WO2013174253A1 - 电磁开关、其制造方法及车辆起动机 - Google Patents

电磁开关、其制造方法及车辆起动机 Download PDF

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Publication number
WO2013174253A1
WO2013174253A1 PCT/CN2013/075981 CN2013075981W WO2013174253A1 WO 2013174253 A1 WO2013174253 A1 WO 2013174253A1 CN 2013075981 W CN2013075981 W CN 2013075981W WO 2013174253 A1 WO2013174253 A1 WO 2013174253A1
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WO
WIPO (PCT)
Prior art keywords
push rod
iron core
electromagnetic switch
movable
movable iron
Prior art date
Application number
PCT/CN2013/075981
Other languages
English (en)
French (fr)
Inventor
博雷斯⋅J
陈国军
陈戟铭
Original Assignee
博世汽车部件(长沙)有限公司
罗伯特·博世有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 博世汽车部件(长沙)有限公司, 罗伯特·博世有限公司 filed Critical 博世汽车部件(长沙)有限公司
Priority to BR112014028799-6A priority Critical patent/BR112014028799B1/pt
Priority to EP13794212.4A priority patent/EP2930734B1/en
Publication of WO2013174253A1 publication Critical patent/WO2013174253A1/zh
Priority to IN9825DEN2014 priority patent/IN2014DN09825A/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits or control means specially adapted for starting of engines
    • F02N11/087—Details of the switching means in starting circuits, e.g. relays or electronic switches
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H49/00—Apparatus or processes specially adapted to the manufacture of relays or parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
    • H01H50/041—Details concerning assembly of relays
    • H01H50/045—Details particular to contactors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/02—Non-polarised relays
    • H01H51/04—Non-polarised relays with single armature; with single set of ganged armatures
    • H01H51/06—Armature is movable between two limit positions of rest and is moved in one direction due to energisation of an electromagnet and after the electromagnet is de-energised is returned by energy stored during the movement in the first direction, e.g. by using a spring, by using a permanent magnet, by gravity
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/02—Non-polarised relays
    • H01H51/04—Non-polarised relays with single armature; with single set of ganged armatures
    • H01H51/06—Armature is movable between two limit positions of rest and is moved in one direction due to energisation of an electromagnet and after the electromagnet is de-energised is returned by energy stored during the movement in the first direction, e.g. by using a spring, by using a permanent magnet, by gravity
    • H01H51/065—Relays having a pair of normally open contacts rigidly fixed to a magnetic core movable along the axis of a solenoid, e.g. relays for starting automobiles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N15/00—Other power-operated starting apparatus; Component parts, details, or accessories, not provided for in, or of interest apart from groups F02N5/00 - F02N13/00
    • F02N15/006—Assembling or mounting of starting devices

Definitions

  • Electromagnetic switch manufacturing method thereof and vehicle starter
  • the present invention relates to an electromagnetic switch for use in a vehicle starter, a method of manufacturing such an electromagnetic switch, and a vehicle starter including such an electromagnetic switch. Background technique
  • the starter of a motor vehicle is usually composed of a direct current motor, a transmission mechanism, a control mechanism, and the like.
  • the electric motor When starting the engine of the vehicle, the electric motor generates a rotational torque that is transmitted to the ring gear on the flywheel of the engine through the drive gear of the transmission mechanism to drive the crankshaft rotation of the engine.
  • the control mechanism is used to control the opening and closing of the starter circuit and to control the engagement and disengagement of the drive gear with the ring gear.
  • the widely used starter control mechanism is an electromagnetic switch.
  • Fig. 1 is a schematic view showing the structure of an electromagnetic switch of a conventional starter.
  • the electromagnetic switch mainly comprises: a fixed iron core 4 and an electromagnetic coil 6 fixedly mounted in the casing 2; two terminal posts 10 carried by the cover portion 8 fixed on the casing 2; axially movable inside the electromagnetic coil 6
  • the electromagnetic coil 6 After the ignition switch of the vehicle is turned on, the electromagnetic coil 6 generates an electromagnetic force in the movable iron core 16, so that the movable iron core 16 moves rearward toward the fixed iron core 4, so that the contact bridge 14 is driven by the push rod 12 to contact the two binding posts. 10 to electrically connect the two, thereby turning on the main circuit of the motor to drive the motor to rotate. After the contact bridge 14 contacts the two terminals 10 and establishes an electrical connection between the two terminals 10, the movable core 16 continues to move toward the fixed core 4 for a short period of retention until it is blocked by the fixed core 4.
  • the front end of the push rod 18 pulls the transmission mechanism through the shifting fork 9, so that its driving gear moves forward to mesh with the ring gear on the engine flywheel, thereby starting the engine.
  • the retention stroke ensures that the electromagnetic switch maintains the above function after ablation occurs at the contact between the contact bridge 14 and the two terminals 10.
  • the front end of the push rod 18 is previously formed with a joint window, and the push rods 12, 18 are pre-assembled on the movable iron core 16, and the electromagnetic coil 6 and the fixed iron core 4 are mounted in the casing 2, Then, the movable iron core 16 with the push rods 12, 18 is mounted inside the electromagnetic coil 6, and then the contact bridge 14 is assembled to the push rod 12, and finally the cover portion 8 is fixed to the housing. 2 on.
  • the positional relationship between the components is determined and cannot be adjusted. Due to the complex size chain from the movable core 16, the electromagnetic coil 6, the housing 2 to the cover 8, the tolerance range of the retention stroke is large.
  • the present invention is directed to solving the problem of low retention accuracy of a drive gear caused by a retention stroke of an electromagnetic switch and a large tolerance range of a joint window size and position in a prior art vehicle starter.
  • a method of manufacturing a vehicle starter electromagnetic switch comprising the steps of:
  • the retention stroke may be from 0.5 to 1.5 mm, preferably about 1 mm.
  • a current sensor is used to detect an initial electrical connection state, and the current sensor determines two when it detects that a current starts flowing between the two terminals. An initial electrical connection state is established between the terminals.
  • fixing the movable core to the push rod in the step (7) is achieved by crimping, riveting or welding a part of the material of the movable core to the push rod.
  • the part of the material of the movable core which is crimped, riveted or welded is previously formed in the form of a cylinder at the front end of the movable core.
  • a portion of the pusher to be crimped or riveted into the part of the material of the movable core is previously formed with a roughened surface, a depression or a projection.
  • the above manufacturing method further includes the following steps performed after the step (7): (8) processing the upper end of the shifting fork into the front end of the push rod while keeping the movable iron core pushed against the fixed iron core The joint window.
  • the joint window is made by mechanical punching or laser cutting.
