Valve body assembly, stator unit, electric valve, air conditioner, method for manufacturing valve body assembly, and method for manufacturing stator unit

Abstract

A valve body assembly, a stator unit, an electric valve, an air conditioner, a manufacturing method of the valve body assembly, and a manufacturing method of the stator unit. In the electric valve, even in a case where a combination of the valve body assembly and the stator unit is different from information involved in measuring a flow rate, the flow rate can be accurately controlled. An electric valve (1) has a valve body assembly (5) having a rotor and a stator unit (6) having a stator. A valve body assembly label (18) attached to an outer surface of the valve body assembly (5) has printed thereon rotor-side correction information including information about an angle of misalignment of a magnetic pole of the rotor and a movable stopper. Also, a stator unit label (118) attached to an outer surface of the stator unit has printed thereon stator-side correction information including information about an angle of misalignment of a pole tooth of the stator and a positioning member.

Description

Technical Field

[0001] This invention relates to a valve body assembly for an electric valve, a stator unit for an electric valve, an electric valve having the valve body assembly and the stator unit, and an air conditioner having the electric valve. Furthermore, this invention relates to methods for manufacturing the valve body assembly and the stator unit. Background Technology

[0002] Patent Document 1 describes an electronic expansion valve as an example of a conventional electric valve. The electronic expansion valve is incorporated into an air conditioner. The electronic expansion valve includes a first refrigerant pipe, a second refrigerant pipe, a valve body, a valve core, and a stepper motor that moves the valve core according to the number of pulses. The valve body has a valve chamber connected to the first refrigerant pipe and a valve port connecting the valve chamber to the second refrigerant pipe. The valve core has a valve portion inserted into the valve port, and a variable throttling section is formed between the valve port and the valve portion. The electronic expansion valve uses the number of pulses from the stepper motor when the amount of fluid flowing through the valve port reaches a predetermined set value as the valve opening point. The electronic expansion valve is equipped with a barcode containing a measured value of the valve opening point obtained through the manufacturing process. Furthermore, the air conditioner uses the measured value of the valve opening point read from the barcode to control the electronic expansion valve.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent No. 5218694

[0006] The technical problem that the invention aims to solve

[0007] An electronic expansion valve has a valve body assembly and a stator unit. The valve body assembly includes a valve body, a conduit that engages with the valve body, and a rotor for moving the valve core. The stator unit has a stator. The rotor and stator constitute a stepper motor. Furthermore, the electronic expansion valve is temporarily disassembled into the valve body assembly and stator unit after the opening point is determined. During the air conditioner manufacturing process (e.g., after the conduit of the valve body assembly is connected to other piping of the air conditioner), the valve body assembly and stator unit are reassembled. At this time, the assembly of the valve body assembly and stator unit assembled in the air conditioner may differ from the assembly at the time of opening point determination. Therefore, in the electronic expansion valve assembled in the air conditioner, the measured value of the opening point read from the barcode may not match the actual opening point, making it impossible to accurately control the flow rate of refrigerant flowing in the electronic expansion valve. Summary of the Invention

[0008] Therefore, the object of the present invention is to provide an electric valve that can accurately control flow even when the combination of the valve body assembly and the stator unit is different from the combination when measuring the information involved in flow control, a valve body assembly for the electric valve, a stator unit for the electric valve, an air conditioner having an electric valve, a method for manufacturing the valve body assembly, and a method for manufacturing the stator unit.

[0009] Technical means for solving technical problems

[0010] To achieve the above objectives, one aspect of the present invention relates to a valve body assembly for an electric valve, comprising:

[0011] Valve body, which is provided with a valve port;

[0012] A rotor having multiple magnetic poles configured to rotate relative to the valve body;

[0013] A movable stop that is fixed relative to the rotor;

[0014] A fixed stop, which is fixed relative to the valve body and abuts against the movable stop, thereby restricting the rotation of the rotor in the valve-closing direction; and

[0015] The valve core changes the opening degree of the valve port as the rotor rotates.

[0016] Rotor-side correction information is attached to the outer surface of the valve body assembly. This rotor-side correction information includes information related to the rotor-side offset angle, which is the offset angle between the magnetic poles of the rotor and the movable stop.

[0017] In this invention, preferably,

[0018] The rotor and the stator of the stator unit together constitute a stepper motor.

[0019] The information related to the rotor-side offset angle is information representing the rotor-side correction pulse number Kr, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the rotor-side offset angle.

[0020] The rotor-side correction pulse number Kr is a relative increase or decrease in the number of pulses used by the valve body assembly when the rotor-side offset angle is 0.

[0021] When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formula (1) is satisfied.

[0022] -((N / 2)-1)≤Kr≤N / 2…(1)

[0023] Where Kr is an integer and N is an even natural number.

[0024] To achieve the above objectives, another aspect of the present invention relates to a stator unit for an electric valve, comprising:

[0025] Stator, which has multiple pole teeth; and

[0026] A positioning component for positioning the stator relative to the valve body assembly.

[0027] Stator-side correction information is attached to the outer surface of the stator unit. This stator-side correction information includes information related to the stator-side offset angle, which is the offset angle between the stator pole teeth and the positioning component.

[0028] In this invention, preferably,

[0029] The stator and the rotor of the valve body assembly together constitute a stepper motor.

[0030] The information related to the stator-side offset angle is information representing the stator-side correction pulse number Ks, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the stator-side offset angle.

[0031] The stator-side correction pulse number Ks is a relative increase or decrease in the number of pulses used by the stator unit with a stator-side offset angle of 0.

[0032] When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formula (2) is satisfied.

[0033] -((N / 2)-1)≤Ks≤N / 2…(2)

[0034] Where Ks is an integer and N is an even natural number.

[0035] To achieve the above objectives, another aspect of the present invention relates to an electric valve having a valve body assembly and a stator unit, wherein...

[0036] The valve body assembly includes: a valve body having a valve port; a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates.

[0037] The stator unit includes: a stator having a plurality of pole teeth; and a positioning component for positioning the stator relative to the valve body assembly.

[0038] Rotor-side correction information is affixed to the outer surface of the valve body assembly. This rotor-side correction information includes information related to the rotor-side offset angle, which is the offset angle between the magnetic poles of the rotor and the movable stop.

[0039] Stator side correction information is attached to the outer surface of the stator unit. This stator side correction information includes information related to the stator side offset angle, which is the offset angle between the pole teeth of the stator and the positioning component.

[0040] In this invention, preferably,

[0041] The rotor and the stator together form a stepper motor.

[0042] The information related to the rotor-side offset angle is information representing the rotor-side correction pulse number Kr, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the rotor-side offset angle.

[0043] The rotor-side correction pulse number Kr is a relative increase or decrease in the number of pulses used by the valve body assembly when the rotor-side offset angle is 0.

[0044] The information related to the stator-side offset angle is information representing the stator-side correction pulse number Ks, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the stator-side offset angle.

[0045] The stator-side correction pulse number Ks is a relative increase or decrease in the number of pulses used by the stator unit with a stator-side offset angle of 0.

[0046] When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formulas (1) and (2) are satisfied.

[0047] -((N / 2)-1)≤Kr≤N / 2…(1)

[0048] -((N / 2)-1)≤Ks≤N / 2…(2)

[0049] Where Kr and Ks are integers, and N is an even natural number.

[0050] To achieve the above objectives, another aspect of the present invention relates to an air conditioner that includes the aforementioned electric valve.

[0051] The electric valve is configured to be controlled based on the rotor-side correction information and the stator-side correction information.

[0052] To achieve the above objectives, another aspect of the present invention relates to an air conditioner that includes the aforementioned electric valve.

[0053] The electric valve is configured to be controlled based on a correction pulse number K, which is calculated using the following formulas (3a), (3b), and (3c).

[0054] K = Kr + Ks…(3a)

[0055] Where -((N / 2)-1)≤Kr+Ks≤N / 2

[0056] K = Kr + Ks - N…(3b)

[0057] Where Kr+Ks>N / 2

[0058] K = Kr + Ks + N…(3c)

[0059] Where -((N / 2)-1)>Kr+Ks.

[0060] To achieve the above objectives, another aspect of the present invention relates to a method for manufacturing a valve body assembly used in an electric valve, wherein...

[0061] A valve body assembly without rotor-side correction information is fabricated. This valve body assembly includes: a valve body having a valve port; a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates.

[0062] Prepare a reference stator unit, which includes: a stator having a plurality of pole teeth; and a positioning member for positioning the stator relative to the valve body assembly, wherein the offset angle between the pole teeth of the stator and the positioning member is 0°.

[0063] The valve body assembly without rotor-side correction information is combined with the reference stator unit, and a stepper motor is formed by the rotor and the stator.

[0064] When the rotor is rotated in the valve-opening direction, a pulse train containing N pulses distributed in the order of [0] to [N-1] is input to the stepper motor in reverse order once or multiple times, and the rotor is rotated in the valve-closing direction until the movable stop abuts against the fixed stop.

[0065] After the movable stop abuts against the fixed stop, when inputting up to pulse [0], the reverse sequence of pulse input is stopped. Then, the pulse train is input to the stepper motor once or multiple times in forward sequence starting from pulse [0], and the rotor-side valve opening pulse count is counted. This rotor-side valve opening pulse count is the number of pulses input until the valve port becomes the opening degree for the reference flow of fluid, or until the opening degree becomes the opening degree where the flow rate changes with the increment of one pulse input.

[0066] The rotor-side correction information is generated based on the rotor-side opening valve pulse count. The rotor-side correction information includes information related to the misalignment angle between the rotor's magnetic poles and the movable stop.

[0067] The rotor-side correction information, generated based on the number of valve opening pulses on the rotor side, is attached to the outer surface of the valve body assembly that does not have rotor-side correction information.

[0068] To achieve the above objectives, another aspect of the present invention relates to a method for manufacturing a stator unit used in an electric valve, wherein...

[0069] A stator unit without stator-side correction information is fabricated. This stator unit comprises: a stator having multiple pole teeth; and a positioning component for positioning the stator relative to the valve body assembly.

[0070] Prepare a reference valve body assembly, which includes: a valve body having a valve port; a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates, wherein the offset angle between the magnetic poles of the rotor and the movable stop is 0°.

[0071] The stator unit without stator-side correction information is combined with the reference valve body assembly, and a stepper motor is formed by the rotor and the stator.

[0072] When the rotor is rotated in the valve-opening direction, a pulse train containing N pulses distributed in the order of [0] to [N-1] is input to the stepper motor in reverse order once or multiple times, and the rotor is rotated in the valve-closing direction until the movable stop abuts against the fixed stop.

