JP2003215169A - Method of manufacturing core for contactless type sensor, core for contactless type sensor, and non-contact type sensor - Google Patents

Abstract

(57) [Problem] To easily manufacture a core for forming a magnetic path of a magnetic field in which almost no iron loss occurs according to a voltage or a current of an object to be measured, in a state of low magnetic loss. . A linear elongated member (45) is cut out from a base material (43), and is bent into a substantially square shape to form a core (41), and sides (45h, 45h) located near both ends of the elongated member (45).
45j, each side 45 connected to those sides 45h, 45j
By folding inward of the core 41 with respect to f and 45g and positioning them in parallel with each other, the sides 45h and 45j
, A holding gap 41a for holding the Hall element 11 therebetween.
Is formed in an area larger than the front surface and the back surface of the Hall element 11.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-contact type which obtains a detection output according to a voltage or current of an object to be measured by the output of a Hall element for detecting a magnetic field generated according to the voltage or current of the object to be measured. Type sensor, a core used in a non-contact type current sensor for forming a magnetic path of a magnetic field according to a voltage or a current to be measured, and a method for manufacturing the core.

[0002]

2. Description of the Related Art A non-contact type voltage sensor utilizing a zero-flux method, also known as a zero-flux method, which is already known as a technique for non-contact detection of a voltage at a specific portion in a circuit and a current flowing through the specific portion. And in the current sensor,
The Hall element is arranged in a gap formed between both ends of the toroidal core having a substantially annular shape.

Then, the Hall element is caused to generate an output corresponding to the density of the magnetic flux having the toroidal core as a magnetic path, which is generated according to the voltage of the specific portion in the circuit and the current flowing through the specific portion, and the output is In addition to the coil wound around the toroidal core, which has a non-contact relationship with the specific part in the circuit,
Magnetic flux is newly generated in the toroidal core in the direction of canceling the magnetic flux generated in the toroidal core.

By doing so, the two magnetic fluxes generated in the toroidal core cancel each other out, and the toroidal core enters a magnetic equilibrium state so that the output of the Hall element becomes zero. In that state, the output of the Hall element is added. If you measure the potential of the coil on the side opposite to that of the coil, it becomes a potential according to the voltage of the specific part, and if you measure the current flowing through the coil, it becomes the current according to the current flowing through the specific part. It will be.

Although different from the zero magnetic flux method described above,
As a non-contact type current sensor, a magnetic flux is generated in the toroidal core according to the current flowing through the conductor to be measured that has been inserted through the toroidal core, and the output of the Hall element placed in the gap of the toroidal core causes It is already well known that there is a Hall amplifier type current sensor that obtains an output according to a current flowing through a conductor to be measured.

In these non-contact type sensors, in order to increase the amount of magnetic flux passing through the Hall element and increase the volume of magnetic-voltage conversion by the Hall element, it is desired to maximize the area of the toroidal core gap. For that reason, if the toroidal core is made thicker, the iron loss becomes larger accordingly, and therefore the following measures have been taken in order to solve these two problems at the same time.

That is, while the core is thinned as a countermeasure against iron loss, a reduction in the gap area accompanying it is prevented by laminating a plurality of thinned cores.

[0008]

By the way, it is known that iron loss in the core of a non-contact type sensor remarkably occurs when the frequency of the AC voltage or AC current to be measured is on the order of several hundred Hz. However, a current such as a charging / discharging current of a battery in an electric vehicle, which is a DC current and on which an AC component of the order of 10 kHz is superimposed due to a slight vertical fluctuation, is hardly generated.

Therefore, for example, Japanese Unexamined Patent Publication No. 2000-28400.
Like the magnetic path forming section in the current detection device of Japanese Patent No. 0,
One end of each of the two substantially U-shaped magnetic plates is overlapped and integrated by welding or the like, and the other ends of the two magnetic plates are opposed to each other with a step, so It is conceivable to use a thin core as a single item such as a Hall element.

However, the above-mentioned Japanese Patent Laid-Open No. 2000-2
In the magnetic path forming portion of Japanese Patent No. 84000, since two magnetic material plates must be integrated by welding or the like, the manufacturing is troublesome, and moreover, one end portion of the two magnetic material plates overlaps each other. If the area of the welded portion is small with respect to the area, magnetic loss due to leakage flux may occur at that portion, and the same problem as iron loss may occur.

The present invention has been made in view of the above circumstances.
An object of the present invention is to provide a core for forming a magnetic path of a magnetic field according to a voltage or a current of an object to be measured, which is a non-contact type sensor used for measuring a voltage or a current in which iron loss hardly occurs. (EN) Provided are a method for easily manufacturing in a state where there is little magnetic loss due to a leakage magnetic flux, a non-contact sensor core suitable for manufacturing using this manufacturing method, and a non-contact sensor using this core. Especially.

