JP2018182904A - Rotary solenoid and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To dramatically improve versatility and expandability by reducing the size and thickness (ultra-thinning) of the entire outer shell shape. SOLUTION: The rectangular parallelepiped shape F is integrally formed with a stator portion Ms having a coil 4 in which a magnet wire W is wound around a center core portion 3c of a stator core 3 formed in a U shape, and a horizontally long rectangular parallelepiped shape F. It has a stator regulating portion 11 ... that guides the stator portion Ms from the opening 2o on one surface to the inside and can regulate at least the position of the stator core 3 at a predetermined position Xs ..., and one of the bottom plate portions 2d facing the opening 2o. The casing 2 having the bearing portion 12 of the above, the cover 13 having the opening 2o closed and the other bearing portion 14, and the magnet 15 arranged between the side core portions 3p and 3q located on both sides of the center core portion 3c are integrated. The magnet rotor portion Mr is provided in the above, and one end side is supported by one bearing portion 12 and the other end side is supported by the other bearing portion 14. [Selection diagram] Fig. 1

Description

  The present invention relates to a rotary solenoid including a stator portion fixed to a casing and a magnet rotor portion rotatably supported by the casing, and a method of manufacturing the same.

  Generally, since a rotary solenoid has a function of switching between two positions by outputting reciprocating rotational displacement, sorting of money, bills, etc., sorting of mail, etc., transport path switching of printed matter, switching of optical path of optical equipment It is used for various applications in many fields, such as ion shutters of semiconductor manufacturing devices. In particular, in switching the optical path of the optical device, not only high speed and high operating angle accuracy but also the installation space is limited, so downsizing (thinning) of the rotary solenoid is required, and in the ion shutter of the semiconductor manufacturing apparatus Since the elements need to be ion-trimmed by arranging the shutters at a narrow pitch according to the size of the elements, an ultra-thin rotary solenoid is required to drive the shutters. Furthermore, in sorting of defective products by a sorting apparatus of chip semiconductors, a very small rotary solenoid is also required along with the miniaturization of chips.

  Conventionally, as the miniaturized rotary solenoids used for such applications, rotary solenoids disclosed in Patent Documents 1 and 2 already proposed by the present applicant are known. The rotary solenoid (rotating electric machine) disclosed in Patent Document 1 efficiently secures a coil accommodation space, achieves compactness (miniaturization), and achieves the overall cost reduction, and uniform characteristics and quality. In particular, it is provided with a magnet rotor having a magnet in the middle part of the shaft, and a stator in which a coil is wound around a coil bobbin covering an iron core part, and in particular, for the shaft The coil bobbin is configured by mounting from opposite sides and facing each other, and a pair of bobbin half portions having a shape in which a coil winding portion for winding a coil overlaps a center side in a radial direction than an outer peripheral surface of the magnet And an iron core part mounted between the pair of bobbin half parts.

  Further, the rotary solenoid (solenoid) disclosed in Patent Document 2 easily realizes an ultra-small solenoid, and mechanically protects the connection portion of the wire end to enhance the reliability of the ultra-small solenoid. In particular, a cylindrical casing, an end face cover closing the opening of the casing, a coil bobbin accommodated in the casing, and one or more coils wound on the coil bobbin A coil, one or more pin terminals attached to the coil bobbin and connecting wire ends derived from the coil, and a movable portion having a magnet displaced by energization of the coil, and in particular, a penetration provided in the coil bobbin When it is possible to connect the wire end to the wire connection when the hole and the through hole are inserted from the one end opening A pin having an intermediate mounting portion which can be stopped at a final position where the position and wire connection portion are shielded by the barrier portion on the coil bobbin, and a pin main body portion projecting from the other end opening of the through hole at the final position. And a terminal.

JP 2001-292557 A JP, 2012-039804, A

  However, the conventional rotary solenoids, including the rotary solenoids disclosed in Patent Document 1 and Patent Document 2 described above, have the following problems to be solved.

  First, the movable portion (rotor portion) that outputs reciprocating rotational displacement is rotatably supported movably by the bearing portion, and the fixed portion (stator portion) facing the movable portion is a circle of the movable portion Since it arrange | positions along the circumferential direction, the outline shape of the whole rotary solenoid seen from the axial direction becomes circular shape or square shape which accommodates this circular shape. Therefore, it is not easy to realize miniaturization, and the outer diameter is limited to about 5 mm. In particular, when the outer diameter is reduced to about 5 mm, the coil winding space is narrowed, so the number of turns of the coil can not be increased, and a magnetic flux and an ampere turn for obtaining necessary torque are secured. It will be difficult to do. As a result, the current becomes excessive, and as the size is reduced, the temperature of the coil rises and the torque decreases.

  Second, since the stator portion is fixed to the circular casing portion (or yoke portion), each pole (N pole, S pole) configured by the stator portion has a core protruding in the radial direction, and It is necessary to make a coil by winding a magnet wire around the core. Therefore, the center position of the coil deviates inward along the arc as it goes outward, which requires a special winding device, complicates the manufacturing process, increases the manufacturing cost, and lowers the yield rate. It can not be ignored. In addition, although the method of attaching the coil bobbin which wound a coil to a core is also adopted in order to simplify winding processing, when the outside diameter is miniaturized to about 5 [mm], the installation space of the coil Due to the limitation, the use of the coil bobbin becomes difficult, and the method of mounting the coil bobbin on the core can not be practically adopted.

  An object of the present invention is to provide a rotary solenoid that solves the problems existing in such background art and a method of manufacturing the same.

  In order to solve the problems described above, the rotary solenoids 1 and 1e according to the present invention are rotatably supported by a stator portion having a coil 4 fixed to the casing 2 and wound around the stator core 3 and the casing 2 When constructing a rotary solenoid having a magnet rotor portion, a stator portion Ms having a coil 4 manufactured by winding a magnet wire W around a center core portion 3c located at an intermediate portion of a U-shaped stator core 3; By integrally forming the rectangular parallelepiped shape F, the stator portion Ms is guided from the opening 2o in one surface of the rectangular parallelepiped shape F to the inside, and at least a position of the stator core 3 can be regulated at a predetermined position Xs. And has one bearing 12 on the bottom plate 2d facing the opening 2o. A cover 13 having a second bearing portion 14 and a pair of side core portions 3p and 3q located on both sides of the center core portion 3c. A magnet rotor portion Mr is supported, with one end side supported by one of the bearing portions 12 and the other end side supported by the other bearing portion.

