KR20040089866A - Assembling process of idle air control valve for automobile - Google Patents

Abstract

PURPOSE: An assembly method of an idle air control valve for a vehicle is provided to easily wind coils around a terminal and to maximize operation and production efficiencies by automatically soldering and impregnating a coil connection portion of the terminal in a vessel containing melted lead. CONSTITUTION: An assembly method of an idle air control valve for a vehicle is composed of steps for preparing and positioning each part on a work table correspondent to each assembly step(ST1); joining and combining two stators or more to each other(ST2); inserting and combining a bearing joined to the rear end of a rotor in a bearing cap(ST3); inserting the rotor by a through-hole formed in the center of the stator and combining the stator with the bearing cap(ST4); bending and setting up a terminal projected from a connector cap and placed in parallel to the center line of the rotor in the direction crossing the center line of the rotor(ST5); inserting the bearing cap combined with the stator in a connector cap(ST6); winding each bent and set-up terminal with plural strips of coils drawn out from the stator(ST7); coating and soldering the terminal part wound with the coil with flux(ST8); lying down the coil and the soldered terminal at the original state(ST9); coating the soldering portion of the coil and terminal with silicon(ST10); inserting and combining an O-ring to the outer periphery of the connector cap(ST11); fitting a housing tube into the housing(ST12); coating the rotor with grease and then inserting a stator/rotor/bearing cap/connector cap assembly with an elastic washer in the housing(ST13); inserting and fixing a pin in a pin-combining hole formed on the correspondent position of the housing and the connector cap(ST14); coating a pintle with the grease and then inserting a pintle spring to the periphery of a pintle shaft(ST15); and combining the pintle shaft to the rotor by inserting the pintle from the front outer side of the housing into the housing(ST16).

Description

ASSEBLING PROCESS OF IDLE AIR CONTROL VALVE FOR AUTOMOBILE

The present invention relates to a method for assembling the idle air control valve of a vehicle, and more particularly, to bend the terminal protruding from the connector cap during the assembly of the idle air control valve applied to the throttle body of the vehicle. This ensures that the coil winding to the terminal is made very easy, and the soldering work on the coil wound on the terminal can be performed automatically to maximize workability and efficiency. The present invention relates to a method for assembling an idle air control valve of a vehicle that can improve the productivity and product quality significantly.

Generally, a throttle body is used to maintain a stable idle state in a change of driving environment, such as operating an air conditioner, turning on a light, or operating a power handle or various hydraulic actuators in a car. It is necessary to control the bypass area of the bypass.

To this end, one side of the throttle body installed to communicate with the engine of the vehicle is equipped with an idle air control valve operated by a small precision step motor as a part for controlling the bypass passage area.

1 is a schematic cross-sectional view showing a state where an idle air control valve is applied to a vehicle throttle body.

Referring to this, the throttle valve 13 is installed inside the intake passage 12 of the throttle body 11 which is installed to communicate with the engine 10 of the vehicle, and corresponds to the installation position above the throttle valve 13. A bypass passage 14 having a predetermined diameter is formed in the body of the throttle body 11 from an inner wall surface, and from any outside of the throttle body 11 to any point inside the bypass passage 14. An idle air control valve 20 is installed to control the amount of air flowing into the engine 10 via the bypass passage 14 when the throttle valve 13 is closed.

FIG. 2 is an exploded perspective view illustrating an idle air control valve applied to a throttle body of a vehicle, FIG. 3 is a perspective view of a coupled state of FIG. 2, and FIG. 4 is a cross-sectional view of an idle air control valve.

Referring to this, the idle air control valve 20 is a housing (Housing) 21 having a predetermined length and diameter, a housing tube 22 is fitted into the housing 21 and coupled, and the inside of the housing 21 A plurality of stators 23 inserted into the rotor to form a rotor magnetic field upon application of current, a rotor 24 fitted on an inner center line of the stator 23, and a rear end of the housing 21; A connector cap (26) electrically connected to the coil (25) constituting the stator (23) in a coupled state, and inserted into the rotor 24 from the outside of the front end of the housing 21 to the inside of the rotor 24. The pintle assembly 27 and the pintle assembly 26 which are screwed together and control the opening and closing state of the bypass passage 14 formed in the throttle body 11 while being moved back and forth in a straight line according to the rotational direction of the rotor 24. Stable movement of pintle assembly in the state of being fitted inside Pintle springs to consist of: a (Pintle Spring 28) and a key component.

