JP2003189386

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DESCRIPTION JP2003189386
[0001]
The present invention relates to a method of manufacturing an electric horn (phone horn) which
is used for a vehicle or the like and in which a diaphragm is vibrated by an electromagnet, and in
particular, an off gap for determining an energization period of a coil of the electromagnet. It is
about adjustment.
[0002]
2. Description of the Related Art In a conventional electric horn, a pressing portion of a movable
contact support plate made of a metal spring material is provided on a movable iron core, and
the movable iron core is attracted to the fixed iron core by the electromagnetic force of an
electromagnet. The movable contact support plate is pressed by the pressing portion to move the
movable contact away from the fixed contact.
[0003]
By the way, in order to exhibit the performance of the electric horn well, it is necessary to set the
off gap described below appropriately and to set the current flowing to the electromagnet within
the appropriate range.
Here, the off gap is the distance between the pressing portion of the movable iron core and the
movable contact support plate when the electromagnet is not energized, and more specifically,
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the pressing portion of the movable iron core when the electromagnet is not energized and When
the electromagnet is energized, the movable contact support plate is pressed by the pressing
portion of the movable iron core, and the distance between the movable contact support plate
and the movable contact support plate is when the movable contact is separated from the fixed
contact.
[0004]
When the off gap is small, the movable contact is quickly separated from the fixed contact, so the
energization time of the electromagnet becomes short, and the current value (effective current
value) flowing through the coil of the electromagnet becomes small. When the current value
decreases, the time for generating attraction force of the movable iron core decreases, the
amplitude of the diaphragm integral with the movable iron core decreases, and the sound
pressure (volume) of the horn buzzing sound decreases.
[0005]
Also, conversely, if the off gap is large, the amount of depression of the movable contact support
plate by the pressing portion of the movable iron core decreases, so the distance between the
two contacts becomes smaller when the movable contact is separated from the fixed contact. The
blocking effect of As a result, the balance between the suction action of the movable iron core
and the return action of the movable iron core due to the interruption of the coil current is lost,
the amplitude of the diaphragm becomes unstable, and the timbre deteriorates.
[0006]
In order to avoid the above problems, it is necessary to strictly manage the off gap within an
appropriate range. Therefore, conventionally, an adjustment screw is provided on the bottom of
the horn housing, and the position of the fixed contact support plate is moved up and down
according to the screwed-in position of the adjustment screw, thereby adjusting the off gap
within an appropriate range.
[0007]
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However, such an off gap adjustment method requires a member dedicated to adjustment
(adjustment screw), and the number of parts increases. In addition, since it is necessary to
process the threaded portion of the adjusting screw on the side of the horn housing, the cost is
increased. Further, since the adjustment screw needs to be screwed in, the number of adjustment
operations is increased.
[0008]
Therefore, in Japanese Utility Model Laid-Open No. 2-85499, the above off gap is adjusted by
rotating a vibrating body consisting of a movable iron core, a diaphragm and a spiral, and the
outer peripheral end of the horn housing 10 is finished after the adjustment operation is
completed. Is fixed on the outer peripheral end of the diaphragm over the entire circumference
to fix the outer peripheral end of the diaphragm to the outer peripheral end of the horn housing
10.
[0009]
According to this adjustment method, adjustment screws and the like can be eliminated, but on
the other hand, the outer peripheral end of the horn housing is bent at the outer peripheral end
of the diaphragm after the adjustment operation of the off gap is completed. Since the diaphragm
is fixed to the horn housing, the bending load causes deformation of the horn housing.
When this deformation occurs, the axial position of the movable iron core changes, which causes
a problem that the angle and the adjusted off gap deviate from the appropriate range.
[0010]
In view of the above-mentioned point, the present invention can adjust the off gap by a simple
method which does not require the screwing operation of the adjusting screw and the like, and
can manufacture the electric horn capable of reliably maintaining the adjusted proper off gap.
Intended to provide.