[0012]

The present invention as set forth in any one of claims 1 to 4 for achieving the above object, relates to a method for manufacturing a core for a non-contact type sensor, and claims 5 to 8. The present invention described above relates to a core for a non-contact type sensor, and the present invention described in claim 9 relates to a non-contact type sensor.

The method for manufacturing a non-contact type sensor core according to the present invention utilizes the output of a Hall element for detecting a magnetic field generated according to the voltage or current of the object to be measured. A core manufacturing method for forming a magnetic path of a magnetic field according to the voltage or current of the object to be measured, which is used in a non-contact sensor for obtaining a detection output according to the voltage or current of the object to be measured. Then, a long member cut out from a thin plate-shaped base material so as to have two ends is bent and formed into an annular shape, and both ends of the long member are opposed to each other, and the vicinity of both ends of the opposed members are opposed to each other. A sandwiching gap for sandwiching the Hall element is formed between the long member portions.

The method for manufacturing the non-contact sensor core according to the present invention is the same as the method for manufacturing the non-contact sensor core according to the present invention. The elongate member portion is bent and opposed to the elongate member portion other than the elongate member portion to form the sandwiching gap.

Further, the method for manufacturing the non-contact type sensor core of the present invention according to claim 3 is the same as the method for manufacturing the non-contact type sensor core of the present invention according to claim 1 or 2. The long member was cut into a linear strip from the base material.

The method for manufacturing the non-contact sensor core of the present invention according to claim 4 is the same as the method for manufacturing the non-contact sensor core of the present invention according to claim 1, 2 or 3. At least an arc-shaped bending process is used for bending the long member into a ring shape.

Furthermore, the non-contact type sensor core of the present invention according to claim 5 utilizes the output of a Hall element for detecting a magnetic field generated according to the voltage or current of the object to be measured. A core used to form a magnetic path of a magnetic field according to the voltage or current of the object to be measured, which is used in a non-contact sensor that obtains a detection output according to the voltage or current of the object to be measured, and is bent in an annular shape. A long member formed between the long member portions near the opposite end portions of the long member formed by bending the annular member and facing each other, and sandwiching the Hall element. Characterize.

According to a sixth aspect of the present invention, there is provided a non-contact sensor core according to the fifth aspect of the present invention, wherein the sandwiching gap has the both ends. It is assumed that the long member portion in the vicinity of the portion is formed by bending the long member portion other than the above portion so as to face each other.

Further, the non-contact type sensor core of the present invention according to claim 7 is formed into the annular shape by bending in the method for manufacturing the non-contact type sensor core of the present invention according to claim 5 or 6. The elongate member is formed of a strip-shaped member that has a straight shape in the unfolded state.

The non-contact sensor core of the present invention as defined in claim 8 is the ring-shaped bent according to the method of manufacturing a non-contact sensor core of the present invention as defined in claim 5, 6 or 7. The formed long member had an arc-shaped bent portion.

Further, the non-contact type sensor of the present invention according to claim 9 utilizes the output of a Hall element for detecting a magnetic field generated according to the voltage or current of the object to be measured. 9. A non-contact type sensor that obtains a detection output according to the voltage or current of claim 5, as a core for forming a magnetic path of a magnetic field according to the voltage or current of the object to be measured, 8. The non-contact sensor core described in 8 is used.

According to the method for manufacturing a core for a non-contact type sensor of the present invention described in claim 1, a plurality of members are welded by bending a long member cut from a thin plate-shaped base material into an annular shape. Compared to manufacturing a core by connecting with
A core with less magnetic loss due to leakage flux can be easily manufactured.

Moreover, by making the vicinity of both ends of the elongated member bent into an annular shape face each other, the sandwiching gap for sandwiching the entire Hall element is long regardless of the size of the elongated member. It is formed between the both ends of the length member.

The sandwiching gap for sandwiching the Hall element is
For example, as in the method for manufacturing the non-contact type sensor core of the present invention described in claim 2, in the method for manufacturing the non-contact type sensor core of the present invention described in claim 1, a long length near both ends is provided. By bending the member portions with respect to the other long member portions so as to face each other, the member portions can be formed between the long member portions near both ends.

According to the method for manufacturing a non-contact type sensor core of the present invention as defined in claim 3, in the method for manufacturing a non-contact type sensor core of the present invention as set forth in claim 1 or 2, the thin plate is used. By making the long member cut out from the base material in the form of a straight strip, the occurrence of a waste part when cutting the long member from the base material is eliminated, compared to the case of cutting the substantially annular core from the base material, The yield for the number of cores collected per thin plate is improved.