In the idle air control valve 20, the housing 21 has a structure in which a flange portion 21b having a mounting hole 21a is formed on the outer circumferential surface of the tip portion thereof.

The stator 23 has a through hole 23a having a predetermined size formed along a center line, and has a ring shape in which a coil winding 23b having a predetermined depth is formed on an outer circumferential surface thereof. The coil 25 is wound around the mounting portion 23b.

Either side of the front and rear of the stator 23 is a joint surface to be integrally bonded to the other stator, a plurality of positions for the assembly of the other parts on the other side other than the joint surface in the correct position The crystal pins 23c protrude at regular intervals.

The housing tube 21 is made of metal and is coupled to the inside of the housing to surround the outer circumference of the stator 23 to serve to reinforce the magnetic field generated by the stator 23.

The rotor 24 is formed in a cylindrical shape having a diameter of a size that can be inserted into the through hole 23a in the center of the stator 23 to be rotated in place.

A screw portion 24 is formed inside the rotor 24, and a permanent magnet 24b is attached to an outer surface thereof so that the rotor 24 is rotated forward and backward in place by a magnetic field formed by the stator 23 when an electric current is applied. It is composed.

In addition, a bearing 24c is coupled to the rear end of the rotor 24 to smoothly perform the in-situ rotation operation.

The bearing 24c is configured to be inserted into and coupled to a bearing cap 29 provided separately, and the positioning pin 23c on the stator 23 is disposed on the front of the bearing cap 29 and the inside of the housing 21. The corresponding positioning groove 29a is formed.

The connector cap 26 is configured to be fitted into the rear end of the housing 21 and coupled therein, and a plurality of terminals 30 for electrical connection are injection molded therein.

The inner end of the terminal 30 is connected to the coil 25 on the stator 23, the outer end is configured to be exposed to the outside to be connected to an external power source.

In order to fix the coupling state of the housing 21 and the connector cap 26, a plurality of pin fastening holes 31 corresponding to each other are formed around the rear portion of the housing 21 and the front of the connector cap 26 to be fitted together. It is configured to be fixed by the pin 32 in the state.

The pintle assembly 27 is a rotor in a state in which it is integrally connected to a pintle 33 fitted into the bypass passage 14 and a seam 34 extending from the inner center of the pintle 33. 24 is composed of a pintle shaft (35) of a predetermined length that is screwed into the inside.

The tip portion of the pintle 33 has a warhead shape in order to be closely fitted in the bypass passage 14.

The joint part 34 extending from the inner side of the center line of the pintle 33 has a substantially rectangular shape so that the pintle shaft 35 is linearly moved in and out of the housing 21 without the pintle shaft 35 being rotated when the rotor 24 is rotated. It consists of a cross-sectional structure or a D-cut (D-Cut) cross-sectional structure, according to the guide hole 36 of the square hole or "D" shape is also formed inside the front end of the housing 21.

The joint portion 34 is made of a metal material having excellent wear resistance.

On the other hand, the inside of the front end of the housing 21 is fitted with an elastic washer (Resilient Washer: 37) for absorbing the vibration transmitted to the stator 23 from the outside.

On the other hand, the outer peripheral surface of the front end portion of the housing 21 and the connector cap 26 is fitted and coupled to the O-ring 38 for sealing, for this purpose O-ring fitting groove (on the outer periphery of the connector cap 26) 39) is formed.

5 is a flowchart illustrating a conventional method of assembling an idle air control valve, and FIG. 6 is a perspective view illustrating a terminal state on a connector cap in a coil winding step of a conventional method of assembling an idle air control valve.

Conventional assembling method for the idle air control valve as described in Figures 2 to 4 is largely as shown in Figure 5 preparation step (s1), stator coupling step (s2), rotor / bearing cap coupling step (s3) , Stator / bearing cap coupling step (s4), connector cap coupling step (s5), coil winding step (s6), soldering step (s7), O-ring insertion step (s8), tube press It consists of a step (s9), the insertion step (s10), the pin fastening step (s11), the pintle spring insertion step (s12), the pintle shaft coupling step (s13).

