JPH053655A - Manufacture of controller for charging generator - Google Patents

Abstract

PURPOSE:To obtain a method for manufacturing a controller for charging generators which can improve the workability of soldering for fixing terminals to electrodes and, at the same time, can easily manufacture a metallic mold for brash holder section and case section which are united to one body. CONSTITUTION:A case section 20b is integrally molded to one body together with a brush holder 20a by using a resin and the opening of the section 20b is formed on the side which is opposite to the side where a brush 12 is slid on the section 20b and in the same direction as that of a hole 20c used for fitting the case section to an AC generator. In addition, terminals 8, 9, and 10 are respectively faced and soldered to the electrodes 308, 309, and 310 of a voltage regulator 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a controller for a charging generator which controls an output voltage of a charging generator to a predetermined value to charge a storage battery.

[0002]

2. Description of the Related Art First, a general circuit of this type will be described with reference to FIG. In FIG. 1, reference numeral 1 denotes an AC generator mounted on a wheel (not shown) and driven by an internal combustion engine (not shown), which has an armature coil 101 and a field coil 102 that are three-phase star-connected. Reference numeral 2 is a full-wave rectifier that rectifies the AC output of the AC generator 1, and 201, 202, and 203 are first, second, and third rectification output terminals, respectively. Reference numeral 3 is a voltage adjusting circuit for controlling the output voltage of the generator 1 to a predetermined value, and is composed of the following parts. That is, 30
Reference numeral 1 is a surge absorbing diode connected to both ends of the field coil 102, 302 is a transistor which is an opening / closing element for cutting off the field current of the field coil 102, and 303 is provided in the base circuit of the transistor 302. A base resistor, 304 is a transistor for controlling the on / off of the transistor 302, 305 is a detector element that detects the output voltage of the generator 1 and constitutes a detection element that is activated when the output voltage reaches a predetermined value or more. Nar diode, 306,
Reference numeral 307 is a resistor that is connected in series to the second rectified output terminal 202 of the generator 1 to form a voltage dividing circuit, 4 is a storage battery, 5 is a key switch, 6 is a charging indicator light, 7 is this charging indicator light 6 It is a resistance for initial excitation connected in parallel with.

The operation of the general device configured as described above will be described. First, when the key switch 5 is closed at the time of starting the internal combustion engine, a base current is supplied from the storage battery 4 to the transistor 302 via the key switch 5, the resistor 7, the charge indicator lamp 6 and the resistor 303, and the transistor 30
Since 2 is conductive, a field current is supplied from the storage battery 4 to the field coil 102 through the transistor 302, and a field magnetomotive force is generated. At this time, since a potential difference is generated in the initial excitation resistance 7, the charge indicator lamp 6 is turned on to display the non-charged state of the storage battery 4.

When the engine is started in this state and the generator 1 is driven, an AC output is induced in the armature coil 101 according to the number of revolutions thereof. This output is full-wave rectified by the full-wave rectifier 2. Here, when the rectified output voltage is equal to or lower than a predetermined value, the voltage dividing point potential of the voltage dividing circuit constituted by the resistors 306 and 307 is still low, so that the Zener diode 305 maintains the non-conduction state. The output voltage of the generator 1 increases as the rotation speed increases. afterwards,
If the number of revolutions of the generator 1 further increases and the output voltage becomes higher than a predetermined value accordingly, the potential of the voltage dividing point of the voltage dividing circuit also increases, which causes the zener diode 305 to conduct and the zener diode 305 to conduct. The transistor 304 becomes conductive through the gate diode 305. If the transistor 304 becomes conductive, the transistor 302 becomes non-conductive, and the field coil 1
The field current of 02 is cut off to reduce the output voltage of the generator 1.

When the output voltage drops to a predetermined value, the Zener diode 305 and the transistor 304 become non-conductive again, the transistor 302 becomes conductive, and the field coil 1 is turned on.
Since 02 is energized, the output voltage of the generator 1 rises again.

By repeating the above-mentioned operation, the output voltage of the generator 1 is controlled to a predetermined value, and the storage battery 4 is charged to a predetermined voltage with this controlled voltage.

On the other hand, the charging indicator light 6 has a second rectification output terminal 2
When the output voltage of 02 reaches a value approximately equal to the power supply voltage value of the storage battery 4, the potential difference of the resistor 7 decreases and the light is turned off.
Displays the charging status of.

Next, the structure of the conventional device shown in FIGS. 2, 3 and 4 will be described. In the figure, 31 is a metal case forming the outer casing of the voltage regulator 3, 311 is adhered to the bottom of the case 31 by a silicone rubber adhesive 312, and the upper surface is composed of a hybrid thick film integrated circuit. A ceramic substrate 313 forming a film is a silicon gel injection-hardened on the upper surface of the ceramic substrate 311.
Reference numerals 9 and 10 are a plus terminal, a field terminal and an earth terminal which form terminals of the brush holder which are respectively connected to the plus electrode 308, the field electrode 309 and the earth electrode 310 of the voltage regulator 3. Reference numeral 11 denotes a brush holder formed of a thermosetting or thermoplastic resin, and 12 denotes two brushes held by the brush holder 11, which are in sliding contact with a slip ring provided on the free end side, and the field coil 102 is magnetized. Supply current. 13 is a pigtail for electrically connecting the brush 12 and the terminals 8 and 9, 17 is a screw for fastening the brush holder 11, 15 is a washer, 1
6 is a spring washer, 14 is a bush for insulating the screw 17, washer 15, spring washer 16 and the terminals 8 and 9, 18 is a coil spring for pressurizing the brush 12, 19 is the voltage regulator 3 , A rear bracket to which the brush holder 11 is attached.

