CN103065723B - A kind of high-power locomotive multiple-limb controls the preparation method of wire harness - Google Patents
A kind of high-power locomotive multiple-limb controls the preparation method of wire harness Download PDFInfo
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- CN103065723B CN103065723B CN201210553693.8A CN201210553693A CN103065723B CN 103065723 B CN103065723 B CN 103065723B CN 201210553693 A CN201210553693 A CN 201210553693A CN 103065723 B CN103065723 B CN 103065723B
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Abstract
The present invention relates to electric wire field, particularly relate to a kind of high-power locomotive multiple-limb and control wire harness.The invention provides a kind of high-power locomotive multiple-limb and control the preparation method of wire harness, comprise the steps: 1) insulated wire cores, braided wires extrude; 2) insulated wire cores of step 1 gained is carried out irradiation technique; 3) branch's welding is carried out after the insulated wire cores of step 2 gained being cut; 4) by step 3 gained insulated wire cores bunchy, and the braided wires of step 1 gained is used to carry out outer braid: 5) at end mounting terminal and the connector of each core.Wire harness prepared by the preparation method controlling wire harness by a kind of high-power locomotive multiple-limb provided by the present invention, each the key technical indexes all can reach, and comprises electric property, hot property, lower temperature resistance, environment resistant, salt water test and burning test.
Description
Technical field
The present invention relates to electric wire field, particularly relate to a kind of high-power locomotive multiple-limb and control wire harness.
Background technology
On nearest market, increasing power vehicle adopts four-cycle diesel as power, its operation of four-stroke engine comprises four strokes: 1) intake stroke: INO, piston moves downward, the mixture of fuel oil and air enters cylinder, when piston movement is to time minimum, intake valve cuts out; 2) compression stroke: intake valve and vent valve are all closed, piston upwards, the mixed gas of fuel oil and air is compressed, and when piston movement is to top, compression stroke terminates, and is interior energy by changes mechanical energy; 3) expansion stroke: spark ignition mixed gas, the gas of burning sharply expands, and promotes descent of piston, can be converted into mechanical energy by interior; 4) exhaust stroke: vent valve is opened, piston upwards, discharges the waste gas after burning, when piston movement is to top, exhaust valve closure.
Novel four-cycle diesel has larger traction power than two stroke diesel engine before this.This type diesel engine adopts modularized design, and EFI cylinder works alone, and control line must be adopted to connect uniform operational, and modular transducer also needs control line to be connected to control system process.But the length of common locomotive (automobile) bunch product is generally long to tens meters at several meters, and novel four-cycle diesel is because locomotive head overall length is at about 20 meters, and therefore, the bunch product of novel four-cycle diesel always reaches more than 20 meter, increase production difficulty.Meanwhile, this bunch product complex circuit, EFI controls wire harness has 12 or 16 branches not, must have corresponding multi-branch connector; And the total joint of sensor control lines bundle reaches 20, therefore, correspondingly also need 20 branch's heads, branch's core that each branch joint is connected reaches more than 60 core, and had more doubly a lot than once logical locomotive (automobile) wire harness, production difficulty is large.
For coordinating the market demand, be necessary that developing a kind of novel high-power locomotive multiple-limb controls bunch product, uses for novel four-cycle diesel.
Summary of the invention
The shortcoming of prior art in view of the above, the object of the present invention is to provide a kind of high-power locomotive multiple-limb to control wire harness, for solving the problems of the prior art.This type of wire harness can be described as the core component of four-cycle diesel, and can liken into is diesel engine " arteries ".
For achieving the above object and other relevant objects, the invention provides the preparation method that a kind of high-power locomotive multiple-limb controls wire harness, comprise the steps:
1) insulated wire cores, braided wires are extruded;
2) insulated wire cores of step 1 gained is carried out irradiation technique;
3) branch's welding is carried out after the insulated wire cores of step 2 gained being cut;
4) by step 3 gained insulated wire cores bunchy, and the braided wires of step 1 gained is used to carry out outer braid:
5) at end mounting terminal and the connector of each core.
