WO2016203736A1 - Electric actuator and manufacturing method for same - Google Patents

Electric actuator and manufacturing method for same Download PDF

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Publication number
WO2016203736A1
WO2016203736A1 PCT/JP2016/002751 JP2016002751W WO2016203736A1 WO 2016203736 A1 WO2016203736 A1 WO 2016203736A1 JP 2016002751 W JP2016002751 W JP 2016002751W WO 2016203736 A1 WO2016203736 A1 WO 2016203736A1
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WO
WIPO (PCT)
Prior art keywords
output shaft
housing
electric actuator
actuator
lever
Prior art date
Application number
PCT/JP2016/002751
Other languages
French (fr)
Japanese (ja)
Inventor
山中　哲爾
尚明 河野
悦豪 柳田
島田　広樹
Original Assignee
株式会社デンソー
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
Priority claimed from JP2016102277A external-priority patent/JP6330850B2/en
Application filed by 株式会社デンソー filed Critical 株式会社デンソー
Priority to CN201680034705.2A priority Critical patent/CN107709727B/en
Priority to US15/736,812 priority patent/US10663076B2/en
Priority to DE112016002745.1T priority patent/DE112016002745B4/en
Publication of WO2016203736A1 publication Critical patent/WO2016203736A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • F02B37/12—Control of the pumps
    • F02B37/18—Control of the pumps by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H1/00—Toothed gearings for conveying rotary motion
    • F16H1/02—Toothed gearings for conveying rotary motion without gears having orbital motion
    • F16H1/04—Toothed gearings for conveying rotary motion without gears having orbital motion involving only two intermeshing members
    • F16H1/06—Toothed gearings for conveying rotary motion without gears having orbital motion involving only two intermeshing members with parallel axes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/116—Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present disclosure relates to an electric actuator for a turbocharger and a manufacturing method thereof.
  • Patent Document 1 As an example of an electric actuator for a turbocharger, a technique disclosed in Patent Document 1 is known.
  • Patent Document 1 discloses a technique for transmitting the output of an electric actuator to a turbocharger valve via a so-called four-bar link.
  • the four-bar link includes an actuator lever fixed to the output shaft of the electric actuator, a valve lever fixed to a valve shaft that rotates integrally with the valve, and a rod that transmits the rotation torque of the actuator lever to the valve lever.
  • the mounting angle of the electric actuator with respect to the turbocharger and the positional relationship between the valve shafts provided in the turbocharger are determined.
  • the versatility of the electric actuator will deteriorate.
  • the design change of the electric actuator is made unnecessary.
  • the position of the valve shaft is different, it is necessary to change the design of the electric actuator.
  • the present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide an electric actuator that is excellent in versatility and that does not cause variations in the fixing angle of the actuator lever with respect to the output shaft, and a manufacturing method thereof. is there.
  • an electric actuator including a housing, an electric motor, a parallel shaft type gear reducer, an output shaft, a cover, and an actuator lever.
  • the housing has an opening that opens in one direction.
  • the electric motor is assembled to the housing.
  • the gear reducer is assembled to the housing and decelerates the rotational force generated by the electric motor.
  • the output shaft is assembled with the housing and driven by the rotational force decelerated by the gear reducer.
  • a cover is assembled
  • the actuator lever is fixed to one end of the output shaft exposed to the outside of the cover, and drives a valve provided in the turbocharger.
  • One end of the output shaft is provided with a cylindrical portion having a reduced diameter through an annular step surface.
  • the actuator lever is provided with a round hole into which the cylindrical portion is inserted.
  • the housing is provided with an exposure hole for exposing the other end of the output shaft to the outside.
  • the other end of the output shaft is provided with a rotation stop shape that can be engaged with a tool that restricts the rotation of the output shaft. The stop shape is visible from the exposed hole.
  • the relative angle between the output shaft and the actuator lever can be set arbitrarily using the non-rotating shape visible from the exposed hole as the reference angle of the output shaft. For this reason, there is no problem that the fixing angle of the actuator lever varies.
  • the fixed angle of the actuator lever with respect to an output shaft can be freely changed by setting the rotation stop shape visually recognizable from the exposure hole as the reference angle of the output shaft. For this reason, the versatility of an electric actuator can be improved.
  • the present disclosure provides a method for manufacturing the above electric actuator.
  • the electric actuator is manufactured using a jig that supports a housing, and the jig includes a tool that can be engaged in a non-rotating shape.
  • the electric actuator manufacturing method of the present disclosure includes a jig assembling step for assembling the housing at a predetermined position of the jig, an internal assembling step for assembling the electric motor, the gear reducer, and the output shaft inside the opening, During this internal assembly process, an engagement process for engaging the rotation shape with the tool to position the output shaft in the rotational direction, a cover assembly process for assembling the cover to the housing, a cylindrical portion and a round hole A lever fitting step of fitting together, and a lever fixing step of determining a fixing angle of the actuator lever with respect to the output shaft and fixing the actuator lever to the output shaft.
  • FIG. 1 is a schematic diagram of an engine intake / exhaust device according to an embodiment of the present disclosure.
  • FIG. 2 is an explanatory diagram of a turbocharger according to an embodiment of the present disclosure.
  • FIG. 3 is a top view of the electric actuator according to the embodiment of the present disclosure.
  • FIG. 4 is a side view of an electric actuator according to an embodiment of the present disclosure.
  • FIG. 5 is a bottom view of the electric actuator according to the embodiment of the present disclosure.
  • 6 is a cross-sectional view taken along line VI-VI in FIG. 7 is a cross-sectional view taken along line VII-VII in FIG.
  • FIG. 8 is a cross-sectional view of a main part of the electric actuator placed on the jig based on the embodiment of the present disclosure.
  • FIG. 9 is a perspective view of the electric actuator mounted on the jig according to the embodiment of the present disclosure.
  • FIG. 10 is an exploded perspective view of the upper end of the output shaft and the actuator lever according to an embodiment of the present disclosure.
  • FIG. 11 is a perspective view of an output shaft provided with a resin component that forms a final gear according to an embodiment of the present disclosure as viewed from below.
  • a traveling engine 1 mounted on an automobile is provided with an intake passage 2 that guides intake air into a cylinder of the engine 1 and an exhaust passage 3 that discharges exhaust gas generated in the cylinder into the atmosphere.
  • an intake compressor 4 of the turbocharger T and a throttle valve 5 for adjusting the intake air amount supplied to the engine 1 are provided.
  • an exhaust turbine 6 of the turbocharger T and a catalyst 7 for purifying exhaust gas are provided in the middle of the exhaust passage 3.
  • the catalyst 7 is a well-known three-way catalyst that adopts a monolithic structure, and purifies harmful substances contained in the exhaust gas by oxidizing and reducing action by raising the temperature to the activation temperature.
  • the exhaust turbine 6 includes a turbine wheel 6a that is rotationally driven by the exhaust gas discharged from the engine 1, and a spiral turbine housing 6b that accommodates the turbine wheel 6a.
  • the intake compressor 4 includes a compressor wheel 4a that rotates in response to the rotational force of the turbine wheel 6a, and a spiral compressor housing 4b that accommodates the compressor wheel 4a.
  • the turbine housing 6b is provided with a bypass passage 8 that bypasses the turbine wheel 6a and flows exhaust gas.
  • the bypass passage 8 guides the exhaust gas flowing into the turbine housing 6b directly to the exhaust outlet of the turbine housing 6b.
  • the bypass passage 8 is provided so as to be opened and closed by a waste gate valve 9.
  • the wastegate valve 9 is a swing valve that is rotatably supported inside the turbine housing 6b. Specifically, the wastegate valve 9 is rotated through a valve shaft 10 that is rotatably supported with respect to the turbine housing 6b.
  • the waste gate valve 9 controls the supercharging pressure by the turbocharger T by adjusting the opening of the bypass passage 8 when the engine 1 is rotating at high speed.
  • the waste gate valve 9 warms up the catalyst 7 by fully opening the bypass passage 8 when the temperature of the catalyst 7 does not reach the activation temperature, such as immediately after a cold start. As a result, high-temperature exhaust gas that is not deprived of heat by the turbine wheel 6a can be guided to the catalyst 7, and the catalyst 7 can be warmed up early.
  • the turbocharger T includes an electric actuator 11 as means for rotating the wastegate valve 9.
  • the electric actuator 11 is energized and controlled by an ECU 12 that performs engine control.
  • the electric actuator 11 is mounted on the intake compressor 4 away from the exhaust turbine 6 for the purpose of avoiding the thermal effect of the exhaust gas.
  • the electric actuator 11 is mounted at a position away from the waste gate valve 9.
  • the turbocharger T is provided with a link mechanism for transmitting the output of the electric actuator 11 to the wastegate valve 9.
  • the link mechanism is a four-bar link, and includes an actuator lever 13 that is rotated by the electric actuator 11, a valve lever 14 that is coupled to the valve shaft 10, and a rotational torque applied to the actuator lever 13. And a rod 15 for transmitting to
  • the electric actuator 11 will be described.
  • the electric actuator 11 includes a housing 20 attached to the intake compressor 4, an electric motor 21, a gear reducer 22, an output shaft 23, a cover 24, and an actuator lever 13 fixed to the upper end of the output shaft 23. And is configured.
  • the upper end of the output shaft 23 corresponds to one end, and the lower end of the output shaft 23 corresponds to the other end.
  • the housing 20 includes an opening ⁇ that opens toward one side.
  • reference numeral 20 a shown in FIG. 3 is a bolt insertion hole used when the electric actuator 11 is assembled to the intake compressor 4.
  • the housing 20 is made of, for example, die-cast aluminum.
  • a cover 24 is attached to the upper portion of the housing 20.
  • the electric motor 21 is assembled to the housing 20. Specifically, the electric motor 21 is inserted into a motor insertion chamber ⁇ formed in the housing 20 and then fixed to the housing 20 with a screw or the like.
  • the structure or the like of the electric motor 21 is not limited, and may be a known DC motor or a known stepping motor, for example.
  • the gear reducer 22 is assembled to the housing 20.
  • the gear reducer 22 is a parallel shaft type that reduces the rotational force generated by the electric motor 21.
  • the gear reducer 22 includes a pinion gear 26 that is driven by the electric motor 21, a first intermediate gear 27 that is rotationally driven by the pinion gear 26, and a second intermediate that is rotationally driven by the first intermediate gear 27.
  • a gear 28 and a final gear 29 that is rotationally driven by the second intermediate gear 28 are provided.
  • the pinion gear 26 is a small-diameter external gear fixed to the rotating shaft of the electric motor 21.
  • the first intermediate gear 27 is a double gear in which a first large-diameter gear 27a and a first small-diameter gear 27b are provided concentrically.
  • the first intermediate gear 27 is rotatably supported by a first intermediate shaft 31 that is fixed to the housing 20.
  • the first large-diameter gear 27a always meshes with the pinion gear 26.
  • the second intermediate gear 28 is a double gear in which a second large diameter gear 28a and a second small diameter gear 28b are provided concentrically.
  • the second intermediate gear 28 is rotatably supported by a second intermediate shaft 32 that is fixed to the housing 20.
