Abstract:
The invention relates to a method for manufacturing a pole tube, with two magnetic pole tube parts, for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile, including the following steps: (a) arranging the pole tube parts on a centering arbor; and (b), connecting, in particular insert molding and/or casting an outer lateral surface of the pole tube parts; wherein the centering arbor has a radially expandable cylinder surface also closed even in the expanded state. Further, the invention relates to, in particular with the method obtainable, a pole tube, an electromagnet for a magnetic valve, in particular for an automatic transmission in an automobile, having a pole tube according to the invention, and an apparatus for the manufacture of the pole tube.

Description:
FIELD 
       [0001]    This invention relates in general to electromagnets and magnetic valves. Specifically, the invention relates to a method for manufacturing a pole tube for electromagnets and magnetic valves, said pole tube, an electromagnet having said pole tube as well as an apparatus for manufacturing the pole tube. 
       BACKGROUND 
       [0002]    Pole tubes for electromagnets, in particular for magnetic valves in automatic transmissions in automobiles, are known in one-part as well as multi-part execution. One-part pole tubes, such as described in DE 10 2006 015 233 B4, are advantageous concerning the possibility of a low-friction guiding of the magnetic armature and a small radial air gap to the inner lateral surface of the pole tube. This is enabled by the uninterrupted or gap-free design of the pole tube, whereby the inner lateral surface can be utilized directly as a guiding surface for the armature. For suppressing a magnetic short circuit via the pole tube, said pole tube is usually machined thinner in one place. 
         [0003]    For all multi-part pole tubes, the magnetic separation of the pole tube is ensured by a nonmagnetic material. The separation of the pole tube can be integrated in the pole tube by a separate part in the form of a pressed sleeve or, such as described in DE 10 2006 015 070 A1, by a welded nonmagnetic ring. For the multi-part execution of the pole tube, it is advantageous to avoid the magnetic short circuit via the pole tube. In principle, it should thereby be able to attained higher magnetic forces. 
         [0004]      FIG. 4  shows a connection, known from DE 10 2013 226 619 A1, of two pole tube halves by means of a nonmagnetic ring and casting with an outer plastic layer serving as a winding carrier for a coil winding. The pole tube  110  consists of a pole core  112 , a magnetic tube  114  as well as an intermediate nonmagnetic ring  116  as pole tube parts. In the manufacture, the pole tube parts are slipped on a centering arbor and thus arranged in mutually concentric relationship. Thereafter, an outer lateral surface  120  of the pole tube parts is insert molded, for example with a plastic.  FIG. 4  shows the pole tube  110  with the insert-molding layer  122  applied to the outer lateral surface  120 . 
         [0005]    Due to the diameter tolerances of the pole tube parts, an offset is inevitable between the respectively mutually adjacent pole tube parts at the armature running surface  124  formed at the interior of the pole tube  110 . No offset-free inner surface can thus be attained for the pole tube. The radial air gap between armature running surface  124  and a magnetic armature (not shown in  FIG. 4 ) displaceably arranged in the pole tube  110  can therefore not be adjusted arbitrarily small. That is, a non-clamping guiding of the magnetic armature directly or by means of an additional PTFE foil in the pole tube  110  can be ensured only by a correspondingly larger dimensioned radial guiding gap at the expenses of the magnetic force to be attained. To avoid this, the mounted pole tube could be reworked. This is not desirable from an economic point of view. A further disadvantage of a multi-part pole tube with intermediate ring  116  are the associated production and mounting expenses. 
       SUMMARY 
       [0006]    Object of the present invention is to propose a pole tube as well as a method for manufacturing a pole tube with which possibly the advantages of the one-part and two-part execution of a pole tube can be attained while avoiding the disadvantages discussed hereinabove as comprehensively as possible. 
         [0007]    The object is achieved respectively with the respective features of one of the independent claims. Further embodiment examples and advantageous developments are defined in the respectively adjoining subclaims. 
         [0008]    The features and details which are described in connection with the inventive method for manufacturing a pole tube accordingly hold for the apparatus for manufacturing the pole tube and, of course, also in connection with the inventive pole tube (as well as an electromagnet with such a pole tube) and respectively vice versa. Hence, with regard to the disclosure of the individual aspects, reference is mutually made to avoid repetitions. 
