Method Of Making A Buzzer Structure

Abstract

A buzzer structure, of the type comprising a housing having a coil unit therein and an armature mounted for vibratory movement adjacent the coil unit, includes an integral portion of the housing which is bent inwardly into engagement with the coil unit to fix the spacing between the coil unit and housing, thereby to determine the dimensions of the gap between the coil unit and armature. The spacing and gap dimensions are adjusted, after the buzzer elements are assembled, by energizing the coil unit, applying a force to a portion of the housing to progressively deform it to displace the coil unit in engagement therewith, and monitoring the magnitude of current flow through the coil unit while simultaneously monitoring the sound output of the buzzer to determine when a proper operating point has been reached, at which time the progressive deformation of the housing and displacement of the coil unit is immediately terminated.

Description

BACKGROUND OF THE INVENTION

Various buzzer structure, adapted to be energized by AC and/or DC, are in themselves well known. Such buzzer structures typically comprise a coil unit associated with a vibratory armature mounted adjacent thereto. In the case of AC operation, the armature may constitute a permanent magnet adapted to be successively attracted to and repelled by the changing polarity poles produced in the AC energized coil unit or, if the armature has a comparatively small mass, the armature may comprise a strip of magnetic metal mounted on a spring and adapted to be successively attracted to one end of the coil unit at a frequency dependent upon the frequency of energization, e.g., a 60-cycle coil energization causes armature vibration at 120 cycles per second. In the case of DC operation, the armature is further associated with a contact pair which controls the energization circuit of the coil in well known fashion to successively make and break said energization circuit and thereby cause vibratory motion of the armature. The present invention is concerned, in general, with buzzers of these various different types.

In buzzer assemblies of the general types described above, proper operation of the buzzer depends, inter alia, on proper positioning of the coil unit and armature relative to one another, i.e., if the gap between these elements is too large the armature will not be attracted to the coil unit when the coil unit is energized. It is possible, of course, to calculate precisely where the parts should be positioned relative to one another in dependence upon the parameters of the coil unit and armature and the operating conditions which are desired, and to carefully engineer and assemble the buzzer based upon such calculations. However an approach of this type, and the resultant precision in manufacture and assembly which it contemplates, is not economically justifiable when it is desired to provide a simple, comparatively inexpensive buzzer assembly; and in this latter case, the usual practice has been to mount the coil unit and armature in general proximity to one another within a housing, and then to manually adjust the positions of these elements relative to one another while observing the operating state of the buzzer thereby to establish the operating point of the buzzer. More particularly, it has been the practice heretofore to provide an adjustable set screw in the buzzer housing positioned to bear upon a portion of the coil unit and, with the coil energized but with the gap between the coil unit and armature too large to cause the armature to be attracted to the energized coil unit, to turn the set screw thereby to force the coil unit toward the armature until the gap has been reduced sufficiently to cause the buzzer to commence its operation, at which time the set screw is locked into place.

The prior art adjustment technique discussed above has a number of disadvantages. It requires, of course, the provision of a set screw and associated tapped hole in the housing which tend to increase the cost of the buzzer somewhat; and while the cost of these items is comparatively small, it may become significant in the case of an extremely inexpensive buzzer construction. In addition, the adjustment procedure, requiring the turning down of the set screw and the subsequent locking thereof into place, is comparatively slow and does not lend itself to an automated procedure. Moreover, the adjustment may not be as permanent as desired since there is always the possibility that an improperly locked screw may shake loose, in which event the dimensions of the gap between the coil unit and armature can change to render the buzzer inoperative.

The present invention obviates all of these disadvantages of the prior art.

SUMMARY OF THE INVENTION

In accordance with the present invention, the housing of a buzzer unit of the type described above is modified to eliminate the tapped hole and associated set screw and, instead, is formed with a pair of generally parallel, comparatively short slots therein which define, between the slots, a housing portion which is depressible or deformable toward the interior of the housing. This deformable portion of the housing is located adjacent the mounting position of the coil unit so that, when a force is applied thereto from the exterior of the housing, the deformable portion is bent into a substantially V-shaped configuration which protrudes toward the interior of the housing in engagement with the coil unit to displace the coil unit. Deformation of the deformable housing portion thereby performs the adjustment function of the prior art set screw arrangement described previously, but does so in a far more economical, efficient, and otherwise generally improved fashion. Adjustment is accomplished simply by applying a force to the deformable portion of the housing, thereby to bend said deformable portion toward the housing interior in progressively greater increments until the desired buzzer operating point is achieved, at which time the applied bending force is removed to leave the coil unit locked at its proper position by the deformed housing portion in engagement therewith. By this arrangement and procedure, the set screw and its tapped hole previously employed are eliminated and the manufacturing cost of the buzzer is accordingly reduced, proper adjustment is accomplished much more quickly and the adjustment is far more permanent than in the case of a set screw.