  • the second large-diameter gear 28a is always meshed with the first small-diameter gear 27b, and the second small-diameter gear 28b is always meshed with the final gear 29.
  • the final gear 29 is a large-diameter external gear fixed to the output shaft 23.
  • the final gear 29 is provided only in a predetermined rotation range.
  • the output shaft 23 is rotatably supported by a lower bearing 33 assembled to the housing 20 and an upper bearing 34 assembled to the cover 24.
  • the electric actuator 11 includes a rotation angle sensor 35 that detects the opening degree of the wastegate valve 9 by detecting the rotation angle of the output shaft 23.
  • the rotation angle sensor 35 is a non-contact type and is provided at a position offset with respect to the axis C of the output shaft 23.
  • the rotation angle sensor 35 includes a magnetic flux generator 36 that rotates integrally with the output shaft 23, and a magnetic detector that is attached to one of the cover 24 or the housing 20 and detects the magnetic flux generated by the magnetic flux generator 36. 37.
  • the magnetic flux generator 36 is provided around the output shaft 23 and in a rotation range where the final gear 29 does not exist.
  • the ECU 12 is an engine control unit in which a microcomputer is mounted, and includes a control program for controlling energization of the electric actuator 11.
  • the ECU 12 calculates the target opening degree of the wastegate valve 9 suitable for the operating state of the engine 1 from the operating state of the engine 1. Then, the electric actuator 11 is feedback controlled so that the calculated target opening and the detected opening detected by the rotation angle sensor 35 coincide.
  • this supercharging pressure control is an example, and is not limited.
  • the ECU 12 performs an early warm-up of the catalyst 7 when the actual temperature or the predicted temperature of the catalyst 7 has not reached the activation temperature, such as immediately after a cold start. Specifically, the ECU 12 sets the wastegate valve 9 to a predetermined opening when the catalyst 7 is warmed up early. Thereby, it is possible to prevent the heat of the exhaust gas from being taken away by the wastegate valve 9.
  • the early warm-up control of the catalyst 7 is an example and is not limited.
  • a jig 60 shown in FIGS. 8 and 9 is used for assembling the electric actuator 11.
  • a cylindrical portion 62 whose diameter is reduced via an annular step surface 61 is provided.
  • the step surface 61 is an annular plane perpendicular to the axial direction of the output shaft 23.
  • the cylindrical portion 62 is provided concentrically with the rotation center of the output shaft 23.
  • the actuator lever 13 is provided with a round hole 63 into which the cylindrical portion 62 is inserted as shown in FIG.
  • the inner diameter of the round hole 63 is slightly larger than the inner diameter of the cylindrical portion 62.
  • the housing 20 is provided with an exposure hole 64 that exposes the lower end of the output shaft 23 to the outside.
  • a lower bearing hole 41 for press-fitting the lower bearing 33 is provided in the housing 20. At the lower end of the lower bearing hole 41, a lower rod 41a for restricting the downward movement of the lower bearing 33 is provided. In this embodiment, the inner side of the lower collar 41 a corresponds to the exposure hole 64.
  • the lower end of the output shaft 23 is provided with a non-rotating shape (also referred to as a non-rotating portion or a shaft side engaging portion) 66 that can be engaged with a tool 65 that restricts the rotation of the output shaft 23.
  • a non-rotating shape also referred to as a non-rotating portion or a shaft side engaging portion
  • the rotation shape 66 can be visually recognized from the outside of the exposure hole 64 as shown in FIGS. That is, the rotation shape 66 can be visually recognized from the outside of the housing 20 to the inside of the exposure hole 64. Specifically, as shown in FIG. 8, the exposure hole 64 is provided so that the tool 65 can be inserted into the exposure hole 64 from the outside of the housing 20 and the tool 65 can be engaged with the rotation shape 66.
  • the rotation stop shape 66 of this embodiment employs a minus groove. That is, the rotation stop shape 66 of this embodiment is provided by a straight groove that passes through the axis C of the output shaft 23.
  • the specific shape of the stop shape 66 is not limited, and any shape that can regulate the rotation of the output shaft 23 by fitting with the tool 65 may be used.
  • a plus groove may be employed, or a polygonal hole such as a hexagonal hole may be employed.
  • a star hole such as a hexagonal star may be employed, or an elliptical hole may be employed.
  • the tool 65 is configured to restrict the rotation of the output shaft 23 by being fitted to the rotation shape 66 and to position the output shaft 23 in the rotation direction.
  • the specific shape of the portion of the tool 65 that fits with the rotation stop shape 66 is a linear protrusion shape. Needless to say, the shape of the tool 65 that fits the stop shape 66 is changed to match the changed stop shape 66 when the stop shape 66 is changed. If a specific example is disclosed, when the turning shape 66 is changed to a hexagonal hole, the tool 65 is also changed to the shape of a hexagonal wrench.
  • the jig 60 supports the housing 20 when the electromagnetic actuator 11 is manufactured, and includes the above-described tool (also referred to as a jig side engaging portion) 65.
  • the tool 65 is provided integrally with the jig 60. That is, a part of the jig 60 is provided as the tool 65.
  • the tool 65 may be provided separately from the jig 60. In this case, it is desirable that the rotation angle of the tool 65 with respect to the jig 60 can be set at an arbitrary angle.
  • the housing 20 is provided with the opening ⁇ that opens upward.
  • an assembly space for the gear reducer 22, the output shaft 23, and the like is provided inside the opening ⁇ . All the components that are directly assembled to the housing 20, including the electric motor 21, the gear reducer 22, the output shaft 23, and the cover 24, are all assembled to the housing 20 from the top to the bottom.
  • the housing 20 is assembled at a predetermined position of the jig 60. Specifically, the housing 20 is placed on the jig 60 so that the opening ⁇ faces upward. At this time, the housing 20 is positioned with respect to the jig 60.
  • the housing 20 is provided with a plurality of positioning recesses 67. Specifically, two positioning recesses 67 are provided on the lower surface of the housing 20 as shown in FIG.
  • the jig 60 is provided with a plurality of positioning pins 68 that fit into the plurality of positioning recesses 67. Specifically, two positioning pins 68 that extend upward and fit into the positioning recesses 67 are provided on the upper surface of the jig 60.
  • the positioning pins 68 are fitted into the positioning recesses 67 when the housing 20 is placed on the jig 60.
  • the housing 20 is assembled at a predetermined position with respect to the jig 60, and the tool 65 is inserted into the central portion of the exposure hole 64.
  • the internal assembly process is a process of assembling the electric motor 21, the gear reducer 22, and the output shaft 23 inside the opening ⁇ .
  • a wave washer 38 is incorporated into the bottom of the motor insertion chamber ⁇ from above.
  • the wave washer 38 is compressed between the bottom of the motor insertion chamber ⁇ and the electric motor 21 to suppress vibration of the electric motor 21.
  • the electric motor 21 is inserted into the motor insertion chamber ⁇ from above.
  • the first intermediate shaft 31 and the second intermediate shaft 32 are press-fitted into the housing 20 from above. Specifically, a first press-fitting hole 39 for press-fitting the first intermediate shaft 31 and a second press-fitting hole 40 for press-fitting the second intermediate shaft 32 are formed in advance on the bottom surface inside the opening ⁇ . ing.
  • first intermediate shaft 31 is press-fitted into the first press-fitting hole 39 and the second intermediate shaft 32 is press-fitted into the second press-fitting hole 40.
  • the lower bearing 33 is press-fitted into the housing 20 from above. That is, the lower bearing 33 is press-fitted into the lower bearing hole 41.
  • the output shaft 23 is press-fitted into the lower bearing 33 from above. Specifically, the output shaft 23 is provided with a final gear 29 and a magnetic flux generator 36. For this reason, the final gear 29 and the magnetic flux generator 36 are also assembled to the housing 20 by press-fitting the output shaft 23 inside the lower bearing 33.
  • the engagement process is performed. That is, the engaging step is performed when the output shaft 23 is assembled.
  • This engagement step is a step of positioning the output shaft 23 in the rotational direction by engaging the rotation shape 66 with the tool 65 when the output shaft 23 is press-fitted into the lower bearing 33.
  • the rotation shape 66 is engaged with the tool 65 while the output shaft 23 is press-fitted inside the lower bearing 33 with the final gear 29 facing the second intermediate shaft 32. Thereby, the rotation direction of the output shaft 23 is positioned in a preset direction.
  • the turning shape 66 of this embodiment employs a minus groove as described above, the turning shape 66 and the tool 65 are engaged at an interval of 180 °. For this reason, it is possible to prevent erroneous assembly in which the output shaft 23 is assembled at an angle different from the prescribed assembly angle.
  • the final gear 29 of this embodiment is integrally provided with a stopper 71 that extends downward.
  • the stopper 71 is inserted into an arc groove 72 formed on the bottom surface of the opening ⁇ .
  • the rotation range of the output shaft 23 is mechanical. Regulated by
  • the stopper 71 can be inserted into the arc groove 72 only with the final gear 29 facing the second intermediate shaft 32. For this reason, even if the output shaft 23 is inserted at an incorrect angle, the stopper 71 interferes with the housing 20 to prevent erroneous assembly of the output shaft 23.
  • the second intermediate gear 28 is assembled to the second intermediate shaft 32.
  • the first intermediate gear 27 is assembled to the first intermediate shaft 31.
  • the cover assembling step is a step of assembling the cover 24 to the housing 20.
  • the cover 24 is attached to the housing 20 from above. At this time, the output shaft 23 is press-fitted inside the upper bearing 34 press-fitted into the cover 24.
  • the cover 24 is made of resin.
  • the resin cover 24 is molded with a metallic cylindrical bearing holder 55 as means for press-fitting the upper bearing 34.
  • the upper bearing 34 is press-fitted inside the bearing holder 55 before the cover assembling step.
  • the cover 24 is provided with a connector 43 that is electrically connected to the electric motor 21 and the magnetic detection unit 37, and is also provided with the magnetic detection unit 37. For this reason, the assembly of the connector 43 and the magnetic detection unit 37 is completed by assembling the cover 24 to the housing 20. Further, the lower surface of the cover 24 is provided with a first fitting hole 31a into which the upper end of the first intermediate shaft 31 is fitted, and a second fitting hole 32a into which the upper end of the second intermediate shaft 32 is fitted. Yes.
  • the lever fitting process is a process of mounting the actuator lever 13 on the upper end of the output shaft 23 from above. Specifically, this is a step of fitting the cylindrical portion 62 and the round hole 63 together.
  • the actuator lever 13 can be rotated 360 ° with respect to the output shaft 23.
  • the pin 44 that is rotatably coupled to the rod 15 on the pivot end side of the actuator lever 13 is coupled to the actuator lever 13 in advance by a process different from the lever fitting process.
  • a lever fixing step is performed.
  • the fixing angle of the actuator lever 13 with respect to the output shaft 23 is determined.
  • the actuator lever 13 is directed in a predetermined direction with respect to the jig 60 or the housing 20.
  • the actuator lever 13 is fixed to the output shaft 23 while maintaining the fixed angle of the actuator lever 13 with respect to the output shaft 23.