The preparation step (s1) is a step of preparing each component to be assembled before the full-scale assembly process.

In the preparation step (s1), the coil 25 is wound around the stator 23, the rotor 24 is coupled to the bearing 24c, bearing cap 29, connector cap 26, housing 21, housing tube (22), pintle assembly 27, pintle spring 28, elastic washer 37 and O-ring 38 are aligned on the worktable corresponding to each assembly step.

In the stator coupling step (s2), the two or more stators 23 wound around the coil 25 are integrally bonded to each other, and each stator 23 to be joined is placed on the jig. The adhesive is applied to the bonding surface and then bonded together.

In the rotor / bearing cap coupling step (s3), the bearing 24c coupled to the rear end of the rotor 24 is fitted to the bearing cap 29 to be coupled.

The stator / bearing coupling step (s4) is a step of coupling the rotor / bearing cap assembly and the stator 23.

In this step, the rotor / bearing cap assembly is positioned on the jig, and the adhesive is applied to the positioning groove 29a formed on the front surface of the bearing cap 29 while the stator 23 is positioned on the other jig.

Then, when a mechanical force is applied while the positioning pin 23c on the stator 23 is exactly aligned with the positioning groove 29a, through the through hole 23a formed at the center of the stator 23, At the same time as the rotor 24 is fitted, the positioning pin 23c on the stator 23 is fitted into the positioning groove 29a of the bearing cap 29, and the rotor / bearing cap assembly and the stator 23 are coupled. .

In the connector cap coupling step (s5), when the rear end of the stator / rotor / bearing cap assembly, that is, the bearing cap 29 is fitted in the connector cap 26, the bearing cap 29 is seated inside the connector cap 26. do.

In the coil connection step (s6), the coils 25 drawn from the stator 23 to each terminal 30 in a state of protruding from the inside of the connector cap 26 and lying in parallel with the center line direction of the rotor 24 Wrap it up.

In the soldering step s7, the coils wound around the terminals 30 are manually soldered and fixed using an electric iron.

In the O-ring insertion step s8, the O-ring 38 prepared in advance is fitted into the O-ring fitting groove 39 formed around the outer side of the connector cap 26.

In the tube pressing step (s9) is inserted into the housing tube 22 of a metal material provided separately inside the housing 21.

In the inserting step (s10) into the housing, grease is applied to the rotor 24, and then the stator / rotor / bearing cap / connector cap assembly is inserted into the housing / housing tube assembly together with the elastic washer 37. do.

In the pin fastening step (s11), the stator / rotor / bearing cap / connector cap assembly is inserted into the pin 32 by a pin fastening hole 31 formed at a position corresponding to each other on the housing 21 and the connector cap 26. (21) is fixed so as not to be separated.

In the pintle spring insertion step (s12), after applying grease to the pintle 33, the pintle spring 28 in the space formed between the outer peripheral surface of the joint portion 34, the pintle shaft 35 is fitted and the inner peripheral surface of the pintle 33 Insert

In the pintle shaft coupling step s13, the pintle shaft 35 is screwed into the rotor 24 by inserting the pintle 33 into the housing 21 from the outside of the front end of the housing 21.

In the conventional method of assembling the idle air control valve, the multiple-stranded coil 25 drawn from the stator 23 after inserting the stator / rotor / bearing assembly into the connector cap 26 is illustrated in FIG. 6. ) Coils (S6) wound around each terminal 30 protruding from the connector cap 26, the coil in each terminal 30 in a state in which the operator is lying side by side parallel to the direction of the center line of the rotor (24) 25) should be wound.

However, when the coil 25 is wound around the terminal 30 lying parallel to the center line direction of the rotor 24 in this way, the distance between the terminal and the terminal and between the terminal 30 and the stator 23 Due to the very narrow intervals, there is a serious problem that the workability and efficiency are significantly lowered and the failure rate is higher.

In addition, after winding the coil 25 in each terminal 30 lying parallel to the direction of the center line of the rotor 24, each terminal spaced at a narrow interval when soldering work to fix the coil wound portion There is a problem in that workability is very poor because the soldering work has to be done manually for 30, and the soldering is not performed properly, thereby degrading the quality of the product.

