KR102291628B1 - Method for manufacturing throttle body of Electronic Throttle Control apparatus and bearing caulking tool used therein - Google Patents

Abstract

The present invention relates to a method for manufacturing a throttle body of an electronically controlled throttle valve device and a bearing caulking tool used therein. , including the bearing caulking step (S40), the throttle body is made of a skeleton part 100 made of aluminum and a housing 20 made of a plastic material, and the caulking tool 400 used in the bearing caulking step (S40) is caulked Since the portion 420 is formed in a quadrangular pyramid shape to enable point caulking, the caulking force is reduced, thereby preventing deformation of the bore diameter of the throttle body.

Description

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a method for manufacturing a throttle body of an electronically controlled throttle valve device, and to a caulking tool used in a bearing caulking step of a throttle body manufacturing method.

The throttle valve is a valve for controlling the amount of air supplied to the engine combustion chamber, and the opening degree is adjusted according to the degree of operation of the accelerator pedal.

Conventionally, the throttle valve is connected to the accelerator pedal with a cable to mechanically control the opening, but in recent years, an electronically controlled throttle valve device that receives signals from the accelerator pedal sensor and the throttle sensor to control the motor connected to the throttle valve is used. have.

This electronic control throttle valve device (ETC; Electronic Throttle Control system) is installed in a rotatable state in which a throttle valve is supported by a bearing on the inside of a cylindrical bore formed in a throttle body, and a motor case for inserting and installing a driving motor in the throttle body and a gearbox in which a gear train connecting the throttle valve to the drive motor is installed is integrally formed, and a cover for covering the gear train from the outside is mounted on the gearbox.

As described above, the throttle body (also referred to as 'ETC housing') of the electronically controlled throttle valve device has a bore, a motor case, and a gear box integrally formed, and the entire body is made of aluminum.

Therefore, the conventional throttle body has a problem of heavy weight and high material cost.

In addition, when the intake manifold (more specifically, the surge tank) is made of a plastic material, the vibration characteristics are different from that of the aluminum throttle body due to the difference in material. This is reduced, and the connection part on the intake manifold side, which is relatively weak in rigidity, is easily deformed, so there is a problem in that the mounting state of the throttle body cannot be firmly maintained.

Korean Patent Laid-Open Publication No. 2004-0031795 (2004.04.14.)

Accordingly, the present invention has been devised to solve the above problems, and to provide a method for manufacturing a throttle body of an electronically controlled throttle valve device in which weight and material cost are reduced and the mounting state of the throttle body can be firmly maintained. There is a purpose.

In addition, in carrying out the method for manufacturing the throttle body, the present invention provides a method for manufacturing a throttle body for an electronically controlled throttle valve device that can prevent the bore diameter of the throttle body from being deformed by the caulking force when the bearing is caulked in the bearing caulking step. It is another object to provide a bearing caulking tool used in

A method for manufacturing a throttle body of an electronically controlled throttle valve device according to the present invention for achieving the above object,

A skeleton part forming step of forming a skeleton part by an aluminum die-casting method, the skeleton part including a valve installation part where the throttle valve is installed, a motor installation part into which a motor is inserted and mounted, and a connection part for integrally connecting the valve installation part and the motor installation part; ;

Inserting the skeleton part into a mold and injecting a plastic material, a bore part forming a part of the inner diameter surface of the valve installation part, a motor case in which the motor installation part forms an inlet part, and a bearing formed on one side of the outer periphery of the valve installation part a housing forming step of forming a housing including a part and a gearbox surrounding a periphery of the motor installation part;

a bearing installation step of press-fitting a bearing into the bearing insertion part; and

a bearing caulking step of caulking the inner edge of the upper surface of the bearing insert with a caulking tool having a cone-shaped caulking part having a single point at the bottom to form a protrusion for preventing the bearing from being separated;

includes

In addition, in the frame forming step, a shaft hole is formed on the same line passing through the center of the valve installation part, and the bearing insertion part centered on one shaft hole is formed on the outer peripheral surface of the valve installation part, and the other shaft hole is formed as the center. A shaft insert is formed.

