Gearbox with moving coil actuator

Abstract

A moving coil actuator (100) for a gearshift (300) for an electric drive, wherein the moving coil actuator (100) comprises the following: a runner (110) with a magnetic component (120) mounted on it; and a coil (130) which is wound around a coil former (160), wherein a reluctance element (162) extending in a circumferential direction and made of a ferro- or ferrimagnetic material is applied to the coil body (160) at an axial position, which exerts a reluctance force on the magnetic element (120) to lock the rotor (110) at an axial locking position (P1).

Description

[0001] The present invention relates to a gearshift of an electric drive, a moving coil actuator, a control unit for activating at least two moving coil actuators, a method for assembling and a method for disassembling a moving coil actuator and in particular to a double coil and sequential switching electronics for a moving coil actuator in electrified vehicle drives. BACKGROUND

[0002] Moving coil actuators are linear actuators in which a rotor is moved linearly along a rotor axis using an electric current via Lorentz forces. The basic concept is that of a moving coil, i.e. a coil wound from a wire to conduct an electric current, which is located in the magnetic field of a permanent magnet. When the coil is energized, a force is generated that displaces the coil relative to the permanent magnet in an axial direction. The permanent magnet can either be fixed to the rotor and the coil implemented as part of the stator, or the coil can be wound around the rotor axis and the permanent magnet part of the stator. Moving coil actuators in various designs are used in many areas of mechanical engineering, sometimes for highly dynamic linear movements.

[0003] In particular, moving coil actuators are used for gear shifting in electric drives. Such electric drives can be used, for example, in automobiles and require appropriately reliable gearshifts. These gearshifts include components, particularly shift rods, that must be moved linearly with great accuracy and fine tuning. Moving coil actuators can perform such movements with the required precision and control.

[0004] Fig. 16 shows a prior art example of a moving coil actuator 410 in a gearshift 430 for changing gears of an electric drive. Shown in cross section are parts of a housing 431 of the gearshift 430, which in particular has an opening through which a shift rod 432 is guided for moving a shift fork 434. The moving coil actuator 410 comprises two coils 4131, 4132 in a cylindrical outer shell 414. A portion 411 of the shift rod 432 extends into a region of the coils 4131, 4132, so that the shift rod 432 itself forms the rotor of the moving coil actuator 410. The portion 411 of the shift rod 432 is fixedly connected to a permanent magnet 412 and, together with the permanent magnet, is movably mounted within the coils 4131, 4132. When the coils 4131, 4132 are energized, a magnetic field is formed which exerts a force on the permanent magnet 412 and thus moves the switching rod 432.

[0005] Fig. Figure 17 shows a view of the casing 414 of the moving coil actuator 410. The casing 414 has a screw flange 415, via which the moving coil actuator 410 is fastened to the housing 431 with screws 416. In this example, the limited space available for the gearshift 430 means that the screw flange 415 cannot simply be round for geometric reasons, but must have the contour shown. These limited space often leads to restrictive requirements regarding the shape and dimensions of components, particularly in automotive drivetrains, which complicate and increase the cost of manufacturing the components.

[0006] Fig. Figure 18 shows further details for the electric drive to illustrate the function of the voice coil actuator 410. A topology of the electric drive is sketched on the left side of the figure. This shows two electric motors 501, 502, each driving a sub-gearbox 510, 520. The sub-gearboxes 510, 520 are connected to one another via a differential gear 530, which transmits the power of the electric motors 510, 520 to wheel axles 540 of an electric vehicle. A sub-gearbox 520 has, in particular, a shifting mechanism 550, which includes a dog clutch 555, as shown on the right side of the figure. The shifting mechanism 550, or a part of the dog clutch 555, is actuated by the shift fork 434 (cf. Fig. 16), so that the electric drive offers a total of three gears. The transmission design with the two non-identical sub-transmissions 510, 520 allows the desired power to be distributed among the electric motors 501, 502. This allows the efficiency and vibration behavior of the entire drive train to be optimized.

[0007] For gearshift devices in which a plurality of voice coil actuators execute movements of components in a strict sequence, ensuring sequential execution is of great importance. An example of a device for sequentially executing actuator movements can be found in document DE10 2015 226 351, which discloses a system with a plurality of actuators connected to one another and to a higher-level electronic control device via data lines. The system is designed to activate the actuators in a variety of patterns. Each actuator is assigned its own control unit, which is designed to send and receive data via the data lines and to activate the respectively assigned actuator based on the data.

[0008] In prior art examples, control units for each moving coil actuator may comprise a microcontroller that activates the moving coil actuator via a full-bridge circuit.

[0009] The disadvantage of this solution is the complicated or redundant control design, particularly due to the use of individual control units for each actuator. This design can be difficult to implement in the confined spaces of vehicle drive systems, for example. Furthermore, it can result in an increased potential for failures.

[0010] When mounting a moving coil actuator in a bracket, reluctance forces may occur between the moving coil actuator and parts of the gearshift. Fig. The moving coil actuator 410 shown in Figure 13 exhibits such reluctance forces, particularly between the casing 414 with the coils 4131, 4132 and the permanent magnet 412. These reluctance forces make it necessary to guide the moving coil actuator or its casing during assembly.

[0011] If a component in a gearshift—such as a shift rod—is moved by a moving coil actuator, the component must generally be securely held in certain positions—which may, for example, correspond to specific gears of the drive. For this purpose, mechanical locking devices are available in the state of the art.

[0012] Fig. Figure 19 shows, on the left, a conventional system for locking a shift sleeve 436 arranged on a shaft, which is combined with a locking device 440 of the shift rod 432 or the shift fork 434. The figure shows, on the right, a more detailed illustration of the locking device 440 for the shift rod 432. In this mechanical locking mechanism, a ball-and-spring unit 442 running along a contour ensures that a force counteracts a deflection and thus the shift rod 432 and thereby the shift fork 434 are held in their position with a specific force (locking force). The positions can correspond, for example, to a first gear, a neutral position, and a second gear. The locking mechanism incurs costs for transmission manufacturers due to the procurement of components and processing steps in the gearshift.

