JPH0955328A - Magnet switch solenoid manufacturing method - Google Patents

Abstract

(57) [PROBLEMS] To provide a solenoid manufacturing method capable of manufacturing a bobbinless type solenoid 1 at low cost. SOLUTION: One insulating washer 4 is fitted and arranged inside a stationary core 7 assembled on one end side of a sleeve 2, and a winding end holding jig is assembled on the other end side of the sleeve 2. The winding frame of the suction coil 3 is formed. After the suction coil 3 is wound around the winding frame, the other end face of the suction coil 3 is regulated by the winding end holding jig, and the other insulating washer 5 and the magnet cover 6 are attached from the winding end holding jig side. After assembly, the opening of the magnet cover 6 is caulked and fixed to the outer circumference of the large-diameter cylindrical portion 7a of the stationary core 7. As a result, the suction coil 3 is sandwiched between the inner surface of the large-diameter cylindrical portion 7a of the stationary core 7 and the bottom wall 6a of the magnet cover 6 via the two insulating washers 4 and 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a solenoid used in a starter magnet switch.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 15, a bobbin, which is a winding frame of a coil 110, is eliminated, and the coil 110 is directly wound around the outer circumference of a sleeve 120 made of a non-magnetic material. Bobbinless type solenoid 100
There is. A method of manufacturing the solenoid 100 will be described. a) First, as shown in FIG. 16, the winding shaft 20 of the winding machine
0 with the sleeve 120 attached, and a pair of side plates 210,
The winding width L of the coil 110 is regulated by 220. b) Subsequently, after winding the coil 110 in multiple layers around the outer circumference of the sleeve 120, the wound coil 1
In order to prevent the shape of 10 from being deformed, an adhesive tape 300 having the same width as the winding width L is provided on the outer circumference of the coil 110 (see FIG. 17).
Paste and fix. Alternatively, instead of using the adhesive tape 300, the coil 110 in which an adhesive or the like is applied to the surface of the insulating coating wire may be used. In this case, the coil 11
After winding 0 around the sleeve 120, the wire rods of the coil 110 can be welded and integrated and fixed by heating by energization from both terminal wires 111 of the coil 110 or heating from the outside.

C) Next, one end surface of the coil 110 (see FIG. 1).
7 the lower surface of 7) and place one of the insulating washers 130,
The small-diameter cylindrical portion 141 of the stationary core 140 is inserted into the inner periphery of the sleeve 120 from the outside of the insulating washer 130 and assembled. Further, the other end of the coil 110 from which the terminal wire 111 is taken out is attached to the other insulating washer 15
0 is placed, and the outer circumference of the insulating washer 150 is covered with a bottomed cylindrical magnet cover 160 on the outer periphery of the coil 110 to enclose the coil 110. d) Finally, the large diameter cylindrical portion 1 of the stationary core 140.
The coil 110 is sandwiched between the large-diameter cylindrical portion 142 of the stationary core 140 and the bottom wall 161 of the magnet cover 160 by caulking and fixing the opening peripheral edge portion of the magnet cover 160 fitted to the outer circumference of the magnet cover 42 inward. The bobbinless type solenoid 100 is completed. The terminal wire 111 of the coil 110 is inserted into a round hole 151 (see FIG. 17) formed in the other insulating washer 150 and a round hole 162 formed in the bottom wall 161 of the magnet cover 160, so that the magnet cover is inserted. It is pulled out to the outside of 160.

[0004]

However, in the above manufacturing method, the stationary core 140 and the magnet cover 160 are kept in the state in which the shape of the bobbinless coil 110 is maintained.
And need to be assembled. Therefore, in order to prevent the coil 110 wound around the sleeve 120 from losing its shape, the adhesive tape 300 is attached and fixed to the outer peripheral surface of the coil 110, or the coil 110 in which an adhesive or the like is applied to the surface of the insulating coated wire is used. Then, it is necessary to integrate them by welding. As a result, not only the adhesive tape 300 or an adhesive material is required, but also expensive processing equipment is required to attach the adhesive tape 300 or to apply and cure the adhesive material, resulting in high product cost. However, there has been a problem that productivity is greatly reduced.