In addition, in the forming step of the skeleton, the connection part connects the bearing inserting part and the outer periphery of the motor installation part to each other.

In addition, a gear installation part is formed on the upper surface of the connection part to which an intermediate gear is installed among the gear trains connecting the motor output shaft and the shaft of the throttle valve.

In addition, in the forming step of the skeleton, the motor installation part has a central axis direction perpendicular to the central axis direction of the valve installation unit and parallel to the central axis direction of the shaft hole.

On the other hand, the bearing caulking tool used in the method for manufacturing the throttle body of the electronically controlled throttle valve device according to the present invention,

a cylindrical body;

a cone-shaped caulking part formed in a plurality of circumferential directions and at equal intervals on the lower edge of the body and having a single point at the lower end;

a shank portion protruding in the axial direction at the center of the upper end of the body;

includes

In addition, the caulking portion is formed in a quadrangular pyramid shape.

In addition, the inner surface of the body in the radial direction of the caulking portion is formed as an inclined surface.

In addition, the outer surface of the body in the radial direction of the caulking portion is formed as a vertical surface.

In addition, one end of the shaft of the throttle valve is inserted in the center of the lower surface of the body to form a shaft groove to avoid interference between the body and the throttle valve shaft.

According to the present invention as described above, since the housing of the throttle body is made of a plastic material, weight and material cost are reduced.

In addition, the bolt loosening and deformation of the bolt fastening portion are prevented, so that the mounting state of the throttle body is firmly and stably maintained.

In addition, since point caulking is possible, the caulking force is reduced, thereby preventing the bore of the throttle body from being deformed.

1 is a view for explaining a throttle body manufacturing method of the electronically controlled throttle valve device according to the present invention.
Figure 2 is a view for explaining the structure and working state of the bearing caulking tool used in the throttle body manufacturing method of the electronically controlled throttle valve device according to the present invention.
3 is a bottom view of the caulking tool;
4 is an enlarged side view of a caulking unit formed at a lower end of the caulking tool;
FIG. 5 is an enlarged cross-sectional view of a portion A of FIG. 2 , an enlarged cross-sectional view of a bearing insertion part to which caulking is performed and its periphery; FIG.
Fig. 6 is a diagram of a deformed state after caulking.
7 and 8 are views for explaining the shape of the protrusion according to the shape of the caulking tool. FIG. 7 is a case where the side surface of the caulking tool has a right-angled triangle shape, and FIG. 8 is a case where the side surface of the caulking tool has an isosceles triangle shape.
9 is a table summarizing the relationship between the shape of the caulking tool and the caulking force and separation force.

Since the present invention can have various changes and can have various embodiments, specific embodiments are illustrated in the drawings and described in detail. However, this is not intended to limit the present invention to specific embodiments, and it should be understood to include all modifications, equivalents and substitutes included in the spirit and scope of the present invention. The thickness of the lines or the size of the components shown in the accompanying drawings may be exaggerated for clarity and convenience of explanation.

In addition, the terms to be described later are terms defined in consideration of functions in the present invention, which may vary according to the intention or precedent of the user or operator. Therefore, definitions of these terms should be made based on the content throughout this specification.

Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the accompanying drawings.

1, the method for manufacturing the throttle body of the electronically controlled throttle valve device according to the present invention includes a skeleton forming step (S10), a housing forming step (S20), a bearing installation step (S30), and a bearing caulking step. (S40).

The skeleton forming step (S10) is a step of forming a portion constituting the inner skeleton of the throttle body by an aluminum die-casting method. The skeleton part 100 of the throttle body includes a valve installation part 110 in which a throttle valve is installed, a motor installation part 120 in which a motor driving the throttle valve is installed, a valve installation part 110 and a motor installation part ( It includes a connector 130 for connecting the 120 to each other.