The improved buzzer arrangement of the present invention lends itself, moreover, to an automated adjustment procedure. More particularly, the adjustment can be effected by a selectively energizable motor which operates, through an appropriate gear box, to advance a tool which is in engagement with the deformable portion of the buzzer housing while the operating condition of the buzzer is monitored. In a preferred embodiment of the invention, the buzzer coil unit is energized at a voltage which is, for example, approximately 30 percent below its nominal or rated voltage, during the adjustment procedure; and the operating condition of the buzzer is monitored by sensing the magnitude of current flowing through the coil unit (the magnitude is comparatively high until the buzzer starts operating, at which time it drops to a significantly lower value) and while simultaneously monitoring the sound output of the buzzer (which is initially silent and which starts to buzz as the adjustment proceeds). The mechanism employed to effect this monitoring procedure senses the current and sonic parameters simultaneously, and preferably includes means for adjusting the thresholds at which the current drop and sonic output increase are detected; and when the characteristic changes in both parameters are sensed, a logic circuit operates to reverse the energization to the motor thereby to immediately reverse the direction of rotation of the motor to return the depressing tool to its zero position.

The adjustment procedure is accordingly accomplished simply by aligning the tool with the depressible housing portion, thereafter energizing the motor, and permitting the motor to run first in its forward direction until the proper operating point of the buzzer has been achieved, at which time the motor drive immediately and automatically reverses to terminate the adjustment procedure.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing construction, operation, and advantages of the present invention will become more readily apparent from the subsequent description and accompanying drawings in which:

FIG. 1 is a top view of a buzzer housing constructed in accordance with the present invention;

FIG. 2 is a vertical cross sectional view of the buzzer of FIG. 1, incorporating the adjustment structure of the present invention;

FIG. 2A depicts a portion of the structure shown in FIG. 2, but with the prior art set screw adjustment incorporated therein; and

FIG. 3 is a schematic diagram of an automatic adjustment mechanism used in conjunction with a buzzer of the type shown in FIG. 2, to practice the automatic adjustment procedure of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIGS. 1 and 2, it will be seen that the buzzer of the present invention (which, except for the adjustment feature to be described hereinafter, is a prior art, commercially available structure) comprises a housing 10 having a cup-shaped upper portion 10a and an opposing lower closure portion 10b mechanically joined to one another at 10c and supporting therebetween, at its periphery, a disc-shaped diaphragm 11 adapted to produce a sonic output via an opening 10d in the lower closure portion. The diaphragm 11 is in turn associated with a buzzer mechanism, disposed within cup-shaped housing portion 10a, comprising an armature 12 which is mounted adjacent a coil unit 13 adapted to be electrically energized via lead 14 to effect vibratory motion of armature 12 to cause said armature to repetitively strike a a stud 15 affixed to the center of diaphragm 11.

Armature 12 takes the form of a strip of magnetic material having its free end disposed adjacent the core 13a of coil unit 13. The other end of armature 12 is attached to a spring 16 which is in turn secured to an L-shaped bracket 17 which is affixed to the upper side (as viewed in FIGS. 2 and 2A) of coil unit 13. The entire buzzer unit, which is thus of unitary construction, is mounted on the base of cup-shaped housing portion 10a by means of a rivet 18, but with armature 12 and core 13a of coil unit 13 being electrically isolated from housing 10 by means of an intervening insulator 19.

