Micro electromagnetic coil for electric drive and manufacturing method

Abstract

The invention discloses a miniature electromagnetic coil for electric driving and a manufacturing method, the miniature electromagnetic coil comprises a winding group, a piston and a shell, the shell is composed of a U-shaped upper shell and an L-shaped lower shell, and the section of the combination of the U-shaped upper shell and the L-shaped lower shell is E-shaped; the U-shaped upper shell is an E-shaped upper part, and a winding group is arranged in the U-shaped upper shell; the winding group is the lower part of the E shape, and the piston is arranged between the U-shaped upper shell and the winding group; the manufacturing method is used for manufacturing the miniature electromagnetic coil for electric driving and is characterized in that the shell is formed by welding the U-shaped upper shell and the L-shaped lower shell, and the U-shaped upper shell and the L-shaped lower shell are both single parts; the piston is an integrated single part.

Description

Technical Field

[0001] This invention belongs to the field of electromagnetic actuators in electric drive systems for automobile transmissions, and specifically relates to a miniature electromagnetic coil for electric drive and its manufacturing method. Background Technology

[0002] Existing electromagnetic coils have the following characteristics, such as Figure 3 The shell is a single complex irregular part with a W shape. The shell needs to accommodate both the winding and the piston at the same time, so the structure is relatively complex and the cost is relatively high. In order for the piston to move with low resistance under the magnetic field, it needs to contain both magnetic conductive material and magnetic shielding material. Therefore, the structure is relatively complex and the cost is relatively high. In addition, the use of two materials will make the radial space of the piston larger.

[0003] The W-shaped shell is complex because it needs to be made into a W shape to accommodate the winding and piston. One of the radially narrow cavities in the W-shape, and the relatively long and deep groove, need to be processed by machining. Machining is difficult, and it is necessary to reduce the machining speed and increase the machining cycle to ensure accuracy, resulting in high production costs.

[0004] The pistons used are also complex. To reduce the moving resistance of the sliding surface, the lower piston needs to be made of a magnetically shielding material; the upper piston needs to move under electromagnetic force, so it needs to be made of a magnetically conductive material; the entire piston is assembled from two parts of materials, each with a small wall thickness, making machining difficult. Summary of the Invention

[0005] This application provides a miniature electromagnetic coil for electric drive, including a winding assembly, a piston, and a housing. The housing is composed of a U-shaped upper housing and an L-shaped lower housing, and the cross-section of the combination of the U-shaped upper housing and the L-shaped lower housing is "E" shaped.

[0006] The U-shaped upper housing is the upper part of the "E" shape, and the interior of the U-shaped upper housing is used to set up the winding assembly;

[0007] The lower part of the winding assembly is "E" shaped, and a piston is installed between the U-shaped upper housing and the winding assembly.

[0008] The technical solution provided in this application also has the following technical features:

[0009] Preferably, in one embodiment of this application, the U-shaped upper shell and the winding assembly are welded together.

[0010] Preferably, in one embodiment of this application, the piston is a single component.

[0011] Preferably, in one embodiment of this application, the piston is made of a magnetically conductive material, and the U-shaped upper shell and the L-shaped lower shell are made of different materials, with the L-shaped lower shell being composed of a magnetically insulating material.

[0012] Preferably, in one embodiment of this application, the U-shaped upper shell does not include magnetic shielding material.

[0013] Preferably, in one embodiment of this application, the inner cavity corner of the winding assembly is chamfered.

[0014] Preferably, in one embodiment of this application, a method for manufacturing a micro electromagnetic coil for electric drive includes a housing composed of a U-shaped upper housing and an L-shaped lower housing welded together, wherein the U-shaped upper housing and the L-shaped lower housing are both single parts; and the piston is a single integrated part.

[0015] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.