[0011]
In order to achieve the above object, according to the invention as set forth in claim 1, a horn
housing (10) and a diaphragm (11) having an outer peripheral end fixed to the horn housing
(10). And a movable iron core (15) fixed to the central portion of the diaphragm (11), a fixed iron
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core (21) disposed opposite to the movable iron core (15), and a movable iron core (15) to the
fixed iron core (21) The coil (14) for suction, the fixed contact (18a) provided in the energizing
circuit of the coil (14), the fixed contact support plate (18) supporting the fixed contact (18a),
and the fixed contact (18a) Provided on a movable iron core (15), a movable contact support
plate (17), a movable contact support plate (17) supporting the movable contact (17a), and a
movable contact support plate (17) A pressing portion (15c) having an inclined surface (15d) to
press And when the movable core (15) is attracted to the fixed core (21) by the electromagnetic
force of the coil (14), the movable contact support plate (17) is pressed by the inclined surface
(15d) to move the movable contact And a diaphragm fixing step of fixing an outer peripheral end
portion of the diaphragm (11) to the horn housing (10). After the process, an adjustment process
of adjusting the off gap which is the distance between the inclined surface (15d) and the movable
contact support plate (17) when the coil (14) is not energized, by the rotational position of the
movable iron core (15); And a movable iron core fixing step of fixing the movable iron core (15)
to the central portion of the diaphragm (11) after the adjustment step.
[0012]
According to this, since the movable gap of the movable contact support plate of the inclined
surface (15d) changes depending on the rotational position of the movable iron core (15) and the
off gap can be adjusted, it is a simple method that does not require screwing operation of
adjustment screws. Can be adjusted.
Therefore, the number of parts can be reduced by eliminating the adjustment screw, and the
operation of screwing the adjustment screw becomes unnecessary, and the cost of the electric
horn can be reduced.
[0013]
Moreover, since the off gap is adjusted after the outer peripheral end of the diaphragm (11) is
fixed to the horn housing (10), the deformation of the horn housing (10) generated in the fixing
step of the diaphragm (11) is turned off It does not affect the gap adjustment.
Therefore, it is possible to reliably maintain the adjusted proper off gap even at the time of
product shipment.
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[0014]
In the second aspect of the present invention, in the first aspect, the movable iron core (15) is
temporarily fixed to the central portion of the diaphragm (11) in advance, and then the
diaphragm fixing step is performed. The movable iron core (15) is firmly fixed to the central
portion of the diaphragm (11) by carrying out a fixing step.
[0015]
By temporarily fixing the movable iron core (15) to the central portion of the diaphragm (11) in
this way, the movable iron core (15) and the diaphragm (11) can be assembled as one assembly.
Therefore, the process of fixing the diaphragm (11) and the process of adjusting the off gap,
which are performed after the above-mentioned temporary fixing, do not become complicated.
[0016]
In the third aspect of the invention, in the second aspect, the central hole portion (11a) of the
diaphragm (11) is fitted to the small diameter portion (15b) of the movable iron core (15), and
the diaphragm (11) is mounted. Of the movable core (15) by pressing the cylindrical portion
(16a) of the central portion of the resonance plate (16) laminated on the small diameter portion
(15b) of the movable core (15) Temporarily fixed to the movable core fixing step and caulking
the small diameter portion (15b) in the movable iron core fixing step, and the diaphragm
between the caulking deformed portion (15g) of the small diameter portion (15b) and the
stepped surface (15f) of the small diameter portion (15b) A peripheral edge portion of the central
hole portion (11a) of (11) and a cylindrical portion (16a) of the resonance plate (16) are
sandwiched.
[0017]
Thereby, temporary fixation of movable iron core (15) can be performed simply and certainly
using cylindrical part (16a) formed in the central part of a resonance board (16).
After adjustment of the off gap, the movable iron core (15) is firmly fixed to the central part of
the diaphragm (11) via the cylindrical part (16a) of the resonance plate (16) by caulking the
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small diameter part (15b). It can be fixed.
[0018]
In the invention according to claim 4, the small diameter portion (15b) of the movable core (15)
is provided with a noncircular tool engagement hole (15e), and the tool engagement hole (15e) is
provided in the adjusting step. Lock the tool to rotate the movable core (15).