  On the other hand, in order to solve the problems described above, the method of manufacturing a rotary solenoid according to the present invention supports the stator portion having the coil 4 fixed to the casing 2 and wound around the stator core 3 and rotatably supported by the casing 2 When manufacturing the rotary solenoid 1 having the magnet rotor portion, the stator wire portion is manufactured by winding the magnet wire W around the center core portion 3c located at the middle portion of the U-shaped stator core 3 By integrally forming a stator manufacturing step (S1 to S7) for obtaining Ms and a horizontally long rectangular parallelepiped shape F having an opening 2o on one side, the stator portion Ms is guided to the inside from the opening 2o and a predetermined position Xs ... Together with the stator restricting portion 11 capable of restricting at least the position of the stator core 3 Stator assembly step (S10 to S12) for housing the stator portion Ms from the opening 2o in the inside of the casing 2 having one bearing portion 12 in the bottom plate 2d facing the portion 2o, and the casing 2 from the opening 2o The magnet 15 is positioned on both sides of the center core portion 3c by housing the magnet rotor portion Mr integrally including the magnet 15 and inserting one end side of the magnet rotor portion Mr into one of the bearing portions 12 Insert the other end of the magnet rotor part Mr into the magnet rotor assembly process (S8, S9, S13) disposed between the pair of side core parts 3p, 3q and the other bearing part 14 of the cover 13, and And a cover assembling step (S14) for closing the opening 2o by the step 13.

  Further, according to the preferred embodiment of the present invention, when the stator core 3 is formed, the clearance between the opposing surfaces 3pf and 3qf of the pair of side core portions 3p and 3q and the circumferential surface 15f of the magnet 15 is constant. Curved surfaces 3pr and 3qr facing each other via Cc can be formed. Therefore, when configuring each part, let L1 and L2 be the outer and inner diameter dimensions of the magnet 15, and L3 and L4 be the maximum and minimum distance dimensions between the pair of side core portions 3p and 3q. When the directional dimension is L5, the relationship L3> L1> L4> L2, L4 = L5 can be selected. Preferably, the casing 2 and / or the cover 13 are integrally formed of a synthetic resin material R. Furthermore, the magnet 15 is oriented in one direction orthogonal to the shaft 16 and is separately cylindrically magnetized in two directions of S pole and N pole in this orientation direction, or is radially oriented in the radial direction of the shaft 16 and This radial orientation can be formed in a cylindrical shape divided and magnetized into two poles of S pole and N pole. On the other hand, in the rotary solenoid 1 according to the present invention, the stopper mechanism 17 can be provided inside or outside the casing 2 for restricting the rotation range of the magnet rotor part Mr by setting the setting range Zr. When manufacturing the same rotary solenoid 1, in the stator manufacturing process (S1 to S7), the stator core 3 is attracted and fixed by the holding magnets 74 provided in the winding device 70, and the magnet wire W is made to the stator core 3. It can be wound. Furthermore, the coating insulating layer 18 can be provided by applying an insulating paint on the surface of the center core portion 3 c in the stator core 3, and the magnet wire W can be wound directly on the coating insulating layer 18. At this time, the heat fusion wire Wh can be used for the magnet wire W. On the other hand, in the magnet rotor assembling step (S8, S9, S13), the magnet fabric before magnetization is assembled and fixed to the shaft, and after assembled to the casing 2, the D cut surface of the shaft 16 is used as a reference. A magnet rotor manufacturing process can be included to magnetize the magnet fabric.

  According to the rotary solenoids 1 and 1e and the method of manufacturing the same according to the present invention, the following remarkable effects can be obtained.

  (1) A stator portion Ms having a coil 4 manufactured by winding a magnet wire W around a center core portion 3c located at an intermediate portion of a U-shaped stator core 3 is integrally formed in a horizontally long rectangular parallelepiped shape F Thus, the casing 2 is provided with a stator restriction 11 that guides the stator Ms to the inside from the opening 2o in one surface of the rectangular parallelepiped shape F and can restrict at least the position of the stator core 3 at a predetermined position Xs. As a result, it is possible to easily realize downsizing and thinning of the entire outer shell shape, in particular, an ultra thin shape having a thickness of 5 mm or less. As a result, it becomes possible to cope with various arrangement spaces, such as arrangement in a narrow space such as a gap between parts and high density arrangement by arraying possible, and the versatility and development are dramatically improved. It can be enhanced.

  (2) Since a reasonable magnetic path can be constructed in consideration of the shapes and volumes of the magnet 15 and the stator core 3, the number of turns can be increased by relatively securing the winding space of the coil 4. As a result, it is possible to easily obtain the magnetic flux and the ampere-turn for obtaining the necessary torque, and it is possible to secure high driving torque even with the structure of the ultra thin shape. In addition, also in manufacturing, a combination of simple manufacturing processes becomes possible, such as eliminating the need for a special winding device, and in particular, facilitation, simplification and cost reduction of the manufacturing automation process can be realized. It can also contribute to the improvement of the product yield rate.

  (3) According to a preferred embodiment, when the stator core 3 is formed, the clearances Cc between the opposing surfaces 3pf and 3qf of the pair of side core portions 3p and 3q with respect to the circumferential surface Mrf of the magnet rotor portion Mr are constant. If the curved surfaces 3pr and 3qr facing each other are formed, the facing area with the circumferential surface Mrf of the magnet rotor unit Mr can be increased without providing a projecting portion with respect to each of the facing surfaces 3pf and 3qf, and the diameter of the magnet 15 Therefore, even when the size of the rotary solenoid 1 is to be reduced, it is possible to secure the necessary torque (magnetic flux) and to enhance the self-holding power at the time of non-energization.

  (4) According to a preferred embodiment, when configuring each part, the outer diameter dimension and the inner diameter dimension of the magnet 15 are L1 and L2, and the maximum distance dimension and the minimum distance distance between the pair of side core portions 3p and 3q are L3 and L4. When the axial dimension of the coil 4 is L5, if the relationship of L3> L1> L4> L2, L4 = L5 is selected, the longitudinal dimension of the center core portion 3c can be utilized to the maximum, and the center core portion 3c Since a space equal to the longitudinal dimension can be secured, the winding process of the magnet wire W can be performed easily and reliably by utilizing a general-purpose winding device, which can contribute to the reduction of the manufacturing cost.