Further, according to the method of manufacturing the non-contact type sensor core of the present invention described in claim 4, in the method of manufacturing the non-contact type sensor core of the present invention described in claim 1, 2 or 3. By forming a long member into an annular shape by using at least arc-shaped bending, a core with less magnetic loss due to leakage magnetic flux due to the annular forming is manufactured than in the case of bending forming. Will be done.

Further, in the non-contact type sensor core of the present invention as defined in claim 5, a non-contact type sensor core used for forming a magnetic path of a magnetic field according to a voltage or a current of an object to be measured. Since it is formed of a long member that is bent and formed into an annular shape, magnetic loss due to leakage magnetic flux is reduced as compared with a core in which a plurality of members are joined by welding or the like.

In addition, between the elongated member portions near the opposite ends of the elongated member bent into a ring shape,
Since the sandwiching gap that sandwiches the Hall element is formed, the sandwiching gap that sandwiches the entire Hall element is formed regardless of the size of the thickness of the long member.

The sandwiching gap for sandwiching the Hall element is
For example, like the core for non-contact type sensor of the present invention described in claim 6, in the core for non-contact type sensor of the present invention described in claim 5, the long member portions near both ends are not the other parts. It can be formed by bending the long member portion so as to face each other.

Further, according to the non-contact type sensor core of the present invention described in claim 7, in the non-contact type sensor core of the present invention described in claim 5 or 6, the elongated member is in a deployed state. By using a strip-shaped member that presents a straight strip shape, there is no generation of a waste part when the strip-shaped member is cut from the thin plate-shaped base material, and compared to the case where the core is cut from the base material like a substantially annular core. The yield of the number of cores collected per thin plate is improved.

According to the non-contact type sensor core of the present invention as defined in claim 8, the non-contact type sensor core of the present invention as defined in claim 5, 6 or 7 is bent into an annular shape. Since the elongated member has the arc-shaped bending portion, the magnetic loss due to the leakage magnetic flux is less than that in the bending forming.

Further, according to the non-contact type sensor of the present invention as set forth in claim 9, the output of the Hall element for detecting the magnetic field generated according to the voltage or the current of the measured object is utilized to measure the measured object. The core for forming a magnetic path of a magnetic field according to a voltage or a current of an object to be measured in a non-contact type sensor that obtains a detection output according to a voltage or a current of the object, as a core. By using the non-contact type sensor core of the above, a non-contact type sensor with less magnetic loss due to leakage magnetic flux is constructed, and the entire hall element is independent of the thickness of the long member. A sandwiching gap for sandwiching is formed.

[0033]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a method for manufacturing a core for a non-contact type sensor according to the present invention, together with a core for a non-contact type sensor according to the present invention and a non-contact type sensor according to the present invention, will be described with reference to the drawings. Before that, the principle configuration of the non-contact type voltage sensor and the non-contact type current sensor to which the non-contact type sensor according to the present invention is applied will be described.

FIG. 1 shows that the applicant of the present invention has previously disclosed Japanese Patent Laid-Open No. 8-86.
In 813, when a circuit for voltage or current detection used for estimating the battery remaining capacity of an electric vehicle is proposed, the basic non-contact type sensor based on the zero magnetic flux method described as the prior art is required. It is a circuit diagram showing a partial configuration.

Further, in FIG. 1, reference numeral 1 is an abbreviation C.
It is a toroidal core having a character shape and having a predetermined gap 1a, that is, a magnetic core.
Is wound.

In the gap 1a of the magnetic core 1, a voltage proportional to the magnetic flux density generated in the magnetic core 1 is output terminal 11
A Hall element 11 for generating between a and 11b is arranged, and an output voltage of the Hall element 11 is amplified by a differential amplifier circuit 13 and then is output to an NPN transistor 15a.
And PNP transistor 15b are applied to a current buffer 15 forming a push-pull circuit, and the current buffer 15 causes a current i ₂ to flow from one end 5a of the winding 5 to the other end 5b.

In the circuit shown in FIG. 1 having the above configuration,
Magnetic flux φ in magnetic core 1 for some reason ₁Occurs, the
Magnetic flux φ₁The output voltage according to the size of the Hall element 11
Generated by the differential amplifier circuit 13
After being dynamically amplified, it is given to the current buffer 15 to
From the one end 5a of the winding 5 to the other end 5b by the buffer 15
Dissipated current i₂Due to the magnetic flux φ₁Direction to cancel
Magnetic flux φ₂Is generated in the magnetic core 1.

If this situation continues, the magnitude of the magnetic flux φ ₂ will converge toward the same magnitude as the magnetic flux φ _1, and as a result,
The magnetic core 1 enters a magnetic equilibrium state, and the output voltage of the Hall element 11 becomes zero.