Preferably, in described step 1, insulated wire cores adopts tinned copper wire.Described tinned copper wire has high conduction performance, and has certain flexibility.
Preferably, in described step 1, the material of the insulating barrier of insulated wire cores is selected from crosslinked Kynoar or Kynoar.
Preferably, in described step 1, the insulated wire cores of gained is 16AWG electric wire or 18AWG electric wire.
It is high to insulated wire cores performance requirement that high-power locomotive multiple-limb provided by the present invention controls wire harness.Require that rated temperature range when cable uses under suitable duty cycle and environment is-50 DEG C to+125 DEG C, the shortest expected service life is 20 years.Insulating barrier comprises thermosets, fire retardant, oil resistant and lipidic compounds, in addition can anti-moisture, anti-caustic scrub solution, high ambient condition, wearing and tearing under electrical overload conditions, pierce through, compress and extrude and a small amount of being fuming and producing sour gas generates.Therefore, PVDF(Kynoar is selected in inventor's design) material, this material is homopolymers based on the partially crystallizable melt-processable of vinylidene fluoride or copolymer, has multiple only physical performance concurrently, can be used for cable processing.PVDF possesses excellent fire resistance and low smokiness, has outstanding mechanical performance, pliability, thermal stability and low-shrinkage concurrently.Can being low to moderate-55 DEG C, high using continuously in the scope of 125 ~ 150 DEG C, possess good chemical resistance, after crosslinked, serviceability temperature even can up to 200 DEG C simultaneously.
Preferably, in described step 1, the braided wires of gained is that nylon yarn surface is extruded PVDF and made, and nylon yarn is as draught line.
Preferably, the nominal thickness that braided wires is extruded is 0.2mm.
Because the braided wires external diameter of gained is little, have elasticity during traction, external diameter more difficult control when extruding, die drawn equilibrium ratio needs moderate; The sizing area of die sleeve can not be oversize, to reduce resistance; Extruded velocity wants fast relatively.
Preferably, in described step 2, irradiation technique adopts high frequency high voltage electron accelerator and integrated coordinated signals bundle lower device to carry out irradiation, and irradiation dose is 9 ~ 15Mrad.
Irradiation dose is a very important parameter, if dosage is excessive, then elongation at break rate of change is excessive, and low temperature difficulty is passed through; If dosage is too small, heat resistance is undesirable.
Preferred, in described step 2, the voltage of high frequency high voltage electron accelerator is 2.5MeV, and line is 20mA.
Preferably, after described step 2 irradiation technique, lettering technique is also comprised.Insulated wire cores after irradiation is according to identification requirement lettering.
Preferably, in described step 3, the concrete grammar of branch's welding manner is: first branch is welded smooth with soldering, and reusable heat contracting conduit insulate.
The present invention, in the middle of wire harness inner branch, for ensureing that circuit is unobstructed, has many places to need to carry out branch's docking.Traditional insulated tube directly crimps mode and finds probably insecure by artificial repeated examinations.Therefore, the present invention adopts welding manner.
Preferably, in described step 4, outer braid adopts autocratic braided wires braiding, and weave and woven to backbone direction by branch, trunk branch count is more than 70%, and branch line count is more than 75%.
Preferably, in described step 5, when mounting terminal and connector, should note following some: the conductor length that wire stripping pliers of controlling well strip out, the conductor length stripped out is approximately 7-10mm wire, for conductor crimping position; During crimping, the position of line is put well and is fixed, and prevents its slippage; The crimp groove that Selective Pressure bonding tool is suitable; After crimping is good, answers static line and pull terminal, seeing whether it comes off; The terminal crimped, when installing with connector, should hear the sound of clamping, and pulls at one and draw, and checks whether firmly.
After production completes, with universal instrument by product structure schematic diagram each circuit energising requirement, check that whether each contact is firm, energising.
