JPH0560772A - Manufacture of sensor and sensor manufactured through said method - Google Patents

Abstract

PURPOSE: To enable almost complete automatic manufacturing without using manual operation space, and enable surely laying the winding of a coil without forming a large loop, in a manufacturing method of a sensor. CONSTITUTION: The starting end of winding of a coil 14 is fixed to the end section 18 of a first current rail 15 facing the coil and protruding outward. The winding is guided to a first trench formed in a coil body 13, and the coil is wound to be multilayered. The terminal part of winding of the coil is guided to a second trench and fixed to the end section 18 of a second current rail 15 facing the coil and protruding outward. The starting end and the terminal part of winding of the coil are soldered with the respective end sections 18 of the current rails. The end sections 18 of the current rails are bent in the direction leaving from the coil, and toward the coil body.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sensor, in particular a rotational speed sensor, in which a casing of the sensor is provided with a coil body having at least one coil and a current rail, The present invention relates to a type in which the ends of the coil windings are fixed to a rail.

The invention further relates to a sensor, in particular a rotation sensor, in which the housing of the sensor is provided with a coil body comprising at least one coil and a current rail, the current rail being wound by the coil. It relates to a type in which the ends of the wire are fixed.

[0003]

PRIOR ART German Patent Application Publication No. 340
In the rotation speed sensor known from the specification of 0870, the end of the current rail on the coil side protrudes outward in the radial direction during assembly, so that the coil can be smoothly fixed to the current rail and wound around the coil body. You can Subsequently, said end of the current rail is folded towards the coil and is joined by brazing to the coil end. However, when the end of the current rail is bent, a relatively large wire loop is formed, which has to be laid manually. At this time, the wire may be damaged. Such a pre-damaged rotation speed sensor may fail due to a damaged coil wire, even under a slight load in actual use.

Furthermore, in the rotational speed sensor disclosed in DE-A-3930702.6, the end of the current rail extends to just before the coil shield provided on the coil body. .. In order to wind the coil wire around the current rail, the end of the current rail on the coil side is slightly bent from the coil body. A wire is wound around this end toward the end of the current rail starting from the bent portion. Subsequent bending of the ends back toward the coil body creates a relatively large loop. Such large loops are susceptible to damage during manufacturing.

[0005]

SUMMARY OF THE INVENTION The object of the invention is to improve a method of the type mentioned at the outset, which enables an almost completely automatic production without manual space and without a large loop formation. The purpose is to provide such a method which allows the reliable laying of the windings.

A further object of the invention is to provide an advantageous sensor manufactured by this method.

[0007]

In order to solve this problem, the method according to the invention is characterized in that the starting end of the winding of the coil is the end of the first current rail which faces the coil and projects outwardly. Fixed to a section, guiding the winding into a first groove provided in the coil body, winding the coil in multiple layers, guiding the end of the winding of the coil into a second groove, terminating A portion is fixed to an end section of the second current rail which faces the coil and projects outward, and a start end and an end section of a winding of the coil are brazed to the end section of the current rail, The end section of the current rail is bent toward the coil body in a direction away from the coil.

In order to solve the above-mentioned problems, in the structure of the sensor of the present invention, each current rail has an end section bent in a direction away from the coil, and the end section of the coil winding is provided at the end section. The part or the end part is brazed.

[0009]

The method according to the invention or the sensor according to the invention has the advantage over the prior art that relatively small loops of wire are created during bending of the current rail. This small loop can hardly be damaged during the manufacturing process. There is no need to manually lay wires. In addition, the folding of the current rails is done mechanically. Next, when the current rail and the coil body are embedded in the plastic material by injection molding of plastic, the plastic material is directly injected into the current rail, and the current rail is pressed against the protrusion provided on the coil body. The method according to the invention can be easily integrated into conventional production methods, so that automatic brazing in the dip bath can be maintained. Similarly,
Almost all conventional manufacturing equipment can continue to be used.

[0010]

Embodiments of the present invention will now be described in detail with reference to the drawings.