[0073] After the movable stop abuts against the fixed stop, when inputting up to pulse [0], the reverse sequence of pulse train input is stopped. Then, the pulse train is input to the stepper motor once or multiple times in forward sequence starting from pulse [0], and the stator-side valve opening pulse count is counted. This stator-side valve opening pulse count is the number of pulses input until the valve port becomes the opening degree for the reference flow of fluid, or until the opening degree becomes the opening degree where the flow rate changes with the increment of one pulse input.

[0074] The stator-side correction information is generated based on the stator-side valve opening pulse count. This stator-side correction information includes information regarding the misalignment angle between the stator pole teeth and the positioning component.

[0075] The stator side correction information, generated based on the number of stator side valve opening pulses, is attached to the outer surface of the stator unit that does not have stator side correction information.

[0076] The effects of the invention

[0077] According to the present invention, rotor-side correction information, including information concerning the misalignment angle (rotor-side misalignment angle) between the rotor's magnetic poles and the movable stop, is affixed to the outer surface of the valve body assembly. Stator-side correction information, including information concerning the misalignment angle (stator-side misalignment angle) between the stator's pole teeth and the positioning member, is affixed to the outer surface of the stator unit. By doing so, when the valve body assembly and the stator unit are combined to form an electric valve, the opening position of the electric valve can be accurately determined based on the rotor-side correction information and stator-side correction information affixed to their respective outer surfaces. Therefore, the flow rate of the refrigerant flowing through the electric valve can be accurately controlled. Attached Figure Description

[0078] Figure 1 This is a front view of the electric valve according to an embodiment of the present invention.

[0079] Figure 2 yes Figure 1 The front view of the valve body assembly of the electric valve.

[0080] Figure 3 yes Figure 2 A cross-sectional view of the valve body assembly.

[0081] Figure 4 yes Figure 2A side view of the guide bushing of the valve body assembly.

[0082] Figure 5 It means Figure 2 A diagram showing the stop components of the valve body assembly.

[0083] Figure 6 It means Figure 2 A diagram of the valve shaft retainer of the valve body assembly.

[0084] Figure 7 yes Figure 2 A top view of the valve body assembly, including the valve shaft retainer and the rotor (rotor side offset angle α = 0).

[0085] Figure 8 yes Figure 2 A top view of the valve body assembly, including the valve shaft retainer and the rotor (rotor side offset angle α≠0).

[0086] Figure 9 yes Figure 1 A cross-sectional view of the stator unit of the electric valve.

[0087] Figure 10 It means Figure 9 A diagram of the positioning components of the stator unit.

[0088] Figure 11 It is a schematic representation Figure 9 A diagram showing the positional relationship between the stator pole teeth and the positioning components of the stator unit (stator side offset angle β = 0).

[0089] Figure 12 It is a schematic representation Figure 9 A diagram showing the positional relationship between the stator pole teeth and the positioning components of the stator unit (stator-side offset angle β≠0).

[0090] Figure 13 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth during the operation of the electric valve, as well as the pulse input to the stator (when pulse P[0] is input).

[0091] Figure 14 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is activated, as well as the pulse input to the stator (when pulse P[1] is input).

[0092] Figure 15 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (when pulse P[2] is input).

[0093] Figure 16 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (when pulse P[3] is input).

[0094] Figure 17 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (pulse P[4] when input).

[0095] Figure 18 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (pulse P[5] when input).

[0096] Figure 19 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (pulse P[6] when input).

[0097] Figure 20 It is a schematic representation Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth when the electric valve is in operation, as well as the pulse input to the stator (pulse P[7] when input).

[0098] Figure 21 This is an explanation Figure 2 A cross-sectional view of the manufacturing method of the valve body assembly (showing the combination of the valve body, guide bushing and stop component).

[0099] Figure 22 This is an explanation Figure 2 A cross-sectional view of the manufacturing method of the valve body assembly (showing the case of further assembly of valve shaft, valve core, valve closing spring and washer).

[0100] Figure 23 This is an explanation Figure 2 A cross-sectional view of the manufacturing method of the valve body assembly (showing the case where the valve shaft retainer, rotor, and fixture are further combined).

[0101] Figure 24 This is an explanation Figure 2 A cross-sectional view of the manufacturing method of the valve body assembly (showing the state in which the movable stop is abutted against the fixed stop).

[0102] Figure 25 This is an explanation Figure 2 A top view of the manufacturing method of the valve body assembly (showing) Figure 24 (state).

[0103] Figure 26 This is an explanation Figure 2 A view of the manufacturing method of the valve body assembly (showing the state in which the rotor has been rotated 180 degrees from the state where the movable stop is against the fixed stop to the valve opening direction).

[0104] Figure 27 This is an explanation Figure 2 A top view of the manufacturing method of the valve body assembly (showing) Figure 26 (state).

[0105] Figure 28 It means Figure 1 The table shows the relationship between the positional relationship of the rotor's magnetic poles and the movable stop in the origin setting state of the electric valve and the corresponding number of rotor-side correction pulses.

[0106] Figure 29 It means Figure 1 The table shows the relationship between the positional relationship of the stator pole teeth and the fixed stop in the origin setting state of the electric valve and the corresponding relationship between the number of stator-side correction pulses.

[0107] Figure 30 It has Figure 1 A schematic diagram of the structure of an air conditioner with an electric valve.

[0108] Figure 31 It means based on Figure 28 Rotor-side correction pulse count and Figure 29 The table shows the number of correction pulses for the electric valve on the stator side.

[0109] Figure 32 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = 0).

[0110] Figure 33 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = 1).

[0111] Figure 34 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = 2).

[0112] Figure 35 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = 3).

[0113] Figure 36 It means Figure 1A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = 4).

[0114] Figure 37 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = -3).

[0115] Figure 38 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = -2).

[0116] Figure 39 It means Figure 1 A diagram showing the valve opening action of an electric valve starting from the origin setting state (correction pulse number K = -1).

[0117] Symbol Explanation

[0118] 1…Electric valve, 1S…Reference electric valve, 5…Valve body assembly, 5S…Reference valve body assembly, 6…Stator unit, 6a…Inner circumferential surface, 6S…Reference stator unit, 10…Valve body, 11…Valve chamber, 12, 13…Conduit, 14…Valve port, 15…Valve seat, 16…Matching hole, 16a…Positioning plane, 18…Valve body assembly label, 20…Housing, 21…Ring component, 30…Valve shaft, 31…Upper end, 32…Spring support part, 35…Fixing part, 36…Fixing part, 37…Flange part, 38…Return spring, 40…Valve core, 50…Guide bushing, 51…Matching part, 51a…D-shaped cutting plane, 53…External thread, 53a…Imaginary lower end position, 60…Stop component, 61…Stop body, 63…Internal thread, 63a…Imaginary lower end position, 64…Fixed stop component, 65…Fixed stop surface, 70…Valve shaft retainer, 71…Peripheral wall portion, 71a…Protrusion, 72…Upper wall portion, 72a…Valve shaft insertion hole, 73…Internal thread, 74…Modible stop component, 75…Modible stop surface, 76…Washer, 77…Closing valve spring, 80…Rotor, 81…Mounting hole, 81a…Recess, 85…Reference magnetic pole, 9 0…Stator, 91…A-phase stator, 92…Magnetic yoke, 92a…Downward-facing pole tooth, 92b…Upward-facing pole tooth, 93…Coil, 95…Reference pole tooth, 96…B-phase stator, 97…Magnetic yoke, 97a…Downward-facing pole tooth, 97b…Upward-facing pole tooth, 98…Coil, 100…Cover, 101…Cover body, 102…Connector cover, 103…Connector, 110…Positioning component, 111…Plate section, 112…Arm section, 112a…Clamping section, 118…Stator unit label, 200…Air conditioner, 201…Compressor, 202…Flow path switching valve, 2 03…Outdoor heat exchanger, 204…Control valve, 205…Indoor heat exchanger, 210…Control device, Jr…Rotor side correction information, Js…Stator side correction information, α…Rotor side offset angle, β…Stator side offset angle, Cr…Rotor side valve opening pulse count, Cs…Stator side valve opening pulse count, C…Valve opening pulse count, CS…Reference valve opening pulse count, K…Correction pulse count, Kr…Rotor side correction pulse count, Ks…Stator side correction pulse count, VS…Reference quantity when opening valve, P…Pulse, S…Pulse train, F…Extension line, G…Center line, L…Axis, M…Axis. Detailed Implementation

[0119] The following is for reference Figures 1-12 The structure of an electric valve according to one embodiment of the present invention will be described. The electric valve 1 of this embodiment is used, for example, to adjust the refrigerant flow rate in the refrigeration cycle of an air conditioner.

[0120] Figure 1 This is a front view of the electric valve according to an embodiment of the present invention. Figure 2 yes Figure 1The front view of the valve body assembly of the electric valve. Figure 3 yes Figure 2 A cross-sectional view of the valve body assembly. Figure 4 yes Figure 2 A side view of the guide bushing of the valve body assembly. Figure 5 It means Figure 2 A diagram showing the stop components of the valve body assembly. Figure 5 (a) is a three-dimensional view of the stop component. Figure 5 (b) is a top view of the stop component. Figure 6 It means Figure 2 A diagram of the valve shaft retainer of the valve body assembly. Figure 6 (a) is a three-dimensional view of the valve shaft retainer. Figure 6 (b) is a top view of the valve shaft retainer. Figure 7 and Figure 8 yes Figure 2 A top view of the valve body assembly, including the valve shaft retainer and rotor. Figure 7 This indicates the case where the rotor-side offset angle α is 0. Figure 8 This indicates the case where the rotor-side offset angle α is not 0. Figure 9 yes Figure 1 A cross-sectional view of the stator unit of the electric valve. Figure 10 It means Figure 9 A diagram of the positioning components of the stator unit. Figure 10 (a) is a three-dimensional view of the positioning component. Figure 10 (b) is a side view of the positioning component. Figure 11 , Figure 12 It is a schematic representation Figure 9 A diagram showing the positional relationship between the stator pole teeth and the positioning components of the stator unit. Figure 11 This indicates the case where the stator side offset angle β is 0. Figure 12 This indicates the case where the stator side offset angle β is not 0.

[0121] exist Figure 1 The symbol represents the electric valve 1 in this embodiment. The electric valve 1 has a valve body assembly 5 and a stator unit 6.

[0122] exist Figure 2 , Figure 3 The valve body assembly 5 is indicated in the image. The valve body assembly 5 includes a valve body 10, a housing 20, a valve shaft 30, a valve core 40, a guide bushing 50, a stop component 60, a valve shaft retainer 70, and a rotor 80. A valve body assembly label 18 is affixed to the outer surface of the valve body assembly 5.