         [0009]    The inventive method for manufacturing a pole tube, having two magnetic (i.e. magnetically conductive) pole tube parts, for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile, comprises the following steps: (a) arranging the pole tube parts on a centering arbor; (b) connecting, in particular insert molding and/or casting an outer lateral surface of the pole tube parts, preferably with a nonmagnetic (i.e. magnetically non-conductive) material, wherein according to the invention the centering arbor has a radially expandable cylinder surface closed even in the expanded state. 
         [0010]    The radially expandable centering arbor can be executed in the manner of an expansion arbor. Here, a radially expandable centering arbor in the context of the invention is understood to be a cylindrical element having a radially expandable cylinder surface which is closed even in the expanded state. This may be an expansion arbor as is known from the field of the machine tools, for example a hydraulic expansion arbor as is known for clamping workpieces in lathes. However, the invention is not restricted to this specific kind of an expansion arbor, but other possibilities for radial clamping from the inside to the outside having a cylinder surface which is closed even in the expanded state can also be used. 
         [0011]    The pole tube&#39;s structural parts are advantageously a magnetic pole core tube and a magnetic tube which is magnetic. The arrangement of the pole tube&#39;s structural parts is effected preferably concentrically to a center longitudinal axis of the pole tube and the radially expandable centering arbor. 
         [0012]    The pole core tube can have a pole core or be configured for receiving a pole core or for connecting to a pole core. 
         [0013]    The pole tube&#39;s core and/or the magnetic tube can preferably be designed with a flange respectively facing away from the pole tube. 
         [0014]    For the later receiving of a magnetic armature, both pole tube&#39;s structural parts have a through bore which have preferably the same inside diameter. As soon as the pole tube&#39;s structural parts are insert molded and/or are cast, both pole tube&#39;s structural parts form a magnetic space for receiving the displaceably arranged magnetic armature in the pole tube. 
         [0015]    In step (a), the pole tube&#39;s structural parts are preferably arranged on the radially expandable centering arbor with a distance apart such that between the pole tube&#39;s structural parts in axial direction a gap is formed for magnetically separating the pole tube&#39;s structural parts sufficiently. 
         [0016]    After step (a), in which the pole tube&#39;s structural parts were arranged on the radially expandable centering arbor, follows a step of radially expanding a lateral cylinder surface of the centering arbor. That is, the outer diameter of the centering arbor is enlarged, for example by supplying a corresponding hydraulic pressure in the interior of the centering arbor. It is thereby attained that the gap between the pole tube&#39;s structural parts is closed by means of the lateral surface of the centering arbor with the respective inner surfaces of the pole tube&#39;s structural parts flush toward the interior of the pole tube. In other words, the radially expandable centering arbor supplies, according to the invention, a radially expandable lateral cylinder surface for the inner-sided offset-free closing of the gap between two gap-forming tubes bordering on each other, namely magnetic tube and pole core tube. 
         [0017]    In step (b) the outer lateral surfaces of the pole tube&#39;s structural parts are connected permanently by the fact that they are insert molded and/or cast with a nonmagnetic material, which likewise completely fills the gap between the pole tube&#39;s structural parts. 
         [0018]    Since the lateral surface of the centering arbor adjoins, in an accurately fitting way, the gap-forming inner surfaces of the pole tube&#39;s structural parts due to the radial expansion of the centering arbor, there results respectively a planar, i.e. offset-free, transition between the inner surface of the pole tube&#39;s structural parts and an inner surface of the nonmagnetic material filling the gap. 
         [0019]    Advantageously, due to the perfect centering of the pole tube&#39;s structural parts by means of the radial expansion of the centering arbor, possibly existing diameter tolerances between the pole tube&#39;s structural parts can be compensated by an offset-free transition between the inner surface of the pole tube&#39;s structural parts and the nonmagnetic material filling the gap. That is, by using the radially expandable centering arbor, a nearly tolerance-free alignment of the pole tube&#39;s structural parts to each other can be attained and thus a nearly perfectly extending inner surface of the created pole tube. 