A method of manufacturing the conventional device having the above structure will be described. First, the case 31 of the voltage regulator 3
A ceramic substrate 311 of a control circuit, which is composed of a mixed thick film integrated circuit, is provided on the bottom of the silicon rubber adhesive 312.
And the silicon gel 313 is injected and cured thereon to form the voltage regulator 3. Next, pass the coil spring 18 through the pigtail 13 protruding from the brush 12,
This is inserted into a resin-molded brush holder 11, and the other end of the pigtail 13 is soldered to the brass terminal 8 and the field terminal 9 for electrical connection. At this time, the ground terminal 10 is also assembled to the brush holder 11 at the same time to complete the related portion of the brush holder 11, and the plus electrode 308, the field electrode 309, and the ground electrode, which are the external extraction electrodes of the completed voltage regulator 3 described above. Each 310 is passed through the holes of the plus terminal 8, the field terminal 9 and the ground terminal 10 of the brush holder 11 and soldered. As described above, the brush holder 11 and the voltage regulator 3 are integrally fixed and integrated into the rear bracket 19.

[0010]

However, in the above-described method of manufacturing the conventional device, the case 31 of the voltage regulator 3 and the brush holder 11 need to be separately manufactured.
Further, since the plus electrode 308, the field electrode 309, and the ground electrode 310 project in different directions, and are not aligned in one direction in one line, the terminals 8 of the brush holder 11,
There was a problem that it took time to solder 9 and 10.

The present invention has been made in order to solve the above problems, and the control device for a charging generator, such as the efficiency of assembly work, is improved by performing the work of soldering the terminals to the electrodes at the same place. It is an object of the present invention to provide a manufacturing method of.

[0012]

A method of manufacturing a control device for a charging generator according to the present invention is a resin molded product which is integrally formed so that a case portion for accommodating a voltage regulator is arranged in parallel with a brush holder portion in an axial direction. And the housing opening in the case is formed in the same direction as the mounting hole for the AC generator in the brush holder, and the board of the control circuit is orthogonal to the axial direction through the heat sink in the case. On the surface and the electrodes of the voltage regulator project in the same direction from the substrate so as to be aligned in a line on the side opposite to the sliding contact surface of the brush, and the voltage of the plate terminals of the brush holder is adjusted. Arranged facing multiple electrodes of the container and soldering each,
After that, resin is injected into the case portion, and the injected resin is cured to fix the substrate of the control circuit.

[0013]

In the present invention, since the brush holder portion and the case portion are formed as an integral resin molded product, and the mounting hole of the brush holder portion and the opening of the case portion are formed in the same direction. Are the same. Further, the facing portions of the terminals and the electrodes are aligned outside the opening of the case portion, and a plurality of soldering operations are performed at the same place.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. 5, 6 and 7. In the figure, reference numeral 20 denotes a brush holder / case, which is formed by integrally molding a brush holder portion 20a for holding the brush 12 and a case portion 20b for accommodating the voltage regulator 3 with resin. Here, the case portion 20b is the brush 1 in the brush holder portion 20a.
The brush 1 is arranged in parallel with the holding hole portion 2 in the axial direction, and
2 has an opening only on the side opposite to the surface in which the slip ring is in sliding contact, and this opening is formed so as to be in the same direction as the mounting hole 20c for mounting the bracket 19 in the brush holder portion 20a. .. Reference numeral 311 denotes a ceramic substrate on which a control circuit for the voltage regulator 3 is formed. The ceramic substrate 311 is arranged in the case portion 20b so as to be orthogonal to the axial direction of the charging generator, and is connected to the substrate 311 by a plus electrode 308.
The field electrode 309 and the ground electrode 310 are the case 2
Through the opening 0b to the brush holder 20a side,
They are arranged in a line.

On the other hand, the plus terminal 8, the field terminal 9 and the ground terminal 10 supported by the brush holder portion 20a.
Respectively extend to the opening side of the case portion 20b, the free ends thereof are located on substantially the same plane, and the voltage regulator 3
Of the plurality of electrodes 308, 309, and 310 are arranged so as to face each other and are soldered to the electrodes. Reference numeral 314 is a metal heat sink provided on the side opposite to the component mounting surface of the ceramic substrate 311, and other configurations are almost the same as those of the conventional example.