Then, the differential amplifier circuit 13 performs differential amplification.
Of the Hall element 11 which is supplied to the current buffer 15
Since the output voltage disappears, the magnetism generated in the magnetic core 1
Bundle φ ₂Decrease, but at that moment, the magnetic core 1
Magnetic flux φ₁Output voltage corresponding to the
Magnetic flux φ₂Is the magnetic flux φ again₁Equal to
Then, the magnetic core 1 returns to the magnetic equilibrium state.
Become.

That is, the magnetic flux φ ₂ always fluctuates in the vicinity of the magnetic flux φ ₁ , and the magnetic core 1 always maintains the magnetic equilibrium state.

If the voltage and current of the object to be measured are measured without contact using the circuit shown in FIG. 1, the object to be measured is connected so that the magnetic flux φ ₁ is generated in the magnetic core 1. .

For example, in the case where the power source is the object to be measured and the power source voltage is measured in a non-contact manner, another winding 3 is provided separately from the winding 5 as shown by the broken line in FIG.
The power source 17 to be measured to one of the terminals 9a.
And the other terminal 9b of the winding 3 is grounded via the energizing resistor 7A to generate the magnetic flux φ ₁ in the magnetic core 1 and the other end of the winding 5 via the detection load 21. 5b
Will be grounded.

Here, when the number of turns of the winding 3 is N ₁ , the number of turns of the winding 5 is N ₂ , the resistance value of the energizing resistor 7A is R _7A , and the resistance value of the detection load 21 is R ₂₁ , the actual value is Assuming that the potential difference between both ends of the detection load 21 measured is E, the current i ₁ flowing through the winding 3 and the current i ₂ flowing through the winding 5 in the state where the magnetic core 1 is in the magnetic equilibrium state are The relationship of
Since i ₁ × N ₁ = i ₂ × N ₂ , the voltage V of the power supply 17 is V = E / {(N ₁ / N ₂ ) × R ₂₁ } × R _7A , and both ends of the load 21 for detection are detected. The value is proportional to the potential difference E between the two.

Therefore, assuming that the resistance values R _7A and R _{21 of} the energizing resistor 7A and the detection load 21 and the turn ratio (N ₂ / N ₁ ) of the windings 3 and 5 are known, the Load 2
By measuring the potential difference E between both ends of 1, it is possible to measure the voltage of the power supply 17 as a value proportional to this.

On the other hand, in the case where a conductor is to be measured and the current flowing through the conductor is to be detected without contact, the winding 3
1 is wound around the magnetic core 1 and the terminals 9a and 9b at both ends thereof are not connected to the power source 17 or the energizing resistor 7A, but inside the magnetic core 1 as shown by a dashed line in FIG. A magnetic flux φ ₁ is generated in the magnetic core 1 by the magnetic field generated around the conductive wire 23 by the current I flowing through the conductive wire 23.

Here, assuming that the current i ₂ flowing through the winding 5 is actually measured, when the magnetic core 1 is in a magnetic equilibrium state, the current I flowing through the conductor 23 and the current i ₂ flowing through the winding 5 are Since the relationship of I × N ₁ = i ₂ × N ₂ is established between the _two , the current I flowing through the conductive wire 23 is I = {N ₂ / N
₁ } × i ₂ , which is a value proportional to the current i ₂ flowing through the winding 5.

Therefore, the turn ratio of the windings 3 and 5 (N ₂ /
If N ₁ ) is known, the current i ₂ flowing in the winding 5 is
By measuring, the voltage of the power supply 17 can be measured as a value proportional to this.

A simpler version of the zero-flux type described above is a Hall amplifier type sensor shown in the conceptual diagram of FIG. 2, in which the Hall element 11 disposed in the gap 1 a of the magnetic core 1 is used. , In that a voltage proportional to the magnetic flux density generated in the magnetic core 1 is generated between the output terminals 11a and 11b and the output voltage is amplified by the differential amplifier circuit 13, this is common to the zero magnetic flux type described in FIG. However, it is different from the zero magnetic flux type in that the amplified output of the differential amplifier circuit 13 is directly used as the final detection output.

Therefore, when the power supply voltage is measured in a contactless manner by using the power supply as the object to be measured, a winding having one end connected to the power supply to be measured is wound around the magnetic core 1 and flows through the winding. A magnetic flux φ ₁ is generated in the magnetic core 1 by the current.

On the other hand, when a conductor is measured and the current flowing through the conductor is detected in a non-contact manner, the conductor to be measured is penetrated into the inside of the magnetic core 1 and the current flowing through the conductor causes the surrounding of the conductor. The magnetic field generated will generate a magnetic flux φ ₁ in the magnetic core 1.

When the voltage of the power supply is measured in a non-contact manner, the amplified output of the differential amplifier circuit 13 is treated as an output proportional to the voltage of the power supply to be measured, and the current flowing through the conductor is detected in a non-contact manner. In that case, the amplified output of the differential amplifier circuit 13 is treated as an output proportional to the current flowing through the conductor to be measured.