[0016] This application, while maintaining the performance of the electromagnetic coil, reduces the cost of the electromagnetic coil, minimizes the radial space, and also has the following technical advantages:

[0017] This application achieves the following technical effects through structural optimization of the housing and piston: The housing, originally a complex W-shaped part, is split into U-shaped and L-shaped parts, significantly reducing the difficulty of machining and surface treatment. Even considering welding processes, the overall manufacturing cost is still significantly reduced. Simultaneously, replacing the L-shaped part with magnetically shielding material not only achieves magnetic shielding but also creates conditions for simplifying the piston structure. The piston is optimized from a combination of magnetically conductive and magnetically shielding materials into a single integral part made of a single magnetically conductive material. This reduces the number of parts, simplifies raw materials and processing techniques, and significantly reduces processing costs and assembly difficulty. It also avoids splicing errors and saves radial space, enabling the electromagnetic coil to achieve greater processing economy and structural reliability while reducing its size. Attached Figure Description

[0018] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0019] Figure 1 This is a partial cross-sectional view of a miniature electromagnetic coil for electric drive according to this application;

[0020] Figure 2 This is a three-dimensional half-sectional view of a micro electromagnetic coil for electric drive according to this application;

[0021] Figure 3 Here is a structural diagram of an existing electrically driven electromagnetic coil;

[0022] Components in the diagram:

[0023] 1. Winding assembly

[0024] 2. U-shaped upper shell

[0025] 3. L-shaped lower shell

[0026] 4. Piston

[0027] 5. W-shaped shell

[0028] 6. Internal piston

[0029] 7. External piston. Detailed Implementation

[0030] The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings. These embodiments are only for illustrating this application and are not intended to limit the invention.

[0031] In the description of this invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0033] Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0034] like Figure 1-2 A miniature electromagnetic coil for electric drive includes a winding assembly 1, a piston 4, and a housing. The housing is composed of a U-shaped upper housing 2 and an L-shaped lower housing 3, and the cross-section of the combination of the U-shaped upper housing 2 and the L-shaped lower housing 3 is "E" shaped.

[0035] The U-shaped upper housing 2 is the upper part of the "E" shape, and the interior of the U-shaped upper housing 2 is used to set the winding assembly 1;

[0036] The lower part of the winding assembly 1 is "E" shaped, and the piston 4 is set between the U-shaped upper housing 2 and the winding assembly 1;

[0037] This application separates the shell into U and L shapes. The narrower radial part is L-shaped, which is easy to process, has a short processing cycle, and low cost. At the same time, after being separated into two parts, the L-shaped part can be made of non-magnetic material, while the original one-piece shell w part needs to be magnetic. Therefore, the whole is made of magnetic material. This reduces the processing difficulty and saves materials.

[0038] Based on the modification of the shell into two parts and the use of magnetically shielding material for the L-shaped part, the piston no longer needs magnetic shielding and can therefore be made into a single unit. A single-unit piston eliminates the need to machine two parts or perform post-assembly machining. Simultaneously, the wall thickness is appropriately increased. Compared to the previous version, the thickness of the single-unit piston before machining is significantly lower than the sum of the thicknesses of the pistons made of the two materials before machining. The thickness of the single-unit piston after machining is also lower than the sum of the thicknesses of the pistons made of the two materials after machining. This improves machinability, reduces machining and material costs, and simultaneously reduces the space required for the part, providing room for improvement in part miniaturization.

[0039] When this application is implemented, the key points are as follows: The housing is formed by welding and fixing together a U-shaped upper housing 2 and an L-shaped lower housing 3, and the whole has an "E" shaped cross section. The internal space of the U-shaped upper housing 2 is used to accommodate the winding assembly 1, and the L-shaped lower housing 3 is made of magnetic shielding material to provide magnetic shielding function. The winding assembly 1 is installed inside the U-shaped upper housing 2, and chamfers are set at its inner cavity corners to improve the adaptability and reliability of the winding installation. The piston 4 is arranged between the U-shaped upper housing 2 and the winding assembly 1. The piston 4 is a one-piece formed magnetic conductive material component, thereby reducing the number of parts and radial space while ensuring the continuity of the magnetic circuit.

[0040] The working principle or process of this application is as follows: When current flows into the winding assembly 1, the winding assembly 1 forms an effective magnetic field under the magnetic guidance of the U-shaped upper housing 2 and the magnetic isolation of the L-shaped lower housing 3. The magnetic lines of force are concentrated on the piston 4, causing the piston 4 to move axially under the action of the magnetic force. Through the reciprocating motion of the piston 4, the corresponding actuator in the automotive transmission system can be driven to complete the opening, closing or adjustment action. Since the piston 4 is a single integral part of a single magnetic material, its movement process has low resistance and high stability, while avoiding the problem of magnetic circuit discontinuity caused by material splicing. The E-shaped structure of the housing not only ensures the effective closure of the magnetic circuit, but also reduces magnetic field leakage through the setting of the magnetic isolation part, thereby achieving high electromagnetic efficiency and reliability in a compact volume.

