Method for manufacturing motor device and motor device
阅读说明:本技术 马达装置的制造方法以及马达装置 (Method for manufacturing motor device and motor device ) 是由 内村浩之 星野大史 荒木聡也 布施川秀一 于 2018-06-26 设计创作,主要内容包括:本发明使一对驱动用导电构件56a、驱动用导电构件56b及四个传感器用导电构件57a~传感器用导电构件57d保持在固定器构件70。在朝固定器构件70的安装后及嵌入成形后,将第一连结部JT1及第二连结部JT2切断来使四个传感器用导电构件57a~传感器用导电构件57d分离。因此,可相对于连接器构件,将导电构件56a、导电构件56b、导电构件57a~导电构件57d(合计六根)高精度地配置在正规的位置。可采用经复杂地弯折的四个传感器用导电构件57a~传感器用导电构件57d,并将它们相互接近配置,因此可抑制马达装置的沿着连接器连接部的开口方向的厚度尺寸的增大。(A pair of driving conductive members 56a, a pair of driving conductive members 56b, and four sensor conductive members 57a to 57d are held by a holder member 70. After the attachment to the anchor member 70 and the insert molding, the first connecting portion JT1 and the second connecting portion JT2 are cut to separate the four sensor conductive members 57a to 57 d. Therefore, the conductive members 56a, 56b, and 57a to 57d (six in total) can be accurately arranged at regular positions with respect to the connector member. Since the four sensor conductive members 57a to 57d that are bent in a complicated manner can be used and arranged close to each other, an increase in the thickness dimension of the motor device in the direction along the opening of the connector connecting portion can be suppressed.)
1. A method of manufacturing a motor apparatus, the motor apparatus comprising:
a rotating shaft;
a power supply member to which a drive current for rotating the rotating shaft is supplied; and
a connector member connected to an external connector and configured to supply the driving current to the power supply member;
the connector member has:
an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted;
a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft;
a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member; and
a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate;
the manufacturing method of the motor device comprises the following steps:
a conductor forming step of forming a separated front conductor including a first connecting portion and a second connecting portion, the first connecting portion and the second connecting portion connecting the plurality of sensor conductors to each other on the insertion portion side and the substrate side, respectively, and bending the separated front conductor such that an extending direction of the first connecting portion is directed in an axial direction of the rotary shaft and an extending direction of the second connecting portion is directed in a direction intersecting the axial direction of the rotary shaft;
a conductor holding step of disposing the plurality of driving conductors and the separation leading conductor on a holder member and holding the plurality of driving conductors and the separation leading conductor on the holder member so as to have predetermined intervals, respectively;
a first separation step of cutting the first connecting portion to separate the insertion portion side of the separated front conductor;
an insert molding step of insert molding the plurality of driving conductors, the separated front conductors, and the holder member to form the insertion portion and the substrate holding portion; and
and a second separation step of separating the substrate side of the pre-separation conductor by cutting the second connection portion.
2. The method of manufacturing a motor apparatus according to claim 1, wherein the holder member has a first opening portion that exposes the first coupling portion to the outside.
3. The method of manufacturing a motor device according to claim 1, wherein the substrate holding portion has a second opening portion that exposes the second coupling portion to the outside.