  • the present invention in another aspect thereof, provides an electromagnetic switch for use in a vehicle starter, which can be manufactured by the aforementioned manufacturing method, and includes: a fixed iron core; a movable iron core movable forward and backward with respect to a fixed iron core; a pair of posts at a position behind the core; a one-piece pusher carried by the movable core, the pusher passing through the fixed iron core such that the rear end of the push rod is exposed from the rear of the fixed iron core; a resilient member; and a contact bridge mounted at the rear end of the push rod and facing the pair of terminals, the push rod being movable rearward relative to the contact bridge against the force of the elastic member;
  • the contact bridge is in contact with the two terminals, and after the initial electrical connection state is established between the two terminals, the push rod is moved backward by a retaining stroke while the movable iron core is pushed against the fixed iron core, The movable iron core is fixed on the push rod.
  • the retention stroke is 0.5 to 1.5 mm, preferably about 1 mmo.
  • a part of the material of the movable core is crimped, riveted or welded to the push rod.
  • the part of the material of the movable core which is crimped, riveted or welded is in the form of a cylindrical portion which is formed in advance at the front end of the movable core.
  • a portion of the push rod that is crimped or riveted into the portion of the material of the movable core is provided with a roughened surface, a recess or a protrusion.
  • the front end of the push rod is provided for inserting the upper end of the shift fork Join the window into it.
  • the present invention in still another aspect thereof, provides a vehicle starter comprising: an electric motor; a transmission mechanism coupled to an output shaft of the electric motor; and an electromagnetic switch as described above that controls operation of the electric motor and the transmission mechanism.
  • a single push rod is employed, and the retention stroke is established by the rearward movement of the push rod after the initial electrical connection state between the contact bridge and the two terminals is detected, so that the retention stroke is not The influence of complex dimensional chains, so that the tolerance of the retention stroke can be reduced.
  • the push rod is further moved backward by a retaining stroke and the movable iron core is pushed against the fixed iron core to fix the push rod and the movable iron core together and form a joint window. Therefore, the size of the joint window and the tolerance of the positioning can be reduced, and the positioning accuracy of the drive gear can be improved.
  • FIG. 1 is a schematic structural view of an electromagnetic switch in a vehicle starter according to the prior art.
  • Fig. 2 is a schematic view showing the initial stage of the structure and assembly process of the electromagnetic switch in the vehicle starter according to a preferred embodiment of the present invention.
  • FIG. 3 is a schematic illustration of the intermediate stages of the assembly process of the electromagnetic switch of Figure 2.
  • Figure 4 is a schematic illustration of the final stage of the assembly process of the electromagnetic switch of Figure 2.
  • Figure 5 is a schematic illustration of a contact bridge that may be employed in the electromagnetic switch of Figure 2 and its manner of installation.
  • Fig. 6 is a schematic structural view of an electromagnetic switch in a vehicle starter according to another preferred embodiment of the present invention. detailed description
  • the electromagnetic switch for use in a vehicle starter in accordance with one embodiment of the present invention is shown in FIG.
  • the electromagnetic switch includes a housing 2 having a substantially cylindrical body and a reduced diameter portion 2a provided at a front end of the body (the left end in Fig. 2, the end facing the side of the vehicle engine).
  • a fixed iron core 4 is fixedly mounted in the rear portion of the body of the casing 2.
  • the fixed iron core 4 A substantially disk-shaped large diameter portion fixed in the body of the casing 2, a substantially cylindrical small diameter portion projecting forward from the large diameter portion, and a substantially frustoconical portion projecting forward from the small diameter portion. Further, a guide through hole penetrating forward and backward in the axial direction is formed in the fixed iron core 4.
  • a substantially cylindrical non-magnetic material (for example, brass) bushing 32 is mounted in the casing 2, wherein the front end of the bushing 32 is inserted into the reduced diameter portion 2a of the casing 2, and the rear end is fitted to the fixed iron core 4 On the small diameter portion, the bushing 32 is thereby fixed in the housing 2.
  • a substantially cylindrical non-magnetic material for example, brass
  • the electromagnetic coil 6 is mounted between the bushing 32 and the body of the housing 2 and supported by the bushing 32.
  • the movable iron core 16 is disposed in an axially movable manner.
  • the movable core 16 is substantially cylindrical, and a mounting through hole, a spring receiving groove, and a frustoconical receiving groove are sequentially formed from the front to the rear.
  • the substantially frustoconical portion of the fixed core 4 is adapted to be inserted into the frustoconical pocket of the movable core 16.
  • a single push rod 30 is fixedly carried by the movable core 16 so as to be axially movable with the movable core 16.
  • the push rod 30 has a substantially cylindrical large diameter front section 30a and a substantially cylindrical small diameter rear section 30b which are coaxially disposed and joined forward and backward.
  • the front side portion of the large diameter front section 30a is fixed in the mounting through hole of the movable iron core 16, and the rear side portion extends in the spring receiving groove of the movable iron core 16.
  • a transition step between the large diameter front section 30a and the small diameter rear section 30b is located in the spring receiving groove or the frustoconical receiving groove.
  • the small-diameter rear section 30b of the push rod 30 extends rearward from the large-diameter front section 30a in the axial direction, passes through the guide through-hole in the fixed iron core 4, and the rear end of the small-diameter rear section 30b is exposed from the rear end surface of the fixed iron core 4.
  • the front end of the large-diameter front section 30a protrudes forward from the front end surface of the movable iron core 16, and the front end of the large-diameter front section 30a has (for example, integrally formed) a flat head 40 in which a joint window is to be processed for
  • An upper end of a shift fork (not shown) is inserted therein, and a substantially central portion of the shift fork is pivotally supported, and a lower end of the shift fork is coupled to the transmission mechanism.
  • the transmission mechanism can be moved axially forward by the shifting fork to move the driving gear of the transmission mechanism toward the ring gear on the engine flywheel and Engage.
  • the transmission mechanism can be moved axially backward by the shifting fork to disengage the drive gear of the transmission mechanism from the ring gear on the engine flywheel.
  • a contact bridge 14 is mounted on the small-diameter rear section 30b of the push rod 30 near the rear end of the push rod 30.
  • a mount 28 is mounted on the small diameter rear section 30b in an axially slidable manner, which may be made of an insulating plastic.
  • the mounting seat 28 has a substantially disk shape and its inner circumference The face is slidably fitted to the small diameter rear section 30b.
  • the mount 28 includes a front flange 28a and a rear cylinder segment 28b.
  • the outer diameter of the front flange 28a is larger than the outer diameter of the rear cylindrical section 28b and larger than the inner diameter of the guide through hole of the fixed core 4.
  • a contact bridge 14 is carried on the rear cylindrical section 28b, the front side of which is urged against the front flange 28a and the rear side is blocked by the fastening means 42.
