JPH0989007A - Manufacture for solenoid clutch core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a solenoid clutch core at low costs within a short time by press machining the outer peripheral part of a circular frame, forming a ring-like outer peripheral wall opposed to an inner peripheral wall with a specified space and forming a coil housing part surrounded by both peripheral walls and a bottom part. SOLUTION: A cylindrical cup 7 having a bottom is formed by press- machining the center part of a circular metallic sheet 6 and a circular frame 8 is formed in its outer periphery. A bottom side for bending the cup 7 is cut and its residual part is left as a ring-like inner peripheral wall 2. A ring-like outer peripheral wall 1 is formed by press-machining the outer peripheral portion of the frame 8 so as to be placed oppostitely to the inner peripheral wall 2 with a specified space. A bottom part 3 is formed between both peripheral walls 1 and 2 and a coil housing part 4 is formed so as to be surrounded by both peripheral walls 1 and 2 and the bottom part 3. A plate-like flange 23 formed by separately performing press machining is fixed to the back surface of a completed core 20 by welding. Further, an electromagnetic coil 5 wound in a donut shape is fitted in the coil housing part 4 and fixed by injecting adhesives.

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 core used in an electromagnetic clutch.

[0002]

2. Description of the Related Art Electromagnetic clutches are used in various machines to transmit power intermittently. For example, they are used in compressors for air conditioners of automobiles and automatic transmissions of automobiles.

FIG. 4 is a sectional view showing an example of an electromagnetic clutch used in a compressor of an automobile air conditioner. This electromagnetic clutch includes an electromagnetic coil 5 wound in a ring shape, a circular core 20 having a ring groove-shaped coil accommodating portion 4 for accommodating the electromagnetic coil 5, an outer peripheral surface of the core 20 and an opening of the coil accommodating portion 4. The rotor 11 has a shape that substantially covers the surface but is arranged so as not to contact the core 20, and a rotatable armature 13 arranged close to the friction surface 12 of the rotor 11. ing. In this electromagnetic clutch, when a current is applied to the electromagnetic coil 5 while the rotor 11 is rotating, the rotor 11 is excited, and the armature 13 adjacent thereto is attracted and brought into contact with the friction surface 12 of the rotor 11, so that the armature 13 together with the rotor 11 Rotate. When the power supply to the electromagnetic coil 5 is stopped, the excitation of the rotor 11 is released, the armature 13 attracted by the rotor 11 until then is separated from the rotor 11 by the pull-back body 18, and the rotation of the armature 13 is stopped. That is, the rotation of the rotor 11 is intermittently transmitted to the armature 13 by turning ON / OFF the power supply to the electromagnetic coil 5.

In the electromagnetic clutch of FIG. 4 mounted on a compressor for an automobile air conditioner, a pulley 14 is mounted on the outer circumference of a rotor 11 so that the pulley 14 is rotated by a V belt 15 connected to an engine (not shown). On the other hand, the armature 13 is connected to the rotary shaft 17 of the compressor 16, and the rotary shaft 17 of the compressor 16 is driven when the amateur 13 is rotated. Amateur 13 in this case
Is a double plate of an inner armature 13a and an outer armature 13b arranged concentrically on the outer side of the inner armature 13a. When the rotor 11 sucks the inner armature 13a, the inner armature 13a is first sucked, and then the outer armature 13a is sucked. Amateur 1
3b is sucked so that the rotational force of the rotor 11 is not rapidly transmitted to the armature 13 side, whereby the impact on the transmission system and the compressor 16 is mitigated and they are not broken. The power supply to the electromagnetic coil 5 is turned on / off by a controller (not shown) of the air conditioner.
When the air conditioner is turned on while the engine is started and the rotor 11 is rotating, the controller causes a current to flow through the electromagnetic coil 5 to drive the rotating shaft 17 of the compressor 16. It Further, even when the air conditioner is operating, if the controller controls ON / OFF of the power supply to the electromagnetic coil 5 according to the temperature inside the vehicle, the rotating shaft 17 of the compressor 16 intermittently rotates and stops accordingly, and the air blown out into the vehicle. Is maintained at a predetermined temperature.