The present invention is to solve such a conventional problem, its purpose is to bend the terminal protruding from the connector cap in the assembly process of the idle air control valve applied to the throttle body of the car to ensure sufficient distance between the terminal and the stator Coil Winding to the terminal can be made very easy, and soldering work on the coil wound on the terminal can be done automatically to maximize workability and efficiency. On the other hand, it is to provide a method for assembling the idle air control valve of a new vehicle that can significantly improve the productivity and product quality.

1 is a schematic cross-sectional view showing a state in which an idle air control valve is applied to a throttle body of a vehicle;

2 is an exploded perspective view showing an idle air control valve applied to a throttle body of a vehicle;

3 is a perspective view of the coupled state of FIG.

4 is a cross-sectional view of the coupling state of the idle air control valve,

5 is a flowchart showing a method of assembling a conventional idle air control valve;

Figure 6 is a perspective view showing the state of the terminal on the connector cap in the coil connecting step of the conventional method of assembling the idle air control valve,

7 is a flowchart showing a method of assembling an idle air control valve according to the present invention;

8 is a perspective view showing the state of the terminal on the connector cap in the coil connection step and the soldering step of the assembling method of the idle air control valve according to the present invention.

** Description of symbols for the main parts of the drawing **

20: step motor 21: housing

22: Housing Tube 23: Stator

24: rotor 25: coil

26: connector cap 27: pintle assembly

28: pintle spring 29: bearing cap

30: terminal 31: pin fastening

32: pin 33: pintle

34: seam 35: pintle shaft

36: guide ball 37: elastic washer

38: O-ring 39: O-ring fitting groove.

In order to achieve the above object, the present invention includes a preparatory step of placing each component to be assembled on a work table corresponding to each assembly step; A stator joining step of joining and bonding two or more stators to each other; A rotor / bearing cap coupling step of fitting a bearing coupled to the rear end of the rotor into a bearing cap; A stator / bearing coupling step of fitting the rotor through a through hole formed in the center of the stator and allowing the stator to be joined to the bearing cap; A terminal bending step of bending a terminal formed parallel to the center line direction of the rotor from the connector cap in a direction orthogonal to the center line direction of the rotor; A connector cap coupling step of inserting a bearing cap coupled to a stator into the connector cap; A coil connection step of winding coils of several strands drawn out from the stator on each terminal bent on the connector cap; A soldering step of applying flux to the coiled terminal portion and then soldering the flux; A terminal restoring step of laying the coil and the soldered terminal back to their original state; A silicon coating step of applying silicon to the soldering portions of the coil and the terminal; O-ring insertion step of fitting the O-ring to the outer periphery of the connector cap; A tube press fitting step of inserting the housing tube into the inside of the housing; Applying grease to the rotor and inserting the stator / rotor / bearing cap / connector cap assembly with the elastic washer into the housing; A pin fastening step of fixing the pins to pin fastening holes formed at positions corresponding to each other on the housing and the connector cap; A pintle spring insertion step of applying grease to the pintle and then inserting the pintle spring around the pintle shaft; Pintle shaft coupling step of inserting the pintle into the housing from the outside of the front end of the housing to couple the pintle shaft to the rotor.

In the present invention as described above includes bonding to each other by applying an adhesive to the bonding surface of the two or more stator for the coupling of the stator.

In the present invention, the coupling of the stator and the bearing cap includes a method in which an adhesive is applied to the positioning groove on the bearing cap, and then the positioning pin on the stator is fitted into the corresponding positioning groove on the bearing cap.

In the present invention as described above, the soldering operation for the connection portion between the terminal and the coil includes automatically performed by impregnating the terminal portion in which the coil is wound in a container in which lead is molten.

Hereinafter, with reference to the accompanying drawings will be described in detail a preferred embodiment of the present invention.

7 is a flowchart showing a method for assembling an idle air control valve according to the present invention, and FIG. 8 shows a terminal state on a connector cap in a coil connection step and a soldering step in the method for assembling an idle air control valve according to the present invention. Perspective view.