4. A method of manufacturing a motor apparatus, the motor apparatus comprising:
a rotating shaft;
a power supply member to which a drive current for rotating the rotating shaft is supplied; and
a connector member connected to an external connector and configured to supply the driving current to the power supply member;
the connector member has:
an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted;
a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft;
a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member; and
a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate;
the manufacturing method of the motor device comprises the following steps:
a conductor forming step of forming a separated front conductor including a first connecting portion and a second connecting portion, the first connecting portion and the second connecting portion connecting the plurality of sensor conductors to each other on the insertion portion side and the substrate side, respectively, and bending the separated front conductor such that an extending direction of the first connecting portion is directed in an axial direction of the rotary shaft and an extending direction of the second connecting portion is directed in a direction intersecting the axial direction of the rotary shaft;
a conductor holding step of disposing the plurality of driving conductors and the separation leading conductor on a holder member and holding the plurality of driving conductors and the separation leading conductor on the holder member so as to have predetermined intervals, respectively;
a first separation step of cutting the first connecting portion to separate the insertion portion side of the separated front conductor;
a first insert molding step of insert molding the plurality of driving conductors, the separated front conductors, and the holder member to form a primary molded article including the substrate holding portion;
a second separation step of separating the substrate side of the pre-separation conductor by cutting the second connection portion; and
a second insert molding step of forming a secondary molded article including the insertion portion by insert molding.
5. The method of manufacturing a motor apparatus according to claim 4, wherein the holder member has a first opening portion that exposes the first coupling portion to the outside.
6. The method of manufacturing a motor device according to claim 4, wherein the substrate holding portion has a second opening portion that exposes the second coupling portion to the outside.
7. A motor apparatus, comprising:
a rotating shaft;
a power supply member to which a drive current for rotating the rotating shaft is supplied; and
a connector member connected to an external connector and configured to supply the driving current to the power supply member;
the connector member has:
an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted;
a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft;
a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member;
a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate; and
a holder member that holds the plurality of driving conductors and the plurality of sensor conductors at predetermined intervals;
a plurality of bent portions are provided between the insertion portions of the plurality of sensor conductors and the substrate,
one end sides of the plurality of sensor conductors are arranged in the axial direction of the rotating shaft,
the other end sides of the plurality of sensor conductors are arranged in a direction intersecting the axial direction of the rotating shaft,
first intermediate portions which are located between one end side and the other end side of the plurality of sensor conductors and are offset to the one end side are arranged in the axial direction of the rotating shaft,
second intermediate portions between one end side and the other end side of the plurality of sensor conductors and offset to the other end side are arranged in a direction intersecting the axial direction of the rotating shaft.
Technical Field
The present invention relates to a method for manufacturing a motor device and a motor device, the motor device including: a rotating shaft; a power supply member to which a drive current for rotating the rotating shaft is supplied; and a connector member connected to the external connector and supplying a driving current to the power supply member.
Background
Conventionally, a thin motor (motor device) with a speed reduction mechanism is used as a drive source of a Power Window (Power Window) device or the like mounted on a vehicle such as an automobile. Thus, the door can be disposed in a narrow space in the door. For example, patent document 1 describes such a motor device.
The motor device described in patent document 1 includes: an armature shaft (rotation shaft), and an output member (output shaft) extending in a direction intersecting the armature shaft. The armature shaft and the output member are rotatably provided in a gear case, and a connector member for connecting an external connector is attached to the gear case. The connector connecting portion (insertion portion) of the connector member opens in the axial direction of the armature shaft. That is, the external connector is inserted into the connector connecting portion of the motor device described in patent document 1 from the front-rear direction of the vehicle, which intersects the thickness direction of the door.
In the motor device described in patent document 1, a mounting surface of a sensor substrate (substrate) on which a rotation sensor (sensor) is mounted is directed in the axial direction of the armature shaft. Thus, the one end and the other end of the plurality of conductive members for sensor (conductive bodies for sensor) embedded in the connector member by insert molding are both directed in the axial direction of the armature shaft. Therefore, the conductive member for a sensor can be formed into a relatively simple shape, in other words, the conductive member for a sensor can be formed without three-dimensionally (three-dimensionally) bending in a complicated manner.
Disclosure of Invention
Problems to be solved by the invention
However, in view of the installation example of the motor device into the vehicle door, the improvement of the assembling property of the motor device, and the like, there is a need to orient the insertion direction of the external connector in the axial direction of the output shaft. However, the motor device described in patent document 1 cannot meet such a demand. Here, even in the case of coping with the above-described demand, it is necessary to suppress an increase in the thickness dimension of the motor device in the axial direction of the output shaft.