  • a sleeve 20 and a compression spring 22 are fitted to the push rod 30.
  • the sleeve 20 is located at the front of the small diameter rear section 30b, and the compression spring 22 is sandwiched between the rear end of the sleeve 20 and the front flange 28a of the mount 28.
  • the outer diameter of the sleeve 20 is adapted to slidably fit in the guide through hole of the fixed core 4.
  • the contact bridge 14 In a state where the contact bridge 14 is clamped to the rear end of the push rod 30 as described above, the contact bridge 14 can move axially forward (sliding) on the small-diameter rear portion 30b of the push rod 30 against the thrust of the compression spring 22. ), but its backward movement will be blocked by the fastening device 42.
  • the fastening device 42 can have any suitable configuration, such as that shown in Figure 5, wherein the fastening device 42 includes a washer 44 that pushes against the rear side of the contact bridge 14, a rim 46 that is located on the rear side of the washer 44, A clip 48 that is fixed to the rear end of the push rod 30 behind the steel ring 46. It will be appreciated that any structure and element that allows the contact bridge 14 to move forward relative to the push rod 30 but prevent it from moving rearward relative to the push rod 30 at the rear end of the push rod 30 can be utilized.
  • the sleeve 20 may be made of an insulating plastic and has a substantially cylindrical shape.
  • the front end of the sleeve 20 abuts against a transition step between the large-diameter front section 30a and the small-diameter rear section 30b, and the rear end is pushed by the front end of the compression spring 22.
  • the cover portion 8 is fixed to the rear of the casing 2, and the two terminals 10 are passed through the cover portion 8 and fixed therein.
  • Most of the front portion of each of the terminals 10 constitutes a contact end 10a, and the front end faces of the two contact ends 10a face the rear surface of the contact bridge 14.
  • the cover portion 8 can be made of plastic.
  • the front portion of each of the posts 10 is fixed in the cover portion 8, and the rear portion is exposed from the rear surface of the cover portion 8.
  • the two terminals 10 can be fixed in the material of the cover 8 by insert molding.
  • the two posts 10 can be secured to the cover 8 with fasteners.
  • the rear portion of each of the posts 10 may be threaded to lock the terminal 10 to the cover 8 with a nut (not shown) that engages the threads.
  • a compression spring 24 is interposed between the movable core 16 and the fixed core 4.
  • the front end of the compression spring 24 is located in the spring receiving groove of the movable iron core 16 and is pushed against the bottom of the spring receiving groove. Ministry.
  • the rear portion of the compression spring 24 is sleeved on the sleeve 20.
  • the rear end of the compression spring 24 is urged against the front end face of the fixed core 4 (which is substantially frustoconical).
  • the compression spring 24 serves as a return spring for the push rod 30.
  • the compression spring 22 serves as a return spring for the contact bridge 14, and also serves as a return spring for the push rod 30. It is conceivable that the push rod and the contact bridge can also be provided with other forms of restoring elastic elements.
  • a flange 16a is formed around the push rod 30, which projects forward from the front end of the body of the movable core 16.
  • the outer diameter of the flange 16a is much smaller than the radial dimension of the body of the movable core 16.
  • a cylindrical fixing connection portion 16b is formed around the push rod 30, which protrudes forward from the front end surface of the flange 16a, and has a radial thickness set by crimping, riveting, welding
  • the tool fixes the outer circumference of the push rod 30 (the large diameter front section 30a) by crimping, riveting, welding, or the like.
  • the respective elements described above are first manufactured, but the joint window has not been machined in the flat head portion 40.
  • the fixed core 4 is mounted in the casing 2 with the bushing 32 and the electromagnetic coil 6.
  • the rear end of the push rod 30 is inserted into the mounting through hole of the movable iron core 16 from the front side of the movable iron core 16 so that the large diameter front portion 30a of the push rod 30 is slidably disposed in the mounting through hole of the movable iron core 16.
  • the movable iron core 16 is loaded into the casing 2 from the front side with the push rod 30, the sleeve 20, and the compression spring 24, wherein the movable iron core 16 is slidably inserted in the bushing 32; the small diameter rear section of the push rod 30 30b passes through the guide through hole of the fixed iron core 4, so that the rear end of the push rod 30 is exposed from the rear side of the fixed iron core 4; the sleeve 20 is at least partially inserted into the guide through hole of the fixed iron core 4, and the compression spring 24 is compressed Between the movable core 16 and the fixed iron core 4.
  • the compression spring 22 is fitted from the rear side to the small-diameter rear section 30b of the push rod 30, and most of it is inserted into the guide through-hole of the fixed iron core 4, and then the mount 28 is assembled on the rear end of the push rod 30 in turn. , the contact bridge 14 and the fastening device 42.
  • the compression spring 22 is pre-compressed between the sleeve 20 and the mount 28.
  • the cover 8 is attached to the casing 2 from the rear side with two terminals 10.
  • the push rod 30 is slidable in the movable core 16.
  • a detecting device such as a current sensor, which can detect an on-off state between the two terminals 10 is connected.
  • the thrust of the axially rearward (to the right in Fig. 2) is applied to the push rod 30 to move the push rod 30 rearward until the contact bridge 14 contacts the contact end 10a of the two terminals 10, as shown in Fig. 3.
  • the movable core 16 may also be moved backwards against the thrust of the compression spring 24 (e.g., by the flat head 40).
  • the contact bridge 14 After the contact bridge 14 initially contacts the two terminals 10, the contact bridge 14 is blocked from continuing to move backwards, and the push rod 30 continues to move rearward. At this time, the compressive force in the compression spring 22 starts to increase, so that the contact pressure between the contact bridge 14 and the two terminals 10 is gradually increased.
  • a very small first distance eg, 0.05 to 0.1 mm
  • the compression force increase value i.e., the current compression force minus the pre-compression force
  • This initial electrical connection state can be detected by the detecting means so that the detecting means obtains an initial turn-on signal. For example, a current flows through two terminals 10, and an initial current signal flowing through the two terminals 10 is obtained by the current sensor.
  • the push rod 30 is further moved rearward by a second distance that is greater than the first distance.
  • the second distance is from 0.5 to 1.5 mm, preferably about 1 mm. This second distance can be seen as a retention stroke to ensure a reliable electrical connection after ablation of the contact between the contact bridge 14 and the two terminals 10.
  • the electromagnetic switch is in the position shown in FIG. 4, wherein the fastening device 42 is separated from the contact bridge 14 by a distance L (equal to the first distance plus the second distance), which is the contact bridge 14 and the two terminals 10 The backward movement distance of the push rod 30 after the initial contact.