Although the non-contact type sensor to which the non-contact type sensor according to the present invention is applied has been described above with reference to FIGS. 1 and 2, it can be used as the magnetic core 1 in these non-contact type sensors. A method for manufacturing a non-contact sensor core according to the present invention will be described below together with the non-contact sensor core according to the present invention with reference to the drawings.

FIG. 3 is a perspective view showing a completed state of the non-contact sensor core according to the first embodiment of the present invention. The non-contact sensor core of the first embodiment shown by reference numeral 31 in FIG. (Hereinafter, abbreviated as “core”) is formed into a substantially square shape, and is used for sandwiching the Hall element 11 as a gap 1a shown in FIGS. 1 and 2 at an intermediate portion of one side thereof. A gap 31a is formed.

As shown in the explanatory view of FIG. 4, the core 31 is cut out from a thin plate-shaped base material 33 made of super permalloy as a strip-shaped long member 35 having a substantially U shape in a plan view, and then a side 35a. As shown in the explanatory view of FIG. 5, a pair of sides 35b and 35c that are continuous with both ends of the sides 35b and 35c and have substantially the same length as the inner sides 35d and 35e of the sides 35b and 35c are formed.
The sides 35b and 35c are bent at right angles to the remaining one side 35a connecting the sides 35b and 35c so that they face each other, and then the sides 35 connected to the tip ends of the sides 35b and 35c.
f, 35g (corresponding to a long member portion other than the long member portion near both ends in the claims), the front side of each side 35f, 35g or each side 35h, 35j continuous to it (both ends in the claims (Equivalent to the long members in the vicinity) overlap each other,
It is manufactured by bending the sides 35b and 35c at right angles.

The above-mentioned holding gap 31a of the core 31 has sides 35h, as shown in the explanatory view of FIG.
It is manufactured by bending 35j toward the inside of the core 31 with respect to each side 35f, 35g and positioning them parallel to each other.

As shown in the distribution diagram of FIG. 7, in the sandwiching gap 31a manufactured between these sides 35h and 35j,
Except for the vicinity of the bent portions on the sides 35f and 35g and the vicinity of the tips of the sides 35h and 35j, a substantially uniform and high magnetic flux density distribution region is formed with an area larger than the front surface and the back surface of the Hall element 11. .

According to the core 31 and its manufacturing method of the first embodiment described above, and the non-contact type voltage or current sensor using this core 31 as the magnetic core 1 shown in FIG. 1 and FIG. Since it is formed by bending the sides 35a to 35c and 35f to 35j of the elongated member 35 including the sandwiching gap 31a, it is not necessary to integrate a plurality of members by welding or the like. The integrated body can be configured in a state in which there is little magnetic loss such as a leakage magnetic flux generated at the joint portion of the multiple members.

Next, FIG. 8 is a perspective view showing a completed state of the non-contact type sensor core according to the second embodiment of the present invention.
The core of the second embodiment indicated by reference numeral 41 in FIG.
Similar to the core 31 of the first embodiment shown in FIG. 1, the core 31 is bent into a substantially square shape, and is formed in an intermediate portion of one side thereof as shown in FIG.
A sandwiching gap 41a for the Hall element 11 shown by is formed.

As shown in the explanatory view of FIG. 9, the core 41 is cut out from a thin plate-shaped base material 43 made of super permalloy as a linear long member 45, and then as shown in the explanatory view of FIG. A part having the same length as one side of the core 41 is left in the center as one side 45a, and parts on both sides of this side 45a are bent at right angles to form a side 45 having substantially the same length as the side 45a.
b, 45c, and thereafter, the sides 45f, 45g (corresponding to the long member portions other than the long member portions near both ends in the claims) connected to the tip side of the respective sides 45b, 45c are set to the respective side 45.
f, 45g tip side or each side 45h, 45j connected to it
It is manufactured by bending at right angles to the sides 45b and 45c so that (corresponding to the long member portions near both ends in the claims) overlap each other.

The sandwiching gap 41a of the core 41 described above has the sides 45 as shown in the explanatory view of FIG.
It is manufactured by bending h and 45j toward the inside of the core 41 with respect to the sides 45f and 45g and arranging them in parallel to each other, and also in the sandwiching gap 41a manufactured between these sides 45h and 45j. Similar to the sandwiching gap 31a of the core 31 of the first embodiment shown in FIG. 7, a region of substantially uniform and high magnetic flux density distribution is formed in an area larger than the front surface or the back surface of the Hall element 11.

Moreover, since the long member 45 cut out from the thin plate-shaped base material 43 is in a straight line shape, the long member 45 having the same shape can be continuously cut out from the single base material 43 without a gap, It is possible to prevent the useless portion from being generated in the base material 43 and improve the yield in terms of material.