The present invention adopts the tinned copper wire of high conduction performance, in order to ensure that product is while having superperformance, has certain flexibility, and conductor adopts 19 cores or the regular stranded structure of 30 cores, also ensures the rounding property of conductor.Insulation system should adopt thermosetting flame-retardant compound (PVDF Insulation Material), insulating barrier should closely be coated on stranded conductor or dacron thread, the nominal thickness of insulated wire cores is 0.4mm, and the thickness of the thinnest point is not less than 0.3mm, and the nominal thickness that braided wires is extruded is 0.2mm.
The preparation method that second aspect present invention provides described high-power locomotive multiple-limb to control wire harness controls the application of wire harness preparation field at high-power locomotive multiple-limb.
Third aspect present invention provides described a kind of transducer wire harness, prepared by the preparation method being controlled wire harness by described high-power locomotive multiple-limb, it is characterized in that, comprise the main line that length is 13571mm, described main line is made up of 30 branch lines, and the code name of each branch line heart yearn is: WGC1S, WGC2S, WGC3S, WGC4S, WGC5S, WGC6S, WGC7S, WGC8S, WGC9S, WGC10S, WGC11S, WGC12S, WGC13S, WGC23S, WGC24S, WGC1R, WGC2R, WGC3R, WGC5R, WGC6R, WGC7R, WGC9R, WGC10R, WGC11R, WGC13R, WGC14R, WGC15R, WGC17R, WGC18R and WGC19R, the initiating terminal of each heart yearn is identical, from initiating terminal, wherein WGC13R, WGC14R, WGC15R, WGC5S, WGC17R, WGC18R, WGC19R, WGC12S, WGC5R, WGC6R, WGC7R, WGC9R, the length of the length of WGC10R and WGC11R heart yearn to be the length of 9296mm, WGC10S and WGC8S heart yearn be 12048mm, WGC3S heart yearn is the length of 12581mm, WGC7S heart yearn is 12835mm, WGC13S, WGC1R, the length of WGC2R and WGC3R heart yearn is 13140mm, WGC1S, the length of WGC2S and WGC4S heart yearn is 13343mm, WGC9S, WGC11S, WGC24S, the length of WGC23S and WGC6S heart yearn is 13571mm,
Concrete, WGC1S, WGC2S, WGC3S, WGC4S, WGC5S, WGC6S, WGC7S, WGC8S, WGC9S, WGC10S, WGC11S, WGC12S, WGC13S, the initiating terminal of WGC23S with WGC24S heart yearn is connected connector by the 15 core connecting lines that length is 152mm with first and is connected, WGC1R, WGC2R, WGC3R, WGC5R, WGC6R, WGC7R, WGC9R, WGC10R, WGC11R, WGC13R, WGC14R, WGC15R, WGC17R, the initiating terminal of WGC18R with WGC19R heart yearn is connected connector by the 15 core connecting lines that length is 152mm with second and is connected,
Apart from main line initiating terminal 9296mm place, 3rd connects 3 core connecting line and the WGC13R that connector is 1930mm by length, WGC14R with WGC15R heart yearn is connected, 4th connects 3 core connecting line and the WGC24S that connector is 3409mm by length, WGC5S with WGC23S heart yearn is connected, 5th connects 3 core connecting line and the WGC17R that connector is 3909mm by length, WGC18R with WGC19R heart yearn is connected, 6th connects connector is connected with WGC12S with WGC24S heart yearn by the 2 core connecting lines that length is 3330mm, 7th connects 3 core connecting line and the WGC5R that connector is 354mm by length, WGC6R with WGC7R heart yearn is connected, 8th connects 3 core connecting line and the WGC9R that connector is 354mm by length, WGC10R with WGC11R heart yearn is connected,
Apart from main line initiating terminal 12048mm place, 9th connects connector is connected with WGC24S with WGC10S heart yearn by the 2 core connecting lines that length is 127mm, and the tenth connects connector is connected with WGC8S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 304mm;
Apart from main line initiating terminal 12581mm place, the 11 connects connector is connected with WGC3S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 381mm;
Apart from main line initiating terminal 12835mm place, the 12 connects connector is connected with WGC7S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 406mm;
Apart from main line initiating terminal 13140mm place, 13 connects connector is connected with WGC24S with WGC13S heart yearn by the 2 core connecting lines that length is 127mm, and the 14 connects connector is connected with WGC3R heart yearn with WGC1R, WGC2R by the 3 core connecting lines that length is 152mm;
Apart from main line initiating terminal 13343mm place, 15 connects connector is connected with WGC1S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 152mm, 16 connects connector is connected with WGC4S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 355mm, and the 17 connects connector is connected with WGC2S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 508mm;
Apart from main line initiating terminal 13571mm place, 18 connects connector is connected with WGC9S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 356mm, 19 connects connector is connected with WGC24S with WGC11S heart yearn by the 2 core connecting lines that length is 203mm, and the 20 connects connector is connected with WGC6S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 889mm.