  • the output shaft 23 and the actuator lever 13 are fixed by a caulking technique that plastically deforms the upper end of the output shaft 23 or a welding technique.
  • the actuator lever 13 is fixed to the output shaft 23 using caulking technology. That is, in this embodiment, the upper end of the output shaft 23 is crushed and the end of the cylindrical portion 62 is expanded, and the actuator lever 13 is firmly fixed between the end of the crushed and expanded cylindrical portion 62 and the step surface 61. And the actuator lever 13 is fixed to the output shaft 23.
  • a plurality of local vertical grooves 63 a are formed at the edge of the round hole 63.
  • the rotation shape 66 provided on the output shaft 23 is engaged with the tool 65 to position the output shaft 23 in the rotation direction. Thereafter, the fixing angle of the actuator lever 13 is determined, and the actuator lever 13 is fixed to the output shaft 23. For this reason, the fixed angle of the actuator lever 13 with respect to the output shaft 23 does not vary.
  • the fixed angle of the actuator lever 13 with respect to the output shaft 23 can be freely changed. For this reason, the versatility of the electric actuator 11 can be improved.
  • the vehicle can be handled without changing the parts of the electric actuator 11.
  • turbocharger T having a different position of the valve shaft 10 can be handled without changing the parts of the electric actuator 11.
  • the electric actuator 11 of this embodiment has high versatility as described above, it can be mounted on various types of vehicles without incurring component changes.
  • the manufacturing cost of the electric actuator 11 can be suppressed, and as a result, the cost of the supercharging device including the turbocharger T mounted on the vehicle can be suppressed.
  • the electric actuator 11 may drive a switching valve that opens and closes the second exhaust scroll provided in the turbine housing 6b.
  • both the waste gate valve 9 and the switching valve may be operated by the electric actuator 11.
  • the present disclosure may be applied to the electric actuator 11 that operates a nozzle vane (an example of a valve) of the turbocharger T that uses a variable nozzle mechanism.
  • the present disclosure may be applied to the electric actuator 11 that switches between the two turbochargers T in a two-stage turbo that uses the two turbochargers T.
  • one intermediate gear may be provided between the pinion gear 26 and the final gear 29, or three or more intermediate gears may be provided. There may be.

Abstract

A rotation prevention form (66) is provided so as to be visible from an exposure hole (64). The relative angle of an output shaft (23) and an actuator lever (13) can be set at will by using the rotation prevention form (66), which is visible from the exposure hole (64), as the reference angle of the output shaft (23). Therefore, faults caused by variations in the fixed angle of the actuator lever (13) do not occur. The fixed angle of the actuator lever (13) relative to the output shaft (23) can be freely modified by using the rotation prevention form (66), which is visible from the exposure hole (64), as the reference angle of the output shaft (23).

Description

電動アクチュエータおよびその製造方法Electric actuator and manufacturing method thereof 関連出願の相互参照Cross-reference of related applications
　本願は、２０１５年６月１８日に出願された日本国特許出願第２０１５－１２３０１３号および２０１６年５月２３日に出願された日本国特許出願第２０１６－１０２２７７号に基づくものであり、この開示をもってその内容を本明細書中に開示したものとする。 This application is based on Japanese Patent Application No. 2015-123013 filed on June 18, 2015 and Japanese Patent Application No. 2016-102277 filed on May 23, 2016. The contents thereof are disclosed in this specification.
　本開示は、ターボチャージャ用の電動アクチュエータと、その製造方法に関する。 The present disclosure relates to an electric actuator for a turbocharger and a manufacturing method thereof.
　ターボチャージャ用の電動アクチュエータの一例として、特許文献１に開示される技術が知られている。 As an example of an electric actuator for a turbocharger, a technique disclosed in Patent Document 1 is known.
　特許文献１には、電動アクチュエータの出力を所謂４節リンクを介してターボチャージャのバルブに伝える技術が開示されている。 Patent Document 1 discloses a technique for transmitting the output of an electric actuator to a turbocharger valve via a so-called four-bar link.
　４節リンクは、電動アクチュエータの出力シャフトに固定されるアクチュエータレバーと、バルブと一体に回動するバルブ軸に固定されるバルブレバーと、アクチュエータレバーの回動トルクをバルブレバーに伝えるロッドとを備える。 The four-bar link includes an actuator lever fixed to the output shaft of the electric actuator, a valve lever fixed to a valve shaft that rotates integrally with the valve, and a rod that transmits the rotation torque of the actuator lever to the valve lever. .
　特許文献１の技術は、出力シャフトにアクチュエータレバーを固定する前の段階において、出力シャフトに対してアクチュエータレバーが自由に回動してしまう。即ち、出力シャフトに対するアクチュエータレバーの固定角度が決まらない問題がある。 In the technique of Patent Document 1, the actuator lever freely rotates with respect to the output shaft before the actuator lever is fixed to the output shaft. That is, there is a problem that the fixing angle of the actuator lever with respect to the output shaft is not determined.
　このように、アクチュエータレバーの固定角度が決まらない状態で、アクチュエータレバーを出力シャフトに固定すると、アクチュエータレバーの回動範囲にバラツキが生じてしまう。すると、４節リンクのリンク比にばらつきが生じてしまう。その結果、ターボチャージャに設けられるバルブの作動性が悪化してしまう。 As described above, when the actuator lever is fixed to the output shaft in a state where the fixing angle of the actuator lever is not determined, the rotation range of the actuator lever varies. As a result, the link ratio of the four-node link varies. As a result, the operability of the valve provided in the turbocharger is deteriorated.
　一方、上記の不具合を回避するために、キー溝や２面幅を用いて出力シャフトに対するアクチュエータレバーの固定角度を決定することが考えられる。 On the other hand, in order to avoid the above problems, it is conceivable to determine the fixing angle of the actuator lever with respect to the output shaft using the keyway and the width of two surfaces.
　この場合、ターボチャージャに対する電動アクチュエータの搭載角度と、ターボチャージャに設けられるバルブ軸の位置関係が決定されてしまう。 In this case, the mounting angle of the electric actuator with respect to the turbocharger and the positional relationship between the valve shafts provided in the turbocharger are determined.
　そのため、電動アクチュエータの汎用性が悪くなってしまう。即ち、ターボチャージャに対する電動アクチュエータの搭載角度が異なる場合には、電動アクチュエータの設計変更を余技なくされてしまう。同様に、バルブ軸の位置が異なる場合にも、電動アクチュエータの設計変更を行う必要がある。 Therefore, the versatility of the electric actuator will deteriorate. In other words, when the mounting angle of the electric actuator with respect to the turbocharger is different, the design change of the electric actuator is made unnecessary. Similarly, even when the position of the valve shaft is different, it is necessary to change the design of the electric actuator.
特開２００２－３４９６４１号公報JP 2002-349441 A
　本開示は、上記問題点に鑑みて成されたものであり、その目的は、汎用性に優れ、且つ出力シャフトに対するアクチュエータレバーの固定角度にバラツキが生じない電動アクチュエータと、その製造方法の提供にある。 The present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide an electric actuator that is excellent in versatility and that does not cause variations in the fixing angle of the actuator lever with respect to the output shaft, and a manufacturing method thereof. is there.
　上記の目的を達成すべく、本開示では、ハウジング、電動モータ、平行軸式の歯車減速機、出力シャフト、カバーおよびアクチュエータレバーを備える電動アクチュエータを提供する。ハウジングは、一方向へ向けて開口する開口部を有する。電動モータは、ハウジングに組み付けられる。歯車減速機は、ハウジングに組み付けられ、電動モータの発生する回転力を減速する。出力シャフトは、ハウジングに組み付けられ、歯車減速機によって減速された回転力により駆動される。カバーは、ハウジングに組み付けられ、ハウジングとの間に電動モータと歯車減速機を収容する空間を形成し、出力シャフトの一端を外部に露出させる。アクチュエータレバーは、カバーの外部に露出した出力シャフトの一端に固定されて、ターボチャージャに設けられるバルブを駆動する。出力シャフトの一端には、環状の段差面を介して縮径された円筒部が設けられている。アクチュエータレバーには、円筒部が挿し入れられる丸穴が設けられている。ハウジングには、出力シャフトの他端を外部に露出させる露出穴が設けられている。出力シャフトの他端には、出力シャフトの回転を規制する工具と係合可能な回止形状が設けられている。回止形状は露出穴から視認できる。 In order to achieve the above object, the present disclosure provides an electric actuator including a housing, an electric motor, a parallel shaft type gear reducer, an output shaft, a cover, and an actuator lever. The housing has an opening that opens in one direction. The electric motor is assembled to the housing. The gear reducer is assembled to the housing and decelerates the rotational force generated by the electric motor. The output shaft is assembled with the housing and driven by the rotational force decelerated by the gear reducer. A cover is assembled | attached to a housing, the space which accommodates an electric motor and a gear reducer between housings is formed, and the end of an output shaft is exposed outside. The actuator lever is fixed to one end of the output shaft exposed to the outside of the cover, and drives a valve provided in the turbocharger. One end of the output shaft is provided with a cylindrical portion having a reduced diameter through an annular step surface. The actuator lever is provided with a round hole into which the cylindrical portion is inserted. The housing is provided with an exposure hole for exposing the other end of the output shaft to the outside. The other end of the output shaft is provided with a rotation stop shape that can be engaged with a tool that restricts the rotation of the output shaft. The stop shape is visible from the exposed hole.
　露出穴から視認できる回止形状を出力シャフトの基準角として、出力シャフトとアクチュエータレバーの相対角度を任意に設定できる。このため、アクチュエータレバーの固定角度にバラツキが生じる不具合がない。 ∙ The relative angle between the output shaft and the actuator lever can be set arbitrarily using the non-rotating shape visible from the exposed hole as the reference angle of the output shaft. For this reason, there is no problem that the fixing angle of the actuator lever varies.
　また、露出穴から視認できる回止形状を出力シャフトの基準角とすることで、出力シャフトに対するアクチュエータレバーの固定角度を自由に変更できる。このため、電動アクチュエータの汎用性を高めることができる。 
　このように、本開示の原理を採用することにより、汎用性に優れ、且つ出力シャフトに対するアクチュエータレバーの固定角度にバラツキが生じない電動アクチュエータを提供できる。 Moreover, the fixed angle of the actuator lever with respect to an output shaft can be freely changed by setting the rotation stop shape visually recognizable from the exposure hole as the reference angle of the output shaft. For this reason, the versatility of an electric actuator can be improved.
Thus, by adopting the principle of the present disclosure, it is possible to provide an electric actuator that is excellent in versatility and that does not cause variations in the fixing angle of the actuator lever relative to the output shaft.