Core 20 used in the electromagnetic clutch of FIG.
Has been conventionally manufactured by the manufacturing process as shown in FIGS. 1. As shown in FIG. 6A, a thick ring-shaped steel plate 21.
Prepare The steel plate 21 is subjected to a bond process (bonderite process), so that workability in press working is enhanced. 2. The steel plate 21 is pressed by cold forging as shown in FIG.
A ring groove-shaped coil accommodating portion 4 as in (b) and (c).
Then, the circular core 20 having the accommodation space 25 capable of accommodating the other members (the inner wall 11a of the rotor 11 and the bearing 19 in FIG. 4) is formed. 3. Annealing the core 20 (annealing),
The residual strain left on the core 20 after pressing is reduced. 4. As shown in FIG. 6D, the open end surface 22 of the core 20 is cut and smoothed so as to come into contact with the rotor 11 even if the space between the open end surface 22 and the rotor 11 (FIG. 4) facing the core 20 is narrow. Try not to. Thus, the core 20 is completed. 5. Normally, the core 20 is distributed in the state of the core assembly shown in FIG. 5 to which a mounting member (usually called a flange) 23 for mounting the core 20 to the compressor 16 is mounted. For this reason, in this case, as shown in FIGS. 6E and 6F, a flange 23 press-formed by cold forging is separately attached to the back side of the core 20 by welding. The flange 23 is provided with a screw hole 23a for screwing to the compressor 16 and a protrusion 23b for positioning at the time of mounting. 6. Normally, in the core assembly, as shown in FIG. 6G, an electromagnetic coil 5 is set in the coil housing portion 4 of the core 20.

[0006]

In the core manufacturing method shown in FIG. 6, the core 20 having the coil accommodating portion 4 having a substantially U-shaped cross section must be prepared by pressing the disk-shaped steel plate once by cold forging. Inevitably, a deep-narrowing press was required to make the core 20. However, conventionally, a bonder treatment is required to perform deep narrowing, and a large strain remains in the core 20 after narrowing, so an annealing treatment (annealing treatment) for eliminating or reducing the strain is performed. Processing) was required. For this reason, there has been a problem that it takes time and cost to manufacture the core 20.

An object of the present invention is to provide a method capable of manufacturing an electromagnetic clutch core in a short time and at low cost.

[0008]

A method for manufacturing an electromagnetic clutch core according to a first aspect of the present invention, as shown in FIG. 1, is a ring-shaped outer peripheral wall 1, a ring-shaped inner peripheral wall 2 and both peripheral walls 1. In a method for manufacturing an electromagnetic clutch core, which is capable of accommodating a toroidal electromagnetic coil 5 in a ring-shaped coil accommodating portion 4 having a U-shaped cross section surrounded by a bottom portion 3 between two circular metal plates 6 The central portion of the cup is pressed to form a cylindrical cup 7 having a bottom and a circular collar 8 is formed on the outer periphery of the cup 7. The bottom side of the cup 7 is cut off and the remaining portion is formed into a ring-shaped inner peripheral wall 2. The outer peripheral portion of the circular collar 8 is pressed to form a ring-shaped outer peripheral wall 1 facing the inner peripheral wall 2 at a predetermined interval and a bottom portion 3 is formed between the both peripheral walls 1, 2. To form a coil housing 4 surrounded by both peripheral walls 1 and 2 and the bottom 3. It is a method that was to so that.