[0013] In the context of the development of electric drives, there is an overall need for moving coil actuators and switching electronics that offer the most cost-effective, uncomplicated and space-saving solutions with the least possible effort in the areas of production, assembly, operation and disassembly. BRIEF DESCRIPTION OF THE INVENTION

[0014] A contribution to this objective is made by a moving coil actuator for a gearshift for an electric drive according to claim 1. The dependent claims relate to advantageous developments of the independent claims.

[0015] The present invention relates to a moving coil actuator with a rotor, a magnetic component, and a coil. The coil has a plurality of coil sections along an axis, which can in particular run parallel to an axis of the rotor. The coil is formed by a wire which, from a first end of the coil to a second end of the coil, successively forms a first winding for each coil section in a winding direction assigned to a respective coil section. There is at least one change in the winding direction between a first coil section and a subsequent second coil section, so that when the wire is energized, each coil section amplifies a force on the magnetic component, resulting in a linear movement of the rotor.Furthermore, from the second end of the coil to the first end of the coil, the wire successively forms a second winding for each coil section in the winding direction assigned to the respective coil section. The wire thus both enters and exits the coil at the first end of the coil.

[0016] The term "winding" refers to a spiral arrangement of the wire in at least one layer. In an advantageous embodiment, the first winding comprises only one layer, while the second winding comprises an equal, larger number of layers in all coil sections. The arrangement of the layers can be selected depending on needs and requirements, such as an orthocyclic, helical, or random winding. Furthermore, the number of turns in each coil section and in each layer can be adapted to geometric constraints, in particular to the shape or size of the magnetic component or the rotor, and / or to operating conditions such as the expected current intensities or the desired forces.

[0017] The advantages of the coil winding presented here lie primarily in its reduced volume. One advantage is that only a single wire is sufficient for winding all coil sections, eliminating the need for a separate wire for each coil section. This reduces the number of connections for powering the moving coil actuator. At the same time, the wire entry and exit on the same side of the coil is advantageous, as this allows the wire to be led out of the moving coil actuator or the coil to be connected to a power source without an additional wire return that does not contribute to the coil's magnetic field.

[0018] In an advantageous embodiment, the magnetic component forms a dipole magnetic field with a magnetic north pole and a magnetic south pole along the axis. The coil comprises two coil sections with opposite winding directions. Due to the opposite winding directions of the coil sections, a current flowing through the coil results in a force in both coil sections that acts in the same direction on the magnetic component and thus on the rotor. The Lorentz force in both coils then acts in the same direction. With the reversed current flow, the effect on the magnetic component and thus the force on the rotor is reversed.

[0019] In embodiments in which the coil of the moving coil actuator has only two coil sections, the coil can alternatively be described as comprising a first coil section with a first winding around the axial axis and a third winding around the axial axis, as well as a second coil section with a counter-rotating, second winding around the axial axis. The second coil section is arranged next to the first coil section with respect to the axial axis (at a certain distance). The counter-rotating, second winding is connected in series between the first winding and the third winding, so that an electric current reverses its direction of rotation twice when the first, second and third windings are energized. The rotor couples to the magnetic component or to one of the coil sections in order to effect the movement when energized.

[0020] Optionally, the magnetic component is permanently connected to the rotor, making the coil part of a stator. In particular, the magnetic component can have a hollow cylindrical shape that surrounds the rotor. Alternatively, the coil can be wound around the rotor, and the magnetic component can be formed as part of the stator, for example, in the form of a tube or cylinder shell.

[0021] Optionally, the plunger coil actuator further comprises an advantageously cylindrical outer shell, which has on an outer side a circumferential groove for applying a shaft retaining ring and / or a circumferential sealing element and / or a common inlet and outlet of the wire for energizing the coil.

[0022] A shaft retaining ring or grooved ring can advantageously be used to guide the moving coil actuator during assembly or disassembly in a device, such as, for example, in a recess in the housing of a gearshift for an electric drive. The circumferential sealing element can, in particular, be an O-ring. The O-ring can be fitted into a further groove on the outside of the outer shell, for example, one that runs parallel to the groove for the shaft retaining ring. The shared inlet and outlet of the wire or the coil connection for power supply exploits the advantage offered by the wire exiting on the same side of the coil. In particular, the wire can be energized very easily in this way on one side of the moving coil actuator (for example, an end face).

[0023] Embodiments also relate to a control unit for activating at least two actuators. The actuators can be moving coil actuators of the aforementioned type. The control unit comprises an electronic switch or switch connection for each actuator, which can in particular comprise a metal oxide semiconductor field-effect transistor (MOSFET) and is designed to activate and deactivate the respective actuator or, when energized, allows the activation of the respective actuator in a first state and prevents activation in a second state.

[0024] The control unit further comprises a bridge switching device, for example a full bridge or a four-quadrant controller, in which the electronic switches or MOSFET switches are connected at a load position such that a current at the load position is distributed between the electronic switches. The bridge circuit is designed to be connected to a supply voltage and, when connected to the supply voltage, to provide parallel current supply to the electronic switches. In particular, the at least two actuators can be arranged in parallel on a bridge branch of a full bridge. The control unit further comprises an electronic control unit, which can in particular have a microcontroller and which comprises a connecting device with a connection to each of the electronic switches.The control unit is designed to control the parallel current supply via the bridge switching device and also to individually set each of the electronic switches to the first state or the second state via the connecting device. The connecting device can, for example, comprise a line from a suitable port of the electronic control unit to a gate terminal of one of the electronic switches.

[0025] Advantageously, using this control unit eliminates the need for constant current supply to each actuator. In exemplary embodiments, the circuit is used in particular for plunger coil actuators for moving shift rods of a gearshift, which is designed to reliably lock or hold the shift rods in a selected shift position.

