Solenoid device and solenoid valve

Abstract

To provide a solenoid device which improves efficiency of assembly work and achieves reduction of manufacturing costs by reduction in the number of components, and to provide an electromagnetic valve having the solenoid device.SOLUTION: A solenoid device 1 includes: a bobbin 2; a core 6 and a yoke 5 which are inserted into the bobbin 2; a plunger 3 which may move at the inner side of the yoke 5; a coil 4 which is wound around the bobbin 2 and generates a magnetic force by energization to move the plunger 3; a pin 7 which is disposed at the inner side of the core 6 and may move with the plunger 2; and a case 9 which houses these components and has a bottomed cylinder shape. The case 9 has a butted part 913 protruding from a bottom part 912. An end surface 913a, which is orthogonal to an axis O direction, of the butted part 913 contacts with an end surface 23 of the bobbin 2, and an inner peripheral surface 913b contacts with an outer peripheral surface 51 of the yoke 5.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a solenoid device and a solenoid valve.

Background Art

[0002] An electromagnetic hydraulic control valve (solenoid valve) using a linear solenoid (solenoid device) is known (see, for example, Patent Document 1). This linear solenoid has a case, a sliding stator disposed within the case, and a plunger that slides within the sliding stator and moves the shaft in the axial direction. Further, a ring-shaped auxiliary core is provided within the case to reinforce the magnetic coupling between the sliding stator and the case.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the linear solenoid having the above configuration, not only does the number of parts increase, but the man - hours for the assembly work also increase, making it easy for the manufacturing cost to rise. An object of the present invention is to provide a solenoid device capable of improving the efficiency of the assembly work and reducing the manufacturing cost by reducing the number of parts, and a solenoid valve having such a solenoid device.

Means for Solving the Problems

[0005] One aspect of the solenoid device of the present invention is a cylindrical bobbin, a cylindrical core inserted into one axial side of the bobbin, a cylindrical yoke inserted into the other axial side of the bobbin, A plunger inserted into the yoke and movable along the axial direction, A coil wound around the outer periphery of the bobbin, generating a magnetic force upon energization to move the plunger along the axial direction, A pin inserted into the core and movable along the axial direction together with the plunger, A bottomed cylindrical case having one axial side open and the other side closed, accommodating the bobbin, the plunger, the coil, the yoke, the core and the pin, and comprising a case made of a magnetic material, The case has a cylindrical abutting portion protruding toward one axial side at the bottom, an end face of the abutting portion perpendicular to the axial direction contacts an end face of the other axial side of the bobbin, and an inner peripheral surface contacts an outer peripheral surface of the yoke.

[0006] Also, one aspect of the solenoid device of the present invention includes the solenoid device having the case made of an iron-based material as the magnetic material, and a valve mechanism mounted on one axial side of the solenoid device, The valve mechanism has a nozzle formed in a cylindrical shape and made of an aluminum-based material, and a valve body disposed in the nozzle and movable along the axial direction together with the pin, The nozzle has a flange portion protruding radially outward at an end portion on the other axial side, The nozzle is connected to the solenoid device by covering the flange portion with the caulking margin, and an end portion on the radially inner side of the caulking margin is joined to the flange portion by a welding alloy portion containing iron and aluminum.

Advantages of the Invention

[0007] According to one aspect of the solenoid device of the present invention, by reducing the number of parts, the efficiency of the assembly work can be improved and the manufacturing cost can be reduced.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Embodiments for Carrying Out the Invention

[0009] Embodiments of the solenoid device and the solenoid valve of the present invention will be described with reference to FIGS. 1 and 2. For convenience of explanation, three axes orthogonal to each other, namely the X-axis, the Y-axis, and the Z-axis, are set below. As an example, the XY plane including the X-axis and the Y-axis is horizontal, and the Z-axis is vertical. Also, the X-axis direction is the "axis O direction", the radial direction centered on the axis O may be simply referred to as the "radial direction", and the circumferential direction centered on the axis O may be simply referred to as the "circumferential direction".

[0010] And the positive side in the X-axis direction corresponds to the "one side in the axis O direction", and the negative side in the X-axis direction corresponds to the "other side in the axis O direction". In this specification, the terms "vertical direction", "horizontal direction", "upper side", and "lower side" are used simply to explain the relative positional relationship of each part. Therefore, the actual positional relationship of each part may be different from the positional relationship indicated by these terms.