Referring to this, the method for assembling the idle air control valve according to the present invention is largely prepared step (ST1), stator coupling step (ST2), rotor / bearing cap coupling step (ST3), stator bearing cap coupling step (ST4), the terminal Bending step (ST5), connector cap coupling step (ST6), coil connection step (ST7), soldering step (ST8), terminal restoring step (ST9), silicon coating step (ST10), O-ring insertion step (ST11), Tube pressing step (ST12), inserting into the housing (ST13), pin fastening step (ST14), pintle spring insertion step (ST15), pintle shaft coupling step (ST16).

In the present invention, the preparation step (ST1) is a step of preparing each component to be assembled before the full-scale assembly process.

In the preparation step ST1, the coil 25 is wound around the stator 23, the rotor 24 to which the bearing 24c is coupled, the bearing cap 29, the connector cap 26, the housing 21, and the housing tube. (22), pintle assembly 27, pintle spring 28, elastic washer 37, and O-ring 38 are aligned on the worktable corresponding to each assembly step.

In the stator joining step ST2, the two or more stators 23 wound around the coil 25 are integrally bonded to each other, and each stator 23 to be joined is placed on the jig. Apply adhesive to the bonding surface.

Then, one of the jig is reversed so that the joining surfaces of the respective stators 23 are joined to each other while facing each other.

In the rotor / bearing cap coupling step ST3, the bearing 24c coupled to the rear end of the rotor 24 is fitted to the bearing cap 29 to be coupled.

The stator / bearing coupling step ST4 is a step of coupling the rotor / bearing cap assembly and the stator 23.

In this step, the rotor / bearing cap assembly is positioned on the jig, and the adhesive is applied to the positioning groove 29a formed on the front surface of the bearing cap 29 while the stator 23 is positioned on the other jig.

Then, when a mechanical force is applied while the positioning pin 23c on the stator 23 is exactly aligned with the positioning groove 29a, through the through hole 23a formed at the center of the stator 23, At the same time as the rotor 24 is fitted, the positioning pin 23c on the stator 23 is fitted and joined to the positioning groove 29a of the bearing cap 29, so that the rotor / bearing cap assembly and the stator 23 are coupled. do.

In the terminal bending step ST5, as shown in FIG. 8, the terminal 30 protrudes from the connector cap 26 and is laid side by side in the center line direction of the rotor 24. Bend to stand in a direction perpendicular to.

In the connector cap coupling step (ST6), if the rear end of the stator / rotor / bearing cap assembly, that is, the bearing cap 29 is fitted in the connector cap 26, the bearing cap 29 is seated inside the connector cap 26. do.

In the coil connection step ST7, the coil 25 of several strands drawn from the stator 23 is wound around each terminal 30 which is bent and erected.

In this case, as the gap between the stator 23 and the terminal 30 is sufficiently secured, the worker can easily connect the coil 25 to the terminal 30 and connect it.

In the soldering step ST8, the soldering is performed by applying a flux to the terminal portion on which the coil 25 is wound with flux, and then impregnating the coiled terminal portion into a lead-melted container.

In the terminal restoring step (ST9), after the coil 25 is connected, the terminal 30, which has been soldered, is laid back to its original state.

In the silicon application step (ST10), the silicon is applied to the coil connection portion on the terminal 30 laid back to its original state from the standing state so that the connection state of the coil can be maintained firmly even from external impact.

In the O-ring insertion step (ST11), the O-ring 38 prepared in advance is fitted into the O-ring fitting groove 39 formed around the outer side of the connector cap 26.

In the tube pressing step (ST12) is inserted into the housing tube 22 of a metal material provided separately inside the housing 21.

In the inserting step into the housing (ST13), after applying grease to the rotor 24, the stator / rotor / bearing cap / connector cap assembly is inserted into the housing / housing tube assembly together with the elastic washer 37.

In the pin fastening step ST14, the stator / rotor / bearing cap / connector cap assembly is inserted into the pin 32 by a pin fastening hole 31 formed at a position corresponding to each other on the housing 21 and the connector cap 26. It is fixed so that it may not be detached from the state fitted in (21).

In the pintle spring insertion step (ST15), after applying grease to the pintle 33, pintle spring 28 in the space formed between the outer peripheral surface of the joint portion 34, the pintle shaft 35 is fitted and the inner peripheral surface of the pintle 33 Insert

In the pintle shaft coupling step (ST16) through the guide hole 36 formed at the front end of the housing 21, the pintle 33 is inserted into the housing 21 to pintle shaft 35 into the rotor 24 Be screwed.