Furthermore, since the adhesive or the like applied to the surface of the insulating coating wire may be remelted by heat, it generates heat above the curing and melting temperature of the adhesive or the like, and the operating environment temperature is high. It is difficult to use with the starter magnet switch. The present invention has been made based on the above circumstances, and an object thereof is to provide a solenoid manufacturing method for a magnet switch, which can manufacture a bobbinless type solenoid at low cost.

[0006]

[Means for Solving the Problems]

(Structure of Claim 1) The winding width is regulated by the stationary core assembled on one end side of the sleeve and the winding end pressing jig assembled on the other end side, and the sleeve width of the sleeve is regulated by the regulated winding width. After winding the coil around the outer circumference, with both end faces of the coil regulated by the stationary core and the winding end holding jig, attach a bottomed cylindrical magnet cover from the winding end holding jig side. A method of manufacturing a solenoid of a magnet switch, which is manufactured by enclosing the coil and fixing an opening of a magnet cover to the stationary core, wherein the winding end holding jig is configured to have an end surface of the coil in a circumferential direction. Has a holding part that holds at multiple points,
A fitting hole is formed in the bottom wall of the magnet cover to allow the winding end pressing jig to pass through, and the magnet cover is put on the outer periphery of the coil while passing the winding end pressing jig through the fitting hole. It is characterized by

(Operation and Effect of Claim 1) The coil wound around the outer circumference of the sleeve has one end face regulated by the stationary core and the other end face regulated by the winding end holding jig, thereby bobbinless The shape of the coil is maintained. Then, with the both end surfaces of the coil being regulated by the stationary core and the winding end pressing jig, the outer circumference of the coil can be covered with a magnet cover and the opening can be fixed to the stationary core. As a result, the shape of the coil can be prevented from being deformed, so that it is not necessary to attach and fix an adhesive tape to the outer peripheral surface of the coil and to weld and integrate the wire materials of the coil coated with an adhesive or the like as in the conventional case.

As a result, not only does the adhesive tape or the adhesive material become unnecessary, but also processing equipment for attaching the adhesive tape or applying or curing the adhesive material is unnecessary, so that the product cost can be reduced. At the same time, productivity can be improved. Further, since it is not necessary to use an adhesive material or the like, there is no problem even if the solenoid manufactured by this manufacturing method is used for the magnet switch of the starter whose working environment temperature becomes high.

(Structure of Claim 2) In the method of manufacturing a solenoid for a magnet switch according to Claim 1, the coil is provided on both end faces thereof with the stationary core,
An insulating washer is arranged between the magnet cover and the bottom wall of the magnet cover, and one insulating washer is arranged between the stationary core and the stationary core before the coil is wound around the outer circumference of the sleeve. The other insulating washer, which is fitted in advance to the outer periphery of the sleeve and is assembled inside the stationary core, and which is arranged between the bottom wall of the magnet cover and the insulating hole, has the same shape as the fitting hole. A fitting hole is formed, the coil is wound around the outer circumference of the sleeve, and then the winding end holding jig is passed through the fitting hole to be arranged on the end surface of the coil.

(Operation and Effect of Claim 2) It is possible to insulate the coil from the stationary core and the magnet cover by insulating washers. In this case, one of the insulating washers can be fitted to the outer circumference of the sleeve and assembled inside the stationary core before winding the coil around the outer circumference of the sleeve. The other insulating washer can be placed on the end surface of the coil after winding the coil around the outer circumference of the sleeve and then passing the winding end holding jig through the fitting hole formed in the insulating washer. At this time, the other insulating washer may be arranged on the end surface of the coil and then the magnet cover may be assembled.
The other insulating washer may be attached to the inner surface of the bottom wall of the magnet cover in advance, and the magnet cover may be attached at the same time.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment showing a method for manufacturing a solenoid of a magnet switch of the present invention will be described with reference to the drawings.
1A is a side sectional view of the solenoid, and FIG. 1B is a front view of the solenoid. The solenoid 1 of this embodiment is used for a magnet switch (not shown) of a starter, and has a cylindrical sleeve 2, a suction coil 3 (coil of the present invention) wound around the outer circumference of the sleeve 2, and a suction coil. Two insulating washers 4, 5 respectively arranged on both end surfaces of the coil 3, a magnet cover 6 including the attraction coil 3,
It is composed of a stationary core 7 assembled in the opening of the magnet cover 6.