[0026] Optionally, the connecting device comprises a safety circuit which has exactly one AND gate and one NOR gate for each actuator and no other gates and is designed to allow activation of at most one actuator at any time.

[0027] For multiple plunger coil actuators used to shift gears in a transmission, it is generally crucial that the plunger coil actuators are activated sequentially. The safety circuit offers the advantage of ensuring sequential activation in a simple and space-saving manner, independent of software or programming of the electronic control unit.

[0028] Embodiments further relate to a gearshift or to a device for changing gears, in particular of an electric drive. The gearshift comprises a housing which has a depression with an opening through which a movable component, in particular a shift rod, is guided for changing gears. The gearshift further comprises an actuator, in particular a voice coil actuator, which is designed to move the component and which is mounted in the depression in particular by an interference fit. The actuator can be mounted in the depression or in a widened part of the opening or in a region of the housing in which the component is guided through a wall of the housing, by means of the interference fit. The interference fit offers the advantage of being able to dispense with screwing the actuator.In embodiments with a moving coil actuator, the switching rod can be identical to the rotor of the moving coil actuator. The moving coil actuator does not necessarily have to have the coil winding described above.

[0029] Optionally, however, the gearshift actuator is designed as a plunger coil actuator as described above. In particular, the coil can have the structure and coil winding described above, and an outer shell of the plunger coil actuator can be provided with a groove for applying a shaft retaining ring for easier assembly or disassembly, as well as with a sealing element.

[0030] Optionally, the gearshift also includes at least two actuators and a control unit of the type described above.

[0031] Embodiments also relate to a method for winding a wire into a coil for a moving coil actuator. The method comprises the steps: Forming a first winding from a first end of the coil for a plurality of coil sections in a winding direction assigned to each coil section, so that there is at least one change in the winding direction between a first coil section and a subsequent second coil section; and Forming a second winding from a second end of the coil for each coil section in the winding direction associated with the respective coil section, so that the wire exits the coil at the first end of the coil.

[0032] The coil can be either part of the stator or part of the rotor of the moving-coil actuator. In exemplary embodiments, the coil is part of the stator, and the rotor comprises a permanent magnet that forms a dipole magnetic field similar to that of a bar magnet with poles on an axis of the rotor. Advantageously, the coil then has two coil sections. The first winding can comprise only one layer. Other geometries are conceivable; in particular, the design of the previous exemplary embodiment can be replicated to include multiple permanent magnets and correspondingly multiple coil sections.

[0033] Embodiments also relate to a method for mounting an actuator, in particular a plunger coil actuator, in a recess of a housing of a device, in particular a gearshift of an electric drive. The method is characterized by the following steps: clamping at least part of the actuator and the housing; and Pressing the clamped part of the actuator into the recess of the housing, and thereby mounting the actuator in the recess.

[0034] For secure and rapid assembly, the actuator can be guided radially and held axially, so that the actuator is advantageously not pulled out of its guide by its own weight or by a reluctance force (e.g., caused by a magnetic device). In an automated manufacturing process, rigid fixation of the actuator can be achieved through axial pressing.

[0035] In embodiments of this method, a moving coil actuator is assembled by pressing a stator of the moving coil actuator or a part of the moving coil actuator, which includes the casing and the coil, into a recess of a gear housing using an interference fit, so that a movable component guided through an opening in the recess of the gear housing represents a rotor of the moving coil actuator. This interference fit then absorbs axial forces occurring during switching. The moving coil actuator does not necessarily have to have the coil winding described above. The actuator casing can be a simple turned part.

[0036] Optionally, in cases where the actuator or moving coil actuator has an outer shell with a preferably circumferential groove as described above, clamping the actuator or moving coil actuator into a mounting device formed with a latch that can engage in the groove. Clamping then further comprises securing the actuator or moving coil actuator with the latch so that the actuator or moving coil actuator cannot fall out. Pressing can then comprise exerting a press-in force on the mounting device in order to mount the actuator in the housing. The press-in force is advantageously higher than a force that can release the actuator or moving coil actuator from its seat in the housing.

[0037] The mounting fixture can, for example, be pot-shaped to at least partially accommodate the actuator or moving coil actuator. Pressing in can then be achieved by applying the press-in force, for example, to a base of the mounting fixture. This allows the press-in force to be transferred directly to the actuator or moving coil actuator. Once the actuator or moving coil actuator is pressed into the housing, the latch can be released by pulling, and the mounting fixture can be lifted off the actuator or moving coil actuator.

[0038] The assembly fixture can be mounted on any linear press tool. For example, a simple hand press can be used. Hydraulic or pneumatic presses in automated or collaborative production lines, such as those commonly used in transmission manufacturing, are also possible. The assembly fixture can also be loaded with the actuator or voice coil actuator manually or automatically, e.g., by a robot.

[0039] Overall, assembly using this method eliminates the need for screwing. The number of work steps can be significantly reduced compared to screwing. The method thus enables external mounting of a moving coil actuator in a recess around a housing opening through which a component to be moved by the moving coil actuator is guided. The component can be permanently connected to the moving coil actuator's rotor or be identical to it.

[0040] Advantageously, the casing of the actuator can have a sealing element on an outer side, in particular an O-ring, which seals against the ingress of air and / or moisture into the housing.

[0041] Embodiments also relate to a method for disassembling an actuator, in particular a plunger-type actuator, which is secured by an interference fit in a recess of a housing of a device, in particular a gearshift of an electric drive. The actuator comprises an advantageously cylindrical outer shell, which has a circumferential groove on an outer side for securing a shaft retaining ring. The method is characterized by the following steps: Applying a ring component with a plurality of threaded holes to the actuator; Securing the ring component on the actuator by fixing the shaft retaining ring in the groove; Insert one screw into each of the threaded holes so that each screw rests on the housing at one end; Loosen the actuator by turning the screws to remove the actuator from the housing via the shaft locking ring.