Therefore, the sensor conductor has to be formed by bending three-dimensionally and complicatedly. In this case, since the plurality of sensor conductors are disposed close to each other, the connector member must be formed so as not to short-circuit each other. In particular, a plurality of sensor conductors are embedded in the connector member by insert molding, but if the positional relationship is disturbed, the position of one end and the other end of each sensor conductor may be displaced, and connection to an external connector or a substrate may be difficult.
The present invention aims to provide a method for manufacturing a motor device and a motor device, wherein even if an insertion part is opened in a direction intersecting with the axial direction of a rotating shaft, the thickness of the motor device along the opening direction can be inhibited from increasing, and a plurality of sensor conductors can be respectively arranged in a connector component with high precision.
Means for solving the problems
In the method for manufacturing a motor device according to the present invention, the motor device includes: a rotating shaft; a power supply member to which a drive current for rotating the rotating shaft is supplied; and a connector member connected to an external connector and supplying the driving current to the power supply member; the connector member has: an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted; a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft; a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member; a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate; the manufacturing method of the motor device comprises the following steps: a conductor forming step of forming a separated front conductor including a first connecting portion and a second connecting portion, the first connecting portion and the second connecting portion connecting the plurality of sensor conductors to each other on the insertion portion side and the substrate side, respectively, and bending the separated front conductor such that an extending direction of the first connecting portion is directed in an axial direction of the rotary shaft and an extending direction of the second connecting portion is directed in a direction intersecting the axial direction of the rotary shaft; a conductor holding step of disposing the plurality of driving conductors and the separation leading conductor on a holder member and holding the plurality of driving conductors and the separation leading conductor on the holder member so as to have predetermined intervals, respectively; a first separation step of cutting the first connecting portion to separate the insertion portion side of the separated front conductor; an insert molding step of insert molding the plurality of driving conductors, the separated front conductors, and the holder member to form the insertion portion and the substrate holding portion; and a second separation step of cutting the second connection portion to separate the substrate side of the pre-separation conductor.
In another embodiment of the present invention, the motor apparatus includes: a rotating shaft; a power supply member to which a drive current for rotating the rotating shaft is supplied; and a connector member connected to an external connector and supplying the driving current to the power supply member; the connector member has: an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted; a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft; a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member; a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate; the manufacturing method of the motor device comprises the following steps: a conductor forming step of forming a separated front conductor including a first connecting portion and a second connecting portion, the first connecting portion and the second connecting portion connecting the plurality of sensor conductors to each other on the insertion portion side and the substrate side, respectively, and bending the separated front conductor such that an extending direction of the first connecting portion is directed in an axial direction of the rotary shaft and an extending direction of the second connecting portion is directed in a direction intersecting the axial direction of the rotary shaft; a conductor holding step of disposing the plurality of driving conductors and the separation leading conductor on a holder member and holding the plurality of driving conductors and the separation leading conductor on the holder member so as to have predetermined intervals, respectively; a first separation step of cutting the first connecting portion to separate the insertion portion side of the separated front conductor; a first insert molding step of insert molding the plurality of driving conductors, the separated front conductors, and the holder member to form a primary molded article including the substrate holding portion; a second separation step of separating the substrate side of the pre-separation conductor by cutting the second connection portion; and a second insert molding step of forming a secondary molded article including the insertion portion by insert molding.
In another embodiment of the present invention, the holder member has a first opening portion exposing the first coupling portion to the outside.
In another embodiment of the present invention, the substrate holding portion has a second opening portion exposing the second coupling portion to the outside.