In the method of manufacturing an electromagnetic clutch core according to a second aspect of the present invention, as shown in FIG. 3, a ring-shaped outer peripheral wall 1, a ring-shaped inner peripheral wall 2, and a bottom portion 3 between both peripheral walls 1, 2 are provided. In a method of manufacturing an electromagnetic clutch core capable of accommodating a toroidal electromagnetic coil 5 in a coil accommodating portion 4 having a U-shaped cross section surrounded by and, a circular hole 9 is formed in a central portion.
The center portion of the circular metal plate 6 provided with is formed to form the ring-shaped inner peripheral wall 2 and the circular flange 8 is formed on the outer periphery thereof, and the outer peripheral portion of the flange 8 is pressed. A ring-shaped outer peripheral wall 1 is formed to face the inner peripheral wall 2 at a predetermined interval, and a bottom portion 3 is formed between the peripheral walls 1 and 2.
Is formed so that the coil housing portion 4 surrounded by both the peripheral walls 1 and 2 and the bottom portion 3 is formed.

In the method of manufacturing an electromagnetic clutch core according to a third aspect of the present invention, as shown in FIG. 2, a portion of the metal plate 6 which becomes the bottom portion 3 is pressed and narrowed down to form the convex portion 10. This is a method in which the convex portions 10 are crushed and the bottom portion 3 is formed thick.

[0011]

FIG. 1 is a first example of an embodiment of a method for manufacturing an electromagnetic clutch core according to the present invention, which is a method for manufacturing an electromagnetic clutch core used in a compressor for an automobile air conditioner. Is shown. This manufacturing method includes the following steps.

1. As a metal plate 6 formed in a disc shape as shown in FIG. 1A, for example, a steel plate for pressing is prepared.
The metal plate 6 does not require a bonder process (bonderite process) for facilitating press working. 2. The central portion of the metal plate 6 is pressed to form a bottomed cylindrical cup 7 as shown in FIG. 1 (b) on the metal plate 6 and a circular flange 8 on the outer periphery thereof. In this case, in the cross-sectional shape of the cup 7, the bottom side (tip portion) is curved in a round shape, but the base side is in a straight line or a state close to it. 3. The curved bottom side of the cup is cut off as shown in FIG. 1 (c), and the remaining portion is left as a ring-shaped inner peripheral wall 2. 4. The flange 8 of the metal plate 6 is pressed near the outer periphery to form a ring-shaped outer peripheral wall 1 facing the inner peripheral wall 2 at a predetermined interval as shown in FIG.
A bottom portion 3 is formed between the two, and a coil housing portion 4 surrounded by both peripheral walls 1 and 2 and the bottom portion 3 is formed. This coil housing 4
Is for accommodating and fixing the electromagnetic coil 5 wound in a donut shape. 5. Tip portions 1a, 2a of the outer peripheral wall 1 and the inner peripheral wall 2 respectively
Are cut to be flush with each other to complete the core 20.

In FIG. 1, the plate-shaped flange 2 of FIG. 1 (f) is formed by pressing the back surface of the completed core 20 separately.
3 is attached, and the core 20 and the flange 23 are fixed by welding, riveting, brazing or the like. Further, as shown in FIG. 1 (g), the electromagnetic coil 5 wound in a donut shape is fitted into the coil housing portion 4 of the core 20, filled with an adhesive, dried and fixed in the coil housing portion 4, Complete the core assembly.

The size of the core 20 is appropriately determined depending on the size of the electromagnetic coil 5 to be housed, the size of the rotor (FIG. 4) arranged so as to surround the core 20, and the like. Further, the lead wire (not shown) of the electromagnetic coil 5 is connected to the core 20.
A hole can be formed in the coil housing 4, and the coil housing portion 4 can be pulled out from this hole.