  (5) According to a preferred embodiment, when forming the casing 2 and / or the cover 13, if both are integrally formed of the synthetic resin material R, they can be integrally molded as a resin molded product, thereby improving mass productivity and low cost. The casing 2 and the cover 13 can be easily integrated by heat welding. Further, even if one or both of the casing 2 and the cover 13 are formed of a material other than the synthetic resin material R, the assembly can be easily assembled with an adhesive or the like because of downsizing.

  (6) According to a preferred embodiment, the magnet 15 is oriented in one direction perpendicular to the shaft 16 and is divided into two poles of S pole and N pole in this orientation direction, or a cylindrical shape or radial direction of the shaft 16 It is possible to generate a large magnetic flux even with a small diameter and to implement as the simplest form by forming in a cylindrical shape that is radially oriented and divided into two poles of S pole and N pole in this radial orientation. , And the stator core 3 can be implemented as an optimum mode.

  (7) According to a preferred embodiment, if the stopper mechanism 17 is provided inside or outside of the casing 2 to limit the setting range Zr of the magnet rotor part Mr by locking, the output of the two-way rotation displacement Since it can be made to function as a position switching actuator, it can be used as the original rotary solenoid 1 and an arbitrary setting range Zr can be easily set.

  (8) When manufacturing the rotary solenoid 1 according to a preferred embodiment, the stator core 3 is attracted and fixed by the holding magnets 74 provided in the winding device 70 in the stator manufacturing step (S1 to S7). If the magnet wire W is wound, sufficient holding and fixing becomes possible even if the size of the stator core 3 is reduced, and the winding device 70 can contribute to downsizing and cost reduction of the whole, etc. It is optimal for use in the manufacture of the rotary solenoid 1 according to the present invention.

  (9) According to a preferred embodiment, the coating insulating layer 18 is provided by applying an insulating paint on the surface of the center core portion 3 c in the stator core 3, and the magnet wire W is wound directly on the coating insulating layer 18. For example, since a short circuit with the coil 4 can be prevented easily and surely and the coil bobbin can be eliminated, the number of turns of the magnet wire W can be increased, and an ultra-thin shape (ultra-small shape) can be easily realized.

  (10) According to a preferred embodiment, if the heat welding wire Wh is used as the magnet wire W, the magnet wires W, W can be fused to each other, so that the winding collapse of the coil 4 during winding can be avoided. At the same time, the winding process of the magnet wire W can be reliably performed without using a coil bobbin, and the strength can be improved, which can also contribute to the prevention of disconnection due to vibration or the like.

  (11) According to a preferred embodiment, in the magnet rotor assembling step (S8, S9, S13), the magnet material before magnetization is assembled and fixed to the shaft, and after assembling to the casing 2, D of the shaft 16 By including a magnet rotor manufacturing step of magnetizing the magnet fabric with reference to the cut surface, it is possible to effectively prevent unnecessary adhesion of dust such as metal powder to the magnet 15 during assembly.

FIG. 2 is a cross-sectional plan view of a rotary solenoid according to a preferred embodiment of the present invention (cross section along line A-A in FIG. 2); Cross sectional front view of the same rotary solenoid, Cross sectional side view of the same rotary solenoid (cross section B-B in FIG. 2) Internal structure view in plan view excluding the cover of the same rotary solenoid, Top view of the casing of the same rotary solenoid, Explanation of dimensional relationship of the same rotary solenoid, The parts drawing which disassembled the same rotary solenoid, Flow chart for explaining the manufacturing method of the same rotary solenoid, A partial sectional side view of a winding device for winding a magnet wire around a stator core provided in the same rotary solenoid; Top view of same winding device, Operation explanation of the same rotary solenoid, Internal structure view in plan view excluding the cover of the rotary solenoid according to a modified embodiment of the present invention, A partial sectional side view showing a modification of the winding device; A partially sectional side view showing another modification of the winding device,

  Next, preferred embodiments according to the present invention will be listed and described in detail based on the drawings.

  First, members constituting the rotary solenoid 1 according to the present embodiment will be described with reference to FIGS. 1 to 7.

  The rotary solenoid 1 includes a casing 2 integrally formed in a horizontally long rectangular parallelepiped shape F having an opening 2 o on one side, and a cover 13 for closing the opening 2 o as shown in FIGS. 1 to 7. The covers 13 are integrally formed of a plastic material (synthetic resin material) R, respectively. As described above, when the casing 2 and the cover 13 are integrally formed of the plastic material R, since it can be integrally formed as a resin molded product, mass productivity and low cost can be enhanced.

  In addition, although it is desirable to form both the casing 2 and the cover 13 with the plastic raw material R, it does not exclude the case where one or both are formed with raw materials other than the synthetic resin raw material R. For example, it may be formed of another material such as a metal material (aluminum or the like) in consideration of strength and the like. Even in this case, the size can be reduced and the assembly can be easily performed using an adhesive or the like.

  The casing 2 has a rectangular parallelepiped shape F having the shortest side Fs as shown in FIG. 5, but the dimension Ls of the shortest side Fs is 5 [mm] in the example. In addition, although both sides of the shortest side Fs have long sides Fm in the perpendicular direction, as shown in FIG. 6, from the viewpoint of constructing the ultra-thin rotary solenoid 1, the dimension Ls of the shortest side Fs and the long side Fm It is desirable to select the relationship of the dimension Lm of to satisfy the condition of (Lm / Ls)> 1.5.

  Further, inside the casing 2, stator restriction portions 11 and 11 capable of accommodating a stator portion Ms described later from the opening portion 2 o are formed. In the case of illustration, as shown in FIG. 5 and FIG. 7, along the inner surfaces 2si, 2si from the pair of opposing long sides Fm, Fm in the opening 2o, the guide recesses 21, 21 for guiding the housing of the stator core 3 are The predetermined positions Xs and Xs in the middle of 2si and 2si are respectively formed. The bottoms of the guide recesses 21 at the predetermined positions Xs... Become the locking portions 22, 22, and the guide recesses 21, 21 and the locking portions 22, 22 constitute the stator regulating portions 11, 11. By providing such stator restricting portions 11, 11, the stator portion Ms can be easily and smoothly accommodated (assembled) inside the casing 2, and after being accommodated, positioning of the stator portion Ms relative to the casing 2 is performed It will be.