[0123] The valve body 10 has a cylindrical shape. A valve chamber 11 is provided in the valve body 10. A conduit 12 extending to the left and a conduit 13 extending downward are installed in the valve body 10. The conduit 12 is connected to the valve chamber 11. The conduit 13 is connected to the valve chamber 11 via a valve port 14. A valve seat 15 is provided in the valve body 10, which is configured to surround the valve port 14. In addition, a fitting hole 16 is provided in the valve body 10. The inner peripheral surface of the fitting hole 16 has a positioning plane 16a facing to the left. The axis L passing through the valve body 10 intersects the axis M passing through the conduit 12 at a right angle.

[0124] A valve body assembly label 18 is affixed to the outer surface of the valve body 10. Rotor-side calibration information Jr is printed on the valve body assembly label 18. The rotor-side calibration information Jr will be described later. Alternatively, the rotor-side calibration information Jr can be directly printed on the outer peripheral surface of the valve body 10, or laser-engraved on the outer peripheral surface of the valve body 10. Alternatively, the valve body assembly label 18 can also be affixed to the outer surface of the housing 20.

[0125] The housing 20 has a cylindrical shape with its upper end blocked. The housing 20 is engaged with the upper end of the valve body 10 via a ring member 21.

[0126] The valve shaft 30 has a slender cylindrical shape. A valve core 40 is integrally provided at the lower end of the valve shaft 30.

[0127] The valve core 40 has a generally conical shape with a diameter that decreases from top to bottom. The top end of the valve core 40 is inserted into the valve port 14. A variable throttling section is formed between the valve core 40 and the valve port 14. The valve core 40 is in contact with the valve seat 15 when the valve is closed. Alternatively, the electric valve 1 can also be configured such that the valve core 40 is not in contact with the valve seat 15 when the valve port 14 is at its minimum opening (non-closing valve configuration).

[0128] exist Figure 4 The guide bushing 50 is indicated in the figure. The guide bushing 50 has a generally cylindrical shape. A fitting portion 51 is provided at the lower part of the guide bushing 50. The fitting portion 51 has a D-shaped cut plane 51a formed by cutting a portion of its outer peripheral surface into a planar shape. The fitting portion 51 is pressed into the fitting hole 16 of the valve body 10. By aligning the D-shaped cut plane 51a with the positioning plane 16a of the fitting hole 16, the axis of the valve body 10 and the axis of the guide bushing 50 are aligned on the axis L, and the valve body 10 and the guide bushing 50 are accurately positioned about the axis L. The guide bushing 50 is configured such that when viewed from the axis L direction, the width direction of the D-shaped cut plane 51a ( Figure 4The center of the valve shaft 30 (in the left-right direction) is through which the axis M passes. The valve shaft 30 is inserted into the guide bushing 50. The guide bushing 50 supports the valve shaft 30 so that it can move along the axis L. In addition, in the electric valve 1, if the offset of the guide bushing 50 about the axis L is suppressed to less than a specified value (e.g., less than ±1 pulse), then the D-shaped cutting plane 51a and the positioning plane 16a of the fitting hole 16 are not necessary. For example, it is also possible to use a structure in which the fitting part 51 is set to a cylindrical shape without the D-shaped cutting plane 51a, the fitting hole 16 is set to a cylindrical shape without the positioning plane 16a, and the cutting start position (lower end position, upper end position) of the external thread 53 (described later) is used as a reference position (mark) about the axis L for alignment.

[0129] An external thread 53 is provided on the outer peripheral surface of the guide bushing 50 at a position above the mating portion 51. The external thread 53 is formed such that the imaginary lower end position 53a of the external thread 53 extending to the upper end of the mating portion 51 coincides with the center of the width direction of the D-shaped cutting plane 51a.

[0130] exist Figure 5 (a) and (b) indicate the stop member 60. The stop member 60 integrally comprises a stop body 61 and a fixed stop member 64. The stop body 61 has a cylindrical shape. An internal thread 63 is provided on the inner circumferential surface of the stop body 61. The fixed stop member 64 protrudes radially outward from the stop body 61. The fixed stop member 64 has a fixed stop surface 65. The fixed stop surface 65 is formed as a plane along the radial direction of the stop body 61. Figure 5 As shown in (b), the fixed stop surface 65 is formed to face counterclockwise around the axis L when viewed from above. The internal thread 63 is formed such that the imaginary lower end position 63a of the internal thread 63 extending to the lower end of the stop body 61 is located on a plane including the fixed stop surface 65.

[0131] By screwing the internal thread 63 into the external thread 53 until the stop body 61 abuts against the fitting portion 51 of the guide bushing 50, the stop member 60 is fixed to the guide bushing 50. Thus, the fixed stop member 64 is fixed relative to the valve body 10. When the stop member 60 is fixed to the guide bushing 50, the imaginary lower end position 53a of the external thread 53 coincides with the imaginary lower end position 63a of the internal thread 63. Therefore, the fixed stop surface 65 is positioned at the center of the width direction of the D-shaped cutting plane 51a, and when viewed from the axis L direction, the fixed stop surface 65 is precisely aligned with the axis M. Alternatively, in the electric valve 1, the fixed stop surface 65 and the axis M can be designed to be offset.

[0132] exist Figure 6(a) and (b) indicate the valve shaft retainer 70. The valve shaft retainer 70 has a cylindrical shape with its upper end blocked. The valve shaft retainer 70 integrally has a peripheral wall portion 71, an upper wall portion 72, and a movable stop 74. The peripheral wall portion 71 has a cylindrical shape. Three protrusions 71a protruding radially outward are provided on the peripheral wall portion 71. The three protrusions 71a are arranged at equal intervals (120-degree intervals) in the circumferential direction. An internal thread 73 is provided on the inner circumferential surface of the peripheral wall portion 71. The internal thread 73 engages with the external thread 53 of the guide bushing 50. The upper wall portion 72 is connected to the upper end of the peripheral wall portion 71. A valve shaft insertion hole 72a is provided in the center of the upper wall portion 72. The movable stop 74 protrudes radially outward from near the lower end of the peripheral wall portion 71. A movable stop surface 75 is provided on the movable stop 74. The movable stop surface 75 is formed as a planar shape along the radial direction of the peripheral wall portion 71. For example... Figure 6 As shown in (b), the movable stop surface 75 is formed so that when viewed from above, it faces clockwise around axis L.

[0133] The upper end 31 of the valve shaft 30 is inserted into the valve shaft insertion hole 72a of the valve shaft retainer 70 in a manner that allows it to move along the axis L. A fixing member 35 is mounted on the upper end 31 of the valve shaft 30. The fixing member 35 integrally has a fixing portion 36 and a flange portion 37. The fixing portion 36 has a stepped cylindrical shape. The upper end 31 of the valve shaft 30 is inserted into the fixing portion 36. The fixing portion 36 is welded to the upper end 31. The flange portion 37 is connected to the lower end of the fixing portion 36. A return spring 38 is disposed on the outside of the fixing member 35. A washer 76 is disposed on the lower surface of the upper wall portion 72 of the valve shaft retainer 70, and a valve closing spring 77 is disposed between the washer 76 and the spring support portion 32 of the valve shaft 30. The valve closing spring 77 is a compression coil spring that presses the valve shaft 30 downward.

[0134] exist Figure 7 The rotor 80, when combined with the valve shaft retainer 70, is shown in the image. The rotor 80 has a cylindrical shape and multiple magnetic poles. In this embodiment, the rotor 80 has 12 N poles and 12 S poles. The N and S poles are arranged alternately in the circumferential direction. A mounting hole 81 is provided on the inner side of the rotor 80. Three recesses 81a, corresponding to three protrusions 71a of the valve shaft retainer 70, are provided in the mounting hole 81. The mounting hole 81 allows the valve shaft retainer 70 to engage. The valve shaft retainer 70 and the rotor 80 are combined in a coaxial manner.

[0135] like Figure 7As shown, when the offset angle (referred to as "rotor-side offset angle α") between the magnetic poles of rotor 80 and movable stop 74 about the axis is 0, the extension line F extending radially along movable stop surface 75 passes through the center of reference magnetic pole 85 of rotor 80. In the accompanying drawings, the reference magnetic pole 85 is marked with a black dot. The valve body assembly 5 with a rotor-side offset angle α of 0, prepared for manufacturing stator unit 6, is referred to as "reference valve body assembly 5S". Furthermore, depending on the dimensional accuracy or assembly accuracy of the parts, there may be cases where the magnetic poles of rotor 80 and movable stop 74 are misaligned about the axis (α≠0). Figure 8 The image shows an example of a valve shaft retainer 70 and a rotor 80 with a rotor-side offset angle α that is not 0.

[0136] exist Figure 9 The stator unit 6 is indicated in the image. The stator unit 6 includes a stator 90, a cover 100, and a positioning component 110. A stator unit label 118 is affixed to the outer surface of the stator unit 6. Figure 1 ).

[0137] The stator 90 has a cylindrical shape. The stator 90 and the rotor 80 constitute a stepper motor. The stator 90 has an A-phase stator 91 and a B-phase stator 96.

[0138] The A-phase stator 91 has a magnetic yoke 92. Coil wire constituting a coil 93 is wound around the magnetic yoke 92. The magnetic yoke 92 has a plurality of downward-facing pole teeth 92a and a plurality of upward-facing pole teeth 92b, which are claw-type pole teeth. The downward-facing pole teeth 92a have pointed tips pointing downwards. The upward-facing pole teeth 92b have pointed tips pointing upwards. In this embodiment, the magnetic yoke 92 has 12 downward-facing pole teeth 92a and 12 upward-facing pole teeth 92b. The downward-facing pole teeth 92a and upward-facing pole teeth 92b are arranged in a staggered pattern in the circumferential direction.

[0139] The B-phase stator 96 has the same structure as the A-phase stator 91. The B-phase stator 96 has a magnetic yoke 97. Coil wire constituting the coil 98 is wound around the magnetic yoke 97. The magnetic yoke 97 has a plurality of downward-facing pole teeth 97a and a plurality of upward-facing pole teeth 97b, which are claw-type pole teeth. The downward-facing pole teeth 97a have pointed tips pointing downwards. The upward-facing pole teeth 97b have pointed tips pointing upwards. In this embodiment, the magnetic yoke 97 has 12 downward-facing pole teeth 97a and 12 upward-facing pole teeth 97b. The downward-facing pole teeth 97a and the upward-facing pole teeth 97b are arranged in a staggered pattern in the circumferential direction.

[0140] Phase A stator 91 and phase B stator 96 are arranged coaxially and overlapped along axis L. Phase B stator 96 is configured relative to phase A stator 91 such that it is offset by half the angle between the downward-facing pole teeth 97a and the upward-facing pole teeth 97b around axis L. In this embodiment, the electric valve 1 is configured such that when 96 pulses are input to phase A stator 91 and phase B stator 96, rotor 80 rotates 360 degrees. Rotor 80 rotates 3.75 degrees per pulse.