Assuming for the moment that the gap between armature 12 and core 13a is of proper size, when coil unit 13 is energized with AC applied across leads 14, it causes armature 12 to be successively attracted to core 13a against the force of spring 16, and thus causes the armature 12 to vibrate between core 13a and stud 15, at a repetition rate which is twice the applied frequency, i.e., with 60 hz coil energization employed, the buzzer will sound at 120 hz. Alternatively, the buzzer may be cause to operate with DC energization by grounding housing 10 thereby to ground diaphragm 11 and its stud 15, by positioning armature 12 to normally engage stud 15, and by applying DC energization to coil 13 through the contact set provided by stud 15 and armature 12 in accordance with known DC buzzer techniques.

When the buzzer unit, comprising interconnected coil unit 13 and its associated armature 12, are initially assembled, it is conventional in the art to provide a gap between the coil unit and armature which is too large to permit the buzzer to operate and thereafter to reduce the size of this gap by an adjustment procedure, effected after the buzzer has been assembled, which adjusts the buzzer to its proper operating point. More particularly, it has been standard practice to mount the buzzer unit within cup-shaped portion 10a of housing 10 with the upper side of its coil unit initially being in close proximity to and in substantially flush engagement with, the interior of the base of housing portion 10a, and to provide said base with an adjustment set screw 20 (see FIG. 2A) disposed within a tapped hole in said base for engagement with the flush mounted buzzer unit at a position comparatively widely spaced from its mounting rivet 18. With coil unit 13 energized, e.g., at a voltage approximately 30 percent below nominal or rated voltage, screw 20 is turned down to cause energized coil 13 to be moved progressively away from the interior of the base of housing portion 10a about mounting rivet 18, thereby to successively reduce the gap between coil unit 13 and armature 12; and when the buzzer starts to operate, set screw 20 is locked into place e.g., by means of a lock nut 21 or by the application of an appropriate cement compound thereto. This conventional adjustment procedure requires that the buzzer housing be provided with a set screw and an associated tapped hole, further requires the provision of means for locking the set screw at its adjusted position and involves a comparatively time consuming manual adjustment procedure, all of which necessarily increase the cost of the buzzer unit. Yet the resultant adjustment may be less permanent than desired since there is always the possibility that, in use, the set screw may work free or become unlocked, causing the buzzer to go out of adjustment and become inoperative. The present invention obviates all of these disadvantages of the prior art.

In accordance with the present invention, instead of using a set screw such as 20, the base of cup-shaped housing portion 10a is provided with a pair of comparatively short, parallel, spaced slots 25 (see FIG. 1) which define therebetween a deformable housing portion 26 located at generally the same position in the overall assembly as was previously associated with set screw 20. The resultant somewhat weakened portion of the housing is reinforced by forming the base of cup-shaped portion 10a with outwardly protruding reinforcing ribs 27 in partially surrounding relation to deformable portion 26.

Deformable portion 26 is located in comparatively widely spaced relation to mounting rivet 18 at a position directly adjacent the coil unit 13. When it is desired to adjust the buzzer to its operating point a force applied to the deformable housing portion 26, from the exterior of the housing directed toward the interior of the housing, deforms said portion 26 into the generally V-shaped configuration shown in FIG. 2, and as this deforming force continues to be applied, the depth "h" of the V-shaped depression increases to successively displace coil unit 13 away from the interior of the base of housing portion 10a thereby to reduce the gap between coil unit 13 and armature 12. When the depth "h" of the depression becomes sufficiently large to set the buzzer unit to its desired operating point, the deforming force is removed from housing portion 26 to leave the coil unit 13 at its then adjusted position relative to armature 12 and, without any subsequent locking procedure, the component parts of the buzzer assembly remain locked in proper position relative to one another by the permanently depressed housing portion 26 during subsequent use of the buzzer mechanism.

The user of a deformable housing portion 26 simplifies the construction of the housing structure itself, reduces its cost by eliminating the set screw and associated tapped hole previously considered necessary, reduces the time needed to adjust the buzzer to its proper operating point, and produces a more permanent adjustment. In addition, the modification of the present invention adapts the entire structure to an automatic adjustment procedure which has not been possible heretofore. This additional aspect of the present invention will now be described with reference to FIG. 3.

As shown in FIG. 3, a buzzer 30, constructed as shown in FIGS. 1 and 2, may be located at an adjustment station with its deformable housing portion 26 underlying a depressing tool 31. Tool 31 may in turn be moved in translation by a gearing mechanism 32 which is driven by a reversible motor 33, and motor 33 is in turn energized through a reversing circuit 34 from a power supply 35 having an on-off switch 36. The coil leads of buzzer unit 30 are connected to terminals 37a, 37b which energizes the coil at a potential approximately 30 percent below nominal or rated voltage from source 38, and which further functions to insert an adjustable current sensor 39 in series with the buzzer coil.