[0019]
Thus, the movable iron core (15) can be easily rotated in the off gap adjustment step.
[0020]
In addition, the code ¦ symbol in the parenthesis of each said means shows correspondence with
the specific means as described in embodiment mentioned later.
[0021]
DESCRIPTION OF THE PREFERRED EMBODIMENTS (First Embodiment) The present embodiment
relates to a method of manufacturing an electric horn for a vehicle, and FIG. 1 is a cross section
of the entire structure of the electric horn for a vehicle manufactured according to the present
embodiment. It is a figure, FIG. 2 is a principal part expanded sectional view of FIG.
FIGS. 3 (a) and 3 (b) show examples of the shape of the inclined surface provided on the movable
core.
[0022]
Before describing the manufacturing method of the present embodiment, the entire structure of
the electric horn will be described first.
A horn housing 10 accommodates an electromagnet 12 or the like that vibrates the diaphragm
11.
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In order to form a part of the magnetic circuit of the electromagnet 12, the horn housing 10 and
the diaphragm 11 are formed by pressing a plate material of an iron-based magnetic material
into a concave shape.
[0023]
The electromagnet 12 is provided with a coil 14 wound around a bobbin 13 made of resin, and
the lower cylindrical portion 15a of the movable iron core 15 formed in a cylindrical shape is
disposed in the central hole portion of the bobbin 13 It is done. A central hole portion 11a of the
diaphragm 11 and a cylindrical portion (burring processed portion) 16a of a central portion of
the resonance plate 16 are fitted, caulked and fixed to the small diameter portion 15b of the
upper portion of the movable core 15. The outer peripheral end 11b of the diaphragm 11 is fixed
by winding and fixing to the flange 10a of the outer peripheral end of the horn housing 10 over
the entire circumference thereof.
[0024]
The concave intermediate flat portion 10b of the horn housing 10 is provided with a projecting
portion 13b projecting radially outward from the upper flange 13a of the bobbin 13, a movable
contact support plate 17 made of a metal spring material, a fixed contact support plate 18, The
insulating members 19 interposed between the two contact support plates 17 and 18 are
stacked, and these members are crimped and fixed on the intermediate flat portion 10b by metal
rivets 20.
[0025]
Here, the insulating member 19 is formed of a resin plate material, and is stacked on the upper
surface of the movable contact support plate 17 over substantially the entire length of the
movable contact support plate 17.
The fixed contact support plate 18 is formed of a relatively easily deformable iron-based
conductor metal, for example, a plate of a cold-rolled steel plate (low carbon steel).
[0026]
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A movable contact 17 a is fixed to the movable contact support plate 17, and a fixed contact 18 a
is fixed to the fixed contact support plate 18. The movable contact 17 a is a normally closed
contact that is crimped to the fixed contact 18 a by a spring force due to elastic deformation of
the movable contact support plate 17 at normal times (when the coil 14 is not energized).
[0027]
A ring-shaped flange portion 15c protruding radially outward is integrally formed on the outer
peripheral surface of the axially intermediate portion of the movable core 15 by cold forging or
the like, and the flange portion 15c of the movable core 15 is A pressing portion is configured to
press a portion of the movable contact support plate 17 closer to the center of the horn
downward.
[0028]
Here, the lower surface of the flange portion 15c forms an inclined surface 15d which is oblique
to the axial direction of the movable iron core 15. Specifically, the inclined surface 15d has a
spiral shape shown in FIG. And any of the taper shape shown in FIG.3 (b) may be sufficient.
The spiral shape in FIG. 3A is formed on the entire circumference of a 360 ° rotation range in
which the inclined surface 15d starts at the start point a and ends at the end point b. On the
other hand, in the tapered shape shown in FIG. 3 (b), the inclined surface 15d is formed in one
direction from the start point c to the end point d at the 180 ° symmetrical position.