[0011] As shown in FIGS. 1 and 2, the solenoid valve 100 has a solenoid device 1 and a valve mechanism 10 mounted on the positive side in the X-axis direction of the solenoid device 1. The valve mechanism 10 includes a cylindrical nozzle 20 having a spool hole 201 and a spool valve (valve body) 30 arranged movably along the X-axis direction within the nozzle 20 (spool hole 201). The nozzle 20 has a plurality of through holes (ports) penetrating through its cylindrical wall through which fluid (for example, oil) passes, and the connection state of the through holes is changed by the movement of the spool valve 30 along the X-axis direction.

[0012] Further, the nozzle 20 is provided with a flange portion 202 that protrudes radially outward at the end on the negative side in the X-axis direction. As shown in FIG. 2, a plurality of caulking margins 911a are formed on the case 9 (barrel portion 911) of the solenoid device 1 described later by deforming the opening edge portion thereof by caulking (hereinafter referred to as "caulking"). Then, by covering the flange portion 202 with these caulking margins 911a, the valve mechanism 10 is connected to the solenoid device 1. The nozzle 20 is made of, for example, an aluminum-based material (such as pure aluminum or an aluminum alloy). Note that the spool valve 30 is biased toward the negative side in the X-axis direction by a coil spring (biasing member) disposed in a spool hole 201 (not shown).

[0013] As shown in FIG. 1, the solenoid device 1 includes a bobbin 2, a plunger 3, a coil 4, a yoke 5, a core 6, a pin 7, and a case 9. The bobbin 2 is a cylindrical member having a through hole 21. The through hole 21 penetrates the bobbin 2 along the X-axis direction. Further, the inner diameter of the through hole 21 is constant along the X-axis direction. The bobbin 2 is made of various resin materials such as polyester and polyimide, for example.

[0014] A coil 4 formed by winding a conductive wire is disposed on the outer peripheral portion 22 of the bobbin 2. With the energization of this coil 4, a magnetic circuit is formed by the bobbin 2, the yoke 5, and the core 6, and a magnetic force is generated. Thereby, the plunger 3 can be moved along the X-axis direction.

[0015] The yoke 5 and the core 6 are inserted into the through hole 21 of the bobbin 2. Further, the plunger 3 is inserted inside the yoke 5, and the pin 7 is inserted inside the core 6. In other words, the yoke 5 is disposed between the bobbin 2 and the plunger 3, and the core 6 is disposed between the bobbin 2 and the pin 7. With respect to the bobbin 2, the yoke 5 is arranged on the negative side in the X-axis direction, and the core 6 is arranged on the positive side in the X-axis direction.

[0016] The yoke 5 is a cylindrical member having a through hole 50 penetrating along the X-axis direction and is arranged along the X-axis direction. Also, the core 6 is a cylindrical member having a through hole 60 penetrating along the X-axis direction and is arranged along the X-axis direction. The yoke 5 and the core 6 are made of a soft magnetic material (soft magnetic metal material) such as iron, for example. Thereby, a magnetic circuit capable of sufficiently moving the plunger 3 can be generated.

[0017] The end portion of the yoke 5 on the positive side in the X-axis direction has a tapered shape with its thickness decreasing toward the positive side in the X-axis direction. Also, the end portion of the core 6 on the negative side in the X-axis direction has a tapered shape with its thickness decreasing toward the negative side in the X-axis direction. With such a configuration, the magnetic force generated by the formed magnetic circuit can be more easily made to act preferentially on the plunger 3.

[0018] The plunger 3 is arranged inside the yoke 5 (inserted into the through hole 50) and is supported so as to be movable alternately in the positive and negative directions along the X-axis direction (that is, reciprocally movable). Also, when the plunger 3 moves in the positive direction in the X-axis direction, the end portion thereof on the positive side in the X-axis direction is located inside the recess 68 formed on the negative side in the X-axis direction of the core 6. The inner diameter of this recess 68 is the same as or slightly larger than the inner diameter of the through hole 50. The plunger 3 has a cylindrical shape, and a through hole 31 is formed along the X-axis direction. The gas inside the solenoid device 1 moves through this through hole 31. Thereby, the movement of the plunger 3 along the X-axis direction is made smooth.