The motor device of the present invention includes: a rotating shaft; a power supply member to which a drive current for rotating the rotating shaft is supplied; and a connector member connected to an external connector and supplying the driving current to the power supply member; the connector member has: an insertion portion that is opened in a direction intersecting an axial direction of the rotary shaft and into which the external connector is inserted; a substrate holding unit that holds a substrate on which a sensor that detects a rotation state of the rotating shaft is mounted, such that a mounting surface of the substrate faces an axial direction of the rotating shaft; a plurality of driving conductors provided between the insertion portion and the power supply member, one end of each of the driving conductors being exposed to the inside of the insertion portion, and the other end of each of the driving conductors being connected to the power supply member; a plurality of sensor conductors provided between the insertion portion and the substrate, one end of each of the sensor conductors being exposed to the inside of the insertion portion, and the other end of each of the sensor conductors being connected to the substrate; and a holder member that holds the plurality of driving conductors and the plurality of sensor conductors at predetermined intervals; a plurality of bent portions are provided between the insertion portions of the plurality of sensor conductors and the substrate, one end sides of the plurality of sensor conductors are arranged in the axial direction of the rotating shaft, the other end sides of the plurality of sensor conductors are arranged in a direction intersecting the axial direction of the rotating shaft, first intermediate portions between the one end sides and the other end sides of the plurality of sensor conductors and offset to the one end sides are arranged in the axial direction of the rotating shaft, and second intermediate portions between the one end sides and the other end sides of the plurality of sensor conductors and offset to the other end sides are arranged in a direction intersecting the axial direction of the rotating shaft.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, since the plurality of driving conductors and the plurality of sensor conductors are held by the holder member, the plurality of driving conductors and the plurality of sensor conductors can be accurately arranged at regular positions with respect to the connector member. Therefore, the sensor conductors bent in a three-dimensional complex manner can be used and arranged close to each other, and an increase in the thickness dimension of the motor device in the direction along the opening of the insertion portion can be suppressed. In the manufacturing process of the connector member, after the connector member is attached to the holder member and after the insertion molding, the sensor conductors are separated by cutting the first connecting portion and the second connecting portion, and therefore, the plurality of sensor conductors can be arranged at regular positions with respect to the connector member with higher accuracy.
Drawings
FIG. 1 is a plan view showing a motor device of the present invention.
Fig. 2(a) is a view of the connector member as viewed from the back side of the sheet of fig. 1, and (b) is a view of the connector member as viewed from the direction of arrow a in fig. 1.
Fig. 3(a) is a view of the connector member viewed from the direction of arrow B in fig. 2(a), and (B) is a view of the connector member viewed from the direction of arrow C in fig. 2 (B).
Fig. 4 is a perspective view showing a driving conductive member, a sensor substrate, and a female terminal.
FIG. 5 is a plan view showing a conductive member before separation.
Fig. 6(a) and (b) are perspective views showing a state in which the separated front conductive member is bent.
Fig. 7(a) and (b) are perspective views showing the front and back sides of the anchor member.
Fig. 8 is a flowchart illustrating an assembly procedure of the connector member.
Fig. 9 is an explanatory view for explaining a step of mounting to a retainer member.
Fig. 10 is an explanatory view for explaining [ a cutting step of the first connecting portion ].
Fig. 11 is an explanatory view for explaining [ first insert molding step ].
Fig. 12 is an explanatory view for explaining the second insert molding step and the second connecting portion cutting step.
FIG. 13 is an explanatory view for explaining a part assembling step.
Fig. 14 is a flowchart illustrating an assembly procedure of the connector member according to embodiment 2.
Detailed Description
Hereinafter, embodiment 1 of the present invention will be described in detail with reference to the drawings.
Fig. 1 is a plan view showing a motor device of the present invention, fig. 2(a) is a view showing a connector member viewed from the back side of the sheet of fig. 1, (B) is a view showing the connector member viewed from the arrow a direction of fig. 1, (a) of fig. 3 is a view showing the connector member viewed from the arrow B direction of fig. 2(a), (B) is a view showing the connector member viewed from the arrow C direction of fig. 2(B), fig. 4 is a perspective view showing a driving conductive member, a sensor substrate, and a female terminal, fig. 5 is a plan view showing a conductive member before separation, fig. 6(a) and (B) are perspective views showing a state where a separation leading conductive member is bent, and fig. 7(a) and (B) are perspective views showing the front side and the back side of a holder member.