[0042] In exemplary embodiments, this method is applied to a moving coil actuator that is secured in a recess of a gearshift housing for an electric drive by an interference fit. The coil of the moving coil actuator does not necessarily have to have the winding described above.

[0043] The ring component can, in particular, be a steel ring. In exemplary embodiments, the ring component has three threaded holes. The shaft retaining ring can be installed, for example, using retaining pliers.

[0044] Embodiments also relate to a method for sequentially activating at least two actuators. The actuators are each connected to an electronic switch, which may in particular comprise a MOSFET, and the electronic switches are configured to activate or deactivate the respective actuator. The method is characterized by the following steps: parallel powering of the electronic switches via a bridge circuit; Sequentially allowing the actuators to be energized via the electronic switches in order to activate the actuators sequentially.

[0045] In exemplary embodiments, the at least two actuators are each moving coil actuators. The moving coil actuators do not necessarily have to have a coil with the winding described above.

[0046] Embodiments also relate to a computer program product having software code stored thereon, which, when the software code is executed by a data processing machine, is intended to carry out one of the methods described above.

[0047] Embodiments of the present invention can be summarized as follows. In a moving coil actuator, instead of two individual coils, a double coil is manufactured using a special winding technique that requires only one end connection.

[0048] A control unit or sequential switching electronics uses a full bridge and a microcontroller together with additional electrical switches to control or energize multiple moving coil actuators sequentially, i.e., one after the other. The control unit offers the advantage that switching electronics for controlling a single moving coil actuator do not need to be duplicated. This advantageously requires that the positions of the moving coil actuators or the positions of the components moved by them are maintained independently, i.e., without power being applied to the moving coil actuators. A logic circuit can be used to prevent multiple actuators from being energized simultaneously, which increases safety.

[0049] Instead of mounting with screws and a screw flange, the actuator housing can be pressed into the gearbox or a housing. For possible disassembly, a steel ring with three threads can be placed over the actuator. A shaft retaining ring is then inserted into a designated groove. Three screws are screwed into the ring, which rests on the shaft retaining ring, and the plunger actuator can be pulled out of the gearbox housing.

[0050] Embodiments of the present invention offer the following advantages: The manufacture, assembly, and disassembly of a voice coil actuator for electric drives can be simplified. Furthermore, the cost, complexity, and installation space of the electronics for multiple voice coil actuators in a drive can be reduced. Embodiments of the voice coil actuator and the control unit can be used in a variety of systems that utilize positive-locking switching elements, such as in switchable all-wheel drives, differential locks, motorsport transmissions, motorcycle transmissions, in machining technology, or in valve control.

[0051] The assembly and disassembly processes also reduce production and material costs, as well as the space required for the switching actuator. These processes can generally be used when a pot-shaped object is to be mounted in a fixture with the open side facing inward and must be capable of being disassembled.

[0052] Further embodiments relate to a moving coil actuator comprising a rotor with a magnetic component mounted thereon and a coil wound around a coil former. A reluctance component made of a ferromagnetic or ferrimagnetic material, such as iron, is applied to the coil former at an axial position and extends in a circumferential direction. The circumferential direction can be defined, in particular, by an angle in a plane perpendicular to an axis of the moving coil actuator, the coil former, or a direction of rotor mobility. The reluctance component locally reduces magnetic resistance at this axial position, resulting in a corresponding reluctance force acting on the magnetic component and thus on the rotor. This causes the rotor to be locked in an axial locking position. The reluctance force acts on the rotor in a region around the locking position as a restoring force into the locking position.The reluctance force is superimposed on the force exerted on the magnetic component or the rotor by energizing the coil. The axial dimension or thickness of the reluctance component is advantageously small compared to the axial dimension or length of the moving coil actuator.

[0053] Local differences in the magnetic resistance can also arise from the design of the coil or coil body, particularly from gaps located in the axial direction. However, the circumferentially extending reluctance component can produce a much higher reluctance force than such a gap or an interruption in the coil body or coil, so that the locking position can be maintained more securely.

[0054] In such embodiments, the moving coil actuator thus causes a gear locking, however not by a Lorentz force, but by the reluctance force, which does not require the coils to be energized.

[0055] Optionally, an additional reluctance component made of the ferromagnetic or ferrimagnetic material is applied to the coil former at at least one additional axial position. The reluctance component and the additional reluctance component each extend over an angle of at least 180° in the circumferential direction and are also offset from each other by 180° in the circumferential direction. The reluctance component and the additional reluctance component can thus each essentially have the shape of a circular arc. This allows the reluctance components to be applied to the coil former particularly easily (particularly compared to a design as complete rings).

[0056] In some of these embodiments, the moving coil actuator thus comprises a plurality of reluctance components to form a reluctance force profile along an axis of the moving coil actuator, with some reluctance components arranged offset or rotated by 180° from one another. It has been found that such arrangements can compensate for a radial force acting on the magnetic component. A radial force can occur, in particular, because the reluctance components are not designed to be rotationally symmetrical in the circumferential direction. The compensation does not have to be complete; therefore, forces can still act locally in the radial direction on the magnetic component or the rotor.

[0057] Optionally, the reluctance components are each inserted or clamped into a groove of the coil body or into a coil body groove and thus fixed, in particular against axial movements.