[0019] The pin 7 arranged inside the core 6 (inserted into the through hole 60) has a columnar shape and is movable in the X-axis direction by being pressed by the plunger 3. By this pin 7 pressing the spool valve 30, the spool valve 30 moves toward the positive side in the X-axis direction. On the other hand, when the energization of the coil 4 is released, the spool valve 30 moves toward the negative side in the X-axis direction by the biasing force of the coil spring in the spool hole 201. Then, the spool valve 30 presses the pin 7 and the plunger 3 to move them toward the negative side in the X-axis direction.

[0020] The pin 7 is made of a lightweight metal material such as aluminum, for example. The pin 7 of the present embodiment has a pin body 71 and a diameter-expanded portion 72 provided at the end of the pin body 71 on the negative side in the X-axis direction and having a diameter larger than the inner diameter of the through hole 60 (core 6). When the pin 7 moves most toward the positive side in the X-axis direction, the diameter-expanded portion 72 contacts the opening edge portion on the negative side in the X-axis direction of the through hole 60. With such a configuration, it is possible to prevent the pin 7 from easily falling off from the core 6 (solenoid device 1) during storage of the solenoid device 1 or when it is attached to the valve mechanism 10.

[0021] Further, the core 6 has a recess 69 recessed toward the positive side in the X-axis direction on the bottom surface of the recess 68. The recess 69 can accommodate the diameter-expanded portion 72 of the pin 7. By providing the recess 69 and the recess 68, the length of the solenoid device 1 in the X-axis direction can be shortened. The diameter-expanded portion 72 is configured such that a part thereof protrudes toward the negative side in the X-axis direction from the recess 69 in a state of being housed in the recess 69. Thereby, the plunger 3 can surely press the pin 7 toward the positive side in the X-axis direction.

[0022] Further, the surface 721 on the negative side in the X-axis direction of the diameter-expanded portion 72 has a spherical shape. In this case, the influence of the inclination of the pin 7 is reduced, and the pressing force of the plunger 3 is easily transmitted in the X-axis direction of the pin 7. The pin 7 further has a diameter-reduced portion 73 having a diameter smaller than the outer diameter of the pin body 71 at the boundary between the pin body 71 and the diameter-expanded portion 72. By providing this diameter-reduced portion 73, it is easy to prevent interference with the core 6 (particularly, the opening edge portion on the negative side in the X-axis direction of the through hole 60) at the boundary between the pin body 71 and the diameter-expanded portion 72.

[0023] The core 6 is provided with a flange portion 61 protruding radially outward at the end on the positive side in the X-axis direction. Case 9 houses a bobbin 2, a plunger 3, a coil 4, a yoke 5, a core 6, and a pin 7. The case 9 has a case body 91 and a connector member 92. A connector (not shown) for energizing the coil 4 is connected to the connector member 92. This connector member 92 is made of, for example, a resin material like the bobbin 2. The case body 91 is a bottomed cylindrical member including a cylindrical body portion 911 extending along the X-axis direction and a bottom portion 912 closing the negative side of the body portion 911 in the X-axis direction. Therefore, the positive side of the case body 91 in the X-axis direction is open.

[0024] Then, with the flange portion 202 of the nozzle 20 in contact with the flange portion 61 of the core 6, the outer peripheral edge portion thereof is covered by three caulking ridges 911a formed on the opening edge portion of the case 9. As a result, the bobbin 2, the plunger 3, the coil 4, the yoke 5, the core 6, and the pin 7 are housed in the case 9, and the core 6 is in a state where its movement in the positive X-axis direction is restricted, so that each part is fixed and the solenoid device 1 is assembled. Also, in this state, the valve mechanism 10 is connected to the solenoid device 1.

[0025] The case body 91 is made of a magnetic material such as, for example, an iron-based material (pure iron, iron alloy, etc.). And in this embodiment, each caulking ridge 911a has its radially inner end joined to the flange portion 202 by a welding alloy portion 94 containing iron and aluminum. Thereby, the valve mechanism 10 can be firmly fixed to the solenoid device 1. Also, during the operation (welding operation) of forming the welding alloy portion 94, since the nozzle 20 is fixed to the case body 91 by the caulking ridges 911a, that operation can be performed more accurately. [[ID=I9]]In this embodiment, the three caulking ridges 911a are arranged at substantially equal intervals along the circumferential direction of the flange portion 202. Thereby, a stable mounting state of the valve mechanism 10 to the solenoid device 1 can be ensured. In addition, in this specification, the term "substantially equally spaced" is a concept that includes not only the aspect where the intervals are constant but also the aspect where there are slight variations.