  In addition, as shown in FIG. 2, the inner surface 2di of the bottom plate 2d facing the opening 2o in the casing 2 is a portion facing the coil 4 wound around a stator portion Ms described later, as shown in FIG. Of the shaft 16 of the magnet rotor unit Mr corresponding to the position of the bottom plate 2d corresponding to the position for housing the magnet rotor unit Mr described later. One bearing portion 12 which can be freely supported is formed. Since the rotary solenoid 1 does not rotate at a high speed like an electric motor, the bearing portion 12 may be a simple circular hole, but if necessary, a separate bearing body may be provided by insert molding or assembly. In addition, as shown in FIG. 4, the reference numerals 25 and 25 shown in FIG. 5 indicate notches having a U-shaped cross section for leading the pair of lead wires 61 and 62.

  On the other hand, the cover 13 is formed in a flat plate shape, and a thick portion 31 fitted to the inner surface 2si of the casing 2 when mounted to the opening 2o of the casing 2 is formed on the inner surface 13i. Moreover, while forming the same acceptance recessed part 32 used as the escape space which accepts accommodation of the coil 4 in the position which opposes the acceptance recessed part 23 in the thick part 31, it respond | corresponds to the position which accommodates the magnet rotor part Mr mentioned later. At the portion of the thick portion 31 to be formed, the other bearing portion 14 capable of rotatably supporting the other end side of the shaft 16 of the magnet rotor portion Mr is formed. In this case, as with the bearing portion 12, the bearing portion 14 may be a simple circular hole, but if necessary, a separate bearing body may be provided by insert molding or assembly.

  Since the cover 13 is positioned by the thick portion 31 when assembled to the casing 2, positioning of the pair of bearing portions 12 and 14 is performed, and positioning of the magnet rotor portion Mr is also performed. Further, since the stator portion Ms is also positioned by the casing 2 described above, the main components of the casing 2, the cover 13, the stator portion Ms and the magnet rotor portion Mr are integrated in a mutually positioned state.

  On the other hand, the rotary solenoid 1 has a stator portion Ms and a magnet rotor portion Mr shown in FIG. It is sufficient for the rotary solenoid 1 according to the present embodiment to prepare a separately manufactured stator portion Ms and magnet rotor portion Mr in addition to the casing 2 and the cover 13 described above, and the basic structure is extremely simple.

  The stator portion Ms is composed of the stator core 3 and the coil 4 as shown in FIG. As shown in FIG. 1, the stator core 3 is formed in a U-shape as a whole, and includes a center core portion 3c located in the middle and a pair of side core portions 3p and 3q extending perpendicularly from both ends of the center core portion 3c. Magnetic steel sheets of soft magnetic materials such as SPCC, SECC, silicon steel sheets, etc. can be integrally formed by press processing. Besides, the soft magnetic material may be molded by forging or the like.

  In this case, the opposing surfaces 3pf and 3qf opposite to each other in the pair of side core portions 3p and 3q are formed in parallel surfaces, and at a portion opposing the peripheral surface 15f of the magnet 15 described later, with respect to the peripheral surface 15f. Arc-shaped curved surfaces 3pr and 3qr facing each other via a fixed clearance Cc are formed. If such curved surfaces 3pr and 3qr are formed, the facing area with the circumferential surface Mrf of the magnet rotor unit Mr can be increased without providing a projecting portion with respect to the facing surfaces 3pf and 3qf, and the diameter of the magnet 15 Therefore, even when the size of the rotary solenoid 1 is to be reduced, it is possible to secure the necessary torque (magnetic flux) and to enhance the self-holding power at the time of non-energization.

  In addition, a coating insulating layer 18 is provided on the surface (outer surface) of the center core portion 3 c in the stator core 3 by applying an insulating paint by electrodeposition of resin, powder electrostatic coating, or the like. Specifically, various resin materials such as fluorine resin, acrylic resin and epoxy resin can be used. In particular, if an imidamide-epoxy modified resin is used, it is possible to obtain an insulating layer having high insulating properties and sufficient strength even in the form of a thin film. In any case, in the case of the present embodiment, even if the thickness of the coating insulating layer 18 is about 10 μm, sufficient insulating ability can be provided. In addition, if the thickness of the coating insulating layer 18 is selected to be smaller than the conductor wire diameter of the coil 4, the number of turns can be increased by securing the winding space, which can also contribute to low power consumption.

  Therefore, if such a coating insulating layer 18 is provided, a short circuit with the coil 4 can be prevented even when the magnet wire W is wound directly on the coating insulating layer 18, and the coil bobbin Since this can be eliminated, the number of turns of the magnet wire W can be increased, and an ultra-thin shape (ultra-small shape) can be easily realized.

  The coil 4 can be manufactured on the center core portion 3c by directly winding the magnet wire W using a winding device 70 described later. In this case, it is desirable to use, as the magnet wire W, for example, a heat fusion wire Wh in which a fusion film such as a thermoplastic resin or a thermosetting resin is provided on the surface of a soft copper wire. When such a heat fusion wire Wh is used as the magnet wire W, the magnet wires W can be fused to each other, so that the winding collapse of the coil 4 at the time of winding can be avoided without using the coil bobbin. Thus, the winding process of the magnet wire W can be surely performed, and the improvement of the strength can also contribute to the prevention of disconnection due to vibration or the like. The magnet wire W may be a general conducting wire having a round cross section, or a flat rectangular conducting wire having a square cross section.

  On the other hand, as shown in FIG. 1 and FIG. 7, the magnet rotor unit Mr includes a shaft 16 formed of a soft magnetic material. The shaft 16 is formed in a round bar shape, and a D cut surface is provided in a predetermined range on one end side (tip end side). Further, a large diameter portion is formed at a predetermined intermediate position in the shaft 16 and the cylindrical magnet 15 is fixed to the large diameter portion by adhesion. Thus, a closed magnetic circuit is configured between the magnet 15 and the shaft 16. The large diameter portion of the shaft 16 can make adhesion to the magnet 15 easier and stronger. The shaft 16 is rotatably supported at one end by a bearing 14 formed on the cover 13 and at the other end rotatably supported by a bearing 12 formed on the casing 2.