　さらに、本開示では、上記の電動アクチュエータの製造方法を提供する。電動アクチュエータは、ハウジングを支持する治具を用いて製造されるものであり、治具は、回止形状に係合可能な工具を備えるものである。本開示の電動アクチュエータの製造方法は、治具の所定位置にハウジングを組付ける治具組付工程と、電動モータ、歯車減速機および出力シャフトを、開口部の内側に組み付ける内部組付工程と、この内部組付工程中に、回止形状を工具に係合させて出力シャフトの回転方向の位置決めを行う係合工程と、カバーをハウジングに組付けるカバー組付工程と、円筒部と丸穴を嵌め合わせるレバー嵌合工程と、出力シャフトに対するアクチュエータレバーの固定角度を決定して、アクチュエータレバーを出力シャフトに固定するレバー固定工程とを備える。 Furthermore, the present disclosure provides a method for manufacturing the above electric actuator. The electric actuator is manufactured using a jig that supports a housing, and the jig includes a tool that can be engaged in a non-rotating shape. The electric actuator manufacturing method of the present disclosure includes a jig assembling step for assembling the housing at a predetermined position of the jig, an internal assembling step for assembling the electric motor, the gear reducer, and the output shaft inside the opening, During this internal assembly process, an engagement process for engaging the rotation shape with the tool to position the output shaft in the rotational direction, a cover assembly process for assembling the cover to the housing, a cylindrical portion and a round hole A lever fitting step of fitting together, and a lever fixing step of determining a fixing angle of the actuator lever with respect to the output shaft and fixing the actuator lever to the output shaft.
図１は、本開示の実施形態に基づくエンジン吸排気装置の概略図である。FIG. 1 is a schematic diagram of an engine intake / exhaust device according to an embodiment of the present disclosure. 図２は、本開示の実施形態に基づくターボチャージャの説明図である。FIG. 2 is an explanatory diagram of a turbocharger according to an embodiment of the present disclosure. 図３は、本開示の実施形態に基づく電動アクチュエータの上視図である。FIG. 3 is a top view of the electric actuator according to the embodiment of the present disclosure. 図４は、本開示の実施形態に基づく電動アクチュエータの側面図である。FIG. 4 is a side view of an electric actuator according to an embodiment of the present disclosure. 図５は、本開示の実施形態に基づく電動アクチュエータの下視図である。FIG. 5 is a bottom view of the electric actuator according to the embodiment of the present disclosure. 図６は、図３のＶＩ－ＶＩ線に沿う断面図である。6 is a cross-sectional view taken along line VI-VI in FIG. 図７は、図３のＶＩＩ－ＶＩＩ線に沿う断面図である。7 is a cross-sectional view taken along line VII-VII in FIG. 図８は、本開示の実施形態に基づく治具に乗せられた電動アクチュエータの要部断面図である。FIG. 8 is a cross-sectional view of a main part of the electric actuator placed on the jig based on the embodiment of the present disclosure. 図９は、本開示の実施形態に基づく治具に乗せられた電動アクチュエータの斜視図である。FIG. 9 is a perspective view of the electric actuator mounted on the jig according to the embodiment of the present disclosure. 図１０は、本開示の実施形態に基づく出力シャフトの上端とアクチュエータレバーの分解斜視図である。FIG. 10 is an exploded perspective view of the upper end of the output shaft and the actuator lever according to an embodiment of the present disclosure. 図１１は、本開示の実施形態に基づく最終ギヤを成す樹脂部品が設けられた出力シャフトを下方から見た斜視図である。FIG. 11 is a perspective view of an output shaft provided with a resin component that forms a final gear according to an embodiment of the present disclosure as viewed from below.
　以下では、図面に基づいて本開示を実施するための形態を説明する。なお、以下で開示する実施形態は、一例を開示するものであって、本開示が実施形態に限定されないことは言うまでもない。 Hereinafter, a mode for carrying out the present disclosure will be described based on the drawings. Note that the embodiment disclosed below discloses an example, and it is needless to say that the present disclosure is not limited to the embodiment.
［実施形態１］
　図１～図１１に基づいて実施形態１を説明する。 [Embodiment 1]
The first embodiment will be described with reference to FIGS.
　自動車に搭載される走行用のエンジン１には、吸気をエンジン１の気筒内へ導く吸気通路２と、気筒内で発生した排気ガスを大気中に排出する排気通路３とが設けられる。 A traveling engine 1 mounted on an automobile is provided with an intake passage 2 that guides intake air into a cylinder of the engine 1 and an exhaust passage 3 that discharges exhaust gas generated in the cylinder into the atmosphere.
　吸気通路２の途中には、ターボチャージャＴの吸気コンプレッサ４と、エンジン１に供給される吸気量の調整を行うスロットルバルブ５とが設けられる。 In the middle of the intake passage 2, an intake compressor 4 of the turbocharger T and a throttle valve 5 for adjusting the intake air amount supplied to the engine 1 are provided.
　排気通路３の途中には、ターボチャージャＴの排気タービン６と、排気ガスの浄化を行う触媒７とが設けられる。なお、触媒７はモノリス構造を採用する周知な三元触媒であり、活性化温度に昇温することで排気ガス中に含まれる有害物質を酸化作用と還元作用により浄化する。 In the middle of the exhaust passage 3, an exhaust turbine 6 of the turbocharger T and a catalyst 7 for purifying exhaust gas are provided. The catalyst 7 is a well-known three-way catalyst that adopts a monolithic structure, and purifies harmful substances contained in the exhaust gas by oxidizing and reducing action by raising the temperature to the activation temperature.
　排気タービン６は、エンジン１から排出された排気ガスによって回転駆動されるタービンホイール６ａと、このタービンホイール６ａを収容する渦巻形状のタービンハウジング６ｂとを備える。 The exhaust turbine 6 includes a turbine wheel 6a that is rotationally driven by the exhaust gas discharged from the engine 1, and a spiral turbine housing 6b that accommodates the turbine wheel 6a.
　吸気コンプレッサ４は、タービンホイール６ａの回転力を受けて回転するコンプレッサホイール４ａと、このコンプレッサホイール４ａを収容する渦巻形状のコンプレッサハウジング４ｂとを備える。 The intake compressor 4 includes a compressor wheel 4a that rotates in response to the rotational force of the turbine wheel 6a, and a spiral compressor housing 4b that accommodates the compressor wheel 4a.
　タービンハウジング６ｂには、タービンホイール６ａを迂回して排気ガスを流すバイパス通路８が設けられる。 The turbine housing 6b is provided with a bypass passage 8 that bypasses the turbine wheel 6a and flows exhaust gas.
　バイパス通路８は、タービンハウジング６ｂに流入した排気ガスを直接タービンハウジング６ｂの排気出口へ導く。このバイパス通路８は、ウエストゲートバルブ９によって開閉可能に設けられる。 The bypass passage 8 guides the exhaust gas flowing into the turbine housing 6b directly to the exhaust outlet of the turbine housing 6b. The bypass passage 8 is provided so as to be opened and closed by a waste gate valve 9.
　ウエストゲートバルブ９は、タービンハウジング６ｂの内部で回動可能に支持されるスイングバルブである。具体的に、ウエストゲートバルブ９は、タービンハウジング６ｂに対して回転自在に支持されるバルブ軸１０を介して回動操作される。 The wastegate valve 9 is a swing valve that is rotatably supported inside the turbine housing 6b. Specifically, the wastegate valve 9 is rotated through a valve shaft 10 that is rotatably supported with respect to the turbine housing 6b.
　このウエストゲートバルブ９は、エンジン１の高回転時などに、バイパス通路８の開度を調整してターボチャージャＴによる過給圧をコントロールする。 The waste gate valve 9 controls the supercharging pressure by the turbocharger T by adjusting the opening of the bypass passage 8 when the engine 1 is rotating at high speed.
　また、ウエストゲートバルブ９は、冷間始動直後など、触媒７の温度が活性化温度に達していない時に、バイパス通路８を全開にして触媒７の暖機を行う。これにより、タービンホイール６ａに熱を奪われていない高温の排気ガスを触媒７へ導くことができ、触媒７の早期暖機を実施できる。 The waste gate valve 9 warms up the catalyst 7 by fully opening the bypass passage 8 when the temperature of the catalyst 7 does not reach the activation temperature, such as immediately after a cold start. As a result, high-temperature exhaust gas that is not deprived of heat by the turbine wheel 6a can be guided to the catalyst 7, and the catalyst 7 can be warmed up early.
　ウエストゲートバルブ９を回動操作する手段として、ターボチャージャＴは、電動アクチュエータ１１を備える。この電動アクチュエータ１１は、エンジン制御を行うＥＣＵ１２によって通電制御される。 The turbocharger T includes an electric actuator 11 as means for rotating the wastegate valve 9. The electric actuator 11 is energized and controlled by an ECU 12 that performs engine control.
　電動アクチュエータ１１は、排気ガスの熱影響を回避する目的で、排気タービン６から離れた吸気コンプレッサ４に搭載される。このように、電動アクチュエータ１１は、ウエストゲートバルブ９から離れた位置に搭載される。このため、ターボチャージャＴには、電動アクチュエータ１１の出力をウエストゲートバルブ９に伝達するためのリンク機構が設けられる。 The electric actuator 11 is mounted on the intake compressor 4 away from the exhaust turbine 6 for the purpose of avoiding the thermal effect of the exhaust gas. Thus, the electric actuator 11 is mounted at a position away from the waste gate valve 9. For this reason, the turbocharger T is provided with a link mechanism for transmitting the output of the electric actuator 11 to the wastegate valve 9.
　リンク機構は、４節リンクであり、電動アクチュエータ１１によって回動操作されるアクチュエータレバー１３と、バルブ軸１０に結合されるバルブレバー１４と、アクチュエータレバー１３に付与される回動トルクをバルブレバー１４に伝えるロッド１５とを備える。 The link mechanism is a four-bar link, and includes an actuator lever 13 that is rotated by the electric actuator 11, a valve lever 14 that is coupled to the valve shaft 10, and a rotational torque applied to the actuator lever 13. And a rod 15 for transmitting to
　電動アクチュエータ１１を説明する。 The electric actuator 11 will be described.
　電動アクチュエータ１１は、吸気コンプレッサ４に取り付けられるハウジング２０と、このハウジング２０に組み付けられる電動モータ２１、歯車減速機２２、出力シャフト２３、カバー２４と、出力シャフト２３の上端に固定されるアクチュエータレバー１３とを備えて構成される。なお、出力シャフト２３の上端が一端に相当し、出力シャフト２３の下端が他端に相当するものである。 The electric actuator 11 includes a housing 20 attached to the intake compressor 4, an electric motor 21, a gear reducer 22, an output shaft 23, a cover 24, and an actuator lever 13 fixed to the upper end of the output shaft 23. And is configured. The upper end of the output shaft 23 corresponds to one end, and the lower end of the output shaft 23 corresponds to the other end.
　ハウジング２０は、一方に向けて開口する開口部αを備える。 The housing 20 includes an opening α that opens toward one side.
　以下では、説明の便宜上、ハウジング２０において開口部αが開口する方向を上、逆方向を下として説明する。もちろん、この上下方向は、搭載方向を限定するものではない。なお、図３に示す符合２０ａは、電動アクチュエータ１１を吸気コンプレッサ４に組付ける際に用いられるボルト挿通穴である。 Hereinafter, for convenience of explanation, the direction in which the opening α opens in the housing 20 will be described as being upward, and the reverse direction will be described as being downward. Of course, this vertical direction does not limit the mounting direction. Note that reference numeral 20 a shown in FIG. 3 is a bolt insertion hole used when the electric actuator 11 is assembled to the intake compressor 4.