  • the movable iron core 16 is pushed in the rearward direction until it pushes against the fixed iron core 4, thereby being prevented from moving further backward.
  • the rear end surface of the movable iron core 16 is pushed against the front end surface of the substantially cylindrical small diameter portion of the fixed iron core 4.
  • the push rod 30 is fixed in the movable iron core 16 in a state where the push rod 30 is maintained at the rearward moving distance and the movable iron core 16 is pushed against the fixed iron core 4.
  • the fixing of the two is to press the fixed connecting portion 16b of the movable iron core 16 by pressure, crimping, welding or the like. This is achieved by attaching, riveting, welding, etc. to fix the outer circumference of the push rod 30 (large diameter front section 30a).
  • the presence of the flange 16a provides a large operating space for tools such as crimping, riveting, and welding.
  • pretreatment may be performed on a portion of the push rod 30 which is expected to be crimped or riveted, for example, a roughened surface or a depression, a projection, or the like.
  • a joint window 40a is formed in the flat head portion 40 of the push rod 30 for the fork Insert the upper end.
  • the joining window 40a can be formed by a method such as punching, laser processing or the like.
  • One or more portions (e.g., surfaces) on the housing 2 can be used as a positioning reference when the joining window 40a is machined.
  • the movable core 16 is released to move forward with the push rod 30 under the thrust of the compression springs 22 and 24 (to the left in Fig. 4).
  • the fastening device 42 contacts the contact bridge 14 and pulls it away from the two terminals 10.
  • the movable iron core 16 continues to move forward with the push rod 30 until the front flange 28a of the mounting seat 28 is pushed against the rear end of the fixed iron core 4, for example, against the fixed iron core. 4 in the rear groove. In this state, the movable core 16 is prevented from moving forward with the push rod 30.
  • the assembly order of the components is not limited to those described above, but may be set according to the specific structure of these components.
  • the retention stroke is established after the initial electrical connection state between the contact bridge 14 and the two terminals 10 is detected and further moved backward by the push rod 30, thus The retention stroke is not affected by the complex size chain, so the tolerance of the retention stroke can be small.
  • a single push rod 30 is employed to replace the two push rods of the prior art.
  • the push rod 30 is further moved backward by a distance and the movable iron core 16 is pushed against the fixed iron core 4 to move the push rod 30 and the movable state.
  • the cores 16 are fixed together and form a joint window 40a. Therefore, there is a simple size chain (contact bridge 14 - single push rod 30) between the joint window 40a and the terminal 10, so the tolerance range of the size and positioning of the joint window is also small.
  • the joint window only exists the most The dimensions and positioning tolerances formed by the post-processing process are avoided, and intermediate assembly tolerances affecting the size of the joint window and the range of positioning tolerances are avoided in the prior art.