  The magnet 15 can be formed by a permanent magnet such as a ferrite magnet or a rare earth magnet. The magnet 15 may be formed in a cylindrical shape which is oriented in one direction orthogonal to the shaft 16 and is divided and magnetized in two directions of the S pole and the N pole in this direction, or in the radial direction of the shaft 16 It may be formed in a cylindrical shape which is radially oriented and is divided and magnetized to two poles of S pole and N pole in this radial orientation. According to this structure, even if the magnet 15 has a small diameter, a large magnetic flux can be generated, and the embodiment can be implemented as the simplest form. Therefore, the embodiment can be implemented as the optimum mode matched with the stator core 3. In particular, if an Nd-Fe-B magnet is used as the magnet 15, a high magnetic flux density in the air gap can be secured, and the torque can be increased.

  Since the rotary solenoid 1 has such a configuration, the overall dimensional relationship is, as shown in FIG. 6, the outer diameter of the magnet 15 as L1, the inner diameter of the magnet 15 as L2, and the pair of side core portions 3p and 3q Between the central position of the curved portion 3pr and the central position of the curved portion 3qr is L3, the minimum distance between the pair of side core portions 3p and 3q, that is, the facing surface 3pf constituting a parallel surface And 3qf, where L4 is the dimension of the coil 4 and L5 is the axial dimension of the coil 4, the relationship of L3> L1> L4> L2, L4 = L5 can be selected.

  If the entire dimension is selected in such a relationship, the longitudinal dimension of the center core portion 3c can be utilized to the maximum, and a space equal to the longitudinal dimension of the center core portion 3c can be secured. Also, by using a general-purpose winding device, it can be performed easily and reliably, and can contribute to the reduction of the manufacturing cost. In addition, it is desirable to select the axial dimension of the magnet 15 to be longer than the axial dimension L5 of the coil 4.

  Next, a method of manufacturing the rotary solenoid 1 according to the present embodiment will be described according to the flowchart shown in FIG. 8 with reference to FIGS. 1 to 7 and 9 to 12.

  FIG. 9 shows a winding apparatus 70 suitable for use in the manufacture of the stator portion Ms. First, the winding device 70 will be described. The wire winding device 70 roughly includes a rotary drive unit 71 which also serves as a machine base, and a rotary table 72 supported on the upper end of a rotary support 71s projecting upward from the rotary drive unit 71. The whole of the rotary table 72 is formed of a magnetic material in a cylindrical plate shape, and in particular, the upper table surface 72u is formed to be a flat surface.

  Then, on the table surface 72u, a core set portion 73 is formed by the concave portion. The core set portion 73 selects an opening shape so that positioning in the horizontal direction is performed when one side core portion 3q (or 3p) in the stator core 3 is fitted from above, and has a predetermined depth. By forming it, the holding magnet 74 in which the SN poles occur vertically is fixed to the bottom. Therefore, the depth of the core setting portion 73 is set such that the upper surface of the side core portion 3 q is positioned at or slightly above the table surface 72 u in a state where the side core portion 3 q is set and held by the holding magnet 74. Do. Preferably, the holding magnet 74 is movable or can be turned on / off by using an electromagnet or the like.

  Further, the position on the table surface 72u on which the core setting portion 73 is provided is such that when the side core portion 3q is set in the core setting portion 73 (including the holding magnet 74), the center core portion 3c is perpendicular to the table surface 72u. The position where the center (axis center) Pc of the center core portion 3c is in alignment with the rotation center of the rotary table 72 is selected.

  Thereby, when one side core portion 3q in the stator core 3 is set (accommodated) in the core set portion 73, as shown in FIG. 9, the side core portion 3q is attracted and fixed to the holding magnet 74 and the core set portion 73 is positioned. The dotted arrow Dm indicates a path of magnetic lines of force.

  By the way, in the stator core 3 according to the present embodiment, since the dimension in the longitudinal direction of the side core portion 3p is about 5 mm, it is not easy to mechanically sandwich and fix it by a chuck or the like. Even if it is sandwiched and fixed temporarily, the holding area becomes small, and it becomes difficult to hold in a stable state, and thus there is a negative effect such as the stator core 3 being easily damaged. Since the winding device 70 used in the present embodiment is attracted by the holding magnet 74, sufficient holding and fixing becomes possible even if the size of the stator core 3 is reduced, and the entire size of the winding device 70 ... It is optimal for use in manufacturing the rotary solenoid 1 according to the present embodiment, such as contributing to cost reduction.

  Thus, the winding device 70 can be modified in various other forms. As an example, FIG. 11 shows a winding device 70e in which the rotating table 72 is changed to a rotating table 72e formed of a plastic material. In this modification, since the rotary table 72e does not form a magnetic path, the magnetic plate 75 is accommodated in the core set portion 73, and the two holding magnet members 74ep and 74en are arranged on the left and right of the magnetic plate 75. The holding magnet 74e arranged in the above is accommodated. The magnetic poles of the two holding magnet members 74ep and 74en are upside down. Thus, a magnetic path can be formed by the two holding magnet members 74ep and 74en, the magnetic plate 75, and the stator core 3, and a rotary table 72e made of an inexpensive and lightweight plastic material can be used.

  Further, FIG. 12 shows a winding device 70f to which a pressing block 76 supported by a support mechanism (not shown) is added. In this modification, the stator core 3 can be held and fixed at the upper and lower sides, so that the stator core 3 can be securely and stably fixed, and the protrusion of the magnet wire W (thermal fusion wire Wh) from the center core portion 3c during winding is restricted. As a result, it is possible to prevent useless deformation of the coil 4 and, by causing the stator core 3 to function as a catcher when setting the stator core 3 to the core setting portion 73, the stator core 3 can be easily set to the core setting portion 73.

  Specifically, as shown in FIG. 12, a core holding portion 77 is formed on the lower surface 76d of the pressing block 76 so as to be fitted and held in the side core portion 3p located on the upper side of the stator core 3 set in the core set portion 73. At the same time, the magnet housing portion 78 is provided on the upper surface of the pressing block 76 located immediately above the core holding portion 77, and the holding magnet 79 is housed in the magnet housing portion 78. In this case, the lower surface of the side core portion 3p is selected to be positioned at or slightly below the lower surface 76d of the pressing block 76, and the upper surface of the side core portion 3q is positioned at or slightly above the upper surface 72u of the rotary table 72. To be selected.