　ハウジング２０は、例えばアルミニウム等によるダイキャスト製である。このハウジング２０の上部には、カバー２４が装着される。 The housing 20 is made of, for example, die-cast aluminum. A cover 24 is attached to the upper portion of the housing 20.
　そして、ハウジング２０とカバー２４との間に形成される空間βに、電動モータ２１や歯車減速機２２等が配置される。 In the space β formed between the housing 20 and the cover 24, the electric motor 21, the gear reducer 22 and the like are arranged.
　電動モータ２１は、ハウジング２０に組み付けられる。具体的に電動モータ２１は、ハウジング２０に形成されたモータ挿入室γに挿入された後、スクリュ等によってハウジング２０に固定される。電動モータ２１の構造等は限定するものではなく、例えば周知の直流モータであっても良いし、周知のステッピングモータであっても良い。 The electric motor 21 is assembled to the housing 20. Specifically, the electric motor 21 is inserted into a motor insertion chamber γ formed in the housing 20 and then fixed to the housing 20 with a screw or the like. The structure or the like of the electric motor 21 is not limited, and may be a known DC motor or a known stepping motor, for example.
　歯車減速機２２は、ハウジング２０に組み付けられる。この歯車減速機２２は、電動モータ２１の発生する回転力を減速する平行軸式である。 The gear reducer 22 is assembled to the housing 20. The gear reducer 22 is a parallel shaft type that reduces the rotational force generated by the electric motor 21.
　具体的に、歯車減速機２２は、電動モータ２１によって駆動されるピニオンギヤ２６と、このピニオンギヤ２６によって回転駆動される第１中間ギヤ２７と、この第１中間ギヤ２７によって回転駆動される第２中間ギヤ２８と、この第２中間ギヤ２８によって回転駆動される最終ギヤ２９とを備える。 Specifically, the gear reducer 22 includes a pinion gear 26 that is driven by the electric motor 21, a first intermediate gear 27 that is rotationally driven by the pinion gear 26, and a second intermediate that is rotationally driven by the first intermediate gear 27. A gear 28 and a final gear 29 that is rotationally driven by the second intermediate gear 28 are provided.
　ピニオンギヤ２６は、電動モータ２１の回転軸に固定された小径の外歯歯車である。 The pinion gear 26 is a small-diameter external gear fixed to the rotating shaft of the electric motor 21.
　第１中間ギヤ２７は、第１大径ギヤ２７ａと第１小径ギヤ２７ｂが同芯で設けられた２重歯車である。この第１中間ギヤ２７は、ハウジング２０に固定される第１中間シャフト３１によって回転自在に支持される。そして、第１大径ギヤ２７ａがピニオンギヤ２６と常に噛合する。 The first intermediate gear 27 is a double gear in which a first large-diameter gear 27a and a first small-diameter gear 27b are provided concentrically. The first intermediate gear 27 is rotatably supported by a first intermediate shaft 31 that is fixed to the housing 20. The first large-diameter gear 27a always meshes with the pinion gear 26.
　第２中間ギヤ２８は、第１中間ギヤ２７と同様、第２大径ギヤ２８ａと第２小径ギヤ２８ｂが同芯で設けられた２重歯車である。この第２中間ギヤ２８は、ハウジング２０に固定される第２中間シャフト３２によって回転自在に支持される。そして、第２大径ギヤ２８ａが第１小径ギヤ２７ｂと常に噛合し、第２小径ギヤ２８ｂが最終ギヤ２９と常に噛合する。 As with the first intermediate gear 27, the second intermediate gear 28 is a double gear in which a second large diameter gear 28a and a second small diameter gear 28b are provided concentrically. The second intermediate gear 28 is rotatably supported by a second intermediate shaft 32 that is fixed to the housing 20. The second large-diameter gear 28a is always meshed with the first small-diameter gear 27b, and the second small-diameter gear 28b is always meshed with the final gear 29.
　最終ギヤ２９は、出力シャフト２３に固定された大径の外歯歯車である。この最終ギヤ２９は、所定の回動範囲のみに設けられる。 The final gear 29 is a large-diameter external gear fixed to the output shaft 23. The final gear 29 is provided only in a predetermined rotation range.
　なお、出力シャフト２３は、ハウジング２０に組み付けられる下ベアリング３３と、カバー２４に組み付けられる上ベアリング３４とによって回転自在に支持される。 Note that the output shaft 23 is rotatably supported by a lower bearing 33 assembled to the housing 20 and an upper bearing 34 assembled to the cover 24.
　電動アクチュエータ１１は、出力シャフト２３の回転角度を検出することでウエストゲートバルブ９の開度を検出する回転角センサ３５を備える。 The electric actuator 11 includes a rotation angle sensor 35 that detects the opening degree of the wastegate valve 9 by detecting the rotation angle of the output shaft 23.
　回転角センサ３５は、非接触型であり、出力シャフト２３の軸芯Ｃに対してオフセットされた位置に設けられる。 The rotation angle sensor 35 is a non-contact type and is provided at a position offset with respect to the axis C of the output shaft 23.
　具体的に、回転角センサ３５は、出力シャフト２３と一体に回動する磁束発生部３６と、カバー２４またはハウジング２０の一方に取り付けられて磁束発生部３６の発生する磁束を検出する磁気検出部３７とを備える。そして、磁束発生部３６は、出力シャフト２３の周囲で、且つ最終ギヤ２９が存在しない回動範囲に設けられる。 Specifically, the rotation angle sensor 35 includes a magnetic flux generator 36 that rotates integrally with the output shaft 23, and a magnetic detector that is attached to one of the cover 24 or the housing 20 and detects the magnetic flux generated by the magnetic flux generator 36. 37. The magnetic flux generator 36 is provided around the output shaft 23 and in a rotation range where the final gear 29 does not exist.
　なお、この実施形態では、磁気検出部３７をカバー２４に設ける例を示す。そして、回転角センサ３５によって検出される出力シャフト２３の回転角度は、ＥＣＵ１２へ出力される。 In addition, in this embodiment, the example which provides the magnetism detection part 37 in the cover 24 is shown. Then, the rotation angle of the output shaft 23 detected by the rotation angle sensor 35 is output to the ECU 12.
　ＥＣＵ１２は、マイクロコンピュータを搭載するエンジン・コントロール・ユニットであり、電動アクチュエータ１１を通電制御する制御プログラムを備える。 The ECU 12 is an engine control unit in which a microcomputer is mounted, and includes a control program for controlling energization of the electric actuator 11.
　具体的に、ＥＣＵ１２は、エンジン１の運転状態からエンジン１の運転状態に適したウエストゲートバルブ９の目標開度を算出する。そして、算出した目標開度と回転角センサ３５によって検出した検出開度とが一致するように電動アクチュエータ１１をフィードバック制御する。もちろん、この過給圧制御は一例であり、限定するものではない。 Specifically, the ECU 12 calculates the target opening degree of the wastegate valve 9 suitable for the operating state of the engine 1 from the operating state of the engine 1. Then, the electric actuator 11 is feedback controlled so that the calculated target opening and the detected opening detected by the rotation angle sensor 35 coincide. Of course, this supercharging pressure control is an example, and is not limited.
　また、ＥＣＵ１２は、冷間始動直後など、触媒７の実温度または予測温度が活性化温度に達していない時に、触媒７の早期暖機を実施する。具体的に、ＥＣＵ１２は、触媒７の早期暖機を行う際に、ウエストゲートバルブ９を所定の開度に設定する。これにより、排気ガスの熱がウエストゲートバルブ９に奪われるのを防ぐことができる。もちろん、この触媒７の早期暖機制御は一例であって、限定するものではない。 Further, the ECU 12 performs an early warm-up of the catalyst 7 when the actual temperature or the predicted temperature of the catalyst 7 has not reached the activation temperature, such as immediately after a cold start. Specifically, the ECU 12 sets the wastegate valve 9 to a predetermined opening when the catalyst 7 is warmed up early. Thereby, it is possible to prevent the heat of the exhaust gas from being taken away by the wastegate valve 9. Of course, the early warm-up control of the catalyst 7 is an example and is not limited.
（実施形態１の特徴技術）
　電動アクチュエータ１１の製造方法を説明する。 (Feature Technology of Embodiment 1)
A method for manufacturing the electric actuator 11 will be described.
　電動アクチュエータ１１の組付けには、図８、図９に示す治具６０が用いられる。 
　出力シャフト２３の上端には、図１０に示すように、環状の段差面６１を介して縮径した円筒部６２を設けている。段差面６１は、出力シャフト２３の軸方向に対して垂直な環状の平面である。また、円筒部６２は、出力シャフト２３の回転中心と同芯に設けられている。 A jig 60 shown in FIGS. 8 and 9 is used for assembling the electric actuator 11.
At the upper end of the output shaft 23, as shown in FIG. 10, a cylindrical portion 62 whose diameter is reduced via an annular step surface 61 is provided. The step surface 61 is an annular plane perpendicular to the axial direction of the output shaft 23. The cylindrical portion 62 is provided concentrically with the rotation center of the output shaft 23.
　アクチュエータレバー１３には、図１０に示すように、円筒部６２が挿し入れられる丸穴６３が設けられている。この丸穴６３の内径寸法は、円筒部６２の内径寸法より僅かに大径に設けられている。 The actuator lever 13 is provided with a round hole 63 into which the cylindrical portion 62 is inserted as shown in FIG. The inner diameter of the round hole 63 is slightly larger than the inner diameter of the cylindrical portion 62.
　ハウジング２０には、出力シャフト２３の下端を外部に露出させる露出穴６４が設けられている。 The housing 20 is provided with an exposure hole 64 that exposes the lower end of the output shaft 23 to the outside.
　この実施形態における露出穴６４を具体的に説明する。ハウジング２０には、下ベアリング３３を圧入するための下ベアリング穴４１が設けられている。この下ベアリング穴４１の下端には、下ベアリング３３の下方への移動を規制する下鍔４１ａが設けられている。この実施形態では、この下鍔４１ａの内側が露出穴６４に相当する。 The exposure hole 64 in this embodiment will be specifically described. A lower bearing hole 41 for press-fitting the lower bearing 33 is provided in the housing 20. At the lower end of the lower bearing hole 41, a lower rod 41a for restricting the downward movement of the lower bearing 33 is provided. In this embodiment, the inner side of the lower collar 41 a corresponds to the exposure hole 64.
　出力シャフト２３の下端には、出力シャフト２３の回転を規制する工具６５と係合可能な回止形状（回止部またはシャフト側係合部とも称する）６６が設けられている。 The lower end of the output shaft 23 is provided with a non-rotating shape (also referred to as a non-rotating portion or a shaft side engaging portion) 66 that can be engaged with a tool 65 that restricts the rotation of the output shaft 23.