A sonic sensor 40 is disposed in facing relation to the sound emitting orifice 10d of the buzzer to determine when buzzer 30 commences producing a sound output. Sonic sensor 40 is preferably arranged to provide an adjustable threshold, so that it can be set for an optimum db output corresponding to the optimum adjustment point of buzzer 30, and adjustment of current sensor 39 similarly permits sensor 39 to be set to a current level which also represents an optimum operating condition. The outputs of the sensor 39 and 40 are coupled as two inputs to an AND gate 41 the output of which is coupled to reversing circuit 34.

Assuming for the moment that depressing tool 31 is in its "zero" position, and that the coil of buzzer 30 is energized from source 38, closure of switch 36 energizes motor 33 through reversing circuit 34 to cause the motor to commence operating in a forward direction, thereby to move tool 31, via gear box 32, in a direction toward the interior of the buzzer housing. This in turn causes deformable housing portion 26 to be depressed by successively greater amounts, and simultaneously causes displacement of the coil unit 13 within the buzzer toward the proper operating point of the buzzer. When the proper operating point has been reached, as monitored by the optimum db output sensed by sensor 40 and by a significant reduction in coil current to a desired optimum value as sensed by sensor 39, the signals simultaneously applied to gate 41 cause the gate output to activate reversing circuit 34 e.g., to energize a relay in said circuit. This reverses the polarity of energization of motor 33 and causes it to immediately withdraw depressing tool 31 toward its zero position. Thus once the automatic adjustment mechanism of FIG. 3 is set into operation, the buzzer is progressively adjusted toward its operating point; and once the optimum point of adjustment is achieved, as monitored by the current flowing through the buzzer coil and by the sound output of the buzzer, all further adjustment is immediately terminated and the system is returned to its starting point.

While I have thus described preferred embodiments of the present invention, many variations will be apparent to those skilled in the art. It must therefore be understood that the foregoing description is intended to be illustrative only and not limitative of the present invention and all such variations and modifications as are in accord with the principles described are meant to fall within the scope of the appended claims.

Claims

Having thus described my invention I claim:

1. The method of optimally and permanently adjusting the relative positions of the elements of a nonoperative buzzer to render said buzzer operative, said buzzer being of the type comprising a housing having an energizable electric coil mounted therein and also having an armature mounted therein for movement adjacent said coil but initially spaced from said coil by a gap the dimensions of which are sufficiently large to prevent said armature from being attracted to said coil if said coil were energized, said method comprising the steps of energizing said coil, progressively deforming a portion of said housing adjacent said coil, on a side of said coil remote from said armature, to cause the deformed portion of said housing to engage said coil and to displace said energized coil toward said armature thereby to progressively reduce the dimensions of said gap, monitoring the operating condition of said buzzer as said progressive deformation step proceeds, and terminating said progressive deformation step and the resultant displacement of said coil when said monitoring step determines that said buzzer has commenced to operate.

2. The method of claim 1 wherein said energizing step comprises energizing said coil at a potential less than its rated potential.

3. The method of claim 1 wherein said progressive deformation step comprises cutting a pair of spaced slots in a predetermined portion of said housing to define the deformable portion of said housing between said slots, and then applying a force between said slots directed from the exterior toward the interior of said housing to progressively deform said portion into the interior of said housing.

4. The method of claim 1 wherein said monitoring step comprises monitoring the magnitude of current flowing through said energized coil.

5. The method of claim 1 wherein said monitoring step comprises monitoring the sonic output of said buzzer.

6. The method of claim 1 wherein said monitoring step comprising monitoring the magnitude of current flow through said energized coil to determine when there is a significant reduction in said magnitude of current flow while simultaneously monitoring the sonic output of said buzzer to determine when there is a significant increase in said sonic output.

7. The method of claim 1 wherein said progressive deformation step includes the step of energizing a motor operative to move a tool in forcible engagement with said housing portion, the terminating of said deformation step comprising the step of reversing the polarity of energization of said motor to reverse the direction of movement of said tool.