field Φ generated by energizing the coil 6, the rotor 1 and the armature 10 are frictionally engaged, and the force is transmitted from the drive source via the belt. The rotational force transmitted to the rotor 1 is transmitted to the rotating shaft 11.

In addition, when releasing the clutch, the energization to the coil 6 is turned off to F.
By this, the above amateur 10 has a leaf spring 13.
Since the rotating shaft 11 separates from the rotor 1 due to the restoring force, the rotating shaft 11 stops.

(Problem to be Solved by the Invention) However, as described above, wrapping the entire circumference of the coil 6 with insulating tape is a problem that occurs when the yoke 5 and the coil 6 are inserted into the coil storage section 4. The purpose is to maintain the insulation of the coil 6, prevent 4111uJI of the coil 6, and prevent the coil 6 from collapsing until the molding with the insulating resin 7 is completed. In addition, a large amount of insulating tape 8 is required, and the workability is poor and the working time is long.

Therefore, there was a problem that the manufacturing cost was high.

The present invention solves the above problems and provides an excitation device for an electromagnetic clutch that is easy to operate and is inexpensive.

(Means for solving problems) The first aspect of the present invention is to solve the above problems.

An insulating film is formed on the entire surface of a coil made by winding self-fused wire or on the surface that contacts the coil housing, and after storing this in the coil housing, an insulating film is applied to the gap between the coil and the coil housing. It is molded with insulating resin.

In addition, the second aspect of the present invention is that the coil wound with the self-fused electric wire is provided with approximately U-shaped insulating spacing members at a plurality of locations on the surface of the yoke facing the coil storage portion, and the coil is left in that state as described above. It is inserted into the coil storage part of the yoke, and an insulating resin is molded into the gap formed by the above-mentioned insulating spacing material.

The third aspect of the present invention is to form an insulating resin coating on the inner surface of a coil storage section having a U-shaped cross section, and then insert a coil wound with self-fused wire into the gap between the coil and the inner wall surface of the coil storage section. It is molded with insulating resin.

(Function) With the above configuration, the coil is formed by winding self-fused wires and is therefore tightly bound, so that the coil will not collapse during the manufacturing process of the excitation device.

Furthermore, the effect of the first invention is that by forming an insulating resin coating on the surface of the coil, when the coil is stored in the coil storage part of the yoke, the insulation layer is secured and the wire coating is protected at the same time. .

The insulating resin coating ensures an insulating distance from the bottom of the coil storage section. Therefore, it is possible to reduce the amount of conventional insulating tape materials and simplify and automate the insulating layer formation work.
Reduce the manufacturing cost of the excitation device.

Further, in the second aspect of the invention, a gap between the coil and the coil storage portion is secured by a plurality of insulating spacing members each having a generally U-shape. Furthermore, since the coil does not come into direct contact with the coil storage section, the insulation will not be damaged.

Therefore, cost reduction is achieved by reducing the amount of insulating tape material and improving workability.

In the third invention, since the insulating coating is formed on the inner surface of the coil housing portion having a U-shaped cross section, the insulating coating ensures an insulating distance between the coil and the yoke. Therefore, manufacturing costs are reduced by reducing the amount of insulating tape material and improving workability.

(Example) Three examples of the present invention will be described with reference to FIGS. 1 to 5.

FIG. 1 is a perspective view of a coil commonly used in one embodiment of the present invention. The coil 14 is formed into a single winding using a self-fusing wire 15, which has an insulating film formed on the surface of the wire as a raw material, and a fusing film that is further melted and fixed by heat or solvent. It is. Self-fused electric wire 15
is fused to form an annular coil 14 during winding. As in the conventional example, the tip end portion 14 of the electric wire for energizing the coil 14
A stands out.

FIGS. 2(a) to 2d) are manufacturing process diagrams of an excitation device showing a first embodiment of the first invention. First, Figure 2 (
As shown in a), hook the coil 14 onto the hook and place it in the tank 2.
When the coil 14 is immersed in the molten insulating resin 16 filled with zero and then taken out, the coil 14
An insulating film 17 of a thickness t of an insulating resin 16 is formed on the surface of the insulating resin 16 . Next, as shown in FIG. 2(c), the coil 14 on which the above-mentioned insulating film 17 is formed is stored in the coil storage portion 4 of the yoke 5.