  • the size and positioning tolerance of the joint window of the present invention is much smaller than in the prior art, and the positioning accuracy of the drive gear can be greatly improved.
  • the present invention improves upon the construction and manner of construction of an electromagnetic switch having a one-piece pusher to reduce the tolerance of the retention stroke and the tolerances of the size and positioning of the engagement window.
  • the structure and arrangement of other components associated with a one-piece pusher for example, the sleeve 20, the mount 28, the structure of the fastening device 42, the arrangement of the compression springs 22, 24, etc., do not limit the above-described ideas of the present invention. .
  • FIG. 6 shows an electromagnetic switch in a vehicle starter according to another preferred embodiment of the present invention, which differs from the electromagnetic switch shown in FIGS. 2-4 mainly in that the sleeve 20 has an enlarged portion. diameter of.
  • the diameter of the guide through hole of the fixed iron core 4 is correspondingly increased.
  • the gap between the inner peripheral wall of the guide through hole of the fixed iron core 4 and the outer peripheral surface of the small diameter rear portion 30b of the push rod 30 is increased, so that the magnetic gap between the fixed iron core 4 and the push rod 30 is increased, thereby pushing
  • the influence of the rod 30 on the magnetic circuit generated by the electromagnetic coil 6 is reduced, which makes it possible to make the push rod 30 with a low-priced magnetic material such as ordinary steel.
  • the push rod 30 in the electromagnetic switch shown in Figures 2-4 is typically made of a high cost non-magnetic material (e.g., copper, copper alloy, stainless steel, etc.).

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Push-Button Switches (AREA)
  • Manufacture Of Switches (AREA)
  • Electromagnets (AREA)

Abstract

一种车辆起动机电磁开关制造方法，包括：将固定铁心（4）、带有单件式推杆（30）的活动铁心（6）安装在壳体（2）中，在推杆上安装弹性元件（22），在推杆后端安装接触桥（14），使推杆向后移动直至检测到两个接线柱（10）之间通过接触桥建立初始电连接状态，使推杆进一步向后移动一段保留行程，然后在保持活动铁心推抵于固定铁心的状态下，将活动铁心固定在推杆上，并在推杆前端加工出用于将拨叉的上端插入其中的接合窗口（40a）。以及根据该方法制成的电磁开关和包含这种电磁开关的车辆起动机。采用该方法制造的电磁开关可减小保留行程的公差、定位公差和接合窗口尺寸，从而提高驱动齿轮的定位精度。

Description

电磁开关、 其制造方法及车辆起动机
技术领域
本发明涉及一种用于车辆起动机中的电磁开关、 这种电磁开关的制 造方法以及包含这种电磁开关的车辆起动机。 背景技术
机动车辆的起动机通常由直流电动机、 传动机构和控制机构等组成。 在起动车辆的发动机时， 电动机产生旋转力矩， 该旋转力矩通过传动机 构的驱动齿轮传递到发动机飞轮上的齿圈， 来驱动发动机的曲轴旋转。
控制机构用于控制起动机电路的通断， 以及控制驱动齿轮与齿圈的 啮合和脱开。 目前， 广泛使用的起动机控制机构是电磁开关。 图 1 示出 了一种现有起动机电磁开关的结构示意图。 该电磁开关主要包括： 固定 安装在壳体 2中的固定铁心 4和电磁线圈 6; 由固定在壳体 2上的盖部 8 承载的两个接线柱 10; 在电磁线圈 6内侧可轴向移动的活动铁心 16; 固 定在活动铁心 16上的推杆 12和 18， 其中推杆 12后端装有接触桥 14， 推杆 18前端设有与拨叉 9接合的接合窗口。
在车辆点火开关接通后， 电磁线圈 6在活动铁心 16中产生电磁力， 从而使得活动铁心 16向后朝向固定铁心 4移动， 以使接触桥 14被推杆 12带动而接触到两个接线柱 10以将二者电连接， 由此接通电动机的主电 路而驱动电动机旋转。 在接触桥 14接触到两个接线柱 10并且在两个接 线柱 10之间建立电连接后， 活动铁心 16继续朝向固定铁心 4移动一小 段保留行程， 直至被固定铁心 4阻止。 在此期间， 推杆 18的前端通过拨 叉 9 拉动传动机构， 从而其驱动齿轮向前移动而与发动机飞轮上的齿圈 发生啮合， 由此起动发动机。 所述保留行程可确保在接触桥 14与两个接 线柱 10之间的接触部位发生烧蚀后， 电磁开关仍能维持上述功能。