[0041] Specifically, in one embodiment of this application, the U-shaped upper housing 2 and the winding assembly 1 are welded together; the piston 4 is a single part; the piston 4 is composed of magnetically conductive material; the U-shaped upper housing 2 and the L-shaped lower housing 3 are made of different materials; the L-shaped lower housing 3 includes magnetically shielding material; the U-shaped upper housing 2 does not include magnetically shielding material; the inner corner of the winding assembly 1 is chamfered.

[0042] Specifically, in one embodiment of this application, a method for manufacturing a micro electromagnetic coil for electric drive is provided, wherein the housing is composed of a U-shaped upper housing 2 and an L-shaped lower housing 3 welded together, and both the U-shaped upper housing 2 and the L-shaped lower housing 3 are single parts; the piston 4 is a single integrated part.

[0043] The shell is made up of complex and difficult-to-machine W-shaped parts, which are then broken down into easier-to-machine U-shaped and L-shaped parts, and the two parts are welded together.

[0044] The piston has been simplified from a combination of magnetically conductive and magnetically shielding materials to a single magnetically conductive material; the magnetic shielding effect is achieved by replacing the L-shaped portion in the housing with magnetically shielding material.

[0045] After the housing is split into two parts, the shape is simpler and easier to machine and surface treat. Even after considering the increased welding costs, the overall cost of the housing is still significantly reduced; at the same time, it provides the possibility of simplifying the piston.

[0046] The piston has been reduced from two parts to one, significantly reducing raw material costs. The manufacturing process has been simplified from machining two parts separately, interference fitting, and finishing after assembly to finishing a single part, greatly reducing manufacturing costs. At the same time, it can reduce a large amount of radial space.

[0047] In summary, this invention aims to solve the problems of complex structure, high processing difficulty, high cost, and large radial space occupation caused by the need for the piston to use both magnetically conductive and magnetically shielding materials. By optimizing the shell into an E-shaped structure composed of a U-shaped upper shell and an L-shaped lower shell welded together, with the L-shaped part undertaking the magnetic shielding function, and simplifying the piston into a single integral part made of a single magnetically conductive material, combined with the chamfering design of the inner cavity of the winding assembly and the simplification of the manufacturing process, the invention achieves the goal of reducing costs, minimizing radial space, and improving processing economy and structural reliability of the electromagnetic coil while maintaining performance.

[0048] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the scope of protection of the present invention.

Claims

1. A miniature electromagnetic coil for electric drive, comprising a winding assembly (1), a piston (4), and a housing, characterized in that, The shell consists of a U-shaped upper shell (2) and an L-shaped lower shell (3), and the cross section of the combination of the U-shaped upper shell (2) and the L-shaped lower shell (3) is "E" shaped; The U-shaped upper shell (2) is the upper part of the "E" shape, and the interior of the U-shaped upper shell (2) is used to set the winding assembly (1); The lower part of the winding assembly (1) is "E" shaped, and a piston (4) is set between the U-shaped upper housing (2) and the winding assembly (1).

2. The miniature electromagnetic coil for electric drive as described in claim 1, characterized in that, The U-shaped upper shell (2) and the winding group (1) are welded together.

3. A miniature electromagnetic coil for electric drive as described in claim 1, characterized in that, The piston (4) is a single part.

4. A miniature electromagnetic coil for electric drive as described in claim 1, characterized in that, The piston (4) is made of magnetically conductive material. The U-shaped upper shell (2) and the L-shaped lower shell (3) are made of different materials. The L-shaped lower shell (3) is made of magnetically insulating material.

5. A miniature electromagnetic coil for electric drive as described in claim 1, characterized in that, The U-shaped upper shell (2) does not include magnetic shielding material.

6. A miniature electromagnetic coil for electric drive as described in claim 1, characterized in that, The inner cavity angle of the winding assembly (1) is chamfered.

7. A method for manufacturing a miniature electromagnetic coil for electric drive, used to manufacture the miniature electromagnetic coil for electric drive according to any one of claims 1-6, characterized in that, The shell is composed of a U-shaped upper shell (2) and an L-shaped lower shell (3) welded together. Both the U-shaped upper shell (2) and the L-shaped lower shell (3) are single parts. The piston (4) is a single part that is integrated into one piece.

Images