[0058] Further embodiments relate to a method for manufacturing a moving coil actuator. The method comprises manufacturing a coil former with a coil former groove at an axial position of the coil former. Furthermore, the method comprises inserting a reluctance component made of a ferromagnetic or ferrimagnetic material into the coil former groove, wherein the reluctance component extends in a circumferential direction on or around the coil former after insertion. BRIEF DESCRIPTION OF THE CHARACTERS

[0059] The embodiments of the present invention will be better understood from the following detailed description and the accompanying drawings of the various embodiments, which, however, should not be construed as limiting the disclosure to the specific embodiments, but are for explanation and understanding only. Fig. 1 illustrates an embodiment of a moving coil actuator with a coil winding according to the present invention. Fig. 2 illustrates a winding scheme of a coil in the moving coil actuator of the Fig. 1. Fig. 3 shows images of an embodiment of the coil. Fig. 4 illustrates an embodiment of a control unit according to the present invention. Fig. 5 illustrates an embodiment of the control unit with a safety circuit. Fig. 6 shows steps of a method according to the present invention for winding a coil for a moving coil actuator. Fig. Figure 7 illustrates the process of winding a coil. Fig. 8 shows steps of a method according to the present invention for assembling a voice coil actuator. Fig. 9 illustrates the method for assembling a voice coil actuator. Fig. 10 shows steps of a method according to the present invention for disassembling a voice coil actuator. Fig. 11 illustrates the procedure for disassembling the voice coil actuator. Fig. 12 shows steps of a method according to the present invention for sequentially activating a plurality of voice coil actuators. Fig. 13 illustrates a reluctance force curve for a moving coil actuator with reluctance components according to the present invention. Fig. 14 shows further embodiments of arrangements of reluctance components in the moving coil actuator. Fig. 15 illustrates a method of manufacturing a voice coil actuator according to the present invention. Fig. 16 illustrates a prior art moving coil actuator. Fig. 17 illustrates further aspects of the moving coil actuator of the Fig. 16. Fig. 18 shows a topology of a drive and a claw clutch in the prior art. Fig. Figure 19 shows a prior art gear locking system. DETAILED DESCRIPTION

[0060] Fig. 1 illustrates a section through a moving coil actuator 100 with a rotor 110, a magnetic component 120, and a coil 130 having a plurality of coil sections 131, 132 along an axis that is identical to an axis of the rotor 110. The coil 130 is formed by a wire that, from a first end of the coil 130 and up to a second end of the coil 130, successively forms a first winding for each coil section 131, 132 in a winding direction associated with a respective coil section (see also Fig. 2). This involves a change in the winding direction between a first coil section 131 and a subsequent second coil section 132. Starting at the second end of the coil 130 and extending up to the first end of the coil 130, the wire successively forms a second winding for each coil section 132, 131 in the winding direction associated with the respective coil section 131, 132. The wire thus enters and exits at the first end of the coil 130.

[0061] When the wire is energized, each coil section 131, 132 amplifies a force on the magnetic component 120. In this embodiment, the magnetic component 120 is firmly connected to the rotor 110; thus, a current through the coil 130 moves the rotor 110.

[0062] In this embodiment, the moving coil actuator 100 comprises a casing 140 having a groove 145 for applying a shaft retaining ring for assembly or disassembly. The moving coil actuator 100 is mounted in a housing 310 having an opening 315. The rotor 110 is guided through the opening 315.

[0063] In this embodiment, the moving coil actuator 100 is mounted by an interference fit in a recess 316 around the opening 315 of the housing 310. The moving coil actuator 100 has a sealing element 150 in the form of an O-ring in a further groove of the casing 140.

[0064] Fig. 2 illustrates the winding scheme of the coil 130 in the moving coil actuator 100 of the Fig. 1. Starting from a first end A of the coil 130, the wire 135 winds an innermost layer of the first coil section 131 in a first winding direction as the first winding. Then, the wire 135 winds an innermost layer of the second coil section 132 in a second winding direction oriented opposite to the first winding direction as the first winding.

[0065] Subsequently, the wire 135 forms a second winding of the second coil section 132 in the second winding direction from a second end B of the coil. The wire 135 then forms a second winding of the first coil section 131 in the first winding direction and exits the coil 130 again at the first end A.

[0066] In this exemplary embodiment, the second winding comprises one layer in each of the two coil sections 131, 132. The number of layers of each individual winding is odd, but, subject to this restriction, can be selected separately in each coil section 131, 132 and for each winding. In this way, different boundary conditions, such as the geometry of the moving coil actuator 100 or the shape of the magnetic component 120, can be taken into account.

[0067] Fig. 3 shows images of an embodiment of the coil 130 of the moving coil actuator 100 from Fig. 1, where the Fig. 2 is present. Together with appropriate aluminum spacers, the coil 130 can be inserted, in particular, into a stator of a moving coil actuator 100. The coil 130 can also be encapsulated in the stator.

[0068] Fig. 4 illustrates an embodiment of a control unit 200 for activating at least two moving coil actuators 100, 410. Particularly in drives with more than three gears, more than one moving coil actuator 100, 410 must generally be used. The moving coil actuators 100, 410 do not necessarily have to have all the features of the moving coil actuator 100 from Fig. 1.

[0069] In the exemplary embodiment shown here, the control unit 200 comprises three electronic switches 210, each for a moving coil actuator 100, 410. Each electronic switch 210 can assume a first state and a second state. In the first state, the electronic switch 210 allows the activation of the respective moving coil actuator 100, 410 when energized. In the second state, the electronic switch 210 interrupts the energization and thus the activation of the respective moving coil actuator 100, 410. In the present exemplary embodiment, each electronic switch 210 comprises, in particular, a MOSFET.

[0070] The control unit 200 further comprises a bridge switching device 220, which is designed to be connected to a supply voltage and, upon connection to the supply voltage, to provide parallel current supply to the electronic switches 210. The bridge switching device 220 can, in particular, be a full-bridge circuit having a bridge branch to which the electronic switches 210 and thus the plunger coil actuators 100, 410 are connected in parallel. In this exemplary embodiment, the bridge switching device 220 is, in particular, connected to a drain terminal of the respective electronic switch 210.

[0071] Bridge switching devices for operating moving coil actuators are known to those skilled in the art; however, in the exemplary embodiments of the control unit 200, instead of an individual bridge switching device (and an individual control unit in each case) for each moving coil actuator 100, 410, only the individual bridge switching device 220 is sufficient.