[0029]
In addition, a tool engagement hole 15e is formed in the small diameter portion 15b of the upper
portion of the movable core 15. For example, a hexagonal hole in cross section is preferable as
the tool engagement hole 15e, but any other non-circular hole shape such as a polygonal shape,
a cross shape, or a negative shape may be used.
[0030]
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The fixed iron core 21 is disposed opposite to the lower end surface of the movable iron core 15
via a predetermined suction gap in the central hole of the bobbin 13 of the electromagnet 12.
The fixed core 21 is fixed to the central portion of the bottom surface 10c of the horn housing
10 by caulking or the like. The fixed core 21 is integrally formed with an externally threaded
portion 21a projecting to the outside of the bottom surface 10c of the horn housing 10. A
mounting stay 22 for the vehicle body is fastened and fixed to the externally threaded portion
21a by a nut 23.
[0031]
One end of the coil 14 is electrically connected to a terminal strip of a connector (not shown)
disposed outside the horn housing 10, and the other end of the coil 14 is electrically connected
to the movable contact support plate 17 . The fixed contact support plate 18 is electrically
connected to the horn housing 10 through a metal rivet 20, and further grounded to the vehicle
body of the vehicle through a fixed iron core 21 fixed to the horn housing 10 and a mounting
stay 22. It has become.
[0032]
Next, a method of manufacturing the electric horn according to the present embodiment will be
described. In the manufacturing method of this embodiment, the process of incorporating the coil
14, the movable contact support plate 17, the fixed contact support plate 18, the fixed iron core
21 and the like wound around the resin bobbin 13 into the horn housing 10 is the same as the
conventional process. Therefore, the description of these steps is omitted, and the assembly step
of the diaphragm 11 portion including the movable iron core 15, the resonance plate 16 and the
like will be described in detail.
[0033]
In the assembling process of the diaphragm 11, first, the small diameter portion 15 b of the
upper portion of the movable core 15 is temporarily fixed to the diaphragm 11. Specifically, the
center hole portion 11a of the diaphragm 11 is fitted to the small diameter portion 15b of the
upper portion of the movable core 15, and the central portion of the diaphragm 11 is a stepped
surface 15f of the root portion of the small diameter portion 15b of the movable core 15. Abut
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on. Next, the cylindrical portion 16 a at the center of the resonance plate 16 is press-fitted and
fixed to the small diameter portion 15 b of the movable core 15.
[0034]
At this time, since the resonance plate 16 is press-fit until the peripheral portion of the
cylindrical portion 16 a of the resonance plate 16 abuts on the central portion of the diaphragm
11, between the resonance plate 16 and the stepped surface 15 f of the movable iron core 15
The diaphragm 11 is sandwiched. Thereby, movable iron core 15 can be temporarily fixed to
diaphragm 11.
[0035]
Next, the diaphragm 11 is incorporated into the horn housing 10, and the outer peripheral end
11b of the diaphragm 11 is wound on the flange portion 10a of the outer peripheral end of the
horn housing 10, whereby the outer peripheral end 11b of the diaphragm 11 is horned It fixes to
the housing 10.
[0036]
Next, the step of adjusting the off gap G is performed.
Here, the off gap G can be defined as shown in FIG. That is, FIG. 2 shows the position of the
movable core 15 when the coil 14 is not energized, and when the coil 14 is not energized, the
lower inclined surface 15d of the flange portion 15c forming the pressing portion of the movable
core 15 and the movable contact support The distance to the insulating member 19 located on
the plate 17 is the off gap G.
[0037]
In FIG. 2, the movable contact support plate 17, the fixed contact support plate 18, the insulating
member 19 and the like are fixed to the horn housing 10 before adjusting the off gap.
[0038]
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In the step of adjusting the off gap G, an appropriate tool (not shown) is inserted into the tool
locking hole 15e provided in the end face of the small diameter portion 15b of the movable core
15, and the tool is rotated to move the movable core 15 Rotate.
Here, since the lower surface of the flange portion 15c of the movable core 15 is formed with the
inclined surface 15d having a helical shape shown in FIG. 3A or a tapered shape shown in FIG.