　この回止形状６６は、図５、図７に示すように、露出穴６４の外部から視認できる。即ち、ハウジング２０の外部から露出穴６４の内側に回止形状６６を視認できる。具体的に露出穴６４は、図８に示すように、工具６５をハウジング２０の外部から露出穴６４に挿し入れて、工具６５を回止形状６６に係合できるように設けられている。 The rotation shape 66 can be visually recognized from the outside of the exposure hole 64 as shown in FIGS. That is, the rotation shape 66 can be visually recognized from the outside of the housing 20 to the inside of the exposure hole 64. Specifically, as shown in FIG. 8, the exposure hole 64 is provided so that the tool 65 can be inserted into the exposure hole 64 from the outside of the housing 20 and the tool 65 can be engaged with the rotation shape 66.
　回止形状６６の具体的な一例を説明する。この実施形態の回止形状６６は、図１１に示すように、マイナス溝を採用する。即ち、この実施形態の回止形状６６は、出力シャフト２３の軸芯Ｃを通る直線の溝によって設けられる。 A specific example of the stop shape 66 will be described. As shown in FIG. 11, the rotation stop shape 66 of this embodiment employs a minus groove. That is, the rotation stop shape 66 of this embodiment is provided by a straight groove that passes through the axis C of the output shaft 23.
　もちろん、回止形状６６の具体的な形は限定するものではなく、工具６５と嵌まり合うことで出力シャフト２３の回転を規制できるものであれば良い。具体的には、回止形状６６の一例として、プラス溝を採用しても良いし、六角穴などの多角穴を採用しても良い。あるいは、六ぼう星などの星穴を採用しても良いし、楕円穴を採用してもよい。 Of course, the specific shape of the stop shape 66 is not limited, and any shape that can regulate the rotation of the output shaft 23 by fitting with the tool 65 may be used. Specifically, as an example of the rotation stop shape 66, a plus groove may be employed, or a polygonal hole such as a hexagonal hole may be employed. Alternatively, a star hole such as a hexagonal star may be employed, or an elliptical hole may be employed.
　工具６５は、回止形状６６に嵌まり合うことで出力シャフト２３の回転を規制して、出力シャフト２３の回転方向の位置決めを行うものである。 The tool 65 is configured to restrict the rotation of the output shaft 23 by being fitted to the rotation shape 66 and to position the output shaft 23 in the rotation direction.
　工具６５において回止形状６６に嵌まり合う箇所の具体的な形状は、直線状の突起形状に設けられている。もちろん、工具６５において回止形状６６に嵌まり合う形状は、回止形状６６が変更された場合に、変更された回止形状６６に合致するように変更されるものである。具体的な一例を開示すると、回止形状６６が六角穴に変更される場合は、工具６５も六角レンチの形状に変更されるものである。 The specific shape of the portion of the tool 65 that fits with the rotation stop shape 66 is a linear protrusion shape. Needless to say, the shape of the tool 65 that fits the stop shape 66 is changed to match the changed stop shape 66 when the stop shape 66 is changed. If a specific example is disclosed, when the turning shape 66 is changed to a hexagonal hole, the tool 65 is also changed to the shape of a hexagonal wrench.
　治具６０は、電磁アクチュエータ１１の製造時にハウジング２０を支持するものであり、上述した工具（治具側係合部とも称する）６５を備える。具体的にこの実施形態では、工具６５が治具６０と一体に設けられる。即ち、治具６０の一部が工具６５として設けられる。 The jig 60 supports the housing 20 when the electromagnetic actuator 11 is manufactured, and includes the above-described tool (also referred to as a jig side engaging portion) 65. Specifically, in this embodiment, the tool 65 is provided integrally with the jig 60. That is, a part of the jig 60 is provided as the tool 65.
　なお、この実施形態とは異なり、工具６５を治具６０と別体に設けても良い。この場合、治具６０に対する工具６５の回転角度が任意の角度で設定できることが望ましい。 Note that, unlike this embodiment, the tool 65 may be provided separately from the jig 60. In this case, it is desirable that the rotation angle of the tool 65 with respect to the jig 60 can be set at an arbitrary angle.
　続いて、具体的な電動アクチュエータ１１の製造方法を説明する。 Subsequently, a specific method for manufacturing the electric actuator 11 will be described.
　ハウジング２０には、上述したように、上方へ向けて開口する開口部αが設けられている。この開口部αの内側には、モータ挿入室γの他に、歯車減速機２２や出力シャフト２３等の組付スペースが設けられる。そして、ハウジング２０に直接組み付けられる全ての部品は、電動モータ２１、歯車減速機２２、出力シャフト２３、カバー２４を含め、全て上方から下方へ向けてハウジング２０に組付けられる。  As described above, the housing 20 is provided with the opening α that opens upward. In addition to the motor insertion chamber γ, an assembly space for the gear reducer 22, the output shaft 23, and the like is provided inside the opening α. All the components that are directly assembled to the housing 20, including the electric motor 21, the gear reducer 22, the output shaft 23, and the cover 24, are all assembled to the housing 20 from the top to the bottom.
　電動アクチュエータ１１の組立を行う際は、治具組付工程と、内部組付工程と、カバー組付工程と、レバー嵌合工程と、レバー固定工程とを実施する。 When assembling the electric actuator 11, a jig assembling step, an internal assembling step, a cover assembling step, a lever fitting step, and a lever fixing step are performed.
　治具組付工程では、治具６０の所定位置にハウジング２０を組付ける。具体的には、開口部αが上方に向くようにしてハウジング２０を治具６０の上に乗せる。この時、治具６０に対してハウジング２０の位置決めを行う。 In the jig assembling step, the housing 20 is assembled at a predetermined position of the jig 60. Specifically, the housing 20 is placed on the jig 60 so that the opening α faces upward. At this time, the housing 20 is positioned with respect to the jig 60.
　このことを具体的に説明する。ハウジング２０には、複数の位置決め凹部６７が設けられる。具体的にハウジング２０の下面には、図５に示すように、２つの位置決め凹部６７が設けられる。 This will be explained in detail. The housing 20 is provided with a plurality of positioning recesses 67. Specifically, two positioning recesses 67 are provided on the lower surface of the housing 20 as shown in FIG.
　一方、治具６０には、複数の位置決め凹部６７に嵌まり合う複数の位置決めピン６８が設けられる。具体的に治具６０の上面には、上方へ延びて位置決め凹部６７に嵌まり合う２つの位置決めピン６８が設けられる。 On the other hand, the jig 60 is provided with a plurality of positioning pins 68 that fit into the plurality of positioning recesses 67. Specifically, two positioning pins 68 that extend upward and fit into the positioning recesses 67 are provided on the upper surface of the jig 60.
　そして、治具組付工程では、ハウジング２０を治具６０に乗せる際に、各位置決め凹部６７に、各位置決めピン６８を嵌め合わせる。これにより、治具６０に対してハウジング２０が所定の位置に組み付けられるとともに、露出穴６４の中心部に工具６５が挿し入れられる。 In the jig assembling step, the positioning pins 68 are fitted into the positioning recesses 67 when the housing 20 is placed on the jig 60. As a result, the housing 20 is assembled at a predetermined position with respect to the jig 60, and the tool 65 is inserted into the central portion of the exposure hole 64.
　続いて、内部組付工程を実施する。 Subsequently, an internal assembly process is performed.
　内部組付工程は、電動モータ２１、歯車減速機２２、出力シャフト２３を、開口部αの内側に組み付ける工程である。 The internal assembly process is a process of assembling the electric motor 21, the gear reducer 22, and the output shaft 23 inside the opening α.
　内部組付工程の詳細を説明する。 The details of the internal assembly process will be described.
　上方からモータ挿入室γの底にウエーブワッシャ３８を組み入れる。このウエーブワッシャ３８は、モータ挿入室γの底と電動モータ２１との間で圧縮されて、電動モータ２１の振動を抑制するものである。 A wave washer 38 is incorporated into the bottom of the motor insertion chamber γ from above. The wave washer 38 is compressed between the bottom of the motor insertion chamber γ and the electric motor 21 to suppress vibration of the electric motor 21.
　次に、上方からモータ挿入室γに電動モータ２１を挿し入れる。 Next, the electric motor 21 is inserted into the motor insertion chamber γ from above.
　次に、上方から複数のスクリュ等をハウジング２０に螺合して、電動モータ２１をハウジング２０に固定する。 Next, a plurality of screws or the like are screwed into the housing 20 from above, and the electric motor 21 is fixed to the housing 20.
　上方から第１中間シャフト３１と第２中間シャフト３２をハウジング２０に圧入する。具体的に、開口部αの内側の底面には、第１中間シャフト３１を圧入するための第１圧入穴３９と、第２中間シャフト３２を圧入するための第２圧入穴４０が予め形成されている。 The first intermediate shaft 31 and the second intermediate shaft 32 are press-fitted into the housing 20 from above. Specifically, a first press-fitting hole 39 for press-fitting the first intermediate shaft 31 and a second press-fitting hole 40 for press-fitting the second intermediate shaft 32 are formed in advance on the bottom surface inside the opening α. ing.
　そして、第１圧入穴３９に第１中間シャフト３１を圧入するとともに、第２圧入穴４０に第２中間シャフト３２を圧入する。 Then, the first intermediate shaft 31 is press-fitted into the first press-fitting hole 39 and the second intermediate shaft 32 is press-fitted into the second press-fitting hole 40.
　上方から下ベアリング３３をハウジング２０に圧入する。即ち、下ベアリング穴４１に下ベアリング３３を圧入する。 The lower bearing 33 is press-fitted into the housing 20 from above. That is, the lower bearing 33 is press-fitted into the lower bearing hole 41.
　上方から出力シャフト２３を下ベアリング３３の内側に圧入する。具体的に、出力シャフト２３には、最終ギヤ２９と磁束発生部３６が設けられている。このため、出力シャフト２３を下ベアリング３３の内側に圧入することで、最終ギヤ２９と磁束発生部３６もハウジング２０に組み付けられる。 The output shaft 23 is press-fitted into the lower bearing 33 from above. Specifically, the output shaft 23 is provided with a final gear 29 and a magnetic flux generator 36. For this reason, the final gear 29 and the magnetic flux generator 36 are also assembled to the housing 20 by press-fitting the output shaft 23 inside the lower bearing 33.
　この時、係合工程を実施する。即ち、出力シャフト２３の組付けを行う際に係合工程を実施する。 At this time, the engagement process is performed. That is, the engaging step is performed when the output shaft 23 is assembled.
　この係合工程は、出力シャフト２３を下ベアリング３３に圧入する時に、回止形状６６を工具６５に係合させて出力シャフト２３の回転方向の位置決めを行う工程である。 This engagement step is a step of positioning the output shaft 23 in the rotational direction by engaging the rotation shape 66 with the tool 65 when the output shaft 23 is press-fitted into the lower bearing 33.
　具体的に、最終ギヤ２９を第２中間シャフト３２に向けた状態で出力シャフト２３を下ベアリング３３の内側に圧入しつつ、回止形状６６を工具６５に係合させる。これにより、出力シャフト２３の回転方向が、予め設定した方向に位置決めされる。 Specifically, the rotation shape 66 is engaged with the tool 65 while the output shaft 23 is press-fitted inside the lower bearing 33 with the final gear 29 facing the second intermediate shaft 32. Thereby, the rotation direction of the output shaft 23 is positioned in a preset direction.