A
The
A plurality of magnets 22 (only two magnets are shown in the drawing) having a substantially circular arc-shaped cross section are fixed to the inside of the
An armature shaft (rotation shaft) 26 is fixed to the axial center of the
A
A plurality of brushes 28 (only two are shown in the drawing) that have been held on the brush holder 60 slidingly contact the outer peripheral portion of the
A
A worm gear 31 is provided on the other side of the
The bottom side (left side in the drawing) of the
The
The worm gear 31 fixed to the
An
Further, a
A connector
That is, as shown in fig. 1, the
Further, the
In this way, the three fixing
As shown in fig. 2 and 3, the
The
Then, in a state where the
The axial center of the
The
Here, the
As shown in fig. 2b, a
The
Thus, as shown in fig. 3(b), when the
In this way, the
In this way, the
The pair of driving
That is, one end of each of the
Female terminals T (see fig. 4 and 13) are attached to the other ends of the pair of driving
In this way, the pair of driving
The other ends of the four sensor
The pair of driving
Specifically, the pair of driving
Further, driving-side bent portions R1 bent at 90 degrees are provided between the first driving conductive portion 56a1, the first driving conductive portion 56b1, the second driving conductive portion 56a2, and the second driving conductive portion 56b2, between the second driving conductive portion 56a2, the second driving conductive portion 56b2, the third driving conductive portion 56a3, and the third driving conductive portion 56b3, and between the third driving conductive portion 56a3, the third driving conductive portion 56b3, the fourth driving conductive portion 56a4, and the fourth driving conductive portion 56b4, respectively.
The thickness directions of the first conductive drive portion 56a1 and the first conductive drive portion 56b1 coincide with the axial direction (X-axis direction) of the
Further, the plate thickness directions of the second conductive drive portion 56a2 and the second conductive drive portion 56b2 coincide with the axial direction (Y-axis direction) of the insertion axis of the
The thickness directions of the third conductive drive portion 56a3 and the third conductive drive portion 56b3 coincide with the axial direction (X-axis direction) of the
Further, the plate thickness directions of the fourth conductive driving portion 56a4 and the fourth conductive driving portion 56b4 coincide with the axial direction (Y-axis direction) of the insertion axis of the
Each of the four sensor
Specifically, the four sensor
Further, a sensor side bent portion R2 bent at 90 degrees is provided between the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 and the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2, between the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2 and the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3, and between the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3 and the fourth sensor conductive portion 57a4 to the fourth sensor conductive portion 57d4, respectively.
However, the first divided portion D1 (see fig. 6) is provided at a substantially central portion in the longitudinal direction of the first conductive sensor portion 57a1 to the first conductive sensor portion 57D 1. Thereby, the other ends of the first sensor conductive portions 57a1 to 57d1 are guided to the
The first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 and the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2 are formed in elongated bar shapes having a substantially square cross section, and thus the
The thickness direction of the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3 coincides with the axial direction (Z-axis direction) of the
Further, the plate thickness direction of the fourth sensor conductive portion 57a4 to the fourth sensor conductive portion 57d4 coincides with the axial direction (Y-axis direction) of the insertion axis of the
Here, inside the
The four sensor
The separated conductive member WK shown in fig. 5 is a metal plate made of brass or the like having excellent conductivity and is pressed before bending. Here, the thick solid line in the drawing indicates a portion bent into a "mountain fold", and the thick broken line in the drawing indicates a portion bent into a "valley fold".