The valve installation part 110 is formed in a cylindrical shape and forms a partial section in the axial direction (through direction) of the inner peripheral surface of the bore part 210 that forms an intake passage in the housing 200 . A bearing insert 111 into which the bearing 300 is inserted and installed, and a shaft insert 112 into which one end of the throttle valve shaft 500 is inserted are formed in the upper and lower portions of the valve installation unit 110 in a cylindrical shape ( see Fig. 2).

The bearing inserting part 111 and the shaft inserting part 112 are formed on the same line crossing the center of the valve installation part 110, and the shaft hole 110a passing through the valve installation part 110 in the center of each. , 110b) is formed so that the shaft 500 of the throttle valve is installed through the shaft holes 110a and 110b (see FIG. 2).

The motor installation unit 120 is formed in a cylindrical shape having a central axis direction perpendicular to the central axis direction of the valve installation unit 110 and parallel to the central axis direction of the shaft holes 110a and 110b, and the A plurality of bolt fastening parts are formed on the outer periphery to correspond to the bolt fastening parts formed in the throttle valve driving motor and are bolted together.

The connection part 130 is a part integrally connecting the bearing insertion part 111 of the valve installation part 110 and one side of the outer peripheral surface of the motor installation part 120, and is formed in a substantially narrow plate shape, and on the upper surface of the motor output shaft A gear installation part is formed so that an intermediate gear (not shown) of the gear train connecting the shaft 500 and the throttle valve can be installed.

The housing molding step (S20) includes inserting the skeleton part 100 into the housing molding mold, injecting a molten plastic material into the mold, and then cooling and taking out the housing surrounding the skeleton part 100 by an insert injection method ( 200) is formed.

The housing 200 includes a bore 210 that is a passage through which intake air passes, a motor case 220 that forms a motor accommodation space, and a gear train connecting the output shaft of the motor and the shaft 500 of the throttle valve. It includes a gearbox 230 that is.

The bore 210 is formed so that the valve installation part 110 is located in the middle of the inside, and the valve installation part 110 is exposed to the inside of the bore 210 so that the inner diameter surface of the valve installation part 110 is It forms a part of the inner diameter surface of the bore portion 210 .

The motor case 220 has a cylindrical shape in which the motor installation part 120 forms an inlet, and the other end (an end opposite to the motor installation part 120 position) has a closed structure. Accordingly, the motor is inserted and accommodated into the motor case 220 through the motor installation unit 120 , and the bolt fastening part of the motor is fixed to the bolt fastening part of the motor installation part 120 with bolts.

The gearbox 230 is formed in the shape of a wall surrounding the periphery of the bearing inserting part 111 and the motor installation part 120, and a driving gear mounted on the motor output shaft therein, and the throttle valve shaft 500. A gear train installation space is formed in which the mounted driven gear and the intermediate gear connecting the driving gear and the driven gear are installed.

The connection part 130 is embedded in the housing 200 , and only the gear installation part for the intermediate gear formed in the middle of the connection part 130 is exposed to the outside through the bottom surface of the gear box 230 .

In addition, a plurality of bolt fastening portions 240 for fixing the throttle body to the intake manifold side with bolts on the outer wall surface of the bore portion 210 and the gearbox 230 are formed on one side surface of the housing 200 . .

The bearing installation step ( S30 ) is a step of press-fitting the bearing 300 , which rotatably supports one end of the throttle valve shaft 500 , into the bearing insertion part 111 . As the bearing 300, a ball bearing may be used, and one end of the shaft 500 protruding to the outside of the valve installation unit 110 through the shaft hole 110a of one side of the valve installation unit 110 is a bearing 300. It is inserted and supported in the inner hole of the (see FIG. 2).