The inner and outer circumferential surfaces of the coil 14 and the side wall surface of the coil storage portion 4 face each other with a thickness t of the insulating coating 17 and a gap 18 interposed therebetween. Next, as shown in FIG. 2(d), the gap 1
8, an insulating resin 16' that is the same type as the insulating resin 16 on which the insulating coating 17 is formed on the surface of the coil 14 or has good adhesion properties.
Inject and harden.

3(a) and 3(b) are part of manufacturing process diagrams of an excitation device showing a second embodiment of the first invention, in which a coil 14 is horizontally fished with an anchor-like hook, and a tank 20 is filled with
The coil 14 is immersed in the molten insulating resin 16 with the upper end surface exposed above the liquid level and then taken out. As shown in FIG. 3(b), the coil 14 taken out from the tank 20 has an insulating coating 17 of thickness t formed on three sides. The subsequent manufacturing steps are the same as those in the first embodiment, so the explanation will be omitted.

As described above, when the coil 14 is wound using the self-welding wire 15, it is fused and tightly bound, so that the winding does not collapse during the process of immersing it in the molten insulating resin 16. An insulating film 17 is easily formed on one surface. Compared to the conventional wrapping of insulating tape, it is possible to insulate a large number of coils 14 in a short time, and since insulating tape is not required, the cost of the excitation device is reduced by reducing the number of man-hours and material costs for each operation. becomes possible.

FIGS. 4(a) to 4(d) are manufacturing process diagrams of an excitation device showing an embodiment of the second invention. FIG. 4(a) is a perspective view of an insulating spacing member 19 formed in a U-shape so that the coil 14 is in contact with three sides facing the coil storage portion 4. FIG. First, as shown in FIG. 4(b), four of the above-mentioned insulating spacing members 19 are attached to the coil 14 at approximately equal intervals. The coil 14 fitted with the insulating spacing material 19 is stored in the coil storage portion 4 of the yoke 5. In this state, the coil 14 is
Between the bottom surface and the side wall surface of the coil storage section 4, at least
A gap 18' corresponding to the wire diameter d of the insulating spacer 19 is secured.

Next, as shown in FIG. 4(d), molten insulating resin 16 is supplied from above the coil housing part 4 to fill the gap 18' formed between the coil 14 and the coil housing part 4. , harden and fix.

As described above, when the coil 14 is wound using the self-welding wire 15, the coil 14 is fused and firmly bound, so that it will not collapse when it is stored in the coil storage section 4. Furthermore, the insulating spacing members 19 are installed at approximately equal intervals at four locations around the periphery.

A substantially uniform gap 18' can be secured between the coil 14 and the wall surface of the coil storage section 4. The insulating resin 16 is injected into the gap 18' and hardened, and the coil 14 and yoke 5 are
Since the insulation and fixation are performed, the conventional work of wrapping insulating tape can be omitted, and the cost of the excitation device can be lowered by improving workability and reducing material costs.

FIGS. 5(a) to 5(c) are manufacturing process diagrams of an excitation device showing an embodiment of the third invention. First, as shown in FIG. 5(a), molten insulating resin 16 is fused to the inner wall surface of the coil housing portion 4 of the yoke 5, which has a U-shaped cross section, to form an insulating coating 17 having a thickness of t. . Next, as shown in FIG. 5(b), the coil 14 is stored in the coil storage section 4 in which the insulating liquid [17] has been formed. In this state, there is a thickness t of the insulating coating 17 between the coil 14 and the bottom surface of the coil storage part 4.
Further, in addition to the thickness t of the insulating film 17, a gap 1'8 is formed between the side wall surface and the side wall surface. Next, as shown in FIG. 5(c), the insulating resin 1 melted from above the coil storage part 4 is
6' is supplied, filled into the gap 18 and hardened and fixed,
Mold. Note that in order to form the insulating coating 17 on the inner wall of the coil storage part 4, after injecting an appropriate amount of molten insulating resin 16 into the coil storage part 4, the yoke 5 is turned upside down and the insulating resin 16 is An insulating coating 17 is formed by flowing the insulating resin 16 toward the opening of the U-shape or by thermally spraying the insulating resin 16 on the inner wall surface of the U-shape.

As described above, when the coil 14 is wound using the self-welding wire 15, it is fused and tightly bound, so that the winding does not collapse during the storage process in the coil storage section 4.

In addition, at that time, an insulating coating 1 is applied to the inner wall surface of the coil storage portion 4.
7 is formed.

Insulation between the coil 14 and the yoke 5 can also be ensured. The process of forming the insulating film 17 is also easy, and compared to the conventional winding of an insulating tape, work efficiency is improved, material costs are reduced, and the cost of the excitation device can be reduced.