　このことをさらに具体的に説明する。 This will be explained more specifically.
　この実施形態の回止形状６６は、上述したようにマイナス溝を採用するため、回止形状６６と工具６５は１８０°の間隔で係合する。このため、出力シャフト２３が規定の組付角度と異なる角度で組み付けられる誤組付けを防止できる。 Since the turning shape 66 of this embodiment employs a minus groove as described above, the turning shape 66 and the tool 65 are engaged at an interval of 180 °. For this reason, it is possible to prevent erroneous assembly in which the output shaft 23 is assembled at an angle different from the prescribed assembly angle.
　誤組付を防ぐ構造をさらに説明する。 構造 The structure to prevent incorrect assembly will be further explained.
　この実施形態の最終ギヤ２９には、下方へ伸びるストッパ７１が一体に設けられる。 The final gear 29 of this embodiment is integrally provided with a stopper 71 that extends downward.
　このストッパ７１は、開口部αの底面に形成された円弧溝７２に挿し入れられるものであり、円弧溝７２のラジアル方向の端にストッパ７１が当たることで出力シャフト２３の回動範囲が機械的に規制される。 The stopper 71 is inserted into an arc groove 72 formed on the bottom surface of the opening α. When the stopper 71 hits the radial end of the arc groove 72, the rotation range of the output shaft 23 is mechanical. Regulated by
　このストッパ７１は、最終ギヤ２９を第２中間シャフト３２に向けた状態でのみ円弧溝７２に挿し入れ可能になっている。このため、出力シャフト２３を誤った角度で挿入しても、ストッパ７１がハウジング２０に干渉して、出力シャフト２３の誤組付けが防がれる。 The stopper 71 can be inserted into the arc groove 72 only with the final gear 29 facing the second intermediate shaft 32. For this reason, even if the output shaft 23 is inserted at an incorrect angle, the stopper 71 interferes with the housing 20 to prevent erroneous assembly of the output shaft 23.
　次に、第２中間シャフト３２に第２中間ギヤ２８を組付ける。続いて、第１中間シャフト３１に第１中間ギヤ２７を組付ける。 Next, the second intermediate gear 28 is assembled to the second intermediate shaft 32. Subsequently, the first intermediate gear 27 is assembled to the first intermediate shaft 31.
　以上により、内部組付工程を終了する。 This completes the internal assembly process.
　続いて、カバー組付工程を実施する。 Subsequently, the cover assembly process is performed.
　カバー組付工程は、ハウジング２０にカバー２４を組付ける工程である。 The cover assembling step is a step of assembling the cover 24 to the housing 20.
　具体的に、上方からカバー２４をハウジング２０に装着する。この時、カバー２４に圧入された上ベアリング３４の内側に出力シャフト２３を圧入する。具体的に、カバー２４は樹脂製である。そして、樹脂製のカバー２４には上ベアリング３４を圧入する手段として金属製で筒状のベアリングホルダ５５がモールドされている。そして、このカバー組付け工程の前に、ベアリングホルダ５５の内側に上ベアリング３４が圧入されている。 Specifically, the cover 24 is attached to the housing 20 from above. At this time, the output shaft 23 is press-fitted inside the upper bearing 34 press-fitted into the cover 24. Specifically, the cover 24 is made of resin. The resin cover 24 is molded with a metallic cylindrical bearing holder 55 as means for press-fitting the upper bearing 34. The upper bearing 34 is press-fitted inside the bearing holder 55 before the cover assembling step.
　次に、上方から複数のボルト４２をハウジング２０に螺合して、カバー２４をハウジング２０に固定する。 Next, a plurality of bolts 42 are screwed into the housing 20 from above, and the cover 24 is fixed to the housing 20.
　なお、カバー２４には、電動モータ２１および磁気検出部３７と電気的な接続を行うコネクタ４３が設けられるとともに、磁気検出部３７が設けられる。このため、カバー２４をハウジング２０に組付けることで、コネクタ４３と磁気検出部３７の組付けも完了する。また、カバー２４の下面には、第１中間シャフト３１の上端が嵌め入れられる第１嵌合穴３１ａと、第２中間シャフト３２の上端が嵌め入れられる第２嵌合穴３２ａとが設けられている。 The cover 24 is provided with a connector 43 that is electrically connected to the electric motor 21 and the magnetic detection unit 37, and is also provided with the magnetic detection unit 37. For this reason, the assembly of the connector 43 and the magnetic detection unit 37 is completed by assembling the cover 24 to the housing 20. Further, the lower surface of the cover 24 is provided with a first fitting hole 31a into which the upper end of the first intermediate shaft 31 is fitted, and a second fitting hole 32a into which the upper end of the second intermediate shaft 32 is fitted. Yes.
　以上により、カバー組付工程を終了する。 Thus, the cover assembling process is completed.
　続いて、レバー嵌合工程を実施する。 Subsequently, a lever fitting process is performed.
　レバー嵌合工程は、上方からアクチュエータレバー１３を出力シャフト２３の上端に装着する工程である。具体的には、円筒部６２と丸穴６３を嵌め合わせる工程である。 The lever fitting process is a process of mounting the actuator lever 13 on the upper end of the output shaft 23 from above. Specifically, this is a step of fitting the cylindrical portion 62 and the round hole 63 together.
　このレバー嵌合工程が完了した状態では、出力シャフト２３に対してアクチュエータレバー１３を３６０°回動させることができる。なお、アクチュエータレバー１３の回動端側においてロッド１５と回動自在に結合されるピン４４は、レバー嵌合工程とは別の工程により、前もってアクチュエータレバー１３に結合したものである。 When the lever fitting process is completed, the actuator lever 13 can be rotated 360 ° with respect to the output shaft 23. The pin 44 that is rotatably coupled to the rod 15 on the pivot end side of the actuator lever 13 is coupled to the actuator lever 13 in advance by a process different from the lever fitting process.
　続いて、レバー固定工程を実施する。 
　レバー固定工程は、先ず、出力シャフト２３に対するアクチュエータレバー１３の固定角度を決定する。具体的には、治具６０またはハウジング２０に対して予め決まった向きにアクチュエータレバー１３を向ける。 Subsequently, a lever fixing step is performed.
In the lever fixing step, first, the fixing angle of the actuator lever 13 with respect to the output shaft 23 is determined. Specifically, the actuator lever 13 is directed in a predetermined direction with respect to the jig 60 or the housing 20.
　次に、出力シャフト２３に対するアクチュエータレバー１３の固定角度を保ったままの状態で、アクチュエータレバー１３を出力シャフト２３に固定する。 Next, the actuator lever 13 is fixed to the output shaft 23 while maintaining the fixed angle of the actuator lever 13 with respect to the output shaft 23.
　出力シャフト２３とアクチュエータレバー１３は、出力シャフト２３の上端を塑性変形させるカシメ技術、あるいは溶接技術によって固定される。 The output shaft 23 and the actuator lever 13 are fixed by a caulking technique that plastically deforms the upper end of the output shaft 23 or a welding technique.
　具体的な一例として、この実施形態では、カシメ技術を用いてアクチュエータレバー１３を出力シャフト２３に固定するものである。即ち、この実施形態では、出力シャフト２３の上端を潰して円筒部６２の端部を拡径するとともに、潰して拡径した円筒部６２の端部と段差面６１の間でアクチュエータレバー１３を強固に挟み付けて、アクチュエータレバー１３を出力シャフト２３に固定する。 As a specific example, in this embodiment, the actuator lever 13 is fixed to the output shaft 23 using caulking technology. That is, in this embodiment, the upper end of the output shaft 23 is crushed and the end of the cylindrical portion 62 is expanded, and the actuator lever 13 is firmly fixed between the end of the crushed and expanded cylindrical portion 62 and the step surface 61. And the actuator lever 13 is fixed to the output shaft 23.
　なお、丸穴６３の縁部には、局所的な縦溝６３ａが複数形成されている。上述したカシメを行うと、塑性変形した出力シャフト２３の一部が各縦溝６３ａに食い込む。これにより、出力シャフト２３とアクチュエータレバー１３の回転方向の結合力が高められる。 A plurality of local vertical grooves 63 a are formed at the edge of the round hole 63. When the above-described caulking is performed, a part of the plastically deformed output shaft 23 bites into each vertical groove 63a. Thereby, the coupling force in the rotational direction of the output shaft 23 and the actuator lever 13 is increased.
　以上により、電動アクチュエータ１１の組付が完了する。 Thus, the assembly of the electric actuator 11 is completed.
（実施形態１の効果）
　この実施形態の電動アクチュエータ１１は、露出穴６４から視認できる回止形状６６を出力シャフト２３の基準角として、出力シャフト２３とアクチュエータレバー１３の相対角度を任意に設定できる。このため、アクチュエータレバー１３の固定角度にバラツキが生じる不具合がない。 (Effect of Embodiment 1)
In the electric actuator 11 of this embodiment, the relative angle between the output shaft 23 and the actuator lever 13 can be arbitrarily set with the rotation shape 66 visible from the exposure hole 64 as the reference angle of the output shaft 23. For this reason, there is no problem that the fixing angle of the actuator lever 13 varies.
　また、露出穴６４から視認できる回止形状６６を出力シャフト２３の基準角とすることで、出力シャフト２３に対するアクチュエータレバー１３の固定角度を自由に変更できる。このため、電動アクチュエータ１１の汎用性を高めることができる。 Further, by making the rotation shape 66 visible from the exposure hole 64 as the reference angle of the output shaft 23, the fixing angle of the actuator lever 13 with respect to the output shaft 23 can be freely changed. For this reason, the versatility of the electric actuator 11 can be improved.
　電動アクチュエータ１１の製造方法では、出力シャフト２３に設けた回止形状６６を、工具６５に係合させて出力シャフト２３の回転方向の位置決めを行う。その後、アクチュエータレバー１３の固定角度を決定して、アクチュエータレバー１３を出力シャフト２３に固定する。このため、出力シャフト２３に対するアクチュエータレバー１３の固定角度にバラツキが生じない。 In the manufacturing method of the electric actuator 11, the rotation shape 66 provided on the output shaft 23 is engaged with the tool 65 to position the output shaft 23 in the rotation direction. Thereafter, the fixing angle of the actuator lever 13 is determined, and the actuator lever 13 is fixed to the output shaft 23. For this reason, the fixed angle of the actuator lever 13 with respect to the output shaft 23 does not vary.
　これにより、４節リンクのリンク比にばらつきが生じる不具合がなく、ウエストゲートバルブ９の作動性の悪化を招く不具合が生じない。 This ensures that there are no problems that cause variations in the link ratio of the four-bar link, and no problems that cause the deterioration of the operability of the wastegate valve 9.
　また、出力シャフト２３に対してアクチュエータレバー１３の固定角度を自由に変更できる。このため、電動アクチュエータ１１の汎用性を高めることができる。 Further, the fixed angle of the actuator lever 13 with respect to the output shaft 23 can be freely changed. For this reason, the versatility of the electric actuator 11 can be improved.