On one end side (upper side in the figure) of the split front conductive member WK, a first connection portion JT1 (hatched portion) that connects the four sensor
On the other hand, on the other end side (lower side in the figure) of the split leading conductive member WK, a second connection portion JT2 (hatched portion) is provided that connects the four sensor
By providing the first connecting portion JT1 and the second connecting portion JT2 in this manner, when the
Further, by disposing the first connecting portion JT1 and the second connecting portion JT2 in the vicinity of the fourth sensor conductive portion 57a4 to the fourth sensor conductive portion 57d4 and in the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1, respectively, the positional accuracy of the portion where the fourth sensor conductive portion 57a4 to the fourth sensor conductive portion 57d4 of the external connector are connected and the portion where the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 of the
Reference lines BD shown in fig. 5 (three points in total) indicate "boundary portions" between the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 and the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2, between the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2 and the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3, and between the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3 and the fourth sensor conductive portion 57a4 to the fourth sensor
When the separation leading member WK is bent following the marks of the "mountain fold" and the "valley fold" (thick solid line and thick broken line), the state shown in fig. 6 is obtained. That is, a plurality of sensor-side bent portions R2 bent at right angles are formed between one end and the other end of the conductive member WK before separation in the longitudinal direction, a first divided portion D1 is formed in the portion from the first sensor conductive portion 57a1 to the first sensor conductive portion 57D1, and a second divided portion D2 is formed in the portion from the third sensor
When the separation front conductive member WK after bending is disposed with reference to the longitudinal width direction of the motor device 10 (the axial direction of the
Referring to fig. 6, on one end side in the longitudinal direction of the four sensor
Further, on the other end side in the longitudinal direction of the four sensor
The four conductive members for
Specifically, as shown in fig. 5, in the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2, one end side of each of the sensor
Next, the
The
As shown in fig. 7, the
A
Further, a
Further, a pair of
Further, a third support portion 77 is provided on the surface 71 side of the
Further, a
Thus, by attaching the pair of driving
Next, a method of manufacturing the
Fig. 8 is a flowchart illustrating an assembly procedure of a connector member, fig. 9 is an explanatory diagram illustrating [ a mounting step to a retainer member ], fig. 10 is an explanatory diagram illustrating [ a cutting step of a first coupling portion ], fig. 11 is an explanatory diagram illustrating [ a first insert molding step ], fig. 12 is an explanatory diagram illustrating [ a second insert molding step ] and [ a cutting step of a second coupling portion ], fig. 13 is an explanatory diagram illustrating [ a component assembly step ], and fig. 14 is a flowchart illustrating an assembly procedure of a connector member according to embodiment 2.
[ manufacturing Process of conductive Member before separation ]
As shown in fig. 8, first, in step S1, the separated leading electrical component WK is manufactured (see fig. 5 and 6). Specifically, a metal plate having excellent conductivity, such as brass, which is a material, is pressed by a press-forming apparatus (not shown). Thus, the pre-separation conductive member WK is formed including the first connection portion JT1 and the second connection portion JT2 that connect the four sensor
Next, the operation of bending the separation leading member WK a plurality of times is performed. Thereby, the pre-separation conductive member WK is formed as shown in fig. 6. As a result of the bending operation in step S1, as shown in fig. 6, the extending direction of the first connecting portion JT1 is oriented in the axial direction (X-axis direction) of the
Thereby, the manufacturing step of separating the front conductive member is completed (step S1).
In addition, the manufacturing step of the conductive member before separation in step S1 constitutes the conductor forming step of the present invention.
In the manufacturing step of separating the front conductive member, the metal plate (material) may be pressed at one stroke and then subjected to a bending operation, or the metal plate may be slowly pressed while being subjected to the bending operation.
[ mounting step to the retainer Member ]
Then, in step S2 (see fig. 8), as shown in fig. 9, an operation is performed in which the pre-separation conductive member WK formed in step S1 and the pair of driving
Then, the portions of the third sensor conductive portion 57a3 to the third sensor conductive portion 57d3 that are offset from the second sensor conductive portion 57a2 to the second sensor conductive portion 57d2 are held at predetermined intervals by the first support portion 75 (see fig. 6 (b)).