在图 1所示的电磁开关的组装时， 推杆 18前端预先形成接合窗口， 并且推杆 12、 18预先组装在活动铁心 16上， 电磁线圈 6和固定铁心 4 被安装在壳体 2中， 再将带有推杆 12、 18的活动铁心 16安装在电磁线 圈 6内侧， 然后再向推杆 12上组装接触桥 14， 最后将盖部 8固定在壳体 2上。 在这种电磁开关中， 在组装完成后， 各部件之间的位置关系就被确 定而无法调节。 由于存在从活动铁心 16、 电磁线圈 6、 壳体 2到盖部 8 的复杂尺寸链， 因此所述保留行程的公差范围较大。 另一方面， 对于接 合窗口的定位精度而言， 也存在电磁开关组装完成后不能调节的问题以 及接合窗口与接线柱 10之间存在复杂尺寸链的问题， 因此接合窗口尺寸 和位置的公差范围也较大。
上述两方面的公差范围较大会带来各种问题， 例如驱动齿轮的定位 精度低等。 发明内容
本发明旨在解决现有技术的车辆起动机中的电磁开关的保留行程和 接合窗口尺寸和位置的公差范围较大导致的驱动齿轮的定位精度低的问 题。
为此， 根据本发明的一个方面， 提供了一种车辆起动机电磁开关制 造方法， 包括下述步骤：
( 1 ) 将固定铁心固定安装在壳体中；
( 2 )将带有单件式推杆的活动铁心安装在壳体中， 其中活动铁心可 前后移动地位于壳体中， 推杆可前后滑动地位于活动铁心中， 并且推杆 穿过固定铁心， 以使推杆的后端从固定铁心的后部露出；
( 3 ) 在推杆上安装弹性元件， 并在推杆的后端上安装接触桥， 以使 得推杆可抵抗着所述弹性元件的作用力相对于接触桥向后移动；
(4 )使推杆向后移动， 直到检测到设于接触桥后面的两个接线柱之 间通过所述接触桥而建立了初始电连接状态；
(5 ) 使推杆进一步向后移动一段保留行程；
(6 )在保持活动铁心推抵于固定铁心的状态下将活动铁心固定在推 杆上。
在上述制造方法中，所述保留行程可以为 0.5至 1.5 mm,优选大约 1 mm。
在上述制造方法中， 优选地， 采用电流传感器来检测初始电连接状 态， 所述电流传感器在检测到开始有电流流经两个接线柱之间时确定两 个接线柱之间建立了初始电连接状态。
在上述制造方法中， 优选地， 在步骤 （7 ) 中将活动铁心固定在推杆 上是通过将活动铁心的一部分材料压接、 铆接或焊接在推杆上而实现的。
在上述制造方法中， 优选地， 所述活动铁心的被压接、 铆接或焊接 的所述一部分材料被预先以圆筒的形式形成在活动铁心前端。
在上述制造方法中， 优选地， 推杆的将被压接或铆接于活动铁心的 所述一部分材料中的部位被预先形成糙化表面、 凹陷或突起。
优选地， 上述制造方法还包括在步骤（7 )之后执行的下述步骤： （8 ) 在保持活动铁心推抵于固定铁心的状态下在推杆前端加工出用于将拨叉 的上端插入其中的接合窗口。
优选地， 所述接合窗口通过机械冲裁或激光切割而制成。
本发明在其另一方面提供了一种用于车辆起动机中的电磁开关， 其 可以利用前述制造方法制成， 并且包括： 固定铁心； 可相对于固定铁心 前后移动的活动铁心； 设于固定铁心后面位置处的一对接线柱； 由活动 铁心承载的单件式推杆， 所述推杆穿过固定铁心， 以使得推杆的后端从 固定铁心的后部露出； 安装在推杆上的弹性元件； 以及安装在推杆后端 并且面对着所述一对接线柱的接触桥， 所述推杆可抵抗着所述弹性元件 的作用力相对于接触桥向后移动； 其中， 在所述接触桥与两个接线柱接 触而在两个接线柱之间建立初始电连接状态之后使推杆向后移动了一段 保留行程、 同时保持活动铁心推抵于固定铁心的状态下， 所述活动铁心 被固定在推杆上。
在上述电磁开关中， 优选地， 所述保留行程为 0.5至 1.5 mm, 优选 大约 1 mmo
在上述电磁开关中， 优选地， 活动铁心的一部分材料被压接、 铆接 或焊接在推杆上。
在上述电磁开关中， 优选地， 所述活动铁心的被压接、 铆接或焊接 的所述一部分材料的形式为预先形成在活动铁心前端的圆筒形部分。
在上述电磁开关中， 优选地， 推杆的被压接或铆接于活动铁心的所 述一部分材料中的部位设有糙化表面、 凹陷或突起。
在上述电磁开关中， 优选地， 推杆的前端设有用于将拨叉的上端插 入其中的接合窗口。
本发明在其又一方面提供了一种车辆起动机， 包括： 电动机； 与电 动机的输出轴相连的传动机构； 以及如前所述的电磁开关， 其控制所述 电动机和传动机构的操作。
根据本发明， 单一的推杆被采用， 并且保留行程是在接触桥与两个 接线柱之间的初始电连接状态被检测到后通过推杆进一步向后移动而确 立的， 因此保留行程不受复杂尺寸链的影响， 从而保留行程的公差可以 减小。
此外， 在接触桥与两个接线柱初始接触后推杆进一步向后移动了一 段保留行程并且保持活动铁心被推抵于固定铁心的状态下将推杆与活动 铁心固定在一起并且形成接合窗口。 因此， 接合窗口的尺寸和定位的公 差范围也可以减小， 驱动齿轮的定位精度可以提高。 附图说明
图 1是一种根据现有技术的车辆起动机中的电磁开关的结构示意图。 图 2是根据本发明的一个优选实施方式的车辆起动机中的电磁开关 的结构和组装过程的初始阶段的示意图。
图 3是图 2中的电磁开关的组装过程的中间阶段的示意图。
图 4是图 2中的电磁开关的组装过程的最后阶段的示意图。
图 5是图 2中的电磁开关中可能采用的接触桥及其安装方式的示意 图。
图 6是根据本发明的另一个优选实施方式的车辆起动机中的电磁开 关的结构示意图。 具体实施方式
下面参照附图描述本发明的一些优选实施方式。
图 2 中显示了根据本发明的一个实施方式的用于车辆起动机中的电 磁开关。该电磁开关包括壳体 2， 其具有大致圆筒形本体和设在本体前端 (图 2中的左端， 朝向车辆发动机那一侧的端部） 的减径部分 2a。
在壳体 2 的本体的后部中， 固定安装着固定铁心 4。 该固定铁心 4 包括固定在壳体 2 的本体中的大致圆盘形大径部分、 从大径部分向前突 出的大致圆柱形小径部分、 从小径部分向前突出的大致截锥形部分。 此 外， 在固定铁心 4中形成有沿轴向前后贯通的导向通孔。
大致圆筒形的非磁性材料 （例如黄铜） 衬套 32安装在壳体 2中， 其 中， 衬套 32的前端插装于壳体 2的减径部分 2a中， 后端套装在固定铁 心 4的小径部分上， 由此将衬套 32固定在壳体 2中。
电磁线圈 6安装在衬套 32与壳体 2的本体之间， 并由衬套 32支撑。 在衬套 32的大致前部中， 以可轴向移动的方式布置着活动铁心 16。 该活动铁心 16大致呈圆柱形， 其内从前至后形成有直径依次增大的安装 通孔、 弹簧容置槽、 截锥形容槽。 固定铁心 4 的大致截锥形部分适于插 入活动铁心 16的截锥形容槽中。
单一的推杆 30由活动铁心 16固定地承载， 从而可随活动铁心 16— 起轴向移动。 推杆 30具有大致圆柱形的大径前段 30a和大致圆柱形的小 径后段 30b， 二者同轴设置且前后衔接。大径前段 30a的前侧部分固定在 活动铁心 16的安装通孔中， 后侧部分在活动铁心 16的弹簧容置槽中延 伸。 大径前段 30a与小径后段 30b之间的过渡台阶位于所述弹簧容置槽 或截锥形容槽中。
推杆 30的小径后段 30b从大径前段 30a沿轴向向后延伸， 穿过固定 铁心 4中的导向通孔， 小径后段 30b的后端从固定铁心 4的后端面露出。
大径前段 30a的前端从活动铁心 16的前端面向前伸出， 并且大径前 段 30a的前端具有 （例如一体形成有） 扁头部 40， 该扁头部中将加工出 接合窗口， 用于将拨叉 （未示出） 的上端插入其中， 该拨叉的大致中部 被可枢转地支撑， 该拨叉的下端与传动机构相连。 这样， 推杆 30沿轴向 向后 （图 2 中向右） 移动时， 可通过拨叉带动传动机构轴向向前移动， 以使传动机构的驱动齿轮朝向发动机飞轮上的齿圈移动并与其啮合。 反 之， 推杆 30沿轴向向前 （图 2中向左） 移动时， 可通过拨叉带动传动机 构轴向向后移动， 以使传动机构的驱动齿轮脱离发动机飞轮上的齿圈。