In FIG. 1, the first casing portion of the rotation speed sensor 11 is indicated by reference numeral 10. This casing part 10
May be made of special steel that is not magnetically conductive, and is open upwards to form a pot. A vertically long coil body 13 having a coil 14 having a winding is inserted in the casing portion 10. Coil 14
The windings of are connected to two current rails 15 (positioned one behind the other in the drawing). The free end of the current rail 15 projecting upwards is
Is connected to the conductor 16 of the two-core connecting cable 17 by, for example, welding for the purpose of supplying power to and receiving signals. The coil-side end section 18 of the current rail 15 is bent and projects away from the coil 14. However, due to this, the current rail 15
The bent portion 19 is located as close as possible to the coil shield 20 of the coil body 13. The coil shields are two limiting portions formed on the coil body for the purpose of partitioning the coil 14. At the end section 18 of the current rail 15, each end of the winding of the coil 14, i.e. the start or end, is fixed. Coil body 13
The magnet core 22 is inserted downwardly in this direction, that is, toward the gear or other rotating part (not shown) whose rotational movement is to be measured.

The first casing part 10 is closed by the second casing part 25. The second casing member 25 is made of thermoplastic, for example, by an injection molding method. Second casing part 2
5 is projecting into the first casing part 10 and at the same time the end section of the cable 17 and the conductor 16 of the cable 17
And covers the current rail 15 and the end of the coil body 13. This second casing member 25 also at least partially covers the end section 18 but does not penetrate into the area of the coil 14. Both casing members 1
0 and 25 are connected to each other by curving and are sealed with an O-ring 26.

Electrical component, namely the current rail 1
5 and the coil 14 are pre-assembled on the coil body 13 and subsequently inserted together as a component unit into the first casing part 10. What is important in this pre-assembly is how both ends of the winding of the coil 14 are fixed to the current rail 15. To explain this, FIGS. 4 and 5 show the individual assembly steps, and FIGS. 2 and 3 show the respective final states.

In the starting position, the end section 18 of the current rail 15 projects radially outwardly away from the coil body 13. In addition, the current rail 15 has a section 30 directly following the end section 18, which section 30 is bent at an acute angle from the coil body 13. The current rail 15 comprises a retaining projection 3 which is provided as close as possible to the folded section 30.
2 can be fixed to the coil body 13. This starting position is indicated by the symbol I in FIG. The beginning of the winding of the coil 14 is wound on the outwardly projecting end section 18 of one of the current rails. In this case, the winding operation is started as close to the end of the end section 18 as possible and the winding is wound towards the bend 19 of the current rail 15. The winding sections located behind the current rail are shown in broken lines in FIGS. In the area of the bend 19, the end section 1 of the current rail 15
8 has two small protrusions 35. These two
The winding is guided diagonally between the two projections 35, which prevents slippage of the winding during assembly, i.e. before brazing. The winding then extends below the end section 18 and is guided in a groove 36 provided in the coil body 13. The size of the groove 36 is set according to the loop of the winding wire produced after the assembling.
The winding is wound between the coil shields 20 in multiple layers around the coil body 13 depending on the desired configuration of the coil 14. The end of the winding of the coil 14 is then guided through the groove 39, which is designed to substantially correspond to the groove 36, to the outwardly projecting end section 18 of the second current rail 15. Furthermore, regarding the dimensions of the grooves 36; 39,
Of course, the thickness of the entire coil 14 must be taken into consideration. This is because the groove 36 communicates with the position of the coil start end of the coil body 13 and the groove 39 communicates with the position of the coil 14 end of the coil body. Both grooves 36 and 39 are formed in the winding direction. The winding is guided under the end section 18 of the current rail 15 as far as possible through the region of the bend 19 of the current rail and is drawn again between the projections 35 of the end section 18, so that The winding located is no longer slipped off. The end of the winding is then further towards the end of said end section 18 said end section 18
Wrapped around a few times. This means that the beginning and end of the winding have been preassembled on both end sections 18 of both current rails 15 and can then be brazed to the current rails. No improvement over conventional brazing methods is required at this step, since a dip brazing method can be used for this.

Subsequently, the radially outwardly projecting end section 18 is bent at the bend 19 towards the current rail 15, so that the end section 18 is bent.
It extends almost parallel to 0. This assembled state is indicated by reference numeral II in FIG. In a subsequent bending step, the bent section 30 and the end section 18 are pressed against the coil body 13 again, in which case the current rail 15 also contacts the coil body 13 in said section 30. The length of the current rail 15 is shown in FIG.
The bending range 19 is set so as to contact the coil shield 20 of the coil body 13 as close as possible in the final state shown by. Furthermore, this final state III
The winding is a relatively small loop so that both grooves 3
Located within 6,39. Such a final state III for the beginning of the winding is shown in FIG. 2 and a final state III for the end of the winding is shown in FIG.