In the bearing caulking step (S40), after the bearing installation step (S30) is performed, caulking is performed using a caulking tool 400 to be described below on the upper surface of the bearing insert 111 into which the bearing 300 is press-fitted. This is a step of more firmly fixing the bearing 300 to the bearing insert 111 so that the bearing 300 does not fall out from the bearing insert 111 by doing so.

By performing the bearing caulking step (S40), a protrusion 111b is formed on the upper surface of the bearing insertion part 111 in a radial direction inward, and the bearing 300 is hung on the protrusion 111b, so that the bearing 300 is Separation from the bearing insert 111 is prevented (see FIG. 6, the protrusion 111b will be described in more detail later in the description of the action of the caulking tool 400).

When the bearing caulking step (S40) is carried out as described above, the manufacture of the throttle body is completed in a state in which the throttle valve can be installed.

As described above, the minimum part necessary for securing the necessary rigidity, that is, the skeleton part 100 is made of aluminum (Al) material, and the remaining housing 200 part is made of a plastic material, so that the weight of the throttle body is reduced and the material cost is reduced

In addition, since the housing 200 of the throttle body is made of plastic and has the same material as the intake manifold made of plastic, vibration characteristics of the intake manifold and the throttle body are similar.

Therefore, the fastening bolts do not loosen well even after a long time has elapsed since the throttle body is installed, and due to this reason and the reduced weight of the throttle body, the bolted part of the intake manifold is not easily deformed. and remain stable.

In addition, caulking is made on the upper surface of the bearing insert 111 to form a protrusion 111b radially inward of the bearing insert 111, so that the bearing 300 is caught by the protrusion 111b and the bearing insert 111 ) does not deviate from it. Therefore, the installation state of the bearing 300 is maintained very firmly.

In addition, since point caulking is performed by the caulking tool 400 , the caulking force is reduced, so that deformation of the valve installation unit 110 does not occur during caulking. That is, the throttle valve can be operated normally and smoothly because the bore diameter of the portion where the throttle valve is installed and operated is not deformed.

A bearing caulking tool used in the method for manufacturing the throttle body of the electronically controlled throttle valve device according to the present invention will now be described.

2, the caulking tool 400 includes a cylindrical body 410, a plurality of caulking parts 420 formed at equal intervals in the circumferential direction on the lower edge of the body 410, and the body ( A shank portion 430 protruding in the axial direction is included in the center of the upper end of the 410 .

The body 410 has a cylindrical (cylindrical) shape and a circular base end 411 having a predetermined width in the radial direction along the edge of the bottom surface is formed to protrude downward. That is, the proximal end 411 and the inner portion thereof (the lower surface of the body 410) have a step difference of a predetermined height. The caulking portions 420 are formed at the base end 411 at regular intervals.

In addition, in the center of the lower surface of the body 410, a circular shaft groove 412 is formed upwardly and inwardly. The shaft groove 412 is formed so that interference does not occur between the caulking tool 400 and the shaft 500 when caulking is performed while the shaft 500 of the throttle valve is press-fitted to the bearing 300 as shown in FIG. 2 . In order to do this, the upper end of the shaft 500 is formed to a sufficient depth that the upper end of the shaft 500 does not contact the inner upper wall surface of the shaft groove 412 even when the caulking tool 400 is lowered to the maximum.

The shank part 430 is a part for fixing the caulking tool 400 to the tool mounting part of the servo press, and the caulking tool 400 is firmly fixed to the tool mounting part of the servo press so that it can move up and down according to the press operation. There is no particular limitation on its shape.

2 to 4 , the caulking part 420 protrudes downwardly from the base end 411 protruding from the lower surface of the body 410 of the caulking tool 400 in a circular ring shape.

The caulking part 420 is formed in a cone shape having a lower end of one point.

In more detail, as shown in FIGS. 3 and 4 , the radially outer surface 421 is formed as a vertical surface, and the radially inner surface 422 is formed as an inclined surface, based on the state formed on the body 410 , and the outer surface Both side surfaces 423 connecting 421 and the inner surface 422 are formed in a quadrangular pyramid shape in which an upper inner angle of the outer surface 421 side is a right angle.