  As mentioned above, although the example which used the magnet as a fixing means of the stator core 3 in the winding apparatus 70 (70e, 70f), various fixing means other than mechanical fixing means, such as a chuck, can be used besides Also, suction means by suction can be used. In FIGS. 11 and 12, the same parts as in FIG. 9 are assigned the same reference numerals to clarify their configurations, and detailed descriptions thereof will be omitted.

  Therefore, when manufacturing the rotary solenoid 1 according to the present embodiment, first, the stator portion Ms is manufactured in the stator manufacturing process. In manufacturing the stator portion Ms, the stator core 3 manufactured in advance is prepared. Then, the stator core 3 is set in the core setting portion 73 of the winding device 70 (step S1). Further, the tip end side of the heat fusion wire Wh drawn out from the wire feeding portion (not shown) is temporarily fixed at the winding start position of the center core portion 3 c in the stator core 3. Then, the hot air discharger (not shown) is operated to release (supply) the hot air locally toward the center core 3c (step S2).

  Next, the winding device 70 is operated (step S3). Since the rotary table 72 is rotated by the operation of the winding device 70 and the stator core 3 set on the rotary table 72 is rotated, an appropriate back tension is applied from the wire feeding portion (not shown) and the feeding position The controlled heat fusion wire Wh is fed out (step S4).

  Thereby, the heat fusion wire Wh is wound around the center core portion 3c of the stator core 3, and the coil 4 is manufactured. At the time of winding, the fusion film of the heat fusion wire Wh is melted and solidified by hot air. A winding process is performed in which the wound heat fusion wires Wh are fixed to each other (step S5). Then, when the set number of turns is wound, the winding process is ended (step S6). Thus, the stator portion Ms shown in FIG. 7 can be manufactured (step S7).

  In addition, a magnet rotor unit Mr is prepared. This magnet rotor part Mr can be obtained by assembling the magnet 15 on the shaft 16 manufactured separately beforehand. That is, the shaft 16 may be inserted into the cylindrical magnet 15, and the outer peripheral surface of the large diameter portion of the magnet 15 and the inner peripheral surface of the magnet 15 may be fixed with an adhesive or the like (step S8). In addition, although the case where the magnet rotor part magnet completed the magnetization completion as a single body was attached to the shaft 16 was demonstrated, the magnet cloth before magnetization is attached to the shaft 16 and fixed, and then the shaft 16 The magnetization may be performed based on the D-cut surface of In this case, in particular, it is desirable that the magnetization timing be performed after assembling to the casing 2, which is advantageous in that unnecessary adhesion of dust such as metal powder to the magnet 15 during assembly can be effectively prevented. As described above, even if the magnet cloth before magnetization is assembled to the shaft 16 and then magnetized, the magnet cloth can be regarded as the magnet 15 in assembly, so the above-mentioned attachment is made. The concept is the same as in the case where the magnet 15 whose magnetism is completed is assembled to the shaft 16. Thus, the magnet rotor unit Mr shown in FIG. 7 can be manufactured (step S9).

  Next, the manufactured stator portion Ms is assembled to the casing 2 by a stator assembling process. In this case, first, the casing 2 is set in a predetermined assembly machine (step S10). Then, as shown in FIG. 7, the assembly can be easily performed only by housing the stator portion Ms in the casing 2 from the opening 2o (step S11). In this case, the stator portion Ms is accommodated inside the casing 2 from the opening 2 o along the arrow D 1 direction. At this time, since the stator core 3 is linearly guided by the guide concave portions 21 and 21, it can be accommodated easily, and after being accommodated, the stator core 3 is engaged with and stopped at the locking portions 22 and 22. As a result, the stator portion Ms is accurately positioned by the stator restricting portions 11 provided on the casing 2.

  Further, when the housing of the stator portion Ms is housed, as shown in FIG. 4, the lead wires 61 and 62 and the coil 4 are connected (step S12). In this case, the lead wires (conductor portions) Wha and Whb of the winding start and end of the heat fusion wire Wh in the coil 4 are tied to the exposed conductor portions 61s and 62s of the lead wires 61 and 62 for soldering. Etc. can be connected.

  Next, the prepared magnet rotor part Mr is assembled to the casing 2 in the magnet rotor assembling process (step S13). In this case, as shown in FIG. 7, the magnet rotor portion Ms may be accommodated inside the casing 2 from the opening 2o (step S13). At this time, the other end side of the shaft 16 is inserted through the spacer 51 into the bearing portion 12 provided on the bottom plate portion 2 d of the casing 2. The spacer 51 is formed in a washer shape using a lubricating resin material such as fluorocarbon resin or POM (polyacetal).

  Next, the prepared cover 13 is assembled to the casing 2 by the cover assembling process (step S14). In this case, when one end of the shaft 16 is inserted through the spacer 51 into the bearing 14 of the cover 13, the opening 2 o of the casing 2 is closed by the cover 13. Then, the cover 13 and the casing 2 are fixed by heat welding. Thereby, the target rotary solenoid 1 shown in FIGS. 1 to 3 can be manufactured.

  Next, the operation (function) of the rotary solenoid 1 according to the present embodiment will be described with reference to FIG.

  When actually using the rotary solenoid 1 according to the present embodiment, a stopper mechanism 17 may be provided inside or outside the casing 2 to restrict the rotation range of the magnet rotor part Mr by setting the setting range Zr. it can. FIG. 13 shows a stopper mechanism 17 provided outside the casing 2 as an example. The stopper mechanism 17 is provided with a locking lever portion having one end fixed to the shaft 16 and is disposed on both sides in the rotational displacement direction of the locking lever portion 41, and locked to the locking lever portion 41 and locked. A pair of stopper portions 42 and 43 for restricting the rotational displacement of the lever portion 41 is provided. As a result, the illustrated rotary solenoid 1 (magnet rotor unit Mr) is set to a setting range Zr of approximately 60 degrees, and the first position and the other position at which the locking lever portion 41 is locked to one of the stopper portions 42. It has a function of reciprocating and displacing between the second positions engaged with the stopper portion 43.