Preferably, the connecting line that described 3rd connection connector, the 4th connects connector, the 5th connection connector is connected connector with the 6th is jointly coated from being connected the 330mm lighted with main line, forms 11 heart yearns; Described 4th connects connector, the 5th connection connector is connected the connecting line of connector from jointly coated with the 330mm-2809mm place of main line tie point meter with the 6th, forms 8 heart yearns.
Preferably, described 7th connection connector is connected connector connecting line with the 8th is jointly coated from being connected the 254mm lighted with main line, forms 6 heart yearns.
Transducer wire harness provided by the present invention, from the first or second plug receptacle to the 20th plug receptacle, total thread nearly 15 meters, each branch line thread adds up to distance more than 20 meters.
Fourth aspect present invention provides described a kind of injection pump to control wire harness, prepared by the preparation method being controlled wire harness by described high-power locomotive multiple-limb, it is characterized in that, comprise the main line that length is 11938mm, described main line is made up of 14 branch lines, the code name of each branch line heart yearn is: A1, A2, A3, A4, A5, A6, AG, B1, B2, B3, B4, B5, B6 and BG, the initiating terminal of each heart yearn is identical, from initiating terminal, wherein A1, A2, A3, A4, A5, A6, the length of AG heart yearn is 9144mm, B1, B2, B3, B4, B5, the length of B6 and BG heart yearn is 11938mm,
Concrete, the initiating terminal of A1, A2, A3, A4, A5, A6 and AG heart yearn by length be 152mm 7 core connecting lines be connected connector A and be connected, the initiating terminal of B1, B2, B3, B4, B5, B6 and BG heart yearn by length be 355mm 7 core connecting lines be connected connector B and be connected;
Apart from main line initiating terminal 9144mm place, connect connector A1 to be connected with A1 with AG heart yearn by the 2 core connecting lines that length is 1968mm, connect connector A2 to be connected with A2 with AG heart yearn by the 2 core connecting lines that length is 2412mm, connect connector A3 to be connected with A3 with AG heart yearn by the 2 core connecting lines that length is 2856mm, connect connector A4 to be connected with A4 with AG heart yearn by the 2 core connecting lines that length is 3300mm, connect connector A5 to be connected with A5 with AG heart yearn by the 2 core connecting lines that length is 3744mm, connect connector A6 to be connected with A6 with AG heart yearn by the 2 core connecting lines that length is 4696mm,
Wherein, the connecting line connecting connector A1, A2, A3, A4 and A5 is provided with the free end that length is 1333mm from respective connection connector, the connecting line connecting connector A6 is provided with the free end that length is 1777mm from connection connector, and the connecting line connecting connector A1, A2, A3, A4, A5 and A6 is equipped with fixing connector in 825mm place from respective connection connector; Each connecting line all carries out coated process except free end, forms split conductor structure;
Apart from main line initiating terminal 11938mm place, connect connector B1 to be connected with B1 with BG heart yearn by the 2 core connecting lines that length is 2095mm, connect connector B2 to be connected with B2 with BG heart yearn by the 2 core connecting lines that length is 2539mm, connect connector B3 to be connected with B3 with BG heart yearn by the 2 core connecting lines that length is 2983mm, connect connector B4 to be connected with B4 with BG heart yearn by the 2 core connecting lines that length is 3427mm, connect connector B5 to be connected with B5 with BG heart yearn by the 2 core connecting lines that length is 3871mm, connect connector B6 to be connected with B6 with BG heart yearn by the 2 core connecting lines that length is 4823mm,
Wherein, the connecting line connecting connector B1, B2, B3, B4 and B5 is provided with the free end that length is 1460mm from respective connection connector, the connecting line connecting connector B6 is provided with the free end that length is 1904mm from connection connector, and the connecting line connecting connector B1, B2, B3, B4, B5 and B6 is equipped with fixing connector in 952mm place from respective connection connector; Each connecting line all carries out coated process except free end, forms split conductor structure;
There is no particular meaning for the code name that the name of each heart yearn and connector is used in the present invention, is only the label to heart yearn and connector, so that Division identification.When each connector is connected with core, the conductor length stripped out is approximately 7-10mm.