在推杆 30的小径后段 30b上靠近推杆 30的后端装有接触桥 14。 具 体而言， 参照图 2并结合图 5， 在小径后段 30b上以可轴向滑动的方式装 有安装座 28， 其可以由绝缘塑料制成。 安装座 28呈大致圆盘状， 其内周 面可滑动地配合于小径后段 30b上。 安装座 28包括前部凸缘 28a和后部 圆筒段 28b。前部凸缘 28a的外径大于后部圆筒段 28b的外径， 并且大于 固定铁心 4的导向通孔的内径。 在后部圆筒段 28b上承载着接触桥 14， 该接触桥 14的前侧推抵于前部凸缘 28a， 后侧被紧固装置 42挡住。
此外， 在推杆 30上套装有套筒 20以及压缩弹簧 22。套筒 20位于小 径后段 30b的前部， 压缩弹簧 22被夹在套筒 20的后端与安装座 28的前 部凸缘 28a之间。 套筒 20的外径适于可滑动地配合在固定铁心 4的导向 通孔中。
在接触桥 14被如上所述的方式夹持于推杆 30后端的状态下， 接触 桥 14能够抵抗着压缩弹簧 22的推力而在推杆 30的小径后段 30b上轴向 向前移动 （滑动）， 但其向后的移动将被紧固装置 42阻挡。
可以理解， 紧固装置 42可以具有任何适宜的结构， 例如图 5中所示 的， 其中紧固装置 42包括推抵于接触桥 14后侧的垫圈 44、 位于垫圈 44 后侧的钢圈 46、在钢圈 46后面固定在推杆 30后端的卡子 48。可以理解， 任何允许接触桥 14相对于推杆 30向前移动、 但阻止其在推杆 30的后端 处相对于推杆 30向后移动的结构和元件都可以采用。
套筒 20可以由绝缘塑料制成， 呈大致圆筒状， 套筒 20的前端抵靠 于大径前段 30a与小径后段 30b之间的过渡台阶， 后端被压缩弹簧 22的 前端推抵。
盖部 8固定在壳体 2的后部， 并且两个接线柱 10穿通盖部 8并固定 于其中。每个接线柱 10的前部加大部分构成接触端 10a,两个接触端 10a 的前端面面对着接触桥 14的后表面。
盖部 8可以由塑料制成。 每个接线柱 10的前部固定在盖部 8中， 后 部从盖部 8的后表面露出。
两个接线柱 10可以通过镶嵌成型而固定在盖部 8的材料中。 或者， 两个接线柱 10可以利用紧固件固定在盖部 8上。 例如， 每个接线柱 10 的后部可以形成有螺紋， 以便利用与所述螺紋啮合的螺母 （未示出） 将 接线柱 10锁紧于盖部 8上。
此外， 在活动铁心 16与固定铁心 4之间装有压缩弹簧 24。该压缩弹 簧 24的前端位于活动铁心 16的弹簧容置槽中并推抵于弹簧容置槽的底 部。 该压缩弹簧 24的后部套设于套筒 20上。 该压缩弹簧 24的后端推抵 于固定铁心 4 (其大致截锥形部分） 的前端面。
压缩弹簧 24用作推杆 30的复位弹簧。 压缩弹簧 22用作接触桥 14 的复位弹簧， 还兼用作推杆 30的复位弹簧。 可以设想， 也可以为推杆和 接触桥配备其它形式的复位弹性元件。
在活动铁心 16的前端， 围绕着推杆 30形成有凸缘 16a， 其从活动铁 心 16 的本体的前端面向前突伸。 该凸缘 16a的外径远小于活动铁心 16 的本体的径向尺寸。
在凸缘 16a的前端，围绕着推杆 30形成有圆筒形的固定连接部 16b， 其从凸缘 16a 的前端面向前突伸， 并且其径向厚度设置成可通过压接、 铆接、 焊接等工具通过压接、 铆接、 焊接等方式固定推杆 30 (大径前段 30a) 的外周。
根据本发明， 在制造图 2所示的电磁开关时， 上面描述的各个元件 首先被制造出来， 但扁头部 40中尚未加工出接合窗口。
然后， 组装各个元件。 首先， 将固定铁心 4带着衬套 32和电磁线圈 6安装在壳体 2中。
接下来， 从活动铁心 16的前侧将推杆 30的后端插入活动铁心 16的 安装通孔中， 以使得推杆 30的大径前段 30a可滑动地位于活动铁心 16 的安装通孔中。
接下来， 在推杆 30上套装套筒 20以及压缩弹簧 24。
接下来， 将活动铁心 16带着推杆 30、 套筒 20、 压缩弹簧 24从前侧 装入壳体 2中， 其中活动铁心 16可滑动地插在衬套 32中； 推杆 30的小 径后段 30b穿过固定铁心 4的导向通孔， 以使得推杆 30的后端从固定铁 心 4后侧露出； 套筒 20至少部分地插在固定铁心 4的导向通孔中， 而压 缩弹簧 24被压缩在活动铁心 16与固定铁心 4之间。
接下来， 从后侧将压缩弹簧 22套装在推杆 30的小径后段 30b上， 并且其大部分插入固定铁心 4的导向通孔中， 然后依次在推杆 30的后端 上装配安装座 28、 接触桥 14和紧固装置 42。 压缩弹簧 22被预压缩在套 筒 20与安装座 28之间。
接下来， 将盖部 8带着两个接线柱 10从后侧安装到壳体 2上。 在如此预组装的电磁开关中， 推杆 30可在活动铁心 16中滑动。 接下来， 在两个接线柱 10 的暴露的后部连接可检测两个接线柱 10 之间通断状态的检测装置， 例如电流传感器。
向推杆 30施加轴向向后 （图 2中向右） 的推力， 以使推杆 30向后 移动， 直至接触桥 14接触到两个接线柱 10的接触端 10a, 如图 3所示。 在此过程中， 活动铁心 16可能也被抵抗着压缩弹簧 24的推力向后移动 (例如由扁头部 40带动）。
在接触桥 14初始接触到两个接线柱 10后， 接触桥 14被阻止而不能 继续向后移动， 而推杆 30则继续向后移动。 此时， 压缩弹簧 22中的压 缩力开始增大， 以使得接触桥 14与两个接线柱 10之间的接触压力逐渐 增大。在接触桥 14初始接触到两个接线柱 10之后推杆 30继续向后移动 了一段非常小的第一距离 （例如 0.05至 0.1 mm) 后， 接触桥 14与两个 接线柱 10之间建立初始电连接状态， 此时压缩弹簧 22中的压缩力增加 值 （即当前压缩力减去预压缩力） 很小。
这种初始电连接状态可通过检测装置检测出来， 从而检测装置获得 初始接通信号。 例如， 开始有电流流经两个接线柱 10， 由电流传感器获 取流经两个接线柱 10的初始电流信号。
在初始接通信号被检测到后， 使推杆 30进一步向后移动第二距离， 该第二距离大于第一距离。例如， 第二距离为 0.5至 1.5 mm, 优选大约 1 mm。 该第二距离可以看作是保留行程， 用以确保在接触桥 14与两个接 线柱 10之间的接触部位发生烧蚀后仍能实现可靠的电连接。
此时， 电磁开关处在图 4所示位置， 其中， 紧固装置 42与接触桥 14 分开一段距离 L (等于第一距离加第二距离），该距离是接触桥 14与两个 接线柱 10初始接触后推杆 30的向后移动距离。
在这种状态下， 将活动铁心 16沿向后方向推压， 直至其推抵于固定 铁心 4， 从而被阻止不能进一步向后移动。 例如， 此时活动铁心 16的后 端面推抵于固定铁心 4的大致圆柱形小径部分的前端面上。
在推杆 30保持处在所述向后移动距离处并且活动铁心 16被推抵于 固定铁心 4上的状态下， 将推杆 30固定在活动铁心 16中。 二者的固定 是通过压接、 铆接、 焊接等工具将活动铁心 16的固定连接部 16b通过压 接、 铆接、 焊接等方式固定推杆 30 (大径前段 30a) 的外周而实现的。 凸缘 16a的存在为压接、 铆接、 焊接等工具提供了较大的操作空间。
为了提高推杆 30与活动铁心 16之间的连接强度， 可在推杆 30的预 期被压接或铆接的部位上进行预处理， 例如形成糙化表面或凹陷、 突起 等。
在推杆 30与活动铁心 16固定在一起后， 在保持活动铁心 16推抵于 固定铁心 4的状态下， 在推杆 30的扁头部 40中加工出接合窗口 40a， 用 以将拨叉的上端插入其中。 接合窗口 40a可以通过冲压、 激光加工等方 法形成。 在加工接合窗口 40a时， 壳体 2上的一或多个部位 （例如表面） 可以用作定位基准。