Although the cores 31 and 41 of the first and second embodiments described above are bent and formed so as to have a substantially square shape as a whole, the shape is not limited to a square shape and may be a rectangular shape or the like. It may be another rectangular shape or another polygon such as a triangle or a hexagon.

Alternatively, for example, as in the core 51 according to the third embodiment of the present invention whose completed state is shown in a perspective view in FIG.
Of the four corners of the core 41 of the second embodiment, two corners may be bent in an arc shape instead of being bent at a right angle to form a substantially horseshoe-shaped ring as a whole, or the completed state is shown in FIG. Like the core 61 according to the fourth embodiment of the present invention shown in the perspective view, all four corners of the core 41 of the second embodiment may be bent in an arc shape to form a ring having a substantially circular shape as a whole.

The cores 51 and 61 and the manufacturing method thereof according to the third and fourth embodiments described above, and the non-contact using these cores 51 and 61 as the magnetic core 1 shown in FIGS. 1 and 2. According to the voltage or current sensor of the formula, the cores 31 and 41 of the first and second embodiments and the manufacturing method thereof, and the cores 31 and 41 are used as the magnetic core 1 shown in FIGS. 1 and 2. It is possible to obtain the same effect as the non-contact type voltage or current sensor.

Moreover, according to the cores 51 and 61 of the third and fourth embodiments and the manufacturing method thereof, and the non-contact type voltage or current sensor using the cores 51 and 61, the first Also, since some or all of the corners that are bent at right angles in the cores 31 and 41 of the second embodiment are bent in an arc shape to form an annular shape, they are manufactured as compared with the case where the cores are bent at right angles. Further, it is possible to reduce the occurrence of magnetic loss due to the leakage magnetic flux due to the annular molding of the cores 51 and 61.

In the core 61 of the fourth embodiment, both ends of the elongated member 45 are bent in parallel toward the inside of the core 61 to form the sandwiching gap 31a for the hall element 11. Like the core 71 according to the fifth embodiment of the present invention, which is shown in a perspective view in a completed state in FIG.
The sandwiching gap 41a may be formed by bending both end portions of the core 31 in parallel toward the outside of the core 71. The sandwiching gaps 41a and 51 of the first to third embodiments may also be formed. You may form 31a, 41a similarly.

Further, instead of bending both ends of the elongated members 35 and 45 together to form the sandwiching gap 31a,
For example, FIG. 1 which is a modification of the core 51 of the third embodiment.
As in the core 81 according to the sixth embodiment of the present invention in which the completed state is shown in FIG. 5 in a perspective view, one end of the long member 45 is bent at a right angle toward the inside of the core 81 to have the core 81. The sandwiching gap 41a may be formed by facing one end of the long member 45 that is not bent at one of the two corners, and the core 31 of the first and second embodiments may be formed. Also for 41, the sandwiching gaps 31a, 41a
May be similarly formed.

Alternatively, for example, like a core 91 according to a seventh embodiment of the present invention, which is a modified example of the core 61 of the fourth embodiment and whose completed state is shown in a perspective view in FIG. The sandwiching gap 31a is formed by bending the member 45 into a substantially spiral arc shape and partially facing both ends of the long member 45 at intervals in the radial direction of the core 91 without bending at right angles. May be.

Further, the cores 31 of the first to third embodiments,
As for 41 and 51, the core 3 is located at one place somewhere.
The long members 35, 45 are formed by bending so that steps are formed in the inner and outer directions of 1, 41, 51.
The sandwiching gap 31a may be formed by partially opposing the both ends which are not bent in the inner and outer directions of the cores 31, 41, 51 at intervals.

Like the core 81 of the sixth embodiment described above, if the sandwiching gap 31a is formed without bending one end of the elongated members 35, 45 at a right angle, the sandwiching gap 31a will be formed. The occurrence of magnetic loss due to the leakage magnetic flux of the core 81 due to the formation can be reduced, and, like the core 91 of the seventh embodiment, the long member 3 can be formed.
If the sandwiching gap 31a is formed without bending both ends of 5, 5 at a right angle, the magnetic loss due to the leakage flux of the core 91 caused by forming the sandwiching gap 31a is further reduced. Can be reduced.

[0071]

As described above, according to the method of manufacturing the non-contact sensor core of the present invention as set forth in claim 1, the hole for detecting the magnetic field generated according to the voltage or the current of the object to be measured. To form a magnetic path of a magnetic field according to the voltage or current of the measured object, which is used in a non-contact sensor that obtains a detection output according to the voltage or current of the measured object by using the output of the element A method of manufacturing a core of
A long member cut from a thin plate-shaped base material so as to have two ends is bent and formed into an annular shape, and both ends of the long member are opposed to each other, and the long member near both ends of the opposed member is opposed to each other. A sandwiching gap for sandwiching the Hall element is formed between the member portions.