3B, when the movable core 15 rotates, The portion of the inclined surface 15 d facing the
insulating member 19 on the movable contact support plate 17 changes. Thereby, the distance
between the inclined surface 15d and the insulating member 19 is changed, and the off gap G
can be adjusted to a value within the appropriate range.
[0039]
Next, the movable core 15 is firmly fixed to the center of the diaphragm 11. Specifically, the
upper end portion of the small diameter portion 15b of the movable iron core 15 is caulked so as
to expand to the outer peripheral side as shown in FIG. 1 to form a caulking deformed portion
15g. Thereby, the peripheral portion of the cylindrical portion 16a of the resonance plate 16 and
the central hole portion 11a of the diaphragm 11 can be firmly sandwiched between the caulking
deformation portion 15g and the stepped surface 15f, and the movable iron core 15 is It can be
fixed firmly to the central part of 11.
[0040]
By the way, according to the above manufacturing method, after the outer peripheral end 11b of
the diaphragm 11 is wound and fixed to the horn housing 10, the off gap G is adjusted.
Therefore, when the outer peripheral end 10a of the horn housing 10 is tightened. Even if
deformation of the horn housing 10 occurs, the deformation does not affect the adjustment of
the off gap G.
[0041]
The caulking process of the small diameter portion 15b of the movable core 15 performed after
the adjustment of the off gap G is a process of caulking deformation in which the small diameter
portion 15b portion is expanded to the outer peripheral side, and the deformed portion 15g of
this caulking process is the movable iron core 15 Even if it is formed, the adjusted off gap G does
not change because it does not affect the axial position of the movable core 15.
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[0042]
Next, the operation of the electric horn according to the present embodiment will be described.
When a horn switch (not shown) is turned on, a current from the on-vehicle power supply flows
from the connector portion (not shown) 17a → fixed contact 18a → fixed contact support plate
18 → rivet 20 → horn housing 10 → fixed iron core 21 → mounting stay 22 → vehicle body
(ground)
[0043]
Thereby, the electromagnetic force of the electromagnetic coil 14 acts on the suction gap
between the movable iron core 15 and the fixed iron core 21, and the movable iron core 15 is
attracted to the fixed iron core 21.
Due to the displacement of the movable core 15, the inclined surface 15d of the flange portion
15c of the movable core 15 presses the insulating member 19 on the movable contact support
plate 17 to separate the movable contact 17a from the fixed contact 18a.
As a result, the energization to the electromagnetic coil 14 is cut off and the electromagnetic
force is eliminated, so that the movable iron core 15 is returned to the original position by the
elastic reaction force of the diaphragm 11, thereby the movable contact 17a and the fixed
contact 18a. Closed state is restored.
Thus, the diaphragm 11 and the resonance plate 16 vibrate at a high frequency to generate a
warning sound by interrupting the energization of the electromagnetic coil 14. (Other
Embodiments) In the above embodiment, the cylindrical portion 16a is formed at the center of
the resonance plate 16, and the cylindrical portion 16a is interposed between the diaphragm 11
and the small diameter portion of the movable iron core 15 Although the movable iron core 15 is
temporarily fixed in advance to the central portion of the diaphragm 11 by press-fitting to 15b,
the cylindrical portion 16a at the central portion of the resonance plate 16 is eliminated and the
center hole of the plate of the resonance plate 16 is removed. The movable iron core 15 may be
temporarily fixed to the central portion of the diaphragm 11 by press-fitting the central hole of
the resonance plate 16 into the small diameter portion 15b of the movable iron core 15.
[0044]
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Further, in the above embodiment, the insulating member 19 on the movable contact support
plate 17 is extended to a portion facing the inclined surface 15d of the flange portion 15c of the
movable iron core 15, and the inclined surface 15d is extended on the movable contact support
plate 17 The insulating member 19 is pressed, but an insulating member is provided below the
inclined surface 15 d and the metal surface of the movable contact support plate 17 is directly
pressed through the insulating member by the inclined surface 15 d. It is also good.
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