         [0020]    As a result, the nonmagnetic material filling the gap forms, together with the inner surfaces of the pole tube&#39;s structural parts a continuously planar, the inner surface of the pol tube. This makes it possible to dimension the radial air gap correspondingly small between the magnetic armature to be used later and the inner surface of the pole tube. Consequently, an particularly high magnetic force can be generated in an electromagnet or magnetic valve containing the pole tube. 
         [0021]    Preferably the pole tube&#39;s structural parts are insert molded and/or cast with the nonmagnetic material, for example a plastic, so that the nonmagnetic material can serve as a winding carrier for receiving a coil for the electromagnet to be created. 
         [0022]    The casting and/or insert molding creates a form-fitting and force-fitting composite of the entire pole tube structural group, which can be further supported by corresponding contouring of the pole tube&#39;s structural parts, for example, a knurling or grooves. 
         [0023]    After hardening of the insert molded and/or cast nonmagnetic material, the radial expansion of the centering arbor is eliminated in a step (c). Then the finished pole tube can be taken from the expansion arbor. 
         [0024]    If the pole core tube does not already have a pole core, a step (d) can follow step (c) in which a pole core is inserted in the pole core tube at one end of the pole tube. 
         [0025]    As a result, the inventive manufacturing method creates a pole tube which is nearly perfect in terms of the running errors for a magnetic armature in the magnetic space of the pole tube. 
         [0026]    This makes it possible primarily to adjust the air gap particularly small between a magnetic armature and the pole core, i.e. the radial air gap in the plunger step formed by the pole core tube and the radial air gap between a movable magnetic armature and the magnetic tube, the additional air gap. Particularly high magnetic forces can be realized with a pole tube manufactured by the inventive manufacturing method with particularly small radial air gap in the plunger step as well as in the additional air gap. 
         [0027]    Likewise, a low-friction bearing of a magnetic armature can be attained in the pole tube because the magnetic transverse forces can be nearly avoided due to eccentricities of the pole tube&#39;s structural parts in the prior art, and no offset can occur respectively in the transitions between the pole tube&#39;s structural parts which could hinder the armature motion. 
         [0028]    Finally, a reworking of the armature running surfaces limiting the magnetic space is omitted, because no thermal tenseness is brought about in the pole tube&#39;s structural parts in contrast to connecting the pole tube&#39;s structural parts by means of a thermal joining method, for example by welding or soldering. 
         [0029]    A second aspect of the present invention relates to a pole tube for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile. In the pole tube, a nonmagnetic (i.e. magnetically non-conductive) material axially fills according to the invention a gap between two, preferably magnetic structural parts (i.e. magnetically conductive) of the pole tube. The pole tube&#39;s structural parts are arranged in a mutually concentric relationship. An outer lateral surface of the pole tube&#39;s structural parts is cast or insert molded with the nonmagnetic material, in particular with a plastic, wherein the nonmagnetic material together with the pole tube&#39;s structural parts configures a continuous planar inner surface of the pole tube. 
         [0030]    The inventive pole tube is obtainable by a manufacture by means of the hereinabove discussed inventive manufacturing method according to the first aspect of the invention. 
         [0031]    Preferably the magnetic tube and the pole core tube are manufactured from a magnetically conducting ironworks substance, for example by machining (e.g. 1.0715), or as a sintered part (e.g. Sint D35) or as a extruded part (e.g. 1.0303). 
         [0032]    Preferably the nonmagnetic material is a plastic, e.g. PA 6.6 GF30. 
         [0033]    Preferably an inner surface of the pole tube formed by the nonmagnetic material in the gap and respectively the inner surface of an adjacent pole tube&#39;s structural part have the same inside diameter at the respective transitions. In other words, the transitions between the inner surfaces of the pole tube&#39;s structural parts and the inner surface of the nonmagnetic material filling the gap transition into each other without offset. 
         [0034]    Preferably one of the pole tube&#39;s structural parts at one end of the pole tube has a pole core or is connected, particularly preferably by joining, with the pole core, for example by pressing. 
         [0035]    A third aspect of the invention concerns an electromagnet for a magnetic valve, in particular for automatic transmission in an automobile, which has a pole tube according to the second aspect of the invention. 