[0141] The cover 100 is made of synthetic resin. The cover 100 has a cap shape. A stator 90 is disposed inside the cover 100. The cover 100, together with the pole teeth of the A-phase stator 91 and the pole teeth of the B-phase stator 96, forms the inner circumferential surface 6a of the stator unit 6. The diameter of the inner circumferential surface 6a of the stator unit 6 is the same as the outer diameter of the housing 20. The inner side of the inner circumferential surface 6a of the stator unit 6 is into which the housing 20 is inserted. The stator unit 6 is disposed outside the housing 20. The pole teeth of the A-phase stator 91 and the pole teeth of the B-phase stator 96 are arranged radially opposite to the magnetic poles of the rotor 80 via the housing 20. The cover 100 has a cover body portion 101 and a connector cover portion 102. A connector 103 is disposed inside the connector cover portion 102.

[0142] A stator unit label 118 is affixed to the outer surface of the cover 100. Stator side correction information Js is printed on the stator unit label 118. The stator side correction information Js will be described later. Alternatively, the stator side correction information Js can be directly printed on the outer surface of the cover 100, or laser-engraved on the outer peripheral surface of the cover 100.

[0143] exist Figure 10 The center indicates the positioning component 110. The positioning component 110 integrally includes a flat plate portion 111 and arms 112, 112. The flat plate portion 111 has a rectangular plate shape. The flat plate portion 111 is fixed to the lower end of the cover 100. The arms 112, 112 have a corrugated plate shape. The arms 112, 112 extend from the flat plate portion 111 in the width direction (…). Figure 10 The opposite sides of (b) extend downwards in the left-right direction. Arms 112, 112 have arc-shaped clamping portions 112a, 112a. Arms 112, 112 are elastically deformable in the width direction of the flat plate 111, and clamping portions 112a, 112a clamp and hold the guide tube 12. The positioning member 110 is configured such that, when viewed from the axis L direction, the center line G of the flat plate 111 in the width direction is highly aligned with the axis M.

[0144] like Figure 11As shown, when the offset angle (referred to as "stator-side offset angle β") between the pole teeth of the stator 90 and the positioning member 110 around the axis is 0, the center line G of the flat plate portion 111 of the positioning member 110 passes through the center of the reference pole tooth 95. In the accompanying drawings, the reference magnetic pole 95 is marked with a black dot. The stator unit 6 with a stator-side offset angle β of 0, prepared for manufacturing the valve body assembly 5, is referred to as the "reference stator unit 6S". Furthermore, depending on the dimensional accuracy or assembly accuracy of the parts, there may be a case where the pole teeth of the stator 90 are misaligned with the positioning member 110 around the axis (β≠0). Figure 12 The image shows an example of a stator 90 and a positioning component 110 where the stator side offset angle β is not 0.

[0145] The housing 20 of the valve body assembly 5 is embedded inside the stator unit 6. The conduit 12 of the valve body assembly 5 is connected to the arm 112, clamping portion 112a, and clamping portion 112a of the positioning member 110 of the stator unit 6. Thus, the valve body assembly 5 and the stator unit 6 are combined to form the electric valve 1. In the electric valve 1, when viewed from the axis L, the center line G of the fixed stop surface 65 and the positioning member 110 is aligned with the axis M with high precision. Therefore, the stator-side offset angle β can be regarded as the offset angle between the pole teeth of the stator 90 and the fixed stop member 64.

[0146] In addition, in the electric valve 1, the valve body 10, housing 20, valve shaft 30, valve core 40, guide bushing 50, stop member 60 (stop member body 61), valve shaft retainer 70 (peripheral wall portion 71), rotor 80, and stator 90 (A-phase stator 91 and B-phase stator 96) are configured such that their respective central axes are aligned with axis L.

[0147] Next, refer to Figures 13-20 An example of the operation of electric valve 1 will be explained.

[0148] Figures 13-20 It means Figure 1 The diagram shows the positional relationship between the rotor's magnetic poles and the stator's pole teeth during the operation of the electric valve, as well as the pulses input to the stator. Figures 13-20 This indicates the state of the stator when it is input pulses P[0] to P[7].

[0149] In the electric valve 1, a pulse train S consisting of N pulses is input to the A-phase stator 91 and B-phase stator 96 of the stator 90 constituting the stepper motor. In this embodiment, N = 8, and the pulse train S contains eight pulses P distributed in the order of [0] to [7]. One pulse P contains a signal input to the A-phase stator 91 and a signal input to the B-phase stator 96.

[0150] In electric valve 1, when pulse train S is input to stator 90 in the order of pulses P[0] to P[7] (positive sequence), rotor 80 rotates in the valve opening direction. If pulse P[7] is input, then pulse P[0] is returned, and pulses P[0] to P[7] are input again. That is, electric valve 1 repeatedly inputs pulse train S in positive sequence when opening the valve. Figures 13-20 The diagram illustrates the situation where the rotor 80 rotates in the valve opening direction when pulses P[0] to P[7] are input to phase A stator 91 and phase B stator 96 in positive order.

[0151] When the rotor 80 rotates in the valve closing direction, the valve shaft retainer 70 also rotates. Through the threaded feed action of the internal thread 73 of the valve shaft retainer 70 and the external thread 53 of the guide bushing 50, the valve shaft retainer 70 moves upward. The retainer 35 is pressed upward through the upper wall portion 72 of the valve shaft retainer 70. As a result, the valve shaft 30 and the valve core 40 move upward. Thus, as the rotor 80 rotates in the valve opening direction, the valve core 40 separates from the valve seat 15, and the opening degree of the valve port 14 is adjusted.

[0152] Alternatively, in electric valve 1, when pulse train S is input to stator 90 in the order of pulses P[7] to P[0] (reverse order), rotor 80 rotates in the valve closing direction. If pulse P[0] is input, then pulse P[7] is returned, and pulses P[7] to P[0] are input again. That is, electric valve 1 repeatedly inputs pulse train S in reverse order when closing the valve.

[0153] When the rotor 80 rotates in the valve-closing direction, the valve shaft retainer 70 also rotates. Through the threaded feed action of the internal thread 73 of the valve shaft retainer 70 and the external thread 53 of the guide bushing 50, the valve shaft retainer 70 moves downward. The valve shaft 30 is pressed downward by the valve-closing spring 77, which is supported by the washer 76 on the upper wall 72 of the valve shaft retainer 70. As a result, the valve shaft 30 and the valve core 40 move downward, and the valve core 40 contacts the valve seat 15. Thus, as the rotor 80 rotates in the valve-closing direction, the valve core 40 contacts the valve seat 15, and the valve port 14 is closed.

[0154] After the valve core 40 contacts the valve seat 15, when the electric valve 1 is further input to the stator 90 in reverse sequence of the pulse train S, the rotor 80 rotates further in the valve closing direction. At this time, since the valve core 40 is in contact with the valve seat 15, the valve shaft 30 and the valve core 40 do not move downward, and the valve shaft retainer 70 moves further downward while compressing the valve closing spring 77. Then, the movable stop surface 75 abuts against the fixed stop surface 65, and the rotation of the valve shaft retainer 70 and the rotor 80 is restricted. Thus, the downward movement of the valve shaft retainer 70 stops.

[0155] Then, with the movable stop surface 75 abutting against the fixed stop surface 65, the final pulse P[0] is input and the reverse sequence of pulse train S is stopped. At this time, in electric valve 1, if the rotor side offset angle α is 0 and the stator side offset angle β is 0 (α=0, β=0), then as follows Figure 13 As shown, when viewed from the axis L direction, the fixed stop surface 65 and the movable stop surface 75 are aligned with the axis M, and the center of the reference magnetic pole 85 and the center of the reference pole tooth 95 are arranged on the axis M.

[0156] Next, refer to Figures 21-27 An example of the manufacturing method of valve body assembly 5 will be described.

[0157] Figures 21-27 This is an explanation Figure 2 A diagram illustrating the manufacturing method of the valve body assembly. Figure 21 It is a cross-sectional view showing the combination valve body, guide bushing, and stop components. Figure 22 This is a cross-sectional view showing the further assembly of the valve shaft, valve core, valve closing spring, and washer. Figure 23 This is a cross-sectional view showing the further combination of the valve shaft retainer, rotor, and fixing components. Figure 24 and Figure 25 This indicates the state in which the movable stop is pressed against the fixed stop. Figure 24 It is a sectional view. Figure 25 It is a top view. Figure 26 and Figure 27 Indicates from Figure 24 and Figure 25 The state shown indicates that the rotor has been rotated 180 degrees in the direction of valve opening. Figure 26 It is a sectional view. Figure 27 It is a top view.

[0158] like Figure 21 As shown, conduits 12 and 13 are joined to valve body 10. At this time, axis L intersects axis M precisely at a right angle. Then, the positioning plane 16a of fitting hole 16 is aligned with the D-shaped cut plane 51a of guide bushing 50, and the fitting portion 51 of guide bushing 50 is pressed into fitting hole 16. Guide bushing 50 is configured such that when viewed from axis L, the width direction of D-shaped cut plane 51a ( Figure 4 The center of the guide bushing (in the left-right direction) is through which the axis M passes. The internal thread 63 of the stop member 60 is screwed into the external thread 53 of the guide bushing 50 until the stop body 61 of the stop member 60 abuts against the fitting portion 51 of the guide bushing 50, thus fixing the stop member 60 to the guide bushing 50. Therefore, the fixed stop surface 65 is aligned with the axis M when viewed from the axis L direction.

[0159] like Figure 22As shown, the valve shaft 30 is inserted into the guide bushing 50. The valve core 40, located at the lower end of the valve shaft 30, contacts the valve seat 15. The valve closing spring 77 and washer 76 are inserted into the upper end 31 of the valve shaft 30.

[0160] like Figure 23 As shown, the valve shaft retainer 70 is fitted into the mounting hole 81 of the rotor 80. The upper end 31 of the valve shaft 30 is inserted into the valve shaft insertion hole 72a of the valve shaft retainer 70. The internal thread 73 of the valve shaft retainer 70 is screwed into the external thread 53 of the guide bushing 50.

[0161] like Figure 24 , Figure 25 As shown, the rotor 80 and valve shaft retainer 70 are rotated in the valve closing direction until the movable stop surface 75 abuts against the fixed stop surface 65. The upper end 31 of the valve shaft 30 is inserted into the fixing portion 36 of the fixing member 35. The flange portion 37 of the fixing member 35 contacts the upper wall portion 72 of the valve shaft retainer 70. At this moment, the fixing member 35 is not welded to the upper end 31 of the valve shaft 30.