在加工出接合窗口 40a后， 松开活动铁心 16， 以使其在压缩弹簧 22 和 24的推力作用下带着推杆 30向前移动 （图 4中向左）。 在推杆 30向 前移动经过了前述距离 L后， 紧固装置 42接触到接触桥 14并将其拉离 两个接线柱 10。 接下来， 在压缩弹簧 24的作用下， 活动铁心 16带着推 杆 30继续向前移动， 直至安装座 28的前部凸缘 28a推抵于固定铁心 4 的后端， 例如推抵于固定铁心 4 的后端凹槽中。 在这种状态下， 活动铁 心 16带着推杆 30被阻止而不能进一步向前移动。
需要指出， 在根据本发明的上述电磁开关的制造过程中， 各部件的 组装次序并不局限于前面描述的， 而是可以根据这些部件的具体结构而 设定。
根据本发明的上述电磁开关的结构和制造过程， 保留行程是在接触 桥 14与两个接线柱 10之间的初始电连接状态被检测到后通过推杆 30进 一步向后移动而确立的， 因此保留行程不受复杂尺寸链的影响， 从而保 留行程的公差可以很小。
此外， 单一的推杆 30被采用， 以取代现有技术中的两个推杆。 在这 种构造中， 在接触桥 14与两个接线柱 10初始接触后推杆 30进一步向后 移动了一段距离并且保持活动铁心 16被推抵于固定铁心 4的状态下将推 杆 30与活动铁心 16固定在一起并且形成接合窗口 40a。 因此， 接合窗口 40a与接线柱 10之间存在简单的尺寸链（接触桥 14-单一推杆 30)， 因此 接合窗口的尺寸和定位的公差范围也很小。 换言之， 接合窗口只存在最 后加工过程形成的尺寸和定位公差， 而现有技术中影响接合窗口尺寸和 定位公差范围的中间装配公差被避免。 本发明的接合窗口的尺寸和定位 的公差远小于现有技术， 驱动齿轮的定位精度可以极大地提高。
可以看到， 本发明对具有单件式推杆的电磁开关的结构和制造方式 进行了改进， 以减小保留行程的公差以及接合窗口的尺寸和定位的公差。 与单件式推杆有关的其它元件的结构和布置， 例如， 套筒 20、安装座 28、 紧固装置 42的结构、 压缩弹簧 22、 24的布置方式等， 不对本发明的上 述思想构成限制。
举例而言， 图 6 中显示了根据本发明的另一个优选实施方式的车辆 起动机中的电磁开关，其与图 2-4中所示电磁开关的不同之处主要在于套 筒 20具有加大的直径。 在这种情况下， 固定铁心 4的导向通孔的直径相 应地增大。 结果， 固定铁心 4的导向通孔的内周壁与推杆 30的小径后段 30b的外周面之间的空隙增大， 以使得固定铁心 4与推杆 30之间的磁隙 加大， 从而推杆 30对电磁线圈 6产生的磁路的影响减小， 这使得利用低 价格的磁性材料（例如普通钢）制成推杆 30成为可能。与此对照， 图 2-4 中所示电磁开关中的推杆 30通常由高价格的非磁性材料 （例如铜、 铜合 金、 不锈钢等） 制成。
本发明的其它方面涉及通过上述制造方法制成的具有前述结构的电 磁开关以及包含这种电磁开关的车辆起动机。
虽然这里参考具体的实施方式描述了本发明， 但是本发明的范围并 不局限于所示的细节。 在不偏离本发明的基本原理的情况下， 可针对这 些细节做出各种修改。

Claims

权 利 要 求
1. 一种车辆起动机电磁开关制造方法， 包括下述步骤：
( 1 ) 将固定铁心固定安装在壳体中；
(2 )将带有单件式推杆的活动铁心安装在壳体中， 其中活动铁心可 前后移动地位于壳体中， 推杆可前后滑动地位于活动铁心中， 并且推杆 穿过固定铁心， 以使推杆的后端从固定铁心的后部露出；
( 3 ) 在推杆上安装弹性元件， 并在推杆的后端上安装接触桥， 以使 得推杆可抵抗着所述弹性元件的作用力相对于接触桥向后移动；
(4 )使推杆向后移动， 直到检测到设于接触桥后面的两个接线柱之 间通过所述接触桥而建立了初始电连接状态；
(5 ) 使推杆进一步向后移动一段保留行程；
(6 )在保持活动铁心推抵于固定铁心的状态下将活动铁心固定在推 杆上。
2. 如权利要求 1所述的车辆起动机电磁开关制造方法， 其中， 所述 保留行程为 0.5至 1.5 mm, 优选大约 1 mm。
3. 如权利要求 1或 2所述的车辆起动机电磁开关制造方法， 其中， 采用电流传感器来检测初始电连接状态， 所述电流传感器在检测到开始 有电流流经两个接线柱之间时确定两个接线柱之间建立了初始电连接状 态。
4. 如权利要求 1至 3中任一项所述的车辆起动机电磁开关制造方法， 其中， 在步骤 （7 ) 中将活动铁心固定在推杆上是通过将活动铁心的一部 分材料压接、 铆接或焊接在推杆上而实现的。
5. 如权利要求 4所述的车辆起动机电磁开关制造方法， 其中， 所述 活动铁心的被压接、 铆接或焊接的所述一部分材料被预先以圆筒的形式
6. 如权利要求 4所述的车辆起动机电磁开关制造方法， 其中， 推杆 的将被压接或铆接于活动铁心的所述一部分材料中的部位被预先形成糙 化表面、 凹陷或突起。
7. 如权利要求 1至 6中任一项所述的车辆起动机电磁开关制造方法， 还包括在步骤 （7 ) 之后执行的下述步骤：
( 8 )在保持活动铁心推抵于固定铁心的状态下在推杆前端加工出用 于将拨叉的上端插入其中的接合窗口。
8. 如权利要求 7所述的车辆起动机电磁开关制造方法， 其中， 所述 接合窗口通过机械冲裁或激光切割而制成。
9. 一种用于车辆起动机中的电磁开关， 包括：
固定铁心；
可相对于固定铁心前后移动的活动铁心；
设于固定铁心后面位置处的一对接线柱；
由活动铁心承载的单件式推杆， 所述推杆穿过固定铁心， 以使得推 杆的后端从固定铁心的后部露出；
安装在推杆上的弹性元件； 以及
安装在推杆后端并且面对着所述一对接线柱的接触桥， 所述推杆可 抵抗着所述弹性元件的作用力相对于接触桥向后移动；
其中， 在所述接触桥与两个接线柱接触而在两个接线柱之间建立初 始电连接状态之后使推杆向后移动了一段保留行程、 同时保持活动铁心 推抵于固定铁心的状态下， 所述活动铁心被固定在推杆上。
10. 如权利要求 9所述的电磁开关，其中，所述保留行程为 0.5至 1.5 mm, 优选大约 1 mm。
11. 如权利要求 9或 10所述的电磁开关， 其中， 活动铁心的一部分 材料被压接、 铆接或焊接在推杆上。
12. 如权利要求 9至 10中任一项所述的电磁开关， 其中， 所述活动 铁心的被压接、 铆接或焊接的所述一部分材料的形式为预先形成在活动 铁心前端的圆筒形部分。
13. 如权利要求 11或 12所述的电磁开关， 其中， 推杆的被压接或铆 接于活动铁心的所述一部分材料中的部位设有糙化表面、 凹陷或突起。
14. 如权利要求 9至 13中任一项所述的电磁开关， 其中， 推杆的前 端设有用于将拨叉的上端插入其中的接合窗口。
15. 一种车辆起动机， 包括：
电动机；
与电动机的输出轴相连的传动机构； 以及
如权利要求 9至 14中任一项所述的电磁开关， 其控制所述电动机和 传动机构的操作。
PCT/CN2013/075981 2012-05-21 2013-05-21 电磁开关、其制造方法及车辆起动机 WO2013174253A1 (zh)

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WO2017187554A1 (ja) * 2016-04-27 2017-11-02 三菱電機株式会社 スタータ用電磁スイッチ装置
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