         [0036]    For this electromagnet there preferably is arranged a bearing foil, for example a PTFE foil or a plastic foil or a plastic-glass tissue, between the pole tube and a lateral surface of a magnetic armature. The bearing foil prevents a unilateral placing of the armature against the magnetic tube or the pole core tube and thus reduces magnetic transverse forces and associated unwanted friction effects. 
         [0037]    Preferably a coil, in particular a copper wire winding, is arranged around the nonmagnetic material surrounding the pole tube, which is shaped as a winding carrier. 
         [0038]    Finally, the fourth aspect of the invention relates to an apparatus for manufacturing a pole tube, having two magnetic pole tube parts, for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile, comprising: a centering arbor for arranging the pole tube parts; and an injection mold which can enclose the pole tube parts arranged on the centering arbor to connect an outer lateral surface of the pole tube parts by insert molding and/or casting by means of an injection molding or casting material. The centering arbor has a radially expandable cylinder surface according to the invention, which is closed even in the expanded state, in the manner of an expansion arbor. For example, the centering arbor can be executed as hydraulic expansion arbor. The apparatus is further so configured to radially expand the centering arbor before the insert molding and/or casting that in the region of a gap between the pole tube parts, a lateral surface of the centering arbor terminates the gap with the respective adjacent inner surfaces of the pole tube parts planar and/or without offset. 
         [0039]    Summing up, it can be ascertained that with the inventive manufacturing method for a pole tube as well as the inventive apparatus for the manufacture of a pole tube, a pole tube with a magnetic separation of the pole tube for an optimal magnetic circuit exploitation can be attained with simultaneous realization of a continuous inner lateral surface for a low-friction guiding of a magnetic armature with a narrow radial air gap. In doing so, the manufacture of the multi-part pole tube is possible in one mounting step, particularly without the need for reworking. Particularly a separate nonmagnetic part can be omitted, for example the intermediate ring known from the prior art discussed at the outset for the magnetically separating the pole tube, thereby avoiding the associated expenses. These advantages are substantially attained by the clamping and centering of the pole tube&#39;s structural parts before insert molding on a centering arbor with a radially expandable lateral cylinder surface, which is also terminated in the expanded state, in an injection-molding tool, accordingly equipped with this centering arbor, as an apparatus for manufacturing the inventive pole tube. 
         [0040]    Further advantages, features and details of the invention will result from the following description, in which embodiment examples of the individual aspects of the invention will be described in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually per se or in arbitrary combination. Likewise, the hereinabove mentioned features and those specified hereinbelow may be employed each per se or in groups in arbitrary combinations. Functionally similar or identical parts or components are furnished in part with the same reference signs. The terms “left”, “right”, “above” and “below” employed in the description of the embodiment examples relate to the drawings as oriented with the figure designation or reference signs in the normally legible way. The embodiments shown and described are not to be understood as exhaustive, but have an exemplary character for explaining the invention. The detailed description is for the skilled person&#39;s information, so that known circuits, structures and methods are not shown or explained in detail in the description so as not to impede the understanding of the present description. Hereinafter the invention will be described by way of example with reference to the accompanying drawings. There are shown: 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0041]      FIG. 1  shows a flowchart of the inventive method for manufacturing an inventive pole tube. 
           [0042]      FIG. 2A  shows a step in a method for manufacturing an inventive pole tube. 
           [0043]      FIG. 2B  shows a step in a method for manufacturing an inventive pole tube. 
           [0044]      FIG. 2C  shows a step in a method for manufacturing an inventive pole tube. 
           [0045]      FIG. 2D  shows a step in a method for manufacturing an inventive pole tube. 
           [0046]      FIG. 3  shows an embodiment of a magnetic valve of an electromagnet according to the invention. 
           [0047]      FIG. 4  shows a connection, known from prior art, of two pole tube halves by means of a nonmagnetic ring and casting with an outer plastic layer. 
       
    
    
     DETAILED DESCRIPTION 
       [0048]      FIG. 1  shows a flowchart as to the method steps shown in  FIG. 2 . In a first step S 10   a , pole tube&#39;s structural parts are arranged on a hydraulic expansion arbor, which is a possible embodiment of a centering arbor with a radially expandable closed cylinder lateral surface. In  FIG. 2( a ) , a magnetic tube  20 , which has a flange  24  at one end forming an end  22  of the pole tube, is arranged on the expansion arbor  10 . 