[0015]

Embodiment 2 FIG. 2 is a second example of an embodiment of a method for manufacturing an electromagnetic clutch core according to the present invention. Most of the steps are the same as those of the first embodiment, but they are different. This is a method of processing the bottom portion 3 of the core 20 into a thick wall. This manufacturing method includes the following steps. 1. 2 (a) to 2 (c) are processed in the same manner as in the first embodiment of FIG. 2. As shown in FIG. 2D, a portion of the metal plate 6 to be the bottom portion 3 is pressed and narrowed down to form the convex portion 10. 3. The flange 8 of the metal plate 6 is pressed near the outer periphery to form a ring-shaped outer peripheral wall 1 facing the inner peripheral wall 2 at a predetermined interval as shown in FIG.
A bottom portion 3 is formed between the two, and a coil housing portion 4 surrounded by both peripheral walls 1 and 2 and the bottom portion 3 is formed. 4. After forming the coil accommodating portion 4 as shown in FIG. 2 (e), the convex portion 10 is scissors-crushed between the upper and lower pushers 30 shown by imaginary lines in FIG. 2 (e) to crush the inner peripheral wall 2 and the outer periphery. The metal plate 6 between the wall 1 and the wall 1 is made thick. 5. Next, the tips of the inner peripheral wall 2 and the outer peripheral wall 1 are cut to be flush with each other to complete the core 20.

In FIG. 2, the plate-like flange 23 of FIG. 2 (f) separately formed by press working is attached to the bottom surface of the core 20, and the core 20 and the flange 23 are fixed by welding, riveting, brazing or the like. Fix by means. Furthermore, FIG.
As shown in (g), the electromagnetic coil 5 wound in a donut shape is fitted into the coil housing portion 4 of the core 20 and filled with an adhesive,
The core assembly is completed by fixing the coil assembly 4 in the coil accommodating portion 4 by drying or the like.

[0017]

Third Embodiment FIG. 3 is a third example of an embodiment of a method for manufacturing an electromagnetic clutch core according to the present invention, which is also a method for manufacturing an electromagnetic clutch core used in a compressor for an air conditioner for automobiles. Is shown. This manufacturing method includes the following steps. 1. As shown in FIG. 3A, a circular metal plate 6 having a circular hole 9 in the center is used. 2. The central portion of the metal plate 6 is pressed to form a ring-shaped inner peripheral wall 2 and an outer flange 8. 3. As shown in FIG. 3C, a ring-shaped outer peripheral wall 1 facing the inner peripheral wall 2 at a predetermined interval is formed by pressing the outer peripheral portion of the collar 8 and a bottom portion between the peripheral walls 1 and 2 is formed. 3 is formed to form the coil accommodating portion 4 surrounded by both the peripheral walls 1 and 2 and the bottom portion 3. The coil accommodating portion 4 is for accommodating and fixing the electromagnetic coil 5 wound in a donut shape. 4. Tip portions 1a, 2a of the outer peripheral wall 1 and the inner peripheral wall 2 respectively
Are cut to be flush with each other to complete the core 20 shown in FIG.

In the present embodiment, the plate-like flange 23 of FIG. 1 (f) separately press-molded is attached to the back surface of the completed core 20, and the core 20 and the flange 23 are welded, riveted, and brazed. Secure with fixing means such as attachment. The electromagnetic coil 5 wound in a donut shape is fitted into the coil housing portion 4 of the core 20 and is fixed in the coil housing portion 4 by filling with an adhesive and drying, and the core assembly is completed.

The manufacturing method described above is a method for manufacturing an electromagnetic clutch core used in a compressor for an automobile air conditioner. However, the core manufacturing method of the present invention is used for another industrial machine. It can also be used for the production of In some electromagnetic clutches, powder of magnetic material is arranged between the rotor and the armature, but it can also be used in such a case.

[0020]

According to the method for manufacturing an electromagnetic clutch core according to the first and second aspects of the present invention, a new step of cutting the cup 7 is required for manufacturing the core, and the pressing step is increased by one. In the pressing process, the degree of processing is small, so there is no need for bonder processing for deep drawing, and because the residual strain after pressing is also small, there is no need for annealing treatment to eliminate residual strain. The cost and the manufacturing time can be remarkably reduced, and the cost is also remarkably reduced.