　具体的には、ターボチャージャＴに対する電動アクチュエータ１１の搭載角度が異なる車両であっても、電動アクチュエータ１１の部品を変更することなく対応できる。 Specifically, even if the mounting angle of the electric actuator 11 with respect to the turbocharger T is different, the vehicle can be handled without changing the parts of the electric actuator 11.
　同様に、バルブ軸１０の位置が異なるターボチャージャＴに対しても、電動アクチュエータ１１の部品を変更することなく対応できる。 Similarly, the turbocharger T having a different position of the valve shaft 10 can be handled without changing the parts of the electric actuator 11.
　この実施形態の電動アクチュエータ１１は、上述したように高い汎用性を備えるため、部品変更を招くことなく種々の車種等への搭載が可能になる。 Since the electric actuator 11 of this embodiment has high versatility as described above, it can be mounted on various types of vehicles without incurring component changes.
　これにより、電動アクチュエータ１１の製造コストを抑えることができ、結果的に車両に搭載されるターボチャージャＴを含む過給装置のコストを抑えることができる。 Thereby, the manufacturing cost of the electric actuator 11 can be suppressed, and as a result, the cost of the supercharging device including the turbocharger T mounted on the vehicle can be suppressed.
［他の実施形態］
　上記の実施形態では、ウエストゲートバルブ９を駆動する電動アクチュエータ１１を例示したが、電動アクチュエータ１１の駆動対象物をウエストゲートバルブ９に限定しない。 [Other Embodiments]
In the above embodiment, the electric actuator 11 that drives the waste gate valve 9 is illustrated, but the drive target of the electric actuator 11 is not limited to the waste gate valve 9.
　具体的な一例を開示すると、電動アクチュエータ１１によってタービンハウジング６ｂに設けた第２排気スクロールの開閉を行う切替バルブを駆動しても良い。もちろん、電動アクチュエータ１１によってウエストゲートバルブ９と切替バルブの両方を操作しても良い。 If a specific example is disclosed, the electric actuator 11 may drive a switching valve that opens and closes the second exhaust scroll provided in the turbine housing 6b. Of course, both the waste gate valve 9 and the switching valve may be operated by the electric actuator 11.
　または、可変ノズル機構を用いるターボチャージャＴのノズルベーン（バルブの一例）の操作を行う電動アクチュエータ１１に本開示を適用しても良い。 Alternatively, the present disclosure may be applied to the electric actuator 11 that operates a nozzle vane (an example of a valve) of the turbocharger T that uses a variable nozzle mechanism.
　あるいは、２基のターボチャージャＴを用いた２ステージターボにおいて、２基のターボチャージャＴの切替を行う電動アクチュエータ１１に本開示を適用しても良い。 Alternatively, the present disclosure may be applied to the electric actuator 11 that switches between the two turbochargers T in a two-stage turbo that uses the two turbochargers T.
　上記の実施形態では、歯車減速機２２の具体的な一例として、ピニオンギヤ２６と最終ギヤ２９との間に第１中間ギヤ２７と第２中間ギヤ２８を設ける例を示した。 In the embodiment described above, an example in which the first intermediate gear 27 and the second intermediate gear 28 are provided between the pinion gear 26 and the final gear 29 is shown as a specific example of the gear reducer 22.
　このように平行軸式の歯車減速機２２を用いる場合は、ピニオンギヤ２６と最終ギヤ２９との間に１つの中間ギヤを設けるものであっても良いし、３つ以上の中間ギヤを設けるものであっても良い。

  When the parallel shaft type gear reducer 22 is used as described above, one intermediate gear may be provided between the pinion gear 26 and the final gear 29, or three or more intermediate gears may be provided. There may be.

Claims (5)

  1. 　一方向へ向けて開口する開口部（α）を有するハウジング（２０）と、
    　前記ハウジング（２０）に組み付けられる電動モータ（２１）と、
    　前記ハウジング（２０）に組み付けられ、前記電動モータ（２１）の発生する回転力を減速する平行軸式の歯車減速機（２２）と、
    　前記ハウジング（２０）に組み付けられ、前記歯車減速機（２２）によって減速された回転力により駆動される出力シャフト（２３）と、
    　前記ハウジング（２０）に組み付けられ、前記ハウジング（２０）との間に前記電動モータ（２１）と前記歯車減速機（２２）を収容する空間（β）を形成し、前記出力シャフト（２３）の一端を外部に露出させるカバー（２４）と、
    　前記カバー（２４）の外部に露出した前記出力シャフト（２３）の一端に固定されて、ターボチャージャ（Ｔ）に設けられるバルブ（９）を駆動するアクチュエータレバー（１３）とを備え、
    　前記出力シャフト（２３）の一端には、環状の段差面（６１）を介して縮径された円筒部（６２）が設けられ、
    　前記アクチュエータレバー（１３）には、前記円筒部（６２）が挿し入れられる丸穴（６３）が設けられ、
    　前記ハウジング（２０）には、前記出力シャフト（２３）の他端を外部に露出させる露出穴（６４）が設けられ、
    　前記出力シャフト（２３）の他端には、前記出力シャフト（２３）の回転を規制する工具（６５）と係合可能な回止形状（６６）が設けられ、
    　前記回止形状（６６）が前記露出穴（６４）から視認できる電動アクチュエータ。     A housing (20) having an opening (α) that opens in one direction;
    An electric motor (21) assembled to the housing (20);
    A parallel shaft type gear reducer (22) that is assembled to the housing (20) and decelerates the rotational force generated by the electric motor (21);
    An output shaft (23) assembled to the housing (20) and driven by a rotational force decelerated by the gear reducer (22);
    A space (β) for housing the electric motor (21) and the gear reducer (22) is formed between the housing (20) and the housing (20), and the output shaft (23) A cover (24) exposing one end to the outside;
    An actuator lever (13) that is fixed to one end of the output shaft (23) exposed to the outside of the cover (24) and drives a valve (9) provided in the turbocharger (T);
    One end of the output shaft (23) is provided with a cylindrical portion (62) having a reduced diameter via an annular step surface (61),
    The actuator lever (13) is provided with a round hole (63) into which the cylindrical portion (62) is inserted,
    The housing (20) is provided with an exposure hole (64) for exposing the other end of the output shaft (23) to the outside.
    The other end of the output shaft (23) is provided with a rotation stop shape (66) that can be engaged with a tool (65) that restricts the rotation of the output shaft (23),
    The electric actuator which can visually recognize the said stop shape (66) from the said exposure hole (64).
  2. 　請求項１に記載の電動アクチュエータにおいて、
    　前記回止形状（６６）は、前記出力シャフト（２３）の軸芯（Ｃ）を通る直線の溝である電動アクチュエータ。     The electric actuator according to claim 1,
    The non-rotating shape (66) is an electric actuator that is a straight groove that passes through the axis (C) of the output shaft (23).
  3. 　請求項１または請求項２に記載の電動アクチュエータにおいて、
    　前記ハウジング（２０）には、複数の位置決め凹部（６７）が設けられている電動アクチュエータ。     The electric actuator according to claim 1 or 2,
    The electric actuator provided with a plurality of positioning recesses (67) in the housing (20).
  4. 　請求項１ないし請求項３のいずれか１つに記載の電動アクチュエータにおいて、
    　前記出力シャフト（２３）と前記アクチュエータレバー（１３）は、前記出力シャフト（２３）の一端を塑性変形させるカシメ技術、あるいは溶接技術によって固定されている電動アクチュエータ。     The electric actuator according to any one of claims 1 to 3,
    The output shaft (23) and the actuator lever (13) are electric actuators fixed by caulking technology or welding technology that plastically deforms one end of the output shaft (23).
  5. 　請求項１ないし請求項４のいずれか１つに記載の電動アクチュエータは、
    　前記ハウジング（２０）を支持する治具（６０）を用いて製造されるものであり、
    　前記治具（６０）は、前記回止形状（６６）に係合可能な工具（６５）を備えるものであり、
    　前記電動アクチュエータの製造方法は、
    　前記治具（６０）の所定位置に前記ハウジング（２０）を組付ける治具組付工程と、
    　前記電動モータ（２１）、前記歯車減速機（２２）および前記出力シャフト（２３）を、前記開口部の内側に組み付ける内部組付工程と、
    　この内部組付工程中に、前記回止形状（６６）を前記工具（６５）に係合させて前記出力シャフト（２３）の回転方向の位置決めを行う係合工程と、
    　前記カバー（２４）を前記ハウジング（２０）に組付けるカバー組付工程と、
    　前記円筒部（６２）と前記丸穴（６３）を嵌め合わせるレバー嵌合工程と、
    　前記出力シャフト（２３）に対する前記アクチュエータレバー（１３）の固定角度を決定して、前記アクチュエータレバー（１３）を前記出力シャフト（２３）に固定するレバー固定工程と、 
    を備える電動アクチュエータの製造方法。 

          The electric actuator according to any one of claims 1 to 4,
    It is manufactured using a jig (60) that supports the housing (20),
    The jig (60) includes a tool (65) that can be engaged with the stop shape (66),
    The method for manufacturing the electric actuator includes:
    A jig assembling step for assembling the housing (20) at a predetermined position of the jig (60);
    An internal assembly step of assembling the electric motor (21), the gear reducer (22) and the output shaft (23) inside the opening;
    An engagement step in which the rotation shape of the output shaft (23) is positioned by engaging the turning shape (66) with the tool (65) during the internal assembly step;
    A cover assembling step for assembling the cover (24) to the housing (20);
    A lever fitting step for fitting the cylindrical portion (62) and the round hole (63);
    Determining a fixing angle of the actuator lever (13) with respect to the output shaft (23), and fixing the actuator lever (13) to the output shaft (23);
    A method of manufacturing an electric actuator comprising:

PCT/JP2016/002751 2015-06-18 2016-06-07 Electric actuator and manufacturing method for same WO2016203736A1 (en)

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Cited By (5)

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CN109838302A (en) * 2017-11-24 2019-06-04 丰田自动车株式会社 Abnormity determining device and method
US10389204B2 (en) 2015-06-18 2019-08-20 Denso Corporation Electric actuator
CN110312850A (en) * 2017-03-01 2019-10-08 株式会社电装 The manufacturing method of plate and plate
US10451154B2 (en) 2015-06-18 2019-10-22 Denso Corporation Electric actuator
US10591079B2 (en) 2015-06-18 2020-03-17 Denso Corporation Electric actuator and manufacturing method for same

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US10389204B2 (en) 2015-06-18 2019-08-20 Denso Corporation Electric actuator
US10451154B2 (en) 2015-06-18 2019-10-22 Denso Corporation Electric actuator
US10591079B2 (en) 2015-06-18 2020-03-17 Denso Corporation Electric actuator and manufacturing method for same
CN110312850A (en) * 2017-03-01 2019-10-08 株式会社电装 The manufacturing method of plate and plate
US11098658B2 (en) * 2017-03-01 2021-08-24 Denso Corporation Plate and method for manufacturing plate
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