[0162] like Figure 26 , Figure 27 As shown, while maintaining the valve core 40 in contact with the valve seat 15, the rotor 80 is rotated by a predetermined angle (180 degrees in this embodiment) in the valve opening direction. The retainer 35 moves upward together with the rotor 80 and the valve shaft retainer 70. Then, the retaining portion 36 of the retainer 35 is welded to the upper end 31 of the valve shaft 30. The return spring 38 is positioned on the outside of the retainer 35. The housing 20 is engaged with the upper end of the valve body 10 via the ring member 21. At this moment, the valve body assembly 5 is assembled without the valve body assembly label 18 (i.e., without rotor-side correction information Jr).

[0163] The housing 20 is inserted into the separately prepared reference stator unit 6S, and the conduit 12 is held in the clamping portions 112a, 112a of the positioning member 110. Thus, the reference stator unit 6S is fixed relative to the valve body 10. The stator-side offset angle β of the reference stator unit 6S is 0. Therefore, in the combination of the valve body assembly 5 and the reference stator unit 6S without rotor-side correction information Jr, there is no misalignment of the pole teeth of the stator 90 with the fixed stop 64 about the axis L. Then, a valve body assembly label 18 is made, which contains rotor-side correction information Jr related to the misalignment (rotor-side offset angle α) of the magnetic poles of the rotor 80 with the movable stop 74 about the axis L.

[0164] To make the movable stop surface 75 abut against the fixed stop surface 65, a sufficient number of pulse trains S are repeatedly input into the stator 90 of the reference stator unit 6S in reverse order, and finally pulse P[0] is input and the input of pulse trains S in reverse order is stopped. This operation is called "origin setting". After origin setting, refrigerant is introduced into conduit 12, and while measuring the amount of refrigerant flowing in conduit 13, pulse trains S are input into the stator 90 once or multiple times in forward order starting from pulse P[0]. In addition, the last pulse P[0] input in origin setting can also serve as the first pulse P[0] input in forward order after origin setting, that is, it can be a structure in which pulse P[0] is input only once before and after origin setting. Then, the number of input pulses P (rotor-side valve opening pulse number Cr) is counted until the measured amount of refrigerant becomes the specified valve opening reference amount VS. The rotor-side correction pulse number Kr corresponding to the rotor-side offset angle α is calculated based on the rotor-side valve opening pulse number Cr. Additionally, the opening degree of valve port 14 when the amount of refrigerant flowing through valve port 14 reaches the specified valve opening reference amount VS is called the "valve opening point". Then, a two-dimensional barcode representing rotor-side correction information Jr, including the rotor-side correction pulse number Kr, is printed on the valve body assembly label 18. The valve body assembly label 18 is affixed to the front of the valve body 10. Thus, the valve body assembly 5 is completed.

[0165] Next, an example of the manufacturing method of stator unit 6 will be described.

[0166] The molding die of cover 100 is opened, and the stator 90 and positioning member 110 are placed in the cavity of the molding die. The molding die is closed, and resin material is injected into the cavity. Thus, the stator unit 6 is embedded and molded, and the stator 90, cover 100, and positioning member 110 are integrated. At this point, the stator unit 6 is assembled without the stator unit label 118 (i.e., without stator-side correction information Js). Alternatively, the cover body 101 and connector cover 102 of cover 100 can be integrally molded, or they can be molded separately and then welded together. Alternatively, cover 100 can also be molded by a molding method other than embedding molding (e.g., casting molding).

[0167] The housing 20 of the separately prepared reference valve body assembly 5S is inserted into the stator unit 6, and the conduit 12 is held in the clamping portions 112a, 112a of the positioning member 110. Thus, the stator unit 6 is fixed relative to the valve body 10 of the reference valve body assembly 5S. The rotor-side offset angle α of the reference valve body assembly 5S is 0. Therefore, there is no misalignment of the magnetic poles of the rotor 80 with the movable stop 74 about the axis L. Then, a stator unit label 118 is made as follows, which contains stator-side correction information Js related to the misalignment (stator-side offset angle β) of the pole teeth of the stator 90 with the fixed stop 64 (positioning member 110) about the axis L.

[0168] To make the movable stop surface 75 abut against the fixed stop surface 65, a sufficient number of pulse trains S are repeatedly input into the stator 90 of the stator unit 6 in reverse order, and finally pulse P[0] is input and the input of pulse trains S in reverse order is stopped (origin setting). After origin setting, refrigerant is introduced into conduit 12, and while measuring the amount of refrigerant flowing in conduit 13, pulse trains S are input into the stator 90 in forward order once or multiple times starting from pulse P[0]. In addition, the last pulse P[0] input in origin setting can also serve as the first pulse P[0] input in forward order after origin setting, that is, it can be a structure in which pulse P[0] is input only once before and after origin setting. Then, the number of input pulses P (stator-side valve opening pulse number Cs) is counted until the measured amount of refrigerant becomes the specified valve opening reference amount VS. The stator-side correction pulse number Ks corresponding to the stator-side offset angle β is calculated based on the stator-side valve opening pulse number Cs. Then, a two-dimensional barcode representing stator-side correction information Js, including the number of stator-side correction pulses Ks, is printed on the stator unit label 118. The stator unit label 118 is then affixed to the front of the cover 100. Thus, the stator unit 6 is completed.

[0169] In this embodiment, the electric valve 1 is configured such that when the rotor 80 rotates more than 180 degrees in the valve opening direction from the state where the movable stop surface 75 abuts against the fixed stop surface 65, the valve core 40 separates from the valve seat 15. When 48 pulses are input to the stator 90, the rotor 80 rotates 180 degrees. Therefore, if the rotor-side offset angle α is 0 and the stator-side offset angle β is 0, the electric valve 1 (referred to as "reference electric valve 1S") will separate from the valve seat 15 when 50 pulses P are input in a positive sequence starting from pulse P[0]. Specifically, when pulse P[0] is input, it becomes the same state as the origin setting. After that, when 48 pulses P are input, the rotor 80 rotates 180 degrees. When one more pulse P is input, the rotor 80 rotates more than 180 degrees. The number of pulses P (50) is used as the reference valve opening pulse number CS. That is, the reference valve opening pulse number CS is the number of pulses that should be input from the origin setting state to the valve opening point in the reference electric valve 1S. In the reference electric valve 1S, the amount of refrigerant flowing in the conduit 13 when the pulses P of the reference valve opening pulse number CS are input in positive sequence is used as the reference quantity VS when the valve is opened. Then, in the manufacturing of the valve body assembly 5, the reference valve opening pulse number CS is subtracted from the rotor-side valve opening pulse number Cr to calculate the rotor-side correction pulse number Kr (Kr = Cr - CS). Similarly, in the manufacturing of the stator unit 6, the reference valve opening pulse number CS is subtracted from the stator-side valve opening pulse number Cs to calculate the stator-side correction pulse number Ks (Ks = Cs - CS).

[0170] Due to improvements in manufacturing technology, the dimensional and assembly precision of parts have increased. Therefore, the rotor-side offset angle α of the valve body assembly 5 and the stator-side offset angle β of the stator unit 6 are suppressed to a relatively small angular range. In this embodiment, the rotor-side offset angle α and the stator-side offset angle β are suppressed to the angular range of the rotor 80 when eight pulses are input in the pulse train S (for example, 3.75 degrees × 8 = 30 degrees when the number of stator poles in phases A and B is 24). Therefore, the rotor-side correction pulse number Kr corresponding to the rotor-side offset angle α is set to eight graphs, and the stator-side correction pulse number Ks corresponding to the stator-side offset angle β is set to eight graphs. In this way, by reducing the number of graphs for the rotor-side correction pulse number Kr and the stator-side correction pulse number Ks, the amount of information contained in the valve body assembly label 18 and the stator unit label 118 can be reduced.

[0171] When the number of pulses contained in the pulse train S is set to N, the number of rotor-side correction pulses Kr satisfies the following formula (1). Wherein, Kr is an integer (positive or negative sign indicates the direction of rotation), and N is an even natural number.

[0172] -((N / 2)-1)≤Kr≤N / 2…(1)

[0173] In this embodiment, N = 8, and the number of rotor-side correction pulses Kr is -3 ≤ Kr ≤ +4.

[0174] exist Figure 28 The graphs [a] to [h] show the rotor-side correction pulse number Kr, the rotor-side correction pulse number Kr, and the positional relationship between the rotor's magnetic poles and the movable stop in the origin setting state. Figure 28 In the process, the positional relationship between the rotor's magnetic poles and the movable stop is manifested as... Figures 13-20 The lower part of the diagram is the same, therefore the symbols for each component are omitted. Additionally, in Figure 28 In the middle, the stator side offset angle β is 0.

[0175] exist Figure 28 In Figure [a], the reference magnetic pole 85 of the rotor 80 is not misaligned relative to the movable stop surface 75 (α = 0), and the rotor-side correction pulse count Kr is "0". In Figure [b], the reference magnetic pole 85 of the rotor 80 is misaligned relative to the movable stop surface 75 by one pulse in the valve-opening direction, and the rotor-side correction pulse count Kr is "+1". In Figure [c], the reference magnetic pole 85 of the rotor 80 is misaligned relative to the movable stop surface 75 by two pulses in the valve-opening direction, and the rotor-side correction pulse count Kr is "+2". In Figure [d], the reference magnetic pole 85 of the rotor 80 is misaligned relative to the movable stop surface 75 by three pulses in the valve-opening direction, and the rotor-side correction pulse count Kr is "+3". In Figure [e], the reference magnetic pole 85 of the rotor 80 is misaligned relative to the movable stop surface 75 by four pulses in the valve-opening direction, and the rotor-side correction pulse count Kr is "+4". In figure [f], the reference magnetic pole 85 of the rotor 80 is offset by 3 pulses relative to the movable stop surface 75 in the valve-closing direction, and the rotor-side correction pulse number Kr is "-3". In figure [g], the reference magnetic pole 85 of the rotor 80 is offset by 2 pulses relative to the movable stop surface 75 in the valve-closing direction, and the rotor-side correction pulse number Kr is "-2". In figure [h], the reference magnetic pole 85 of the rotor 80 is offset by 1 pulse relative to the movable stop surface 75 in the valve-closing direction, and the rotor-side correction pulse number Kr is "-1".

[0176] The valve body assembly 5 shown in Figure [a] can control the opening degree of the valve port 14 in the same way as the structure using the reference valve body assembly 5S, by using the same number of pulses as the reference valve body assembly 5S used for rotor-side offset angle α of 0. The valve body assemblies 5 shown in Figures [b] to [h] can control the opening degree of the valve port 14 in the same way as the structure using the reference valve body assembly 5S, by using the number of pulses after correcting the number of pulses used by the reference valve body assembly 5S with the rotor-side correction pulse number Kr.