In the method of manufacturing the core for the electromagnetic clutch according to the second aspect of the present invention, in addition to the above effects, the step of cutting the tip of the cup is omitted, so that the manufacturing of the core is facilitated and the manufacturing time is shortened. And the cost can be further reduced.

In the method of manufacturing the core for the electromagnetic clutch according to the third aspect of the present invention, the bottom portion 3 can be easily made thick and a core having a large exciting force can be obtained. It is possible to obtain a high-performance electromagnetic clutch.

[Brief description of drawings]

1A to 1G are explanatory views illustrating an embodiment of a method for manufacturing an electromagnetic clutch core according to the present invention.

2A to 2G are explanatory views illustrating another embodiment of the method for manufacturing the core for an electromagnetic clutch according to the present invention.

3 (a) to 3 (e) are explanatory views for explaining still another embodiment of the method for manufacturing an electromagnetic clutch core of the present invention.

FIG. 4 is a partial sectional view showing an example of a conventional electromagnetic clutch.

5A is a perspective view showing an example of a core in a conventional electromagnetic clutch, and FIG. 5B is a sectional view taken along line XX of the core.

6A to 6G are explanatory views showing a conventional method for manufacturing a core.

[Explanation of symbols]

 1 Outer peripheral wall 2 Inner peripheral wall 3 Bottom part 4 Coil accommodating part 5 Electromagnetic coil 6 Metal plate 7 Cup 8 Tsuba 9 Hole 10 Convex part

Claims (3)

[Claims] 1. A coil-shaped coil housing having a U-shaped cross section surrounded by a ring-shaped outer peripheral wall (1), a ring-shaped inner peripheral wall (2), and a bottom portion (3) between the both peripheral walls (1, 2). In a method of manufacturing an electromagnetic clutch core capable of accommodating a donut-shaped electromagnetic coil (5) in a portion (4), a circular metal plate (6) is press-molded at a central portion thereof to form a bottomed cylindrical cup. (7) is formed and a circular collar (8) is formed on the outer periphery thereof, the bottom side of the cup (7) is cut off, and the remaining portion is made into a ring-shaped inner peripheral wall (2). The outer peripheral portion of 8) is pressed to form a ring-shaped outer peripheral wall (1) facing the inner peripheral wall (2) at a predetermined interval, and a bottom portion (3) is formed between both peripheral walls (1, 2). ) Is formed, and both peripheral walls (1,
A method of manufacturing a core for an electromagnetic clutch, characterized in that a coil accommodating portion (4) surrounded by 2) and a bottom portion (3) is formed. 2. A ring-shaped coil housing having a U-shaped cross section surrounded by a ring-shaped outer peripheral wall (1), a ring-shaped inner peripheral wall (2) and a bottom plate (3) between the both peripheral walls (1, 2). In a method of manufacturing an electromagnetic clutch core capable of accommodating a donut-shaped electromagnetic coil (5) in a portion (4), a circular metal plate (6) having a circular hole (9) in a central portion thereof is used. The central portion is pressed to form a ring-shaped inner peripheral wall (2), a circular collar (8) is formed on the outer periphery of the ring, and the outer peripheral portion of the collar (8) is pressed to form the inner peripheral wall (2). 2) and a ring-shaped outer peripheral wall (1) facing each other at a predetermined interval and a bottom portion (3) formed between the both peripheral walls (1, 2),
A method of manufacturing a core for an electromagnetic clutch, characterized in that a coil housing portion (4) surrounded by both peripheral walls (1, 2) and a bottom portion (3) is formed. 3. A portion of the metal plate (6) that will become the bottom portion (3) is pressed and narrowed down to form a convex portion 10, and the convex portion (10) is crushed to flesh the bottom portion (3). 3. The method for manufacturing an electromagnetic clutch core according to claim 1 or 2, wherein the core is formed to have a large thickness.