FIG. 5 is an enlarged view of part A of FIG. 2 , that is, the part where caulking is performed by the caulking part 420 of the caulking tool 400, reference numeral 300 denotes a bearing, 111 denotes a bearing insertion part, and 200 denotes a housing. . As shown, a step B exists between the upper surface of the bearing 300 and the upper surface of the bearing insert 111 in a state in which the bearing 300 is completely press-fitted. In more detail, the upper surface of the bearing insert 111 is formed as high as the step B compared to the upper surface of the bearing 300 .

Accordingly, when caulking is performed on a predetermined portion close to the inner edge of the upper surface of the bearing inserting part 111 by the caulking part 420, the upper surface of the bearing inserting part 111 has the same shape as the end shape of the caulking part 420. At the same time as the caulking groove 111a of the shape is formed, the outer side of one side of the caulking groove 111a (the inner corner portion of the upper surface of the bearing inserting part 111) is radially inside the bearing inserting part 111, that is, the bearing 300. The protruding portion 111b is formed by protruding deformation toward the side.

The protrusion 111b is caught on the upper edge of the bearing 300 to suppress the bearing 300 from being separated from the bearing insertion portion 111 . Since a plurality of these protrusions 111b are formed at regular intervals along the inner diameter of the bearing insertion portion 111 in one-to-one correspondence with the plurality of caulking portions 420 , the separation of the bearing 300 can be strongly suppressed.

On the other hand, the deformation of the upper surface of the bearing insertion part 111 by caulking is made according to the side shape of the caulking part 420 as shown in FIGS. 7 and 8 . That is, the protrusion 111b is formed as the material of the bearing insert 111 is pushed toward the side of the caulking portion 420 formed as an inclined surface.

The caulking portion 420 of FIG. 7 has a radially outer surface formed as a vertical surface and an inner surface formed as an inclined surface. This is made so that the protrusion 111b for holding the upper portion of the bearing 300 is easily and reliably formed.

On the other hand, the caulking part 420 of FIG. 8 is a case in which both the radially inner and outer surfaces are formed as inclined surfaces, and the protrusions 111b are formed in both directions, but the amount of protrusion is insignificant, so that the separation of the bearing 300 is effectively prevented. can't That is, in a state in which the same caulking force is applied, the caulking force is dispersed to both sides to form the protrusion 111b having a weak protrusion degree, thereby reducing the detachment force (the force for suppressing the detachment of the bearing 300 ).

In consideration of the contents of FIGS. 7 and 8, the caulking part 420 has a radially outer surface 421 of the body 410 is formed as a vertical surface, and an inner surface 422 is formed as an inclined surface of the bearing 300. It can be seen that it is more effective in preventing the escape of

Referring to FIG. 9 , a preferred shape of the caulking part 420 will be considered once again.

9 is a summary of the caulking force and detachment force according to the cone shape (conical, quadrangular pyramid), the angle of the horn (60 degrees, 45 degrees), and whether the outer surface is vertical (vertical surface, inclined surface), etc. of the caulking part 420 .

Comparing shapes 1 and 2 and shapes 3 and 4, when the caulking part 420 is a cone or a quadrangular pyramid, the caulking force is the same, but the detaching force is greater when the caulking unit 420 is a quadrangular pyramid. This is due to the fact that the width of the protrusion 111b is formed wider than that of a quadrangular pyramid when it is a quadrangular pyramid, and thus the area hung on the bearing 300 is increased. It can be seen that the shape is preferable.