The sleeve 2 is made of a metal non-magnetic material (for example, brass), and its inner peripheral surface serves as a sliding surface of a plunger (not shown). As shown in FIG. 2, an engaging piece 2a obtained by cutting and raising a part of the wall surface to the outside is provided on the peripheral edge portion on one end side of the sleeve 2 (end portion on the side of the stationary core 7). An engagement groove 2b for engaging the winding start wire 3a of the suction coil 3 is formed in 2a. The suction coil 3 is obtained by covering the outer circumference of a core wire made of copper or the like with an insulating film made of polyester or the like, and wound around the outer circumference of the sleeve 2 in multiple layers by a winding machine (not shown). The winding start wire 3a of the suction coil 3 is on the ground side (for example, the magnet cover 6 or the stationary core 7).
The winding end wire 3b is connected to a terminal (not shown) provided on the magnet switch. However,
It goes without saying that the winding start wire 3a may be connected to the terminal and the winding end wire 3b may be connected to the ground side.

One of the insulating washers 4 is a suction coil 3
Is provided in a disk shape with an insulating member such as insulating resin or insulating paper, and is fitted to the outer circumference of the sleeve 2 to fit one end surface 3c of the suction coil 3 and the stationary core. It is arranged between the core 7 and the inner surface of the outer peripheral portion. As shown in FIG.
As shown in (a), a fitting hole 4a for fitting the outer circumference of the sleeve 2 is formed in the central portion thereof. Note that FIG.
(B) is a side sectional view of the insulating washer 4. The other insulating washer 5 ensures insulation between the suction coil 3 and the magnet cover 6, and is provided in a disk shape with an insulating member such as an insulating resin or insulating paper, and is fitted to the outer periphery of the sleeve 2. Is disposed between the other end surface 3d of the suction coil 3 and the bottom wall 6a of the magnet cover 6. As shown in FIG. 4 (a), the insulating washer 5 has a fitting hole 5 a corresponding to the outer peripheral shape of a winding end holding jig 8 (see FIGS. 7 and 8), which will be described later, at the center thereof. Has been. In addition,
FIG. 4B is a side sectional view of the insulating washer 5.

The magnet cover 6 is made of a magnetic material such as iron, and as shown in FIG. 5 (a), is provided in the shape of a bottomed cylinder with one end side (the right side in the figure) being open, and the bottom wall 6a. As shown in FIG. 5B, a fitting hole 6b (the same shape as the fitting hole 5a formed in the other insulating washer 5) corresponding to the outer peripheral shape of the winding end pressing jig 8 is formed. ing. The stationary core 7 is made of a magnetic material such as iron, and as shown in FIG. 1 (a), a large-diameter cylindrical portion 7a, a medium-diameter cylindrical portion 7b, and a small-diameter cylindrical portion 7c are formed in stages, and the center thereof is formed. A through hole 7d for allowing a plunger rod (not shown) to pass therethrough is formed in the portion. The stationary core 7 has a medium diameter tubular portion 7b.
The outer periphery of the large-diameter cylindrical portion 7 a is crimped and fixed to the opening of the magnet cover 6 with the outer periphery of the outer peripheral portion fitted in the inner periphery of the sleeve 2. One end of a spring (not shown) that biases the plunger is engaged with the outer circumference of the small-diameter cylindrical portion 7c.

Next, a manufacturing method (assembly method) of the solenoid 1 will be described. First, as shown in FIG.
After fitting and assembling the through hole 7d of the stationary core 7 to the winding shaft 9a of the winding jig 9, one end side of the sleeve 2 is fitted to the outer circumference of the medium diameter cylindrical portion 7b of the stationary core 7. Further, one insulating washer 4 is fitted on the outer circumference of the sleeve 2 and arranged inside the stationary core 7.