         [0049]    Thereafter, as shown in  FIG. 2( b ) , the second pole tube&#39;s structural part, namely a pole core tube  26 , is slipped on the expansion arbor  10 . It can be readily recognized in  FIG. 2( b )  that the pole tube&#39;s structural parts, namely the magnetic tube  20  and the pole core tube  26 , are arranged to each other on the expansion arbor  10  with a distance D. The distance D is so chosen or adjusted that between the pole tube&#39;s structural parts  20 ,  26 , a gap  28  is formed sufficient for magnetically separating the pole tube&#39;s structural parts. The gap-forming arrangement is step S 10   b  of  FIG. 1 . 
         [0050]    The expansion arbor  10 , as a possible embodiment of a centering arbor having a radially expandable cylinder lateral surface closed even in the expanded state, is in principle known concerning its manner of functioning and its construction in the field of the workpiece clamping and tool clamping, and can therefore substantially be constructed like a hydro expansion arbor known there. The expansion arbor  10  shown schematically in  FIGS. 2( a ) to 2( d )  corresponds in its construction and its function to a hydro expansion arbor known for workpiece clamping. 
         [0051]    Instead of the expansion arbor  10 , a centering arbor having a radially expandable lateral cylinder surface, which is closed even in the expanded state, can of course be employed while the centering arbor can have any other arbitrary setup, as long as the effect of the radially expandable closed cylinder surface required here can be supplied for closing the gap  28  on the inside between two gap-forming adjacent pole tube&#39;s structural parts  20 ,  26 . 
         [0052]    Inside of the expansion arbor  10  there is a chamber system  12  into which a pressurizing medium, for example a hydraulic oil, can be pressed via a feed line  14 , whereby the pressure built up in the pressurizing medium acts substantially against the inner walling of the thin-walled expansion sleeve  16 . Consequently, the expansion sleeve  16  expands radially uniformly, centrically and cylindrically to the center axis M corresponding to the pressure fed on the entire clamping length L. Thereby the two pole tube&#39;s structural parts  20 ,  26  are centered to each other by their inner surfaces on the expansion arbor. The expanding of the expansion arbor  10  corresponds to the step S 20  in  FIG. 1 . 
         [0053]    In contrast to a centering by means of cone surfaces at an intermediate ring, like in the prior art, here the influence of concentricity tolerances on the later functional inner surfaces is at least minimized, ideally excluded, by means of the clamping. By using the hydraulic expansion arbor  10 , the present diameter tolerances between the two pole tube&#39;s structural parts are perfectly distributed, ideally compensated, over the entire circumference of the pole tube&#39;s structural parts. Additionally, the region forming the gap  28  between the two pole tube&#39;s structural parts to the interior of the pole tube to be manufactured is sealed splash-tightly or tightly and delimited planarly by means of the expansion arbor  10 . 
         [0054]    In the details shown in  FIGS. 2( a ) to 2( d )  of the inventive manufacturing method, in order to facilitate the clamping of the pole tube&#39;s structural parts  20 ,  26  to the expansion arbor  10 , a pole core  30  (cf. Figure (d)), where applicable including flange, is joined with the finished pole tube advantageously only after the insert molding. The open construction of the pole tube during manufacture, i.e. with a through bore, allows a central positioning of both pole tube&#39;s structural parts on the hydraulic expansion arbor  10 . 
         [0055]    In  FIG. 2( c )  step S 30  of  FIG. 1  is illustrated, where the pole tube&#39;s structural parts  20 ,  26  are connected by insert molding of the outer lateral surface of the pole tube&#39;s structural parts with a nonmagnetic material, for example a plastic. The nonmagnetic material forms, beside the inner surfaces of the pole tube&#39;s structural parts  20 ,  26 , a part of the inner surface of the pole tube in the region of the gap  28 . For this purpose, it is represented in  FIG. 2( c )  that the pole tube&#39;s structural parts  20 ,  26  arranged on the expansion arbor  10  are enclosed by two halves of an injection mold  18   a ,  18   b  in such a way that the space formed thereby between the pole tube&#39;s structural parts  20 ,  26 , the lateral surface of the expansion arbor  10  in the region of the gap  28  as well as the inner surface of the injection mold parts  18   a  and  18  has the form of a winding carrier  32 . For this purpose, a nonmagnetic material, for example a plastic, is insert molded in a per se known manner into this space in liquid form, and thus the outer lateral surfaces of the pole tube&#39;s structural parts  20 ,  26  are insert molded and/or cast. In this way the pole tube&#39;s structural parts  20 ,  26  are permanently connected. 