[0026] As shown in FIG. 2, the welding alloy portion 94 is in a spot shape and is located across the caulking margin 911a and the flange portion 202. Thereby, the valve mechanism 10 can be firmly fixed by the solenoid device 1. Also, when the welding alloy portion 94 is viewed from the positive side in the X-axis direction, the ratio of the area of the portion 94a located on the flange portion 202 to the area of the portion 94b located on the caulking margin 911a is preferably 4 / 6 to 6 / 4, and more preferably 5 / 6 to 5 / 4. In this case, the strength of the welding alloy portion 94 can be further increased. The aluminum content in the welding alloy portion 94 is preferably 45% by mass or less, more preferably 5 to 40% by mass, and even more preferably 10 to 33% by mass. In this case, the ratio of the amounts of iron and aluminum in the welding alloy portion 94 becomes appropriate, and its strength and wear resistance can be further improved.

[0027] Each welding alloy portion 94 is preferably a welding alloy portion formed by laser welding. According to laser welding, it is easy to form the welding alloy portion 94 having a desired size (in other words, the aluminum content is a desired value). When laser welding is used, the spot diameter of the laser beam is not particularly limited, but is preferably about 0.15 to 0.35 mm, and more preferably about 0.2 to 0.3 mm. In addition, examples of the laser beam that can be used include a gas laser, a solid laser, a semiconductor laser, and a liquid laser, but a carbon dioxide laser and a YAG laser are preferred.

[0028] Also, the case 9 has a cylindrical abutting portion 913 that protrudes toward the positive side in the X-axis direction at its bottom portion 912. The abutting portion 913 has an end face 913a orthogonal to the X-axis direction thereof in contact with the end face 23 on the negative side in the X-axis direction of the bobbin 2, and an inner peripheral surface 913b in contact with the outer peripheral surface 51 of the yoke 5. According to such a configuration, by reducing the number of components of the solenoid device 1, the efficiency of the assembly work can be improved, and the manufacturing cost can be reduced. Further, the magnetic flux is transferred between the case 9 and the yoke 5 without disturbance and surely, so that the plunger 3 can move more accurately.

[0029] The end face 23 of the bobbin 2 is also orthogonal to the X-axis direction. In other words, the end face 913a of the abutting portion 913 and the end face 23 of the bobbin 2 are not inclined with respect to the X-axis direction. For this reason, when assembling the solenoid device 1, it becomes difficult for the case 9 and the bobbin 2 to be displaced in the radial direction. As a result, it is possible to prevent the inner peripheral surface of the bobbin 2 and the outer peripheral surface 51 of the yoke 5 from being separated, and to prevent disturbance of the magnetic flux. The case 9 further has an annular groove 914 that is located on the radially outer side of the abutting portion 913 at the bottom portion 912 and is recessed in the negative X-axis direction. This groove 914 functions to secure a space between the case 9 and the bobbin 2. Due to the presence of such a groove 914, it is possible to prevent unnecessary portions of the bobbin 2 from interfering with the bottom portion 912 of the case 9, and to more surely prevent the inner peripheral surface of the bobbin 2 and the outer peripheral surface 51 of the yoke 5 from being separated due to deformation of the bobbin 2 caused by this interference.

[0030] As described above, the solenoid device and the electromagnetic valve of the present invention have been described with respect to the illustrated embodiments. However, the present invention is not limited to this, and each part constituting the solenoid device and the electromagnetic valve can be replaced with any configuration that can exhibit the same function. Further, any component may be added. Further, in the above embodiment, the core 6 is restricted from moving in the positive X-axis direction by the caulking margin 911a of the case 9 indirectly covering the positive X-axis side via the flange portion 202. However, when the valve mechanism 10 is omitted, the core 6 (flange portion 61) may be restricted from moving in the positive X-axis direction by the caulking margin 911a of the case 9 directly covering the positive X-axis side. In this case, the solenoid device 1 can be mounted and used on a mounted body such as a valve body.