Therefore, as compared with a case where a core is manufactured by joining a plurality of members by welding or the like by bending a long member cut from a thin plate-shaped base material into an annular shape, a magnetic flux due to a leakage magnetic flux is produced. The core with less loss can be easily manufactured as having a sandwiching gap that can sandwich the entire Hall element regardless of the thickness of the long member.

Similarly, according to the non-contact sensor core of the present invention as defined in claim 5, the output of the Hall element for detecting the magnetic field generated according to the voltage or current of the object to be measured is utilized. A core for forming a magnetic path of a magnetic field according to the voltage or current of the object to be measured, which is used in a non-contact sensor for obtaining a detection output according to the voltage or current of the object to be measured, A long member bent into
The elongated member formed into a ring shape by bending is formed between the elongated member portions near both ends facing each other, and a sandwiching gap for sandwiching the Hall element.

Therefore, the core of the non-contact type sensor used for forming the magnetic path of the magnetic field corresponding to the voltage or current of the object to be measured is compared with the core in which a plurality of members are joined by welding or the like. The magnetic loss due to the leakage magnetic flux is less likely to occur, and the holding element has a holding gap that can hold the entire Hall element regardless of the thickness of the elongated member.

The sandwiching gap for sandwiching the Hall element is
For example, like the method for manufacturing the non-contact type sensor core of the present invention described in claim 2 or the non-contact type sensor core of the present invention described in claim 6, the present invention described in claim 1 is used. In the method for manufacturing a non-contact type sensor core, or in the non-contact type sensor core of the present invention as set forth in claim 5, the long member portions near both ends are bent and opposed to each other. Thus, it can be formed between the long member portions near both ends.

According to the method for manufacturing a non-contact type sensor core of the present invention described in claim 3, the method for manufacturing a non-contact type sensor core of the present invention according to claim 1 or 2, The long member was cut into a linear strip shape from a thin plate-shaped base material.

Further, according to the non-contact type sensor core of the present invention as set forth in claim 7, in the method for manufacturing the non-contact type sensor core of the present invention as set forth in claim 5 or 6, the ring is bent into the annular shape. The formed long member is formed of a belt-shaped member that has a straight line shape in the unfolded state.

Therefore, according to the method for manufacturing the non-contact type sensor core of the present invention described in claim 3, in the method for manufacturing the non-contact type sensor core of the present invention described in claim 1 or 2, Further, according to the non-contact type sensor core of the present invention described in claim 7, in the non-contact type sensor core of the present invention described in claim 5 or 6, when a substantially annular core is cut from a base material. Compared with the above, it is possible to eliminate the generation of a waste part when cutting the long member from the thin plate-shaped base material, and to improve the yield of the number of cores collected per thin plate.

According to the method for manufacturing the non-contact type sensor core of the present invention described in claim 4, the method for manufacturing the non-contact type sensor core of the present invention according to claim 1, 2 or 3 At least an arc-shaped bending process is used for bending the long member into a ring shape.

Therefore, in the method for manufacturing a non-contact sensor core according to the present invention as set forth in claim 1, 2 or 3, the magnetic flux due to the leakage magnetic flux caused by the annular molding is used rather than the bending molding. A core with low loss can be manufactured.

Similarly, according to the non-contact type sensor core of the present invention described in claim 8, in the method for manufacturing the non-contact type sensor core of the present invention described in claim 5, 6 or 7, The elongate member bent and formed into an annular shape has an arc-shaped bent portion.

Therefore, in the non-contact type sensor core of the present invention as defined in claim 5, 6 or 7, it is possible to obtain a core in which the magnetic loss due to the leakage flux is less than that in bending molding.

Furthermore, according to the non-contact type sensor of the present invention as defined in claim 9, the output of the Hall element for detecting the magnetic field generated according to the voltage or current of the object to be measured is used to output the object to be measured. 7. A non-contact sensor that obtains a detection output according to a voltage or current of a measurement target, wherein the non-contact sensor is a core for forming a magnetic path of a magnetic field according to the voltage or current of the measurement target. The non-contact sensor core described in 7 or 8 is used.

For this reason, the non-contact type sensor that obtains the detection output according to the voltage or current of the object to be measured is constructed so that the magnetic loss due to the leakage magnetic flux is small, and the thickness of the long member is large or small. Regardless of the above, it is possible to adopt a configuration having a sandwiching gap that sandwiches the entire Hall element.

[Brief description of drawings]

FIG. 1 is a circuit diagram showing a main part configuration of a basic non-contact type sensor based on a zero magnetic flux method.

FIG. 2 is a conceptual diagram of a Hall amplifier type sensor.

FIG. 3 is a perspective view showing a completed state of the non-contact sensor core according to the first embodiment of the present invention.