         [0056]      FIG. 2( d )  shows the finished pole tube  34 , consisting of the magnetic tube  20  and the pole core tube  26 , the pole core  30  inserted into pole core tube  26  as well as the insert molded/cast winding carrier  32  connecting the pole tube&#39;s structural parts  20 ,  26 . Particularly advantageously there results a nearly offset-free inner surface  36  for the pole tube  34  through the manufacturing method according to the invention. 
         [0057]    Preferably the pole tube&#39;s structural parts  20 ,  26  and the pole core  30  are manufactured from a magnetically conducting ironworks substance, for example by machining (e.g. 1.0715), or as a sintered part (e.g. Sint D35) or as a extruded part (e.g. 1.0303). Preferably the nonmagnetic material is a plastic, e.g. PA 6.6 GF30. 
         [0058]      FIG. 3  shows a section through an inventive electromagnet  40  for a magnetic valve with an inventive pole tube  34 , which has preferably been manufactured with the inventive manufacturing method of  FIGS. 1 and 2 . 
         [0059]    In the electromagnet  40 , the pole tube  34  is arranged concentrically to a center longitudinal axis  42  of the electromagnet  40 . As shown in  FIG. 2( d ) , the pole tube  34  consists of the magnetic tube  20 , the pole core tube  26  and the pole core  30  inserted therein at one end. The magnetic tube  20 , the pole core tube  28  and the pole core  30  are manufactured from a magnetic material. 
         [0060]    On the outer lateral surfaces of the pole tube&#39;s structural parts  20 ,  26 , an insert molding or casting layer of a nonmagnetic material, preferably plastic, is applied. This insert-molded or cast layer acts as a winding carrier  32  for a coil  44  arranged thereon, for example in the form of a copper wire winding. Outwardly, the winding carrier  32  and the coil  44  supported thereon are enclosed by a cylindrical housing  46  of the electromagnet  40 . 
         [0061]    On the side of the pole tube  34  having the flange  24 , the housing  46  is closed with a cover  48 . Opposite of the cover  48 , at the other pole tube&#39;s end at which the pole core  30  is located, the housing  46  is likewise closed by an element of the pole core  30  forming a flow disk  31 . 
         [0062]    The pole core  30  has a centric through bore  50 , in which an actuation pin  52  is displaceably guided, for example for a valve element. A magnetic armature  54  in the pole tube  34  is mounted on an inner surfaces  36  of the pole tube  34  forming an armature running surface. The actuation pin  52  is actuatable by the magnetic armature  34  or, more precisely, by an armature bolt  56  connected to the magnetic armature  54 . 
         [0063]    The connection of both pole tube&#39;s structural parts  20 ,  26  by means of the plastic insert molding completely fills the gap  28  provided for the magnetic separation of the pole tube&#39;s structural parts. The continuous interior inner surface  36  serving as an armature running surface according to the inventive method is continuous and offset-free so that a guiding of the magnetic armature  54  is possible with minimal radial air gap  58 . 
         [0064]    Finally, it should be noted that the outer lateral surfaces of the pole tube&#39;s structural parts  20 ,  26  can be furnished with surface structures not shown in the Figures, for example in the form of knurling or grooves, prior to the insert molding to attain a better connection of the pole tube&#39;s structural parts  20 ,  26  with the nonmagnetic material. 
         [0065]    For centering the magnetic armature  54  in the pole tube  34  with defined radial air gap  58  between outer lateral surface of the magnetic armature  54  and inner lateral surfaces  36  of the pole tube  34 , a bearing foil (not shown in the Figure), for example of PTFE or plastic or a plastic-glass tissue, can be provided between the inner surface  36  of the pole tube  34  and the magnetic armature  54 . This avoids a unilateral applying, connected with high magnetic transverse forces, of the magnet armature  54  to the magnetically conducting single parts of the pole tube  34 .