[0072] The control unit 200 further comprises an electronic control unit 230, which comprises a connection device 240 with a connection 241, 242, 243 to each of the electronic switches 210. The control unit 230 can, in particular, be a microcontroller. The control unit 230 is designed to control the parallel current supply via the bridge switching device 220. In addition, the control unit 230 is designed to individually set each of the electronic switches 210 to the open state or the closed state via the connection device 240. In this exemplary embodiment, the control unit 230 is, in particular, connected to a gate terminal of each of the electronic switches 210.

[0073] For use of the control unit 200, it is advantageous if a constant current supply to each plunger coil actuator 100 is not necessary. Devices for gear changes in electric drives are known in the prior art, in which shift rods 432 or shift forks 434 moved by the plunger coil actuators 100, 410 have a mechanical locking mechanism and thus ensure reliable retention in the selected shift position.

[0074] The control unit 200 simplifies the circuitry of multiple moving coil actuators 100, 410. Known full bridges, in particular, have four MOSFETs for controlling one moving coil actuator 100, 410. If each of the three moving coil actuators 100, 410 is controlled by its own control unit, each with a microcontroller and a full bridge, a total of twelve MOSFETs and three microcontrollers are required. In contrast, the control unit 200 in the illustrated embodiment requires only seven MOSFETs and one microcontroller.

[0075] Fig. Figure 5 illustrates an embodiment of the control unit 200 in which the connecting device 240 comprises a safety circuit 245. The safety circuit 245 comprises exactly one AND gate and one NOR gate for each moving coil actuator 100, 410, and no other gates. The safety circuit 245 is configured to allow activation of at most one moving coil actuator 100, 410 at any time.

[0076] In multi-gear vehicle drives, one of the greatest dangers for vehicle occupants is the simultaneous engagement of several gears, which usually results in the locking of the drive wheels. Instead of a mechanical solution or a solution in higher-level switching electronics, the control unit 200 offers protection against the simultaneous actuation of two moving coil actuators 100, 410 using the logic circuit 245 shown. The combination of a NOR and an AND gate means that only one moving coil actuator 100, 410 can be energized at a time, regardless of the programming of the control unit 230 (e.g., a microcontroller software). This represents a particular safety advantage. The security that two moving coil actuators 100, 410 are never activated simultaneously is ensured at the lowest operating level immediately before the moving coil actuators 100, 410 are connected.

[0077] Fig. 6 shows steps of a method according to the present invention for winding a wire 135 into a coil 130 for a moving coil actuator 100. The method comprises forming a first winding S110 from a first end A of the coil 130 for a plurality of coil sections 131, 132 in a winding direction each associated with a coil section 131, 132, such that there is at least one change in the winding direction between a first coil section 131 and a subsequent second coil section 132.

[0078] The method further comprises forming a second winding S120 from the second end B of the coil 130 for each coil section 132, 131 in the winding direction associated with the respective coil section 131, 132, such that the wire 135 exits the coil 130 at the first end A of the coil 130.

[0079] Fig. 7 shows the coil 130 after Fig. 2 or Fig. 3 during an embodiment of the method for winding the wire 135. The figure illustrates in particular how the change of the winding direction between a first coil section 131 and a second coil section 132 can be carried out.

[0080] In this case, a first winding is first carried out with the wire 135 in the first coil section 131. The wire 135 is then guided further into the second coil section 132, where the winding direction is reversed for the first time. There, a first winding is also carried out up to a second end B of the coil 130, followed directly by a second winding. A winding direction of the first winding and the second winding in the second coil section 132 is opposite to a winding direction of the first winding in the first coil section 131. The wire 135 is then guided back into the first coil section 131 from an end of the second coil section 132 close to the first coil section 131, with the winding direction being reversed again. There, the wire is wound into a second winding of the first coil section 131, wherein the winding direction corresponds to that of the first winding in the first coil section 131.The wire 135 then exits the coil 130 again at the first end A of the coil 130.

[0081] Fig. Figure 8 shows steps of a method for mounting a moving coil actuator 100, 410 in a recess 316 of a housing 310 of a device for changing gears of an electric drive. For this method, the moving coil actuator 100, 410 does not necessarily have to have all the features of the Fig. 1. The method comprises clamping S210 the moving coil actuator 100, 410 and the housing 310. The method further comprises pressing S220 the moving coil actuator 100, 410 into the recess 316 of the housing 310, by which the moving coil actuator 100, 410 is fixed in the recess 316.

[0082] Fig. 9 illustrates an advantageous embodiment of the method for assembling a moving coil actuator 100, 410.

[0083] Part (a) of the figure shows a mounting device 600 having a cutout for a latch 610. The mounting device 600 is cup-shaped and adapted to the dimensions of an outer shell of the moving coil actuator 100, 410 in order to accommodate the moving coil actuator 100, 410 or a part of the moving coil actuator 100, 410.

[0084] Parts (b) and (c) of the figure show two views of a situation in which the mounting device 600 is applied to the moving coil actuator 100, 410 and to a stator part of the moving coil actuator 100, 410, respectively. The moving coil actuator 100, 410 comprises an outer shell with a preferably circumferential groove 145.

[0085] Clamping S210 comprises inserting the moving coil actuator 100, 410 into the mounting device 600, which is formed with the latch 610 that can engage the groove 145. Clamping S210 further comprises securing the moving coil actuator 100, 410 by the latch 610 so that the moving coil actuator 100, 410 cannot fall out. Pressing S220 comprises exerting a press-in force on the mounting device 600 to thereby mount the moving coil actuator 100, 410 in a recess 316 of the housing 310.

[0086] In particular, the moving coil actuator 100, 410 is pushed into the mounting device 600 and secured against falling out by the latch 610. The latch 610 engages in the groove 145; this can also be used for a shaft retaining ring during disassembly. The actual press-in force, which will be higher than the force that could cause the moving coil actuator 100, 410 to fall out, is transferred directly to the moving coil actuator 100, 410 via the bottom of the mounting device 600. Once the moving coil actuator 100, 410 has been pressed into the housing 310, the latch 610 can be released again by pulling, and the mounting device 600 can be lifted off the moving coil actuator 100, 410.