Then, a winding end holding jig 8 for preventing the shape of the suction coil 3 from being deformed toward the magnet cover 6 side is attached. As shown in FIGS. 7 and 8, the winding end holding jig 8 has a cylindrical portion 80 having a shaft hole 8a (see FIG. 6) formed in the central portion, and an outer periphery of a cylindrical portion 81 following the cylindrical portion 80. The cylindrical portion 80 is inserted into the inner circumference of the other end side of the sleeve 2 so that the shaft hole 8a has the shaft core 9a of the winding jig 9a. Is fitted to.
At this time, as shown in FIG. 6, the tip end surface of the cylindrical portion 80 of the winding end pressing jig 8 has a small diameter cylindrical portion 7c of the stationary core 7.
The end surface 82a of each holding portion 82 that faces the insulating washer 4 by being attached in contact with the end surface of the
Is fixed, and the winding width L of the suction coil 3 is regulated by the end face 82a of each holding portion 82 and the insulating washer 4. The height h of each holding portion 82 in the radial direction (the height from the center of the cylindrical portion 81 to the tip of the holding portion 82) is
The radius of the suction coil 3 wound around the sleeve 2 is r (see FIG. 9) or more. In addition, as shown in FIG. 8A, a holding groove 82 b for holding the winding end line 3 b of the suction coil 3 is provided at one place of the holding portion 82.
It is formed over the entire length of 2.

Subsequently, in order to hold the end face (the other end face 3d) of the suction coil 3 together with the winding end holding jig 8, a winding frame jig 10 is assembled on the outer periphery of the winding end holding jig 8 (FIG. 9).
reference). As shown in FIG. 10, the reel jig 10 has an inner peripheral shape that matches the outer peripheral shape of the reel end holding jig 8 and is fitted into the reel end holding jig 8 in the cylinder direction. It is assembled. However, the reel jig 10 facing the insulating washer 4
It is needless to say that the end surface 10a of the above is assembled so as to be flush with the end surface 82a of the winding end holding jig 8. A guide groove 10b for guiding the winding end line 3b of the suction coil 3 to the holding groove 82b is provided at a portion fitted into the holding portion 82 of the winding end holding jig 8 where the holding groove 82b is formed. ing.

Subsequently, the sleeve 2, the insulating washer 4,
The suction coil 3 is wound in multiple layers on the winding frame formed by the winding end pressing jig 8 and the winding jig 10 by a winding machine. At this time, as shown in FIG. 2, the suction coil 3 has the engagement groove 2 formed in the engagement piece 2 a of the sleeve 2.
It can be wound around the outer circumference of the sleeve 2 with the winding start wire 3a engaged with b. Alternatively, as shown in FIG. 11, the winding start wire 3 a of the suction coil 3 is formed on the outer peripheral surface of the winding jig 9.
A holding mechanism 11 for locking the tip of the winding start wire 3a is provided. With the holding mechanism 11 locked with the tip of the winding start wire 3a, the winding start wire 3a is further inserted in the engagement groove 2b of the engaging piece 2a. Can also be engaged and wound. When the winding start wire 3a of the suction coil 3 is engaged with the engagement groove 2b, the joining of the suction coil 3 to the ground portion can be omitted by bringing the engagement piece 2a into conduction.

After winding the suction coil 3 around the winding frame, the winding end line 3b of the suction coil 3 is inserted from the guide groove 10b of the winding jig 10 into the holding groove 82b of the winding end holding jig 8. The reel jig 10 holds the reel end holding jig 8 while it is held.
(See Fig. 12). In this state, one end face 3c of the suction coil 3 is regulated by the insulating washer 4 arranged inside the stationary core 7, and the other end face 3d thereof is regulated by each holding portion 82 of the winding end pressing jig 8. Therefore, the coil ends 3c and 3d are prevented from being deformed, and the shape of the bobbinless coil can be maintained.

Then, the winding coil is held by the winding end holding jig 8.
Assembling the other insulating washer 5 and the magnet cover 6 with the other end surface 3d of the other is restricted (see FIG. 1).
3). First, attach the other insulating washer 5 to the fitting hole 5
The winding end pressing jig 8 is passed through a and is attached to the other end surface 3d of the suction coil 3. At this time, since the insulating washer 5 can be assembled by fitting the fitting hole 5a to the outer circumference of the winding end pressing jig 8, the assembly can be easily carried out.