  On the other hand, the rotary solenoid 1 operates as follows. In the illustrated rotary solenoid 1, the magnet 15 is magnetized in the radial direction passing through the locking lever portion 41, and the S pole is on the locking lever portion 41 side with the shaft 16 as a boundary, and the N pole is on the opposite side. Assume that it has occurred. Further, the lead wires 61 and 62 derived from the rotary solenoid 1 are connected to a controller 65 that incorporates a power supply unit, and it is assumed that the coil 4 is energized in the positive direction.

  Therefore, in this state, the coil 4 is excited in the positive direction, an S pole is generated in the upper side core portion 3p in FIG. 13, and an N pole is generated in the lower side core portion 3q. As a result, the N pole of the magnet 15 is attracted to the side core portion 3p side of the S pole and repelled to the side core portion 3q of the N pole, and the S pole of the magnet 15 is on the side core portion 3q side of the N pole. It is sucked and repelled against the side core portion 3p of the south pole.

  Thereby, the magnet 15 is rotationally displaced in the clockwise direction in FIG. 13 and is stopped at the first position where the locking lever portion 41 is locked to the stopper portion 42. If the coil 4 is de-energized after or immediately after stopping at the first position, the N pole and the S pole of the magnet 15 are respectively attracted to the side core portions 3p and 3q which are adjacent magnetic members, and are self-retained The function holds the stopped state of the first position.

  Next, when the energization polarity of the rotary solenoid 1 is switched by the control of the controller 65, the coil 4 is energized in the reverse direction, and an N pole is generated in the upper side core portion 3p in FIG. An S pole is generated in the side core portion 3q of As a result, the N pole of the magnet 15 is attracted to the side core portion 3q side of the S pole and repelled against the side core portion 3p of the N pole, and the S pole of the magnet 15 is on the side of the side core portion 3p of the N pole. It is sucked and repelled against the side core portion 3q of the south pole.

Thereby, the magnet 15 is rotationally displaced in the counterclockwise direction in FIG. 13 and is stopped at the second position where the locking lever portion 41 is locked to the stopper portion 43. Also,
If the coil 4 is de-energized after or immediately after stopping at the second position, the N pole and the S pole of the magnet 15 are respectively attracted to the side core portions 3q and 3p, which are adjacent magnetic members, by the self-holding function. Hold the second position stop state. As described above, if the stopper mechanism 17 is provided inside or outside of the casing 2 to limit the setting range Zr of the magnet rotor unit Mr by locking, the switching actuator of two positions by the output of the reciprocating rotation displacement As it can be made to function as, while being able to use it as the original rotary solenoid 1, arbitrary setting range Zr can be set easily. As mentioned above, although FIG. 13 showed an example which provided the stopper mechanism 17 in the exterior of the casing 2, you may arrange | position this stopper mechanism 17 in the interior space of the casing 2 similarly.

  Next, a rotary solenoid 1e according to a modified embodiment of the present invention will be described with reference to FIG.

  The rotary solenoid 1e shown in FIG. 14 prepares two identically configured stator sections Ms, and distributes the first stator section Ms on one side in the left-right direction (radial direction Dd) with respect to the magnet rotor section Mr. In addition, the second stator portion Ms is disposed on the other side in the opposite direction of 180 °. Therefore, in this case, with respect to one stator portion Ms, the right and left sides of the other stator portion Ms are reversed, and the curved surfaces 3pr and 3qr of the side core portions 3p and 3q of one stator portion Ms and the other stator portion Ms. The curved surfaces 3pr and 3qr of the side core portions 3p and 3q overlap each other so that the positions overlap. For this reason, each stator part Ms ... is distribute | arranged to the axial direction of the shaft 16 in a step difference. Further, with respect to the rotary solenoid 1 of the basic mode (FIG. 1), the magnet 15 is formed to have a longer axial length and to form the longitudinal length of the casing 2 longer.

  As a result, the rotary solenoid 1e according to the modified embodiment can further increase the driving force (driving torque) while maintaining the thickness of the rotary solenoid 1 of the basic mode to be the same (5 mm). Furthermore, the rotary solenoid 1e can be configured to be provided with three or more stator portions Ms, on condition that the plurality of stator portions Ms are arranged in a step difference in the axial direction of the shaft 16.

  Therefore, the rotary solenoids 1 and 1e (and the method for manufacturing the same) according to the present embodiment have a magnet wire W at the center core portion 3c located at the middle portion of the stator core 3 formed in a U shape as a basic configuration. By integrally forming a stator portion Ms having a coil 4 manufactured by winding and a horizontally long rectangular parallelepiped shape F, thereby guiding the stator portion Ms to the inside from an opening 2o in one surface of the rectangular parallelepiped shape F and at a predetermined position The casing 2 has at least one stator restricting portion 11 that can restrict the position of the stator core 3 by Xs, and has one bearing 12 at the bottom plate 2d facing the opening 2o, and closes the opening 2o It is disposed between the cover 13 having the other bearing portion 14 and a pair of side core portions 3p and 3q located on both sides of the center core portion 3c. Since the magnet rotor part Mr having the gnett 15 integrally supported at one end and supported by one of the bearings 12 and the other end supported by the other bearing 14 is provided, the overall outer shape is reduced in size. In addition, it is possible to easily realize thinning, in particular, an ultra-thin shape having a thickness of 5 mm or less. As a result, it becomes possible to cope with various arrangement spaces, such as arrangement in a narrow space such as a gap between parts and high density arrangement by arraying possible, and the versatility and development are dramatically improved. It can be enhanced.

  Further, since a reasonable magnetic path can be constructed in consideration of the shapes and volumes of the magnet 15 and the stator core 3, the number of turns can be increased by relatively securing the winding space of the coil 4. As a result, it is possible to easily obtain the magnetic flux and the ampere-turn for obtaining the necessary torque, and it is possible to secure high driving torque even with the structure of the ultra thin shape. In addition, also in manufacturing, a combination of simple manufacturing processes becomes possible, such as eliminating the need for a special winding device, and in particular, facilitation, simplification and cost reduction of the manufacturing automation process can be realized. It can also contribute to the improvement of the product yield rate.

  As mentioned above, although preferred embodiment (modification embodiment) including a modification example was described in detail, the present invention is not limited to such embodiment, composition of a detail, shape, material, quantity, a numerical value, etc. In the above, the present invention can be arbitrarily changed, added or deleted without departing from the scope of the present invention.