[0087] The assembly device 600 can be mounted on any linear press tool. A simple hand press serves as an example. However, hydraulic or pneumatic presses in automated or collaborative production lines, such as those commonly used in transmission manufacturing, are also possible. The assembly device can also be equipped with the voice coil actuator 100, 410 manually or automatically, e.g., by a robot.

[0088] Fig. 10 shows steps of a method for disassembling a moving coil actuator 100, which is fixed by an interference fit in a recess (316) of a housing 310 of a device for changing gears of an electric drive. The moving coil actuator 100 does not necessarily have to have all the features of the moving coil actuator 100 of Fig. 1. However, the moving coil actuator 100 to which this method is applied comprises a cylindrical outer shell 140 which has at least the circumferential groove 145 on an outer side for applying a shaft retaining ring.

[0089] The method comprises applying S310 a ring component, e.g., a steel ring, with a plurality of threaded holes onto the moving coil actuator 100. The method further comprises securing S320 the steel ring by fixing the shaft retaining ring in the groove 145. The method further comprises inserting S330 a screw into each of the threaded holes so that each screw rests on the housing 310 at one end. The method further comprises loosening S340 the moving coil actuator 100 by screwing in the screws, in order to disassemble the moving coil actuator 100 from the housing 310 via the steel ring and the shaft retaining ring.

[0090] Fig. 11 illustrates the method for disassembling the moving coil actuator 100 of Fig. 10. Shown is a portion of a housing 310 into which the moving coil actuator 100 is pressed into a recess 316 (not visible). A ring component, here a steel ring 710, is already applied to the moving coil actuator 100. A shaft retaining ring 730 secures the steel ring 710 by engaging in the groove 145 (not visible) in the casing 140 of the moving coil actuator 100. In this exemplary embodiment, the steel ring 710 has three threaded holes 715. Three screws 720 are screwed into the threaded holes 715 and are supported on the housing 310. By further turning the screws 715, an axial force is applied between the housing 310 and the shaft retaining ring 710, which ultimately pulls the moving coil actuator 100 out of the housing 310. A guide of the moving coil actuator 100 can be added if required, but is already at least partially achieved by this method.

[0091] Fig. 12 shows steps of a method for sequentially activating at least two moving coil actuators 100, 410. The moving coil actuators do not necessarily have to have all the features of the moving coil actuator according to Fig. 1.

[0092] The moving coil actuators 100, 410 are each connected to an electronic switch 210. The electronic switches 210 are configured to allow activation of the respective moving coil actuator 100, 410 in an open state and to prevent activation in a closed state. The electronic switches 210 can, in particular, each comprise a MOSFET.

[0093] The method includes parallel energization S410 of the electronic switches 210 via a bridge circuit. The method further includes sequentially allowing S420 the energization of the moving coil actuators 100, 410 via the electronic switches 210 in order to activate the moving coil actuators 100, 410 sequentially.

[0094] Fig. 13 illustrates a reluctance force for the case of a non-energized moving coil actuator 100, in which a reluctance component 162 made of a ferro- or ferrimagnetic material, in particular iron, is applied to a coil body 160 at a plurality of axial positions, each extending in a circumferential direction.

[0095] In the illustrated embodiment, a total of six such reluctance components 162 are present, as shown in a lower part of the figure for three locking positions P1, P2, P3 of the rotor 110. The reluctance components 162 each span an angular interval of slightly more than 180° in the circumferential direction. They can also be designed as half rings. Furthermore, the reluctance components 162 are applied to the coil former 160, alternately offset by 180° in the circumferential direction. The reluctance components 162 are fixed on the coil former 160 in corresponding grooves of the coil former (coil former grooves).

[0096] The reluctance components 162 result in a curve 60 of the reluctance force over an axial position, or over a length of the coil former 160 or the plunger coil actuator 100. The curve 60 is shown in the upper part of the figure. The rotor 110 is movable along an axis in two opposite directions. The force shown moves the rotor 110 in one direction for positive values ​​and in the other direction for negative values. The rotor 110 is held stable at three locking positions P1, P2, P3 along the axis; each of these positions thus represents a local attractive fixed point with a vanishing reluctance force. For the movable component or the shift rod, the three locking positions P1, P2, P3 can correspond, for example, to positions for a first gear, a neutral position, and a second gear.

[0097] The arrangement of the reluctance components 162 shown in this figure has the particular advantage that the sum of the radial forces acting on the rotor 110 is zero, since the reluctance components 162 are installed rotated by 180°, thus canceling out the radial forces. Only a torque and the desired axial force are applied to the rotor 110.

[0098] Fig. 14 shows embodiments of two further arrangements of the reluctance components 162 on the coil body 160.

[0099] In the embodiment on the left, only four reluctance components 162 are mounted at four different axial positions. The reluctance components 162 each span approximately 180° of the angle in the circumferential direction. Again, the reluctance components 162 form pairs, whose partners are offset by 180° from each other. However, in contrast to the embodiment of the Fig. 13 does not occur in a strictly alternating sequence along the axis. However, even in the embodiment shown here, three locking positions P1, P2, P3 are obtained, with the reluctance components 162 that effect the corresponding locking position being indicated in the figure. The locking positions P1, P2, P3 can again correspond approximately to a first gear, a neutral position, and a second gear.

[0100] The example on the right has, like the example in Fig. 13 has six reluctance components 162. In this exemplary embodiment, however, the reluctance components 162 are not arranged in a strictly alternating manner in the axial direction, offset by 180°. Again, this results in three locking positions P1, P2, and P3, with the respective reluctance components 162 marked in the figure. The first gear (locking position P1) and the second gear (locking position P3) are determined by the upper reluctance components 162, and the neutral position (locking position P2) by the lower reluctance components 162.

[0101] Due to the arrangement of the reluctance components 162 shown in this figure, the rotor 110 experiences a radial force in each of the locking positions P1, P2, and P3. This can be advantageous because the radial force can push the rotor 110 in a specific direction against the coil body 160, thus causing additional static friction.