Next, the magnet cover 6 is assembled so as to cover the outer circumference of the winding end holding jig 8 from its own opening side, and the winding end holding jig is fitted in the fitting hole 6b formed in the bottom wall 6a. While passing through 8, the suction coil 3 is covered by covering the outer circumference of the suction coil 3. At this time, the winding end line 3b of the suction coil 3
Is held in the holding groove 82b of the winding end holding jig 8, so that the winding end line 3b can be formed when the magnet cover 6 is assembled.
The magnetic cover 6 can be easily assembled without any obstruction. The insulating washer 5 may be attached to the inner surface of the bottom wall 6a of the magnet cover 6 in advance by bonding, press fitting, or the like so that the insulating washer 5 is attached at the same time as the magnet cover 6 is attached. .

Subsequently, with the winding end pressing jig 8 assembled, the opening of the magnet cover 6 covering the outer circumference of the suction coil 3 is inserted into the large-diameter cylindrical portion 7a of the stationary core 7.
The outer periphery of the magnet cover 6 is fitted and the opening of the magnet cover 6 is caulked and fixed to the inner peripheral side (see FIG. 14). As a result, the suction coil 3 is sandwiched between the inner surface of the large-diameter cylindrical portion 7a of the stationary core 7 and the bottom wall 6a of the magnet cover 6 via the two insulating washers 4 and 5. Finally, the solenoid 1 is completed by pulling out and removing the cylindrical portion 80 of the winding end pressing jig 8 from the sleeve 2.

(Effect of this Embodiment) According to the manufacturing method of this embodiment, suction is performed between the insulating washer 4 disposed inside the stationary core 7 and each holding portion 82 of the winding end pressing jig 8. The solenoid 1 can be completed by fixing the magnet cover 6 to the stationary core 7 with the coil 3 held therebetween. Therefore, as in the prior art, in order to prevent the shape of the suction coil 3 from being deformed, it is necessary to attach and fix an adhesive tape to the outer peripheral surface of the coil or to weld and integrate the wire materials of the coil coated with an adhesive or the like. There is no. As a result, not only does the adhesive tape or adhesive material become unnecessary, but also the processing equipment for attaching the adhesive tape or applying or curing the adhesive material is unnecessary, so that the product cost can be reduced and the production It is possible to improve the sex. Also, since there is no need to use adhesives,
Even if the solenoid 1 manufactured by this manufacturing method is used for a magnet switch of a starter in which the operating environment temperature becomes high, no problem occurs.

Further, since the sleeve 2, the insulating washer 4 arranged inside the stationary core 7, and the winding end holding jig 8 can form the winding frame of the suction coil 3, a set of conventional sets is formed. It is not necessary to control the winding width L by the side plate, and the means for maintaining the form of the bobbinless coil can be simplified. As a result, the manufacturing process is simplified, and the solenoid 1 of the magnet switch that does not use the bobbin can be easily manufactured.

(Modification) In this embodiment, since the fitting hole 6b corresponding to the outer peripheral shape of the winding end holding jig 8 is formed in the bottom wall 6a of the magnet cover 6, the area of the magnetic passage is reduced. there is a possibility. Therefore, the other insulating washer 5 arranged on the inner surface of the magnet cover 6 is not made of only an insulating member, but may be made of, for example, a magnetic material coated with an insulating coating or an iron plate washer overlaid with an insulating member. By using it, it is possible to compensate for the reduction in area as a magnetic path. Alternatively, the bottom wall 6a of the magnet cover 6
The wall thickness may be increased.

In the suction coil 3, one end face 3c is regulated by the insulating washer 4 arranged inside the stationary core 7, and the other end face 3d is regulated by each holding portion 82 of the winding end pressing jig 8. Both end surfaces 3c are
Although the shape of the suction coil 3 is prevented from deforming, if the wound state needs to be firmly held, only the winding end portion of the suction coil 3 may be fixed with a fixing member such as tape or yarn. However, it is not necessary to fix the entire winding width of the suction coil 3 as in the conventional case. In the present embodiment, the suction coil 3 is started to be wound from the stationary core 7 side, and the winding end holding jig 8 is provided.
It is wrapped so that it ends on the side, but the reverse is also possible. That is, it is also possible to start the winding from the winding end pressing jig 8 side and finish the winding on the stationary core 7 side.