[0031] Also, the number of caulking portions 911a is not limited to three, and may be one, two, or four or more. Also, although the case where one welding alloy portion 94 is provided for each caulking portion 911a has been shown, a plurality of welding alloy portions 94 may be provided. Note that the shape of the welding alloy portion 94 is not limited to a spot shape, and may be an arc shape along the inner end portion in the radial direction of the caulking portion 911a. Also, the valve body disposed in the nozzle is not limited to the spool valve 30, and may be a valve body having other functions.

Description of Reference Numerals

[0032] 100... solenoid valve, 1... solenoid device, 2... bobbin, 21... through hole, 22... outer peripheral portion, 23... end face, 3... plunger, 31... through hole, 4... coil, 5... yoke, 50... through hole, 51... outer peripheral surface, 6... core, 60... through hole, 61... flange portion, 7... pin, 71... pin body, 72... enlarged diameter portion, 721... surface, 73... reduced diameter portion, 9... case, 91... case body, 911... barrel portion, 911a... caulking portion, 912... bottom portion, 913... abutting portion, 913a... end face, 913b... inner peripheral surface, 914... groove, 92... connector member, 94... welding alloy portion, 94a, 94b... portions, 10... valve mechanism, 20... nozzle, 201... spool hole, 202... flange portion, 30... spool valve, O... axis

Claims

1. A cylindrical bobbin, A cylindrical core inserted into one axial side of the bobbin, A cylindrical yoke inserted into the other axial side of the bobbin, A plunger inserted into the yoke and movable along the axial direction, A coil wound around the outer peripheral portion of the bobbin, which generates a magnetic force upon energization and moves the plunger along the axial direction, A pin inserted into the core and movable along the axial direction together with the plunger, A bottomed cylindrical case having an opening on one axial side and a closed end on the other axial side, and comprising the case made of a magnetic material that houses the bobbin, the plunger, the coil, the yoke, the core, and the pin, The case has a cylindrical abutting portion protruding toward one axial side at the bottom, and an end face orthogonal to the axial direction of the abutting portion contacts the end face on the other axial side of the bobbin, and the inner peripheral surface contacts the outer peripheral surface of the yoke, The end face on the other axial side of the bobbin has a recess recessed toward one axial side of the bobbin, and the end face of the abutting portion is accommodated in the recess, The case further has an annular groove provided on the bottom, located outside the radial direction of the abutting portion, and recessed toward the other axial side, to secure a space between the case and the bobbin, The annular groove covers an end face other than the recess and a part of the recess among the end faces on the other axial side of the bobbin, and a part of the annular groove is formed by the abutting portion. A solenoid device characterized by this.

2. The solenoid device according to claim 1, wherein the core is directly or indirectly covered by at least one caulked edge obtained by deforming the opening edge of the case by caulking on one axial side, thereby restricting movement in the axial direction on one axial side.

3. The solenoid device according to claim 2, comprising the case made of an iron-based material as the magnetic material, and a valve mechanism mounted on one axial side of the solenoid device, The valve mechanism has a nozzle formed in a cylindrical shape and made of an aluminum-based material, and a valve body disposed in the nozzle and movable along the axial direction together with the pin, The nozzle has a flange portion protruding radially outward at the end on the other axial side, The nozzle is connected to the solenoid device by covering the flange portion with the caulking margin, and the end portion on the radially inner side of the caulking margin is joined to the flange portion by a welding alloy portion containing iron and aluminum. A solenoid valve characterized by this.

4. The solenoid valve according to claim 3, wherein the case has a plurality of the caulking margins arranged at substantially equal intervals along the circumferential direction of the flange portion.

5. The solenoid valve according to claim 3 or 4, wherein the welding alloy portion is in a spot shape and is located across the caulking margin and the flange portion.

6. The solenoid valve according to claim 5, wherein when the welding alloy portion is viewed from one axial side, the ratio of the area of the portion located on the flange portion to the area of the portion located on the caulking margin is 4 / 6 to 6 / 4.

7. The solenoid valve according to any one of claims 3 to 6, wherein the welding alloy portion is a welding alloy portion by laser welding.

8. The solenoid valve according to any one of claims 3 to 7, wherein the aluminum content in the welding alloy portion is 45% by mass or less.

9. The solenoid valve according to any one of claims 3 to 8, wherein the valve body is a spool valve movable along the axial direction together with the pin.

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