[0102] Fig. 15 illustrates an embodiment of the manufacturing method for a moving coil actuator 100. First, the coil body 160 is manufactured S510, which has a plurality of coil body grooves 165 at specific axial positions. Subsequently, reluctance components 162, here essentially semicircular (spanning 180° or slightly more in the circumferential direction) iron ring elements, are inserted S520 into the coil body grooves 165. The reluctance components 162 are axially positioned by the coil body grooves 165 and held captively by their clamping device. Subsequently, the coil 130 is fully automated, for example, according to the method described in Fig. 6 wound S110, S120.

[0103] The features of the invention disclosed in the description, the claims and the figures may be essential for the realization of the invention both individually and in any combination. LIST OF REFERENCE SYMBOLS 60 Course of a force 100 moving coil actuators 110 runners 120 magnetic component 130 coil 131, 132 coil sections 135 wire 140 cover 145 groove 150 sealing element 160 coil bodies 162 Reluctance component 165 Coil body groove 200 control unit 210 electronic switch 220 bridge switching device 230 electronic control unit 240 connecting device 241, 242, 243 connections 245 Safety circuit 300 Device for changing gears of an electric drive 310 housing 315 Opening 316 depression 410 conventional moving coil actuator 411 runners 412 permanent magnet 4131, 4132 coils 414 cover 415 screw flange 416 screws 420 conventional control unit 430 Device for changing gears 431 housing 432 shift rod 434 shift fork 440 locking device 442 ball-spring unit 501, 502 electric motors 510, 520 partial transmission 530 differential gear 540 wheel axles 550 switching mechanism 555 claw coupling 600 mounting device 610 bars 710 steel ring 715 threaded holes 720 screws 730 Shaft retaining ring A, B ends of a coil P1, P2, P3 locking positions S110, S120 Steps of a method for winding a wire for a moving coil actuator S210, S220 Steps of a method for assembling a moving coil actuator S310, S320, S330, S340 Steps of a method for disassembling a moving coil actuator S410, S420 Steps of a method for sequentially activating several moving coil actuators S510, S520 Steps of a method for manufacturing a moving coil actuator QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2015 226 351

[0007]

Claims

[1] A moving coil actuator (100) for a gearshift (300) for an electric drive, the moving coil actuator (100) comprising: a rotor (110) having a magnetic component (120) mounted thereon; and a coil (130) wound around a coil body (160), wherein a reluctance component (162) made of a ferromagnetic or ferrimagnetic material extending in a circumferential direction is applied to the coil body (160) at an axial position, which reluctance component exerts a reluctance force on the magnetic component (120) to lock the rotor (110) at an axial locking position (P1). [2] The moving coil actuator (100) according to claim 1, wherein at least one further axial position a further reluctance component (162) made of the ferro- or ferrimagnetic material is applied to the coil body (160), and wherein the reluctance component (162) and the further reluctance component (162) each extend at least over an angle of 180° in the circumferential direction and are arranged offset from one another by 180° in the circumferential direction in order to compensate for a radial force on the magnetic component (120). [3] The moving coil actuator (100) according to claim 1 or claim 2, wherein the reluctance component (162) and / or the further reluctance component (162) is / are each inserted into a coil body groove (165). [4] The moving coil actuator (100) according to any one of the preceding claims, wherein the moving coil actuator (100) comprises an outer shell (140) having at least one of the following features on an outer side: - a circumferential groove (145) for applying a shaft retaining ring, - a circumferential sealing element (150), - a common input and output for a wire (135) to supply current to the coil (130). [5] The moving coil actuator (100) according to one of the preceding claims, wherein the coil (130) has a plurality of coil sections (131, 132) along an axis, wherein when the coil (130) is energized, each coil section (131, 132) amplifies a force on the magnetic component (120) to cause a linear movement of the rotor (110); wherein the coil (130) is formed by a wire (135), wherein the wire, from a first end (A) of the coil (130), successively for each coil section (131, 132), forms a first winding in a winding direction associated with a respective coil section (131, 132), so that there is at least one change in the winding direction, and wherein the wire (135) forms, from a second end (B) of the coil (130), successively for each coil section (132, 131), a second winding in the winding direction associated with the respective coil section (131, 132) and exits the coil (130) at the first end (A) of the coil (130). [6] The moving coil actuator (100) according to any one of the preceding claims, wherein the magnetic component (120) is fixedly connected to the rotor (110). [7] A gearshift (300) for an electric drive, the gearshift (300) comprising: a housing (310) having a depression (316) with an opening (315) through which a movable component is guided; and the voice coil actuator (100) according to any one of the preceding claims, wherein the voice coil actuator (100) is further configured to move the component and is mounted in the depression (316). [8] The gearshift (300) according to claim 7, which comprises at least one further plunger coil actuator (100, 410) and a control unit (200) for activating at least two plunger coil actuators (100, 410), and the control unit (200) comprises: for each moving coil actuator (100, 410) an electronic switch (210) for activating and deactivating the respective moving coil actuator (100, 410); a bridge switching device (220) which is designed to be connected to a supply voltage and, when connected to the supply voltage, to provide a parallel current supply to the electronic switches (210); and an electronic control unit (230) which comprises a connecting device (240) with a connection (241, 242, 243) to each of the electronic switches (210) and which is designed to control the parallel current supply via the bridge switching device (220) and to activate or deactivate each of the at least two moving coil actuators (100, 410) individually via the connecting device (240) and the electronic switches (210). [9] The gearshift (300) according to claim 8, wherein the connecting device (240) comprises a safety circuit (245) which has exactly one AND gate and one NOR gate for each moving coil actuator (100, 410) and no other gates and is designed to allow activation of at most one moving coil actuator (100, 410) at any time. [10] The gearshift (300) according to one of claims 7 to 9, wherein the component is the rotor (110) of the plunger coil actuator (100).

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