The current rail 15, coil 14, and coil body 13 can be embedded in the plastic during plastic injection molding, as described above. No manual space is required for the assembly steps, as all the assembly steps can be carried out automatically. These prefabricated components are inserted into the first casing part 10 in a known general-purpose manner and the second casing part 12 is integrally injection-molded.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view showing a sensor according to the present invention in a completely assembled state.

FIG. 2 is a side view of the coil side end of the current rail as viewed from the winding start end side.

FIG. 3 is a side view of the coil side end of the current rail as viewed from the winding terminal end side.

FIG. 4 is a cross-sectional view of the portion shown in FIG. 2 or FIG. 3 as seen from the direction A in a state where the ends of the current rail are not bent.

FIG. 5 is a cross-sectional view showing individual bending steps of an end section of a current rail.

[Explanation of symbols]

 10 Casing Part 11 Rotational Speed Sensor 13 Coil Body 14 Coil 15 Current Rail 16 Conductor 17 Connection Cable 18 End Section 19 Bending Part 20 Coil Shield 22 Magnet Core 25 Casing Part 26 O Ring 30 Section 32 Holding Protrusion 35 Protrusion 36, 39 Groove

Claims (10)

[Claims] 1. A method of manufacturing a sensor, wherein a casing (10, 25) of the sensor is provided with a coil body (13) comprising at least one coil (14) and a current rail (15). A type in which the end of the winding of the coil (14) is fixed to the current rail (15), the starting end of the winding of the coil (14) faces the coil (14) and is outward. Fixed to the end section (18) of the first current rail (15) projecting in the first winding (3) and the winding is provided in a first groove (3) provided in the coil body (13)
6), the coil (14) is wound in multiple layers, the terminal end of the winding of the coil (14) is guided to the second groove (39), and the terminal end is wound around the coil (14). A second current rail (1 facing and projecting outward)
5) fixed to the end section (18) of the coil (14), the beginning and end of the winding of the coil (14) are brazed to each end section (18) of the current rail (15), 1
5) Method for manufacturing a sensor, characterized in that the end section (18) of 5) is bent towards the coil body (13) away from the coil (14). 2. The current rail (15) is provided with an end section (18) projecting radially outwardly, the end section being arranged at an acute angle with respect to the coil body (13). Bend parallel to the section (30) of
Subsequently, the section (30) and the end section (18) are bent toward the coil body (13) so that the bent portion (19) of the current rail can be aligned with the coil shield (20) of the coil body (13) as much as possible. The method of claim 1, wherein the method is located nearby. 3. The first end of the winding of the coil (14) is
Wrap it around the end section (18) of the current rail (15) of
Method according to claim 1 or 2, wherein the winding of the coil (14) is fixed in position on the current rail (15) by guiding it through two projections (35) provided on the current rail. .. 4. The end of the winding of the coil (14) is guided through two projections (35) formed on the end section (18) of the second current rail (15), The winding of the coil (14) is fixed in position on the second current rail (15), and the end of the winding is fixed to the second current rail (1).
Method according to any one of claims 1 to 3, wherein the winding is towards the end of 5). 5. The method as claimed in claim 1, wherein the winding of the coil (14) is contact-connected to the end section (18) of the current rail (15) by dip brazing. 6. The method according to claim 1, wherein the coil body (13), the current rail (15) and the coil (14) are embedded in the plastic during the injection molding of the plastic. 7. A sensor comprising at least one coil (14) in a casing (10, 25) of the sensor,
Coil body (13) with current rail (15)
In which the ends of the windings of the coil (14) are fixed to the current rail (15), each current rail (15) moves in the direction away from the coil (14). A sensor having a bent end section (18) to which the beginning or end of the winding of the coil (14) is brazed. 8. A groove (3) in which the winding of the coil (14) is arranged in the coil body (13) between the end section (18) of the current rail (15) and the coil (14).
Sensor according to claim 7, which is arranged at 6,39). 9. The end section (1) of the current rail (15).
8) has two lateral protrusions (3) near the bend (19).
9. The sensor according to claim 7, which has 5). 10. The interior of the casing (10, 25) is
Sensor according to any one of claims 7 to 9, which is filled with plastic by injection molding of plastic.