FIG. 4 is an explanatory view showing a shape of a long member cut out from a super-permalloy thin plate-shaped base material for manufacturing the non-contact sensor core shown in FIG.

5 is an explanatory view showing a process of manufacturing the non-contact sensor core of FIG. 3 using the elongated member of FIG.

6 is an explanatory view showing a process of manufacturing the non-contact sensor core of FIG. 3 using the elongated member of FIG.

FIG. 7 is a distribution diagram of magnetic flux density in the sandwiching gap shown in FIG.

FIG. 8 is a perspective view showing a completed state of a non-contact sensor core according to a second embodiment of the present invention.

9 is an explanatory view showing the shape of a long member cut out from a super-permalloy thin plate-shaped base material for manufacturing the non-contact sensor core shown in FIG. 8. FIG.

10 is an explanatory view showing a process of manufacturing the non-contact sensor core of FIG. 8 using the elongated member of FIG.

FIG. 11 is an explanatory view showing a process of manufacturing the non-contact sensor core of FIG. 8 using the elongated member of FIG.

FIG. 12 is a perspective view showing a completed state of a non-contact sensor core according to a third embodiment of the present invention.

FIG. 13 is a perspective view showing a completed state of a non-contact sensor core according to a fourth embodiment of the present invention.

FIG. 14 is a perspective view showing a completed state of a non-contact sensor core according to a fifth embodiment of the present invention.

FIG. 15 is a perspective view showing a completed state of a non-contact sensor core according to a sixth embodiment of the present invention.

16 is a perspective view showing a completed state of a non-contact sensor core according to a seventh embodiment of the present invention, which is a modification of the core of the fourth embodiment shown in FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 magnetic core 1a Gap 11 Hall element (magnetoelectric conversion element) 17 Power supply (measurement object) 23 Conductive wire (measurement object) 31,41 Non-contact sensor core 31a, 41a Clamping gap 33,43 Base material 35,45 Long members 35f, 35g, 45f, 45g Sides (long members other than the long members near both ends) 35h, 35j, 45h, 45j Sides (long members near both ends)

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Ken Ito             1500 Onjuku, Susono City, Shizuoka Prefecture Yazaki Corporation             Within (72) Inventor Akio Kurihara             1500 Onjuku, Susono City, Shizuoka Prefecture Yazaki Corporation             Within F-term (reference) 2G025 AA17 AB02

Claims (9)

[Claims] 1. A non-contact sensor that obtains a detection output according to the voltage or current of the measured object by using the output of a Hall element that detects a magnetic field generated according to the voltage or the current of the measured object. A method for manufacturing a core for forming a magnetic path of a magnetic field according to a voltage or a current of an object to be measured, which is a long plate cut from a thin plate-shaped base material so as to have two ends. The member is formed into an annular shape by bending so that the vicinity of both ends of the elongated member are opposed to each other, and a sandwiching gap for sandwiching the Hall element is formed between the elongated member portions near the opposed ends. The method for producing a core for a non-contact sensor according to the above. 2. The sandwiching gap is formed by bending the long member portions near the both ends with respect to the long member portions other than the portions so as to face each other, thereby forming the sandwiching gap. A method for manufacturing a core for a contact sensor. 3. The elongated member is formed from the thin plate-shaped base material,
The method for producing a core for a non-contact sensor according to claim 1 or 2, wherein the core is cut into a linear band. 4. The method for manufacturing a core for a non-contact sensor according to claim 1, wherein at least arc-shaped bending is used for bending the elongated member into an annular shape. 5. A non-contact sensor that obtains a detection output according to the voltage or current of the measured object by utilizing the output of a Hall element that detects a magnetic field generated according to the voltage or the current of the measured object. A core for forming a magnetic path of a magnetic field according to the voltage or current of the object to be measured, which is a long member bent in an annular shape, and the long member bent in an annular shape. A non-contact sensor core, comprising: a sandwiching gap that is formed between the long member portions near both ends facing each other and that sandwiches the Hall element. 6. The non-contact type according to claim 5, wherein the sandwiching gap is formed by bending a long member portion near the both ends to a long member portion other than the end portion so as to face each other. Sensor core. 7. The elongated member bent and formed into an annular shape,
The core for a non-contact type sensor according to claim 5 or 6, which is formed of a belt-shaped member that is in a straight line shape in a deployed state. 8. The elongated member bent and formed into an annular shape,
8. An arc-shaped bent part is provided, and the bent part is formed.
A method for manufacturing the core for a non-contact type sensor described. 9. A non-contact sensor that obtains a detection output according to the voltage or current of the measured object by using the output of a Hall element that detects a magnetic field generated according to the voltage or the current of the measured object. The non-contact sensor core according to claim 5, 6, 7, or 8 is used as a core for forming a magnetic path of a magnetic field according to the voltage or current of the measurement target. A non-contact sensor characterized in that