The second divided portion D2 (see fig. 6 b) of the third conductive sensor portion 57D3 of the conductive member for sensor 57D is held by the pair of second support portions 76 (see fig. 7 a).
Further, the third sensor conductive portions 57a3 to 57d3 (see fig. 6(b)) of the four sensor
The pair of driving
Therefore, the pair of driving
Thereby, the mounting step to the holder member is completed (step S2).
In addition, the step of attaching to the holder member in step S2 constitutes the conductor holding step of the present invention.
[ cutting step of first connecting part ]
Then, in step S3 (see fig. 8), as shown in fig. 10, the operation of cutting first connecting portion JT1 of pre-separation conductive member WK assembled to
Thus, the
Thereby, the first connecting portion cutting step is completed (step S3).
The first connecting portion cutting step in step S3 constitutes a first separating step of the present invention.
[ first insert Molding step ]
Then, in step S4 (see fig. 8), as shown in fig. 11, a pair of driving
Then, the
Thereby, the first insert molding step is completed (step S4).
[ second insert Molding step ]
Then, in step S5 (see fig. 8), as shown in fig. 12, the primary molded resin part PP1 including the pair of driving
Then, the secondary molded resin part PP2 is molded to form the
Thereby, the second insert molding step is completed (step S5).
Here, [ first insert molding step ] (shaded portion) of step S4 and [ second insert molding step ] (shaded portion) of step S5 shown in fig. 8 constitute the insert molding step of the present invention.
[ cutting procedure of second connecting part ]
Then, in step S6 (see fig. 8), as shown in fig. 12, the second connecting portion JT2 embedded in the lead separating member WK of the primary molded resin part PP1 is cut. Specifically, a cutting jig (not shown) is faced to the
Thereby, the sensor substrate 54 (see fig. 2 b) side (the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 side) of the leading conductive member WK is separated. Therefore, the first sensor conductive portion 57a1 to the first sensor conductive portion 57d1 are electrically independent from each other (not short-circuited with each other), and the four sensor
Thereby, the second coupling part cutting step is completed (step S6), and the
The second connecting part cutting step in step S6 constitutes a second separating step in the present invention.
[ parts assembling steps ]
Then, in step S7 (see fig. 8), as shown in fig. 13, the operation of assembling the pair of female terminals T, the
First, as indicated by an arrow M4, a pair of female terminals T are inserted into the
Then, as indicated by an arrow M5, the surface of the
Thereafter, as indicated by an arrow M6, the O-
Thereby, the parts assembling step is completed (step S7).
As described above in detail, according to embodiment 1, since the pair of driving
Therefore, the four conductive members for
In the manufacturing process of the
Next, embodiment 2 of the present invention will be described in detail with reference to the drawings. Note that the same reference numerals are given to portions having the same functions as those in embodiment 1, and detailed description thereof is omitted.
Fig. 14 is a flowchart illustrating an assembly procedure of the connector member according to embodiment 2.
In embodiment 2, only a part of the assembly procedure of the
More specifically, in embodiment 2, as indicated by an arrow M7 in fig. 11, at a stage after completion of the [ first insert molding step ] (hatched portion) in step S4 in fig. 14, the operation of removing the second connecting portion JT2, that is, the [ second connecting portion cutting step ] in step S6 is performed.
In embodiment 2 configured as described above, the same operational effects as those of embodiment 1 can be obtained.
The present invention is not limited to the above embodiments, and various modifications can be made without departing from the scope of the invention. For example, in the above embodiments, as shown in fig. 1, the example in which the opening direction of the
In the above embodiments, the
Further, in the above embodiments, the case where the
In the above embodiments, the
The material, shape, size, number, installation location, and the like of each constituent element in the above-described embodiments are not limited to the above-described embodiments as long as the present invention can be achieved.
Industrial applicability
The motor device can be used as a drive source of a power window device mounted in a vehicle such as an automobile.
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