Next, a method of manufacturing the control device configured as described above will be described. First, the plus electrode 308 for external extraction is provided in the through hole of the electrode portion of the ceramic substrate 311 of the voltage regulator whose upper surface is formed of the hybrid thick film integrated circuit.
The field electrode 309 and the ground electrode 310 are removed and soldered. The substrate 311 is bonded to the heat sink 314 with the silicone rubber adhesive 312 to form the voltage regulator 3. Next, the brush 12 is inserted into the brush holding hole of the brush holder / case 20 and the coil spring 18 is inserted into the pigtail 13. Then, the plate-shaped terminals 8, 9,
10 is fixed to the brush holder / case 20 and the pigtails 13 are soldered to the terminals 8 and 9, respectively.

Next, with the lead side on which the electrodes of the voltage regulator 3 are attached facing you, the electrodes 308, 309,
The ceramic substrate 311 is inserted into the case portion 20b of the brush holder / case 20 so that the substrate 310 protrudes to the outside, so that the substrate 311 is arranged on a surface orthogonal to the axial direction of the charging generator. Then, the terminals 8, 9, 10 of the brush holder portion 20a facing each other are provided.
And the terminals 309, 308, 310 of the voltage regulator 3 are soldered.

After that, a flexible resin is injected and cured in the case portion 20b of the brush holder / case 20. In this way, the brush holder and the voltage regulator 3 are integrated into the rear bracket 19 through the mounting hole 20c of the brush holder portion 20a, and the pair of brush terminals 8 and 9 are connected via the insulating bush 14 and the ground. Terminal 10 is directly attached to rear bracket 19 with washer 15 and spring washer 1.
6. Tighten with screws 17 to complete the production of the device. At this time, the brush holder / case 20 is screwed between the plate-shaped brush terminals 8 and 9 and the ground terminal 10.

[0019]

As described above, according to the method of manufacturing the control device for the charging generator of the present invention, the brush holder portion and the case portion are formed of an integral resin molded product so as to be juxtaposed in the axial direction. At the same time, the opening of the case is on the side opposite to the sliding contact surface of the brush and is formed in the same direction as the mounting hole for the AC generator, so at least the mounting hole for the brush holder and the die cutting direction for the case are the same. Thus, the mold can be easily manufactured, the molding work can be efficiently performed, and the radial space can be suppressed to a necessary minimum. In addition, by arranging each terminal and electrode on the side opposite to the sliding contact surface of the brush, there is a problem such as a short circuit between the terminals due to adhesion of abrasion powder on the brush, a short circuit between the electrodes, or a disconnection due to sparks caused by sliding contact between the brush and the slip ring. Prevent,
The reliability of the device can be improved. Furthermore, since the brush and the voltage regulator are arranged side by side in the axial direction, the length of the terminal and the electrode connecting them can be made as short as possible.
Moreover, since the opposing portions of the terminals and the electrodes are arranged outside the opening of the case portion, a plurality of soldering operations can be performed at the same location, so that the operations can be efficiently performed.

[Brief description of drawings]

FIG. 1 is an electric circuit diagram of a control device for a charging generator.

FIG. 2 is a plan view showing an example of a conventional controller for a charging generator.

FIG. 3 is a front view of FIG.

4 is a sectional view taken along line IV-IV in FIG.

FIG. 5 is a plan view showing an embodiment of the present invention.

FIG. 6 is a front view of FIG.

7 is a sectional view taken along line VII-VII of FIG.

[Explanation of symbols]

 1 Charging Generator 101 Armature Coil 102 Field Coil 2 Full Wave Rectifier 3 Voltage Regulator 4 Storage Battery 5 Key Switch 6 Charging Indicator Light 7 Initial Excitation Resistance 8, 9, 10 Brush Holder Terminal 11 Brush Holder 12 Brush 13 Pick Tail 14 Insulation Bush 15 Washer 16 Spring Washer 17 Screw 18 Coil Spring 19 Rear Bracket 20 Brush Holder / Case 20a Brush Holder 20b Case 20c Mounting Hole 308, 309, 310 Voltage Regulator Electrode 311 Ceramic Substrate 312 Adhesive 313 Note Shape Resin 314 Heat Sink

Claims (1)

Claim: What is claimed is: 1. A plurality of brushes that are slidably mounted on a plurality of slip rings to supply a field current to a field coil of an AC generator, and a brush holder portion that holds these brushes. A control device for a charging generator having a control circuit for controlling an output voltage to a predetermined value by controlling a field current flowing in the field coil, and a voltage regulator attached to the AC generator. In the manufacturing method, a case part for accommodating the voltage regulator is formed of an integral resin molded product so as to be juxtaposed in the axial direction with the brush holder part, and the accommodating part opening in the case part is formed by the brush holder part. In the same direction as the mounting holes for the AC generator in the above, and through the heat sink in the case portion on the surface orthogonal to the axial direction of the substrate of the control circuit, and a plurality of the voltage regulators. The electrodes are arranged so as to project in the same direction from the substrate and aligned in a line on the side opposite to the sliding contact surface of the brush, and the plurality of plate-shaped terminals of the brush holder are arranged to face the plurality of electrodes of the voltage regulator. And soldering each, and then injecting a resin into the case portion, and curing the injected resin to fix the substrate of the control circuit.