In the above embodiment, it goes without saying that the insulating coating 17 and the insulating spacing material 19 are made of materials having insulating properties and heat resistance that can withstand the conditions of use, and the coating 17 and the thickness t and Needless to say, the wire diameter d of the spacing member 19 is set to a size that can ensure an insulation distance that can withstand the withstand voltage conditions of the excitation device.

In the embodiment of the second invention, the insulating spacer 19 is a wire rod with a circular cross section, but it may be a wire rod with a rectangular cross section or may be in the form of a sheet.

(Effects of the Invention) As explained above, according to the present invention, since a coil is formed by winding self-fused wires, it is tightly bound, does not collapse during the manufacturing process, and is easy to handle. It becomes extremely easy.

In addition, since an insulating coating is pre-formed on the surface of the coil or the inner wall surface of the coil storage part using insulating resin, the coil will not be damaged when inserted into the coil storage part of the yoke. There is no loss of sex.

In addition, when the coil is left as it is, it is protected by multiple insulating spacing materials attached to the coil, so the coil and the coil housing will not collide directly.

The coil will not be damaged when stored.

Furthermore, the work of wrapping insulating tape, which was traditionally done to prevent deterioration of insulation due to collapse and damage to the coil during handling, is now replaced with the simple process of forming an insulating film, resulting in a significant reduction in The working time is reduced, and therefore an exciting device for an electromagnetic clutch that is easy to manufacture, highly reliable, and inexpensive is obtained.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a coil according to the present invention, FIGS. Figures (a) and (b) are cross-sectional views showing a part of the manufacturing process of an excitation device showing a second embodiment of the first invention, and Figures 4 (a) to 4d) are according to the second invention. A perspective view and a cross-sectional view showing the manufacturing process of the excitation device, FIGS. 5(a) to c) are cross-sectional views showing the manufacturing process of the exciting device according to the third invention, and FIG. 6 is a cross-sectional view of a conventional electromagnetic clutch. , FIG. 7 is an enlarged sectional view of a main part of the excitation device shown in FIG. 6, and FIG. 8 is a perspective view of a conventional coil. DESCRIPTION OF SYMBOLS 1... Rotor, 2... V groove, 3... Excitation device, 4... Coil storage part 5... Yoke, 6.14
... Coil, 6a, 14a... Wire tip. ? , 16.16'... Insulating resin, 8... Insulating tape, 9... Ball bearing, 10... Armature, 11... Rotating shaft, 12... Hub, 13...
・Leaf spring. 15... Self-fused electric wire, 17... Insulating coating. 18, 18'... Gap, 19... Insulating spacing material,
20...tank. Patent applicant: Matsushita Electric Industrial Co., Ltd. Figure 1 14-Coil 14 a, -t #l first line 15
．． - Eyes and power resistance Figure 2 17-f Parental trace armpit 16'AeJ#, Takuo Utsuki Figure 3 17-Kien Mori 41. Belly Fig. 4 14-, Coil 4, -Coil L fanning +6J cicada resin Fig. 5 4-0-Coil H imaginary part 50. -Yoke 17,-
, t ~ 橡拡 Armpit 140. - Coil 18- Corpse space 16' ~ place a resin Fig. 6

Claims (3)

[Claims] (1) In an excitation device for an electromagnetic clutch in which a coil is housed and fixed in an annular yoke made of a magnetic material having a U-shaped coil housing section, an insulating film is formed on the surface of the coil made of self-fused wire. Thereafter, the above-mentioned coil is stored in a coil storage part, and then an insulating resin is molded and fixed in the gap between the coil and the coil storage part. (2) In an excitation device for an electromagnetic clutch in which a coil is housed and fixed in an annular yoke made of a magnetic material having a U-shaped coil storage section, a generally U-shaped After the insulating spacing material is attached and inserted into the coil storage section, an insulating resin is molded and fixed in the gap between the coil formed by the insulating spacing material and the inner wall surface of the coil storage section. A method for manufacturing an excitation device for an electromagnetic clutch. (3) In an excitation device for an electromagnetic clutch in which a coil is housed and fixed in an annular yoke made of a magnetic material having a U-shaped coil housing section, an insulating coating is formed on the inner wall surface of the coil housing section. , an electromagnetic clutch characterized in that the above-mentioned coil formed from a self-fused electric wire is inserted, and an insulating resin is molded and fixed in the gap formed between the above-mentioned insulating coating and the above-mentioned coil. A method for manufacturing an excitation device.