The idle air control valve 20 completed through such an assembly process maintains a combined state as shown in FIGS. 3 and 4.

The assembled idle air control valve 20 is finally applied to the throttle body 11 as shown in Figure 1 through the performance test, the operation relationship will be described as follows.

When the engine 10 of the vehicle is in the idle state, when the air conditioner is activated or the light is turned on, the coil constituting the stator 23 through the terminal 30 on the connector cap 26 according to the signal from the control device ( A current flows through 25 to form a rotating magnetic field in the inner space of the stator 23.

At the same time, the rotor 24 is rotated in the forward or reverse direction in a predetermined angular range by the influence of the magnetic field, so that the pintle shaft 35 screwed inside the rotor 24 has a It moves linearly in and out.

In accordance with the linear movement of the pintle shaft 35, the pintle 33 is also linearly moved inward or outward of the housing 21 to control the opening and closing state of the bypass passage 14 formed on the throttle body 11 to control the engine. It is to control the amount of air flowing into (10).

According to the present invention, the stator / rotor / bearing cap assembly is coupled to the connector cap so that the terminal protruding from the connector cap is bent to stand in a direction orthogonal to the direction of the center line of the rotor. The coil connection work is very simple and the soldering operation on the coil connection part on the terminal is automatically performed by impregnating the container with the molten lead, which maximizes workability and productivity, and reduces the defective rate. You can improve the quality.

Claims (4)

A preparation step (ST1) for placing each part to be assembled on a work table corresponding to each assembling step; A stator joining step (ST2) for joining and joining two or more stators 23 to each other; A rotor / bearing cap coupling step (ST3) for fitting the bearing coupled to the rear end of the rotor 24 into the bearing cap 29; A stator / bearing coupling step (ST4) for fitting the rotor through a through hole formed in the center of the stator and allowing the stator 23 to be coupled to the bearing cap 29; A terminal bending step (ST5) of bending the terminal 30 protruding from the connector cap and lying down in parallel with the direction of the center line of the rotor in a direction orthogonal to the direction of the center line of the rotor; A connector cap coupling step (ST6) for inserting the bearing cap coupled to the stator into the connector cap 26; A coil connection step (ST7) for winding several coils 25 drawn from the stator 23 to each terminal 30 which is bent and erected; A soldering step (ST8) of soldering after applying flux to the coiled terminal portion; A terminal restoration step (ST9) for laying the coil and the soldered terminal 30 back to its original state; A silicon coating step (ST10) of applying silicon to soldering portions of the coil and the terminal; O-ring insertion step (ST11) for fitting the O-ring to the outer circumference of the connector cap 26; A tube press fitting step (ST12) for inserting and inserting the housing tube 22 into the housing 21; Applying grease to the rotor 24 and inserting the stator / rotor / bearing cap / connector cap assembly together with the elastic washer 37 into the housing (ST13); A pin fastening step (ST14) of fixing the pins 32 to the pin fastening holes 31 formed at positions corresponding to each other on the housing and the connector cap; A pintle spring insertion step (ST15) of applying a grease to the pintle 33 and inserting the pintle spring around the pintle shaft 35; A method of assembling an idle air control valve for a vehicle including a pintle shaft coupling step (ST16) for inserting the pintle into the housing from the outside of the front end of the housing so that the pintle shaft 35 is coupled to the rotor 24. The method of claim 1, Assembling the idle air control valve of the vehicle, characterized in that for bonding the stator by applying an adhesive to the bonding surface of the two or more stator to be bonded to each other. The method of claim 1, The coupling of the stator 23 and the bearing cap 29 is performed by applying an adhesive to the positioning groove 29a on the bearing cap, and then positioning pins 23c of the stator image 23 on the bearing cap corresponding positions. Assembling method of the idle air control valve of the vehicle, characterized in that made in the manner of being fitted into the groove. The method of claim 1, Idle air control of the vehicle, characterized in that the soldering to the connection between the terminal 30 and the coil 25 is automatically performed by impregnating the terminal portion wound the coil in a container in which lead is molten Assembly method of the valve.