[0177] Specifically, for example, in a structure (referred to as "structure A") that combines a reference valve body assembly 5S and a stator unit 6 (or reference stator unit 6S), the number of pulses used to set the valve port 14 to a specified opening degree is used as the pulse number PA. In the structure that combines the valve body assembly 5 and the stator unit 6 as shown in the above figures [a] to [h], the opening degree of the valve port 14 can be controlled in the same way as in structure A by adding the rotor-side correction pulse number Kr to the pulse number PA. That is, the rotor-side correction pulse number Kr is the increment or decrement used to correct the reference pulse number used by the reference valve body assembly 5S when the rotor-side offset angle α is 0.

[0178] When the number of pulses contained in the pulse train S is set to N, the number of stator-side correction pulses Ks satisfies the following formula (2). Wherein, Ks is an integer (positive or negative sign indicates the direction of rotation), and N is an even natural number.

[0179] -((N / 2)-1)≤Ks≤N / 2…(2)

[0180] In this embodiment, N = 8, and the number of stator-side correction pulses Ks is -3 ≤ Ks ≤ +4.

[0181] exist Figure 29 In the figure, the stator side correction pulse number Ks is shown in graph form [1] to [8], the stator side correction pulse number Ks and the positional relationship between the stator pole teeth and the fixed stop in the origin setting state. Figure 29 In the middle, the positional relationship between the stator's pole teeth and the fixed stop is expressed as follows: Figures 13-20 The lower part of the diagram is the same, therefore the symbols for each component are omitted. Additionally, in Figure 29 In the middle, the rotor side offset angle α is 0.

[0182] exist Figure 29In Figure [1], the fixed stop surface 65 is not misaligned relative to the reference pole tooth 95 of the stator 90 (β=0), and the stator-side correction pulse number Ks is “0”. In Figure [2], the fixed stop surface 65 is misaligned relative to the reference pole tooth 95 of the stator 90 by one pulse in the valve opening direction, and the stator-side correction pulse number Ks is “+1”. In Figure [3], the fixed stop surface 65 is misaligned relative to the reference pole tooth 95 of the stator 90 by two pulses in the valve opening direction, and the stator-side correction pulse number Ks is “+2”. In Figure [4], the fixed stop surface 65 is misaligned relative to the reference pole tooth 95 of the stator 90 by three pulses in the valve opening direction, and the stator-side correction pulse number Ks is “+3”. In Figure [5], the fixed stop surface 65 is misaligned relative to the reference pole tooth 95 of the stator 90 by four pulses in the valve opening direction, and the stator-side correction pulse number Ks is “+4”. In Figure [6], the fixed stop surface 65 is offset from the reference pole tooth 95 of the stator 90 by three pulses in the valve-closing direction, and the stator-side correction pulse number Ks is "-3". In Figure [7], the fixed stop surface 65 is offset from the reference pole tooth 95 of the stator 90 by two pulses in the valve-closing direction, and the stator-side correction pulse number Ks is "-2". In Figure [8], the fixed stop surface 65 is offset from the reference pole tooth 95 of the stator 90 by one pulse in the valve-closing direction, and the stator-side correction pulse number Ks is "-1".

[0183] The stator unit 6 shown in Figure [1] can control the opening degree of the valve port 14 in the same way as the structure using the reference stator unit 6S, by using the same number of pulses as the reference stator unit 6S used for stator-side offset angle β of 0. The stator unit 6 shown in Figures [2] to [8] can control the opening degree of the valve port 14 in the same way as the structure using the reference stator unit 6S, by using the number of pulses after correcting the number of pulses used by the reference stator unit 6S with the number of stator-side correction pulses Ks.

[0184] Specifically, for example, in a structure (referred to as "structure B") that combines a reference stator unit 6S and a valve body assembly 5 (or a reference valve body assembly 5S), the number of pulses used to set the valve port 14 to a specified opening is referred to as the pulse number PB. In the structure that combines the stator unit 6 as shown in the above figures [1] to [8] and the valve body assembly 5, the opening of the valve port 14 can be controlled in the same way as in structure B by using the pulse number obtained by adding the stator-side correction pulse number Ks to the pulse number PB. That is, the stator-side correction pulse number Ks is the increment or decrement used to correct the reference pulse number used by the reference stator unit 6S when the stator-side offset angle β is 0.

[0185] Next, the air conditioner with electric valve 1 will be described.

[0186] exist Figure 30The text indicates that the air conditioner is unit 200. Air conditioner 200 operates in either cooling or heating mode. Figure 30 In the diagram, solid arrows schematically represent the refrigerant flow during cooling operation, while dashed arrows schematically represent the refrigerant flow during heating operation. During cooling operation, the refrigerant flows from compressor 201 through flow path switching valve 202, outdoor heat exchanger 203, control valve 204, and indoor heat exchanger 205, then returns to compressor 201 after passing through flow path switching valve 202, thus circulating. During heating operation, the refrigerant flows from compressor 201 through flow path switching valve 202, indoor heat exchanger 205, control valve 204, and outdoor heat exchanger 203, then returns to compressor 201 after passing through flow path switching valve 202, thus circulating. Electric valve 1 is used as control valve 204 of air conditioner 200.

[0187] Additionally, the air conditioner 200 includes a compressor 201, a control valve 204, and an electronic control unit (not shown) for controlling the fan, etc. The electronic control unit controls the electric valve 1, which serves as the control valve 204, via a control device 210. The control device 210 is, for example, a microcomputer with non-volatile memory. The control device 210 adjusts the opening degree of the valve port 14 of the electric valve 1, which serves as the control valve 204, during cooling operation and heating operation to control the refrigerant flow. The control device 210 may also be incorporated into the stator unit 6 of the electric valve 1. In this embodiment, the control device 210 and the electronic control unit are separate, but it is also possible to integrate the control device 210 and the electronic control unit, and directly control the control valve 204 through the electronic control unit.

[0188] As described above, among the various electric valves 1 assembled into the air conditioner 200, there are cases where the rotor-side offset angle α and the stator-side offset angle β are different, that is, there are cases where the number of pulses (valve opening pulse number C) that should be input from the origin setting state to the valve opening point position is different. Here, the control device 210 obtains the valve opening pulse number C based on the rotor-side correction information Jr and the stator-side correction information Js read from the valve body assembly label 18 and the stator unit label 118 of the electric valve 1, and accurately determines the valve opening point of the electric valve 1.

[0189] The memory of the control device 210 stores the number of pulses (reference valve opening pulse number CS) that should be input from the origin setting state to the valve opening position in the reference electric valve 1S. Additionally, the memory of the control device 210 stores rotor-side calibration information Jr and stator-side calibration information Js of the electric valve 1, which are read using a barcode reader. The reference valve opening pulse number CS, rotor-side calibration information Jr, and stator-side calibration information Js are stored in the memory, for example, during the manufacturing of the air conditioner 200.

[0190] Control device 210 obtains the rotor-side correction pulse number Kr and stator-side correction pulse number Ks from the rotor-side correction information Jr and the stator-side correction information Js. Control device 210 calculates the correction pulse number K based on the rotor-side correction pulse number Kr and the stator-side correction pulse number Ks. Then, control device 210 adds the correction pulse number K to the reference valve opening pulse number CS, and uses the resulting value as the valve opening pulse number C of the electric valve 1 incorporated into the air conditioner. Control device 210 adjusts the valve opening degree of valve port 14 based on the valve opening pulse number C input as a reference (valve opening point).

[0191] The number of correction pulses K is calculated using the following formulas (3a), (3b) and (3c).

[0192] K = Kr + Ks…(3a)

[0193] Where -((N / 2)-1)≤Kr+Ks≤N / 2

[0194] K = Kr + Ks - N…(3b)

[0195] Where Kr+Ks>N / 2

[0196] K = Kr + Ks + N…(3c)

[0197] Where -((N / 2)-1)>Kr+Ks.

[0198] exist Figure 31 In the figure, K represents the number of correction pulses K calculated based on the number of correction pulses Kr on the rotor side and the number of correction pulses Ks on the stator side.

[0199] Furthermore, although in this embodiment the rotor-side correction information Jr includes the rotor-side correction pulse number Kr and the stator-side correction information Js includes the stator-side correction pulse number Ks, the rotor-side correction information Jr and the stator-side correction information Js are not limited to this structure. For example, the control device 210 will... Figure 31 The table shown is pre-stored in memory. The rotor-side correction information Jr contains symbols (a to h) corresponding to the rotor-side correction pulse number Kr, and the stator-side correction information Js contains symbols (1 to 8) corresponding to the stator-side correction pulse number Ks. Then, the control device 210 can obtain the symbols from the rotor-side correction information Jr and the stator-side correction information Js, and retrieve the correction pulse number K from the table again.

[0200] exist Figures 32-39 In the middle, it indicates the valve opening action starting from the origin setting state in electric valve 1. Figures 32-39 It is to Figure 31The diagram illustrates the valve opening action in the structure corresponding to the shaded area (correction pulse number K = 0, +1, +2, +3, +4, -3, -2, -1), but for... Figure 31 The structure outside the shaded area also performs the same valve-opening action. Figures 32-39 In the middle, (i)~(viii) are arranged in time sequence, representing the state of input pulses P[0]~P[7] to stator 90.

[0201] Figure 32 This indicates the opening action of electric valve 1 when the calibration pulse number K is 0 (Kr = 0, Ks = 0). After the electric valve 1 is set at the origin, when a pulse P[0] is input to the stator 90, the movable stop surface 75 of the electric valve 1 is in a state where it abuts against the fixed stop surface 65. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[1], P[2]..., the movable stop surface 75 of the electric valve 1 gradually moves away from the fixed stop surface 65. The electric valve 1 reaches the opening point when it is input with pulse P of the reference opening pulse number CS.

[0202] Figure 33 This indicates the opening action of the electric valve 1 with a correction pulse number K of 1 (Kr = 1, Ks = 0). When the electric valve 1 inputs a pulse P[0] to the stator 90 after being set at the origin, the movable stop surface 75 abuts against the fixed stop surface 65. Even when a pulse P[1] is input to the stator 90, the electric valve 1 maintains the state where the movable stop surface 75 abuts against the fixed stop surface 65. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[2], P[3]..., the movable stop surface 75 of the electric valve 1 gradually moves away from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 rotates in the opening direction with a delay of one pulse. The electric valve 1 reaches the opening point when the input reference opening pulse number CS is increased by 1 pulse P.