Wire harness prepared by the preparation method controlling wire harness by a kind of high-power locomotive multiple-limb provided by the present invention, each the key technical indexes all can reach, and comprises electric property, hot property, lower temperature resistance, environment resistant, salt water test and burning test.
Accompanying drawing explanation
Fig. 1 is shown as the structural representation of transducer wire harness of the present invention.
Fig. 2 is shown as the structural representation that injection pump of the present invention controls wire harness.
Fig. 3 is shown as insulated wire cores structural representation of the present invention.
Fig. 4 is shown as present invention process flow chart.
Fig. 5 is shown as the joint design schematic diagram of each core.
Element numbers explanation
101 conductors
102 insulating barriers
103 cores
104 insulating barriers
105 connectors
1 first connects connector
2 second connect connector
3 the 3rd connect connector
4 the 4th connect connector
5 the 5th connect connector
6 the 6th connect connector
7 the 7th connect connector
8 the 8th connect connector
9 the 9th connect connector
10 the tenth connect connector
11 the 11 connect connector
12 the 12 connect connector
13 the 13 connect connector
14 the 14 connect connector
15 the 15 connect connector
16 the 16 connect connector
17 the 17 connect connector
18 the 18 connect connector
19 the 19 connect connector
20 the 20 connect connector
A connects connector A
B connects connector B
A1 connects connector A1
A2 connects connector A2
A3 connects connector A3
A4 connects connector A4
A5 connects connector A5
A6 connects connector A6
B1 connects connector B1
B2 connects connector B2
B3 connects connector B3
B4 connects connector B4
B5 connects connector B5
B6 connects connector B6
Embodiment
By particular specific embodiment, embodiments of the present invention are described below, person skilled in the art scholar the content disclosed by this specification can understand other advantages of the present invention and effect easily.
Refer to Fig. 1 to Fig. 4.Notice, structure, ratio, size etc. that this specification institute accompanying drawings illustrates, content all only in order to coordinate specification to disclose, understand for person skilled in the art scholar and read, and be not used to limit the enforceable qualifications of the present invention, therefore the not technical essential meaning of tool, the adjustment of the modification of any structure, the change of proportionate relationship or size, do not affecting under effect that the present invention can produce and the object that can reach, still all should drop on disclosed technology contents and obtain in the scope that can contain.Simultaneously, quote in this specification as " on ", D score, "left", "right", " centre " and " one " etc. term, also only for ease of understanding of describing, and be not used to limit the enforceable scope of the present invention, the change of its relativeness or adjustment, under changing technology contents without essence, when being also considered as the enforceable category of the present invention.