Comparing shapes 3 and 4 with shapes 5 and 6, when all of the caulking portions 420 are formed in a quadrangular pyramid shape, and both the outer and inner surfaces are formed as inclined surfaces (shape 3 and 4) and the outer surface is a vertical surface, A case where only the inner surface is an inclined surface (shape 5 and 6) can be compared (however, shape 3 and shape 5 with the same angular condition are compared, and shape 4 and shape 6 are compared). In this case, it can be seen that the caulking force is small and the detachment force is large when the outer surface is vertical (shapes 5 and 6), compared to the case where both sides are inclined surfaces (shapes 3 and 4).

In carrying out the bearing caulking operation, it is advantageous to have a small caulking force to prevent bore diameter deformation, and to have a large separation force to prevent bearing separation. ), it can be seen that the shape is more preferable.

On the other hand, comparing Shape 5 and Shape 6, in which both outer surfaces are vertical, the caulking force is smaller (shape 6) than when the angle of the horn (more precisely, the angle between the inner and outer surfaces) is large (shape 5). Since this is smaller, it can be seen that a smaller angle of the horn is more advantageous from the viewpoint of the caulking force. (must be more than 1kN) is satisfied).

Considering all of the above, the caulking part 420 of the caulking tool 400 is a quadrangular pyramid in which both the radially outer surface 421 and the inner surface 422 of the body 410 are flat, and the outer surface 421 ) is a vertical surface, and the inner surface 422 is formed as an inclined surface, and it can be seen that the smaller the angle between the horn angle, that is, the outer surface 421 and the inner surface 422, the more advantageous.

However, when the angle between the outer surface and the inner surface is too small, the amount of protrusion of the protrusion 111b may decrease, so that the separation force may not satisfy the required level. The angle is appropriately determined.

As described above, when the caulking tool 400 according to the present invention is used, the caulking force is reduced because the caulking part 420 is formed in a cone shape to perform point caulking.

In addition, since the outer surface of the caulking part 420 is formed as a vertical surface and the inner surface is formed as an inclined surface, the protrusion 111b may be more easily formed.

Accordingly, it is possible to reduce the caulking force while securing the necessary breaking force.

As the caulking force is reduced as described above, it is possible to prevent the bore part inner diameter (more specifically, the inner diameter of the valve installation part 110) from being deformed by caulking, so that the throttle valve does not interfere with the bore part inner diameter surface. As a result, normal and smooth operation is possible, and collision noise does not occur during operation.

As described above, the present invention has been described with reference to the embodiments shown in the drawings, which are merely exemplary, and those of ordinary skill in the art can make various modifications and equivalent other embodiments therefrom. You will understand that it is possible. Therefore, the true technical protection scope of the present invention should be defined by the following claims.

100: skeleton 110: valve installation part
110a, 110b: shaft hole 111: bearing insertion part
112: shaft insertion part 120: motor installation part
130: connection 200: housing
210: bore 220: motor case
230: gearbox 300: bearing
400: caulking tool 410: body
411: base end 412: shaft groove
420: caulking portion 421: outer surface
422: inner side 423: both sides
430: shank part

Claims (10)

delete delete delete delete delete a cylindrical body;
a cone-shaped caulking part formed in a plurality of circumferential directions and at equal intervals on the lower edge of the body and having a single point at the lower end;
Including; and a shank portion protruding in the axial direction at the center of the upper end of the body;
The caulking portion has a quadrangular pyramid shape, an inner surface of the body in a radial direction of the caulking portion is formed as an inclined surface, an outer surface of the body in a radial direction of the caulking portion is formed as a vertical surface, and both sides between the inner surface and the outer surface are upper portions of the outer surface side A bearing caulking tool used in a method for manufacturing a throttle body of an electronically controlled throttle valve device, characterized in that the interior angle is formed in a right-angled triangle. delete delete delete 7. The method of claim 6,
A bearing caulking tool used in a throttle body manufacturing method of an electronically controlled throttle valve device, characterized in that one end of the shaft of the throttle valve is inserted in the center of the lower surface of the body, and a shaft groove is formed to avoid interference between the body and the throttle valve shaft.

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