[0203] Figure 34 This indicates the opening action of the electric valve 1 with a calibration pulse number K of 2 (Kr = 2, Ks = 0). When the electric valve 1 inputs a pulse P[0] to the stator 90 after being set at the origin, the movable stop surface 75 abuts against the fixed stop surface 65. Even when pulses P[1] to P[2] are input to the stator 90 in sequence, the electric valve 1 maintains the state where the movable stop surface 75 abuts against the fixed stop surface 65. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[3], P[4]..., the movable stop surface 75 of the electric valve 1 gradually moves away from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 rotates in the opening direction with a delay of two pulses. The electric valve 1 reaches the opening point when the input reference opening pulse number CS is increased by 2 times the number of pulses P.

[0204] Figure 35This indicates the opening action of the electric valve 1 with a calibration pulse number K of 3 (Kr = 3, Ks = 0). When the electric valve 1 inputs a pulse P[0] to the stator 90 after being set at the origin, the movable stop surface 75 abuts against the fixed stop surface 65. Even when pulses P[1] to P[3] are input to the stator 90 in sequence, the electric valve 1 maintains the state where the movable stop surface 75 abuts against the fixed stop surface 65. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[4], P[5]..., the movable stop surface 75 of the electric valve 1 gradually moves away from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 rotates in the opening direction with a delay of three pulses. The electric valve 1 reaches the opening point when the input reference opening pulse number CS is increased by a number of pulses P equal to 3.

[0205] Figure 36 This indicates the opening action of the electric valve 1, which has a calibration pulse number K of 4 (Kr = 4, Ks = 0). When the electric valve 1 is set at the origin and a pulse P[0] is input to the stator 90, the movable stop surface 75 is in a state where it abuts against the fixed stop surface 65. Even if pulses P[1] to P[4] are input to the stator 90 in sequence, the electric valve 1 maintains the state where the movable stop surface 75 abuts against the fixed stop surface 65. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[5], P[6]..., the movable stop surface 75 of the electric valve 1 gradually moves away from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 rotates in the opening direction with a delay of four pulses. The electric valve 1 reaches the opening point when the input reference opening pulse number CS is increased by a number of pulses P equal to 4. In addition, as Figure 36 As shown in (i), when the electric valve 1 with a correction pulse number K of 4 is input pulse P[0], with the movable stop surface 75 abutting against the fixed stop surface 65, the reference pole tooth 95 (the N pole with black dots) of the stator 90 is opposite to the N pole of the reference magnetic pole 85 (the S pole with black dots) adjacent to the rotor 80. Therefore, when vibration is applied to the electric valve 1, the S pole (but not the magnetic pole of the reference magnetic pole 85) of the rotor 80 adjacent to the N pole opposite to the reference pole tooth 95 is attracted by the reference pole tooth 95, and the rotor 80 may deflect in the valve opening direction. Therefore, when combining the valve body assembly 5 and the stator unit 6, it is preferable to avoid combinations with a correction pulse number K of 4.

[0206] Figure 37This indicates the opening action of the electric valve 1 with a calibration pulse number K of -3 (Kr = -3, Ks = 0). When the electric valve 1 inputs a pulse P[0] to the stator 90 after being set at the origin, the movable stop surface 75 separates from the fixed stop surface 65 to a position where it has advanced three pulses. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[1], P[2]..., the movable stop surface 75 of the electric valve 1 further separates from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 advances three pulses and rotates in the opening direction. The electric valve 1 reaches the opening point when it is input with a pulse P equal to the number of pulses P that is 3 less than the reference opening pulse number CS.

[0207] Figure 38 This indicates the opening action of the electric valve 1 with a calibration pulse number K of -2 (Kr = -2, Ks = 0). When the electric valve 1 inputs a pulse P[0] to the stator 90 after being set at the origin, the movable stop surface 75 separates from the fixed stop surface 65 to a position where it has advanced two pulses. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[1], P[2]..., the movable stop surface 75 of the electric valve 1 further separates from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 advances two pulses and rotates in the opening direction. The electric valve 1 reaches the opening point when it is input with a pulse P equal to the number of pulses P that is 2 less than the reference opening pulse number CS.

[0208] Figure 39 This illustrates the opening action of the electric valve 1 with a calibration pulse number K of -1 (Kr = -1, Ks = 0). When the electric valve 1 is set at the origin and a pulse P[0] is input to the stator 90, the movable stop surface 75 separates from the fixed stop surface 65 to a position where it has advanced one pulse. Then, when a pulse train S is input to the stator 90 in the positive sequence of pulses P[1], P[2]..., the movable stop surface 75 of the electric valve 1 further moves away from the fixed stop surface 65. That is, in this electric valve 1, the rotor 80 advances one pulse and rotates in the opening direction. The electric valve 1 reaches the opening point when it is input with a pulse P equal to the number of pulses P that is 1 less than the reference opening pulse number CS.

[0209] As described above, the electric valve 1 of this embodiment has a valve body assembly 5 and a stator unit 6. The valve body assembly 5 includes: a valve body 10 having a valve port 14; a rotor 80 having a plurality of magnetic poles configured to rotate relative to the valve body 1; a movable stop 74 fixed relative to the rotor 80; a fixed stop 64 fixed relative to the valve body 10 and abutting against the movable stop 74, thereby restricting rotation of the rotor 80 in the valve closing direction; and a valve core 40 that changes the opening degree of the valve port 14 as the rotor 80 rotates. The stator unit 6 includes: a stator 90 having a plurality of pole teeth; and a positioning member 110 for positioning the stator 90 relative to the valve body assembly 5. Rotor-side correction information Jr is attached to the outer surface of the valve body assembly 5. This rotor-side correction information Jr includes information relating to the offset angle (rotor-side offset angle α) between the magnetic poles of the rotor 80 and the movable stop 74. Furthermore, stator-side correction information Js is attached to the outer surface of the stator unit 6. This stator-side correction information Js includes information relating to the offset angle (stator-side offset angle β) between the pole teeth of the stator 90 and the positioning member 110.

[0210] The electric valve 1 is configured as a stepper motor via a rotor 80 and a stator 90. The information related to the rotor-side offset angle α refers to the number of pulses (rotor-side correction pulse number Kr) required to rotate the rotor 80 in the stepper motor by the rotor-side offset angle α. The rotor-side correction pulse number Kr is a relative increase or decrease in the number of pulses used by the valve body assembly 5 when the rotor-side offset angle α is 0. The information related to the stator-side offset angle β refers to the number of pulses (stator-side correction pulse number Ks) required to rotate the rotor 80 in the stepper motor by the stator-side offset angle β. The stator-side correction pulse number Ks is a relative increase or decrease in the number of pulses used by the stator unit 6 when the stator-side offset angle β is 0. Furthermore, when the number of pulses contained in the pulse train S input to the stepper motor when rotating the rotor 80 in the valve-opening direction is set to N, the following formulas (1) and (2) are satisfied.

[0211] -((N / 2)-1)≤Kr≤N / 2…(1)

[0212] -((N / 2)-1)≤Ks≤N / 2…(2)

[0213] Where Kr and Ks are integers, and N is an even natural number.

[0214] Furthermore, the air conditioner 200 with electric valve 1 is configured to control electric valve 1 based on rotor-side correction information Jr and stator-side correction information Js.

[0215] In addition, the air conditioner 200 is configured to control the electric valve 1 based on the number of correction pulses K calculated using the following formulas (3a), (3b) and (3c).

[0216] K = Kr + Ks…(3a)

[0217] Where -((N / 2)-1)≤Kr+Ks≤N / 2

[0218] K = Kr + Ks - N…(3b)

[0219] Where Kr+Ks>N / 2

[0220] K = Kr + Ks + N…(3c)

[0221] Where -((N / 2)-1)>Kr+Ks.

[0222] The manufacturing method of the valve body assembly 5 used in the electric valve 1 is as follows: A valve body assembly 5 without rotor-side correction information Jr is manufactured. A reference stator unit 6S is prepared. The valve body assembly 5 without rotor-side correction information Jr and the reference stator unit 6S are combined, and a stepper motor is formed by a rotor 80 and a stator 90. When the rotor 80 is rotated in the valve-opening direction, a pulse train S (wherein the pulse train S contains N pulses distributed in the order of [0] to [N-1]) is input to the stepper motor in reverse order once or multiple times, and the rotor 80 is rotated in the valve-closing direction until the movable stop 74 abuts against the fixed stop 64. After the movable stop 74 abuts against the fixed stop 64, the reverse order input of the pulse train is stopped when the input continues up to pulse [0]. Then, the pulse train S is input to the stepper motor one or more times in positive sequence starting from pulse [0], and the number of pulses input (rotor-side opening valve pulse number Cr) is counted until the valve port 14 becomes the opening for fluid flow of the reference quantity. Based on the rotor-side opening valve pulse number Cr, the rotor-side correction information Jr contains information related to the rotor-side offset angle α. Then, a valve body assembly label 18 is attached to the outer surface of the valve body assembly 5 without the rotor-side correction information Jr. The valve body assembly label 18 is printed with the rotor-side correction information Jr generated based on the rotor-side opening valve pulse number Cr. The rotor-side correction information Jr is information related to flow control. In addition, the rotor-side correction information Jr may also include the rotor-side opening valve pulse number Cr. In addition, as the rotor-side opening valve pulse number Cr, the number of pulses input can also be counted until the opening changes with the increment of the input of one pulse to become the flow rate. In other words, the flow rate at valve port 14 increases by X with each input pulse. When a pulse is input at a certain moment T and the flow rate increases by Y (Y≠X), the number of pulses input up to that moment T is taken as the rotor-side valve opening pulse number Cr. In this structure, the point where the flow rate changes relative to the pulse input is used as the reference for controlling the opening degree of valve port 14.

[0223] The manufacturing method of the stator unit 6 used in the electric valve 1 is as follows: A stator unit 6 without stator-side correction information Js is manufactured. A reference valve body assembly 5S is prepared. The stator unit 6 without stator-side correction information Js and the reference valve body assembly 5S are combined, and a stepper motor is formed by a rotor 80 and a stator 90. When the rotor 80 is rotated in the valve-opening direction, a pulse train S (wherein the pulse train S contains N pulses distributed in the order of [0] to [N-1]) input to the stepper motor is input to the stepper motor in reverse order once or multiple times, and the rotor 80 is rotated in the valve-closing direction until the movable stop 74 abuts against the fixed stop 64. After the movable stop 74 abuts against the fixed stop 64, the reverse order input of the pulse train is stopped when the input continues up to pulse [0]. Then, the pulse train S is input to the stepper motor one or more times in positive sequence starting from pulse [0], and the number of pulses input (stator-side valve opening pulse number Cs) up to the opening degree at which the valve port 14 becomes the fluid flow supplying the reference quantity is counted. Stator-side correction information Js is generated based on the stator-side valve opening pulse number Cs, which includes information related to the stator-side offset angle β. Then, a stator unit label 118 is attached to the outer surface of the stator unit 6 without stator-side correction information Js, which is printed with the stator-side correction information Js generated based on the stator-side valve opening pulse number Cs. The stator-side correction information Js is information related to flow control. Alternatively, the stator-side correction information Js may also include the stator-side valve opening pulse number Cs. Alternatively, the stator-side valve opening pulse number Cs may also be the number of pulses input up to the opening degree at which the flow rate changes relative to the input of one pulse. In other words, the flow rate at valve port 14 increases by X with each input pulse. When a pulse is input at a certain moment T and the flow rate increases by Y (Y≠X), the number of pulses input up to that moment T is taken as the stator-side valve opening pulse number Cs. In this structure, the point of flow rate change where the flow rate increment changes relative to the pulse input is taken as the reference for controlling the opening degree of valve port 14.