Embodiment 1
The preparation of transducer wire harness:
1) insulated wire cores, braided wires are extruded; Conductor adopts the tinned copper wire of high conduction performance, in order to ensure that product is while having superperformance, has certain flexibility, and conductor adopts regular stranded structure, also ensures the rounding property of conductor.Insulation system should adopt thermosetting flame-retardant compound (PVDF Insulation Material), insulating barrier should closely be coated on stranded conductor or dacron thread, the nominal thickness of insulated wire cores is 0.4mm, and the thickness of the thinnest point is not less than 0.3mm, and the nominal thickness that braided wires is extruded is 0.2mm.Concrete structure as shown in Figure 3.The insulated wire cores of transducer wire harness is 18AWG electric wire;
2) insulated wire cores of step 1 gained is carried out irradiation technique; Insulated wire cores should be 2.5MeV through voltage, and the high frequency high voltage electron accelerator of line 20mA and the irradiation of integrated coordinated signals bundle lower device, irradiation dose is 12Mrad.Insulated wire cores after irradiation is according to identification requirement lettering;
3) branch's welding is carried out after the insulated wire cores of step 2 gained being cut;
4) by step 3 gained insulated wire cores bunchy, and the braided wires of step 1 gained is used to carry out outer braid: weave and woven to backbone direction by branch, trunk branch count is more than 70%, and branch line count is more than 75%; Braid surface should be smooth;
5) at end mounting terminal and the connector of each core, as shown in Figure 5, the exposed length of core 103 is 700mm to joint design, and checks whether that firmly overall procedure as shown in Figure 4.
The concrete structure of transducer wire harness as shown in Figure 1, comprises the main line that length is 13571mm, and described main line is made up of 30 branch lines, and the code name of each branch line heart yearn is: WGC1S, WGC2S, WGC3S, WGC4S, WGC5S, WGC6S, WGC7S, WGC8S, WGC9S, WGC10S, WGC11S, WGC12S, WGC13S, WGC23S, WGC24S, WGC1R, WGC2R, WGC3R, WGC5R, WGC6R, WGC7R, WGC9R, WGC10R, WGC11R, WGC13R, WGC14R, WGC15R, WGC17R, WGC18R and WGC19R, the initiating terminal of each heart yearn is identical, from initiating terminal, wherein WGC13R, WGC14R, WGC15R, WGC5S, WGC17R, WGC18R, WGC19R, WGC12S, WGC5R, WGC6R, WGC7R, WGC9R, the length of the length of WGC10R and WGC11R heart yearn to be the length of 9296mm, WGC10S and WGC8S heart yearn be 12048mm, WGC3S heart yearn is the length of 12581mm, WGC7S heart yearn is 12835mm, WGC13S, WGC1R, the length of WGC2R and WGC3R heart yearn is 13140mm, WGC1S, the length of WGC2S and WGC4S heart yearn is 13343mm, WGC9S, WGC11S, WGC24S, the length of WGC23S and WGC6S heart yearn is 13571mm,
WGC1S, WGC2S, WGC3S, WGC4S, WGC5S, WGC6S, WGC7S, WGC8S, WGC9S, WGC10S, WGC11S, WGC12S, WGC13S, WGC23S are connected connector 1 by the 15 core connecting lines that length is 152mm with first with the initiating terminal of WGC24S heart yearn and are connected, and WGC1R, WGC2R, WGC3R, WGC5R, WGC6R, WGC7R, WGC9R, WGC10R, WGC11R, WGC13R, WGC14R, WGC15R, WGC17R, WGC18R are connected connector 2 by the 15 core connecting lines that length is 152mm with second with the initiating terminal of WGC19R heart yearn and are connected;
Apart from main line initiating terminal 9296mm place, 3rd connects 3 core connecting line and the WGC13R that connector 3 is 1930mm by length, WGC14R with WGC15R heart yearn is connected, 4th connects 3 core connecting line and the WGC24S that connector 4 is 3409mm by length, WGC5S with WGC23S heart yearn is connected, 5th connects 3 core connecting line and the WGC17R that connector 5 is 3909mm by length, WGC18R with WGC19R heart yearn is connected, 6th connects connector 6 is connected with WGC12S with WGC24S heart yearn by the 2 core connecting lines that length is 3330mm, 7th connects 3 core connecting line and the WGC5R that connector 7 is 354mm by length, WGC6R with WGC7R heart yearn is connected, 8th connects 3 core connecting line and the WGC9R that connector 8 is 354mm by length, WGC10R with WGC11R heart yearn is connected,