In this embodiment, both end faces 3 of the suction coil 3 are
Insulation washers 4 and 5 are arranged on c and 3d to ensure insulation between the suction coil 3 and the stationary core 7 and the magnet cover 6, but the large diameter of the stationary core 7 facing the end surface of the suction coil 3 It is also possible to eliminate the insulating washers 4, 5 by forming an insulating film on the inner surface of the cylindrical portion 7a and the inner surface of the bottom wall 6a of the magnet cover 6 or by applying a method such as attaching an insulating tape. .

[Brief description of drawings]

FIG. 1 is a side sectional view (a) and a front view (b) of a solenoid.
It is.

FIG. 2 is a perspective view of a sleeve.

FIG. 3 is a plan view (a) and a side sectional view (b) of one insulating washer.

FIG. 4 is a plan view (a) and a side sectional view (b) of the other insulating washer.

FIG. 5 is a bottom view (a) and a side sectional view (b) of the magnet cover.

FIG. 6 is a cross-sectional view showing a step of the method of manufacturing the solenoid.

FIG. 7 is a perspective view of a winding end pressing jig.

FIG. 8 is a plan view (a) and a side view (b) of the winding end pressing jig.
It is.

FIG. 9 is a cross-sectional view showing a step of the method of manufacturing the solenoid.

FIG. 10 is a plan view of a reel jig.

FIG. 11 is a perspective view showing one step of a method of manufacturing a solenoid.

FIG. 12 is a perspective view showing one step of a method of manufacturing a solenoid.

FIG. 13 is a perspective view showing one step of a method of manufacturing a solenoid.

FIG. 14 is a perspective view showing one step of a method of manufacturing a solenoid.

FIG. 15 is a side sectional view (a) and a front view (b) of a solenoid (prior art).

FIG. 16 is a cross-sectional view showing one step of a method for manufacturing a solenoid (prior art).

FIG. 17 is a perspective view showing the steps of a method for manufacturing a solenoid (prior art).

[Explanation of symbols]

 1 Solenoid 2 Sleeve 3 Suction coil 4 One insulating washer 5 The other insulating washer 5a The other insulating washer's fitting hole 6 Magnet cover 6b The magnet cover's fitting hole 7 Stationary core 8 Winding end holding jig 82 Holding Part L winding width

Claims (2)

[Claims] 1. A winding core is regulated by a stationary core assembled on one end side of the sleeve and a winding end holding jig assembled on the other end side, and the outer periphery of the sleeve is regulated by the regulated winding width. After winding the coil, with both end surfaces of the coil being regulated by the stationary core and the winding end holding jig, a bottomed cylindrical magnet cover is assembled from the winding end holding jig side to attach the coil. Is a method of manufacturing a solenoid of a magnet switch manufactured by fixing the opening of the magnet cover to the stationary core, wherein the winding end holding jig has a plurality of circumferential end faces of the coil. The magnet cover has a fitting hole formed in the bottom wall through which the winding end pressing jig can pass, and the winding end pressing member is inserted into the fitting hole. Solenoid manufacturing method of the magnet switch, characterized in that for covering the outer periphery of the coil while passing e jig. 2. An washer for insulation is arranged on both end faces of the coil between the stationary core and the stationary core, and between the stationary core and the bottom wall of the magnet cover, and is arranged between the stationary core and the stationary core. One of the insulating washers is fitted inside the stationary core by being fitted to the outer circumference of the sleeve in advance before winding the coil around the outer circumference of the sleeve, and is attached to the bottom wall of the magnet cover. The other insulating washer is provided with a fitting hole having the same shape as the fitting hole, and the coil is wound around the outer periphery of the sleeve, and then the winding end pressing member is fitted into the fitting hole. The method for manufacturing a solenoid for a magnet switch according to claim 1, wherein the coil is disposed on an end surface of the coil through a tool.