[0224] According to the electric valve 1, rotor-side correction information Jr is attached to the outer surface of the valve body assembly 5. This rotor-side correction information Jr includes information related to the offset angle (rotor-side offset angle α) between the magnetic poles of the rotor 80 and the movable stop 74. Stator-side correction information Js is attached to the outer surface of the stator unit 6. This stator-side correction information Js includes information related to the offset angle (stator-side offset angle β) between the pole teeth of the stator 90 and the positioning member 110. By doing so, when the valve body assembly 5 and the stator unit 6 are combined to form the electric valve 1, the opening position (opening point) of the electric valve 1 can be accurately determined based on the rotor-side correction information Jr and the stator-side correction information Js attached to their respective outer surfaces. Therefore, the flow rate of the refrigerant flowing in the electric valve 1 can be accurately controlled.

[0225] In the above embodiment, both the offset angle between the magnetic poles of the rotor 80 and the movable stop member 74 (rotor-side offset angle α) and the offset angle between the pole teeth of the stator 90 and the positioning member 110 (stator-side offset angle β) are attached as correction information to the outer surfaces of the valve body assembly 5 and the stator unit 6. However, it is also possible to attach only either the rotor-side offset angle α or the stator-side offset angle β as correction information. When the valve body assembly 5 and the stator unit 6 are manufactured using a manufacturing apparatus suitable for mass production, the distribution of the rotor-side offset angle α and the stator-side offset angle β may deviate depending on the characteristics of the manufacturing apparatus. Then, if a significant deviation in the distribution of the offset angles is found only in one of the valve body assembly 5 and the stator unit 6, it is considered that the quality fluctuation of that side is smaller. In such a case, in the electric valve 1, the correction information for one of the valve body assembly 5 and the stator unit 6 is omitted, and only the correction information for the other side is attached. As a result, compared with conventional electric valves, the error range of the valve opening point can be reduced (e.g., less than 4 pulses) and the number of manufacturing steps can be reduced. The structure that omits the correction information of either the valve body assembly 5 or the stator unit 6 is effective in reducing manufacturing costs, provided that the error range of the valve opening point is within acceptable limits.

[0226] The embodiments of the present invention have been described above, but the present invention is not limited to these examples. For the above embodiments, those skilled in the art may appropriately add, remove, or modify structural elements, or appropriately combine features of the embodiments; such modifications, as long as they do not violate the spirit of the present invention, are also included within the scope of the present invention.

Claims

1. A valve body assembly for an electric valve, characterized in that, have: Valve body, which is provided with a valve port; A rotor having multiple magnetic poles configured to rotate relative to the valve body; A movable stop that is fixed relative to the rotor; A fixed stop, which is fixed relative to the valve body and abuts against the movable stop, thereby restricting the rotation of the rotor in the valve-closing direction; and The valve core changes the opening degree of the valve port as the rotor rotates. Rotor-side correction information is attached to the outer surface of the valve body assembly. This rotor-side correction information includes information related to the rotor-side offset angle, which is the offset angle between the magnetic poles of the rotor and the movable stop.

2. The valve body assembly according to claim 1, characterized in that, The rotor and the stator of the stator unit together constitute a stepper motor. The information related to the rotor-side offset angle is information representing the rotor-side correction pulse number Kr, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the rotor-side offset angle. The rotor-side correction pulse number Kr is a relative increase or decrease in the number of pulses used by the valve body assembly when the rotor-side offset angle is 0. When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formula (1) is satisfied. -((N / 2)-1)≤Kr≤N / 2…(1) Where Kr is an integer and N is an even natural number.

3. A stator unit for an electric valve, characterized in that, have: Stator, which has multiple pole teeth; and A positioning component for positioning the stator relative to the valve body assembly. Stator side correction information is attached to the outer surface of the stator unit. This stator side correction information includes information related to the stator side offset angle, which is the offset angle between the pole teeth of the stator and the positioning component.

4. The stator unit according to claim 3, characterized in that, The stator and the rotor of the valve body assembly together constitute a stepper motor. The information related to the stator-side offset angle is information representing the stator-side correction pulse number Ks, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the stator-side offset angle. The stator-side correction pulse number Ks is a relative increase or decrease in the number of pulses used by the stator unit with a stator-side offset angle of 0. When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formula (2) is satisfied. -((N / 2)-1)≤Ks≤N / 2…(2) Where Ks is an integer and N is an even natural number.

5. An electric valve comprising a valve body assembly and a stator unit, characterized in that, The valve body assembly includes: a valve body having a valve port; The valve comprises: a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates. The stator unit includes: a stator having a plurality of pole teeth; and a positioning component for positioning the stator relative to the valve body assembly. Rotor-side correction information is affixed to the outer surface of the valve body assembly. This rotor-side correction information includes information related to the rotor-side offset angle, which is the offset angle between the magnetic poles of the rotor and the movable stop. Stator side correction information is attached to the outer surface of the stator unit. This stator side correction information includes information related to the stator side offset angle, which is the offset angle between the pole teeth of the stator and the positioning component.

6. The electric valve according to claim 5, characterized in that, The rotor and the stator together form a stepper motor. The information related to the rotor-side offset angle is information representing the rotor-side correction pulse number Kr, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the rotor-side offset angle. The rotor-side correction pulse number Kr is a relative increase or decrease in the number of pulses used by the valve body assembly when the rotor-side offset angle is 0. The information related to the stator-side offset angle is information representing the stator-side correction pulse number Ks, which is the number of pulses required to rotate the rotor in the stepper motor by the amount of the stator-side offset angle. The stator-side correction pulse number Ks is a relative increase or decrease in the number of pulses used by the stator unit with a stator-side offset angle of 0. When the number of pulses in the pulse train input to the stepper motor when the rotor is rotated in the valve opening direction is set to N, the following formulas (1) and (2) are satisfied. -((N / 2)-1)≤Kr≤N / 2…(1) -((N / 2)-1)≤Ks≤N / 2…(2) Where Kr and Ks are integers, and N is an even natural number.

7. An air conditioner, characterized in that, Having the electric valve of claim 5, The electric valve is configured to be controlled based on the rotor-side correction information and the stator-side correction information.

8. An air conditioner, characterized in that, Having the electric valve of claim 6, The electric valve is configured to be controlled based on a correction pulse number K, which is calculated using the following formulas (3a), (3b), and (3c). K = Kr + Ks…(3a) Where -((N / 2)-1)≤Kr+Ks≤N / 2 K = Kr + Ks - N…(3b) Where Kr+Ks>N / 2 K = Kr + Ks + N…(3c) Where -((N / 2)-1)>Kr+Ks.

9. A method for manufacturing a valve body assembly for use in an electric valve, characterized in that, A valve body assembly without rotor-side correction information is manufactured, the valve body assembly having: a valve body having a valve port; The valve comprises: a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates. Prepare a reference stator unit, which includes: a stator having a plurality of pole teeth; and a positioning member for positioning the stator relative to the valve body assembly, wherein the offset angle between the pole teeth of the stator and the positioning member is 0°. The valve body assembly without rotor-side correction information is combined with the reference stator unit, and a stepper motor is formed by the rotor and the stator. When the rotor is rotated in the valve-opening direction, a pulse train containing N pulses distributed in the order of [0] to [N-1] is input to the stepper motor in reverse order once or multiple times, and the rotor is rotated in the valve-closing direction until the movable stop abuts against the fixed stop. After the movable stop abuts against the fixed stop, when inputting up to pulse [0], the reverse sequence of pulse input is stopped. Then, the pulse train is input to the stepper motor once or multiple times in forward sequence starting from pulse [0], and the rotor-side valve opening pulse count is counted. This rotor-side valve opening pulse count is the number of pulses input until the valve port becomes the opening degree for the reference flow of fluid, or until the opening degree becomes the opening degree where the flow rate changes with the increment of one pulse input. The rotor-side correction information is generated based on the rotor-side valve opening pulse count. The rotor-side correction information includes information related to the misalignment angle between the rotor's magnetic poles and the movable stop. The rotor-side correction information, generated based on the number of valve opening pulses on the rotor side, is attached to the outer surface of the valve body assembly that does not have rotor-side correction information.

10. A method for manufacturing a stator unit, the stator unit being used in an electric valve, characterized in that, A stator unit without stator-side correction information is fabricated. This stator unit comprises: a stator having multiple pole teeth; and a positioning component for positioning the stator relative to the valve body assembly. Prepare a reference valve body assembly, which includes: a valve body having a valve port; The valve comprises: a rotor having a plurality of magnetic poles configured to rotate relative to the valve body; a movable stop fixed relative to the rotor; a fixed stop fixed relative to the valve body and abutting against the movable stop, thereby restricting rotation of the rotor in the valve-closing direction; and a valve core that changes the opening degree of the valve port as the rotor rotates, wherein the offset angle between the magnetic poles of the rotor and the movable stop is 0°. The stator unit without stator-side correction information is combined with the reference valve body assembly, and a stepper motor is formed by the rotor and the stator. When the rotor is rotated in the valve-opening direction, a pulse train containing N pulses distributed in the order of [0] to [N-1] is input to the stepper motor in reverse order once or multiple times, and the rotor is rotated in the valve-closing direction until the movable stop abuts against the fixed stop. After the movable stop abuts against the fixed stop, when inputting up to pulse [0], the reverse sequence of pulse train input is stopped. Then, the pulse train is input to the stepper motor once or multiple times in forward sequence starting from pulse [0], and the stator-side valve opening pulse count is counted. This stator-side valve opening pulse count is the number of pulses input until the valve port becomes the opening degree for the reference flow of fluid, or until the opening degree becomes the opening degree where the flow rate changes with the increment of one pulse input. The stator-side correction information is generated based on the stator-side valve opening pulse count. This stator-side correction information includes information regarding the misalignment angle between the stator pole teeth and the positioning component. The stator side correction information, generated based on the number of stator side valve opening pulses, is attached to the outer surface of the stator unit that does not have stator side correction information.

Images