Apart from main line initiating terminal 12048mm place, 9th connects connector 9 is connected with WGC24S with WGC10S heart yearn by the 2 core connecting lines that length is 127mm, and the tenth connects connector 10 is connected with WGC8S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 304mm;
Apart from main line initiating terminal 12581mm place, the 11 connects connector 11 is connected with WGC3S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 381mm;
Apart from main line initiating terminal 12835mm place, the 12 connects connector 12 is connected with WGC7S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 406mm;
Apart from main line initiating terminal 13140mm place, 13 connects connector 13 is connected with WGC24S with WGC13S heart yearn by the 2 core connecting lines that length is 127mm, and the 14 connects connector 14 is connected with WGC3R heart yearn with WGC1R, WGC2R by the 3 core connecting lines that length is 152mm;
Apart from main line initiating terminal 13343mm place, 15 connects connector 15 is connected with WGC1S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 152mm, 16 connects connector 16 is connected with WGC4S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 355mm, and the 17 connects connector 17 is connected with WGC2S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 508mm;
Apart from main line initiating terminal 13571mm place, 18 connects connector 18 is connected with WGC9S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 356mm, 19 connects connector 19 is connected with WGC24S with WGC11S heart yearn by the 2 core connecting lines that length is 203mm, and the 20 connects connector 20 is connected with WGC6S heart yearn with WGC23S, WGC24S by the 3 core connecting lines that length is 889mm.
The connecting line that described 3rd connection connector 3, the 4th connects connector 4, the 5th connection connector 5 is connected connector 6 with the 6th is jointly coated from being connected the 330mm lighted with main line, forms 11 heart yearns; Described 4th connects connector 4, the 5th connection connector 5 is connected the connecting line of connector 6 from jointly coated with the 330mm-2809mm place of main line tie point meter with the 6th, forms 8 heart yearns.
Described 7th connection connector 7 is connected connector 8 connecting line with the 8th is jointly coated from being connected the 254mm lighted with main line, forms 6 heart yearns.
Embodiment 2
Injection pump controls the preparation of wire harness:
1) insulated wire cores, braided wires are extruded; Conductor adopts the tinned copper wire of high conduction performance, in order to ensure that product is while having superperformance, has certain flexibility, and conductor adopts regular stranded structure, also ensures the rounding property of conductor.Insulation system should adopt thermosetting flame-retardant compound (PVDF Insulation Material), insulating barrier should closely be coated on stranded conductor or dacron thread, the nominal thickness of insulated wire cores is 0.4mm, and the thickness of the thinnest point is not less than 0.3mm, and the nominal thickness that braided wires is extruded is 0.2mm.Concrete structure as shown in Figure 3.The insulated wire cores that injection pump controls wire harness is 16AWG electric wire;
2) insulated wire cores of step 1 gained is carried out irradiation technique; Insulated wire cores should be 2.5MeV through voltage, and the high frequency high voltage electron accelerator of line 20mA and the irradiation of integrated coordinated signals bundle lower device, irradiation dose is 9 ~ 15Mrad.Insulated wire cores after irradiation is according to identification requirement lettering;
3) branch's welding is carried out after the insulated wire cores of step 2 gained being cut;
4) by step 3 gained insulated wire cores bunchy, and the braided wires of step 1 gained is used to carry out outer braid: weave and woven to backbone direction by branch, trunk branch count is more than 70%, and branch line count is more than 75%; Braid surface should be smooth;
5) at end mounting terminal and the connector of each core, as shown in Figure 5, the exposed length of core 103 is 700mm to joint design, and checks whether that firmly overall procedure as shown in Figure 4.