  For example, as a configuration example in which the stopper mechanism 17 for restricting the setting range Zr of the rotation range of the magnet rotor part Mr by locking is provided inside or outside of the casing 2, a part of the rotary solenoid 1 is also used. Alternatively, without providing the stopper mechanism 17, the rotary solenoid 1 may directly follow the restricted range in the mechanism to be switched. Furthermore, without providing the stopper mechanism 17, it is also possible to apply as a motor by changing some parts or the like. On the other hand, although the case where the coating insulating layer 18 is provided by applying the insulating paint to the surface of the center core portion 3c in the stator core 3 has been shown, applying the insulating paint means exerting similar functions such as sticking an insulating tape. It is a concept that includes other means. In addition, although the case where the heat fusion wire Wh is used as the magnet wire W is shown, without using the heat fusion wire Wh, for example, winding processing is performed using the winding device 70f shown in FIG. After the winding process, fixing may be applied by a method such as applying a fixing agent.

The rotary solenoid according to the invention uses the reciprocation rotational property to sort money, bills, etc., sort mails, etc., switch conveyance of printed matter, switch light path of optical equipment, ion shutter of semiconductor manufacturing apparatus, etc. It can be used for various applications in many fields.

  1: rotary solenoid, 2: casing, 2o: opening, 2d: bottom plate, 3: stator core, 3c: center core, 3p: side core, 3q: side core, 3pf: opposing surface, 3qf: opposing surface, 3pr: Curved surface, 3 qr: Curved surface, 4: Coil, 11 ...: Positioning control part, 12: Bearing part, 13: Cover, 14: Bearing part, 15: Magnet, 16: Shaft, 17: Stopper mechanism, 18: Coating insulation Layer 70: Winding device 74: Holding magnet (S1 to S7): Stator manufacturing process, (S10 to S12): Stator assembling process, (S8, S9, S13): Magnet rotor assembling process, (S14) ): Cover assembling step, L1: Maximum spacing dimension between a pair of side core portions, L2: Outer diameter dimension of magnet, L3: Minimum spacing dimension between a pair of side core portions L4: axial dimension of coil, L5: inner diameter of magnet, Dd: radial direction, F: rectangular parallelepiped shape, Ms: stator portion, Mr: magnet rotor portion, Mrf: circumferential surface of magnet rotor portion, Cc: clearance, R: Synthetic resin material, Zr: setting range, W: magnet wire, Wh: heat fusion wire, Xs: predetermined position

Claims (12)

  A rotary solenoid including a stator portion fixed to a casing and having a coil wound around a stator core and a magnet rotor portion rotatably supported by the casing, the rotary solenoid being positioned at an intermediate portion of the U-shaped stator core By integrally forming a stator portion having a coil manufactured by winding a magnet wire around a center core portion to be formed and a horizontally long rectangular parallelepiped shape, the stator portion is guided internally from an opening in one surface of the rectangular body, and predetermined A casing has at least a stator restricting portion capable of restricting the position of the stator core, and a casing having one bearing at a bottom plate facing the opening, and closing the opening and having the other bearing It is disposed between the cover and a pair of side core portions located on both sides of the center core portion. Rotary solenoid magnet with integrally includes, and is supported on one end the one bearing portion, and the other end side characterized in that it comprises a magnet rotor portion which is supported by the bearing portion of the other that.   The stator core is characterized in that a curved surface facing the circumferential surface of the magnet rotor portion via a constant clearance is formed on the opposing surfaces of the pair of side core portions facing each other. Rotary solenoid described.   When the outer diameter dimension of the magnet is L1 and the inner diameter dimension is L2, the maximum gap dimension between the pair of side core portions is L3 and the minimum gap dimension is L4, and the axial dimension of the coil is L5, L3> L1 3. The rotary solenoid according to claim 2, wherein the relationship of L4> L2 and L4 = L5 is selected.   2. The rotary solenoid according to claim 1, wherein the stator core is provided with a coating insulating layer using an insulating paint on the surface of the center core portion.   The rotary solenoid according to claim 1, wherein the casing and / or the cover are integrally formed of a synthetic resin material.   The magnet is oriented in one direction perpendicular to the shaft, and cylindrically polarized in two directions of S pole and N pole in this direction, or radially oriented in the radial direction of the shaft and in this radial orientation 2. The rotary solenoid according to claim 1, wherein the rotary solenoid is formed in a cylindrical shape divided and magnetized to two poles of an S pole and an N pole.   2. The rotary solenoid according to claim 1, further comprising: a stopper mechanism for restricting the rotation range of the magnet rotor portion to a set range by locking the inside or the outside of the casing.   A method of manufacturing a rotary solenoid including a stator portion fixed to a casing and having a coil wound around a stator core and a magnet rotor portion rotatably supported by the casing, the middle of a U-shaped stator core The stator section is integrally formed in a horizontally long rectangular parallelepiped shape having an opening on one side, and a stator manufacturing process for obtaining a stator section by winding a magnet wire around a center core section located in a section and manufacturing a coil. The housing has a stator restricting portion capable of guiding the inside from the opening and restricting at least the position of the stator core at a predetermined position, and the casing having one bearing on the bottom plate facing the opening. A stator assembling step for accommodating the stator portion from the opening; A magnet rotor unit integrally including a magnet is housed in the casing from the section, and one end side of the magnet rotor unit is inserted into the one bearing unit to position the magnet on both sides of the center core unit. And a cover assembling step of inserting the other end side of the magnet rotor into the other bearing part of the cover and closing the opening by the cover. A method of manufacturing a rotary solenoid, comprising:   9. The method of manufacturing a rotary solenoid according to claim 8, wherein in the stator manufacturing step, the stator core is attracted and fixed by a holding magnet provided in a winding device, and the magnet wire is wound around the stator core.   10. A method of manufacturing a rotary solenoid according to claim 8, wherein a coating insulating layer is provided by applying an insulating paint on the surface of the center core portion, and the magnet wire is directly wound on the coating layer. .   10. The method for manufacturing a rotary solenoid according to claim 8, wherein a heat fusion wire is used for the magnet wire.   In the magnet rotor assembling step, the magnet fabric before magnetization is assembled and fixed to the shaft, and after assembling to the casing, the magnet fabric is magnetized based on the D cut surface of the shaft. 9. A method of manufacturing a rotary solenoid according to claim 8, further comprising the step of manufacturing the magnet rotor.

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