Injection pump controls the concrete structure of wire harness as shown in Figure 2, comprise the main line that length is 11938mm, described main line is made up of 14 branch lines, the code name of each branch line heart yearn is: A1, A2, A3, A4, A5, A6, AG, B1, B2, B3, B4, B5, B6 and BG, the initiating terminal of each heart yearn is identical, from initiating terminal, wherein the length of A1, A2, A3, A4, A5, A6, AG heart yearn is 9144mm, B1, the length of B2, B3, B4, B5, B6 and BG heart yearn is 11938mm;
Concrete, the initiating terminal of A1, A2, A3, A4, A5, A6 and AG heart yearn by length be 152mm 7 core connecting lines be connected connector A and be connected, the initiating terminal of B1, B2, B3, B4, B5, B6 and BG heart yearn by length be 355mm 7 core connecting lines be connected connector B and be connected;
Apart from main line initiating terminal 9144mm place, connect connector A1 to be connected with A1 with AG heart yearn by the 2 core connecting lines that length is 1968mm, connect connector A2 to be connected with A2 with AG heart yearn by the 2 core connecting lines that length is 2412mm, connect connector A3 to be connected with A3 with AG heart yearn by the 2 core connecting lines that length is 2856mm, connect connector A4 to be connected with A4 with AG heart yearn by the 2 core connecting lines that length is 3300mm, connect connector A5 to be connected with A5 with AG heart yearn by the 2 core connecting lines that length is 3744mm, connect connector A6 to be connected with A6 with AG heart yearn by the 2 core connecting lines that length is 4696mm,
Wherein, the connecting line connecting connector A1, A2, A3, A4 and A5 is provided with the free end that length is 1333mm from respective connection connector, the connecting line connecting connector A6 is provided with the free end that length is 1777mm from connection connector, and the connecting line connecting connector A1, A2, A3, A4, A5 and A6 is equipped with fixing connector in 825mm place from respective connection connector; Each connecting line all carries out coated process except free end, forms split conductor structure;
Apart from main line initiating terminal 11938mm place, connect connector B1 to be connected with B1 with BG heart yearn by the 2 core connecting lines that length is 2095mm, connect connector B2 to be connected with B2 with BG heart yearn by the 2 core connecting lines that length is 2539mm, connect connector B3 to be connected with B3 with BG heart yearn by the 2 core connecting lines that length is 2983mm, connect connector B4 to be connected with B4 with BG heart yearn by the 2 core connecting lines that length is 3427mm, connect connector B5 to be connected with B5 with BG heart yearn by the 2 core connecting lines that length is 3871mm, connect connector B6 to be connected with B6 with BG heart yearn by the 2 core connecting lines that length is 4823mm,
Wherein, the connecting line connecting connector B1, B2, B3, B4 and B5 is provided with the free end that length is 1460mm from respective connection connector, the connecting line connecting connector B6 is provided with the free end that length is 1904mm from connection connector, and the connecting line connecting connector B1, B2, B3, B4, B5 and B6 is equipped with fixing connector in 952mm place from respective connection connector; Each connecting line all carries out coated process except free end, forms split conductor structure.
Embodiment 3
Transducer wire harness and injection pump control the key technical indexes of wire harness:
1, electric property:
1.1,25 DEG C of insulation resistances (in water)
Electric wire 25ft(7.62m), first carry out withstand voltage test, then carry out megger test, test value is all greater than 1524M Ω km.
1.2,125 DEG C of insulation resistances (in air)
Under 125 DEG C ± 2 DEG C conditions after lasting 24 hours, at 125 DEG C, the insulation resistance of test and measurement is all greater than 0.6096M Ω km.
2, hot property:
2.1,168 hours heat resistant tests are continued at 158 DEG C: all by insulation resistance requirement when proof voltage and 25 DEG C.
2.2,96 hours heat resistant tests are continued at 175 DEG C: electric wire is all by withstand voltage test, and the insulation shrinkage of each termination is all no more than 0.79375mm.
2.3, thermal shock
6 circles in the axle that insulated conductor sample is wrapped in 6.35mm all tightly.1 hour is continued under sample fix tightly being placed on 225 DEG C of temperature.After at room temperature cooling, with the naked eye check that the insulated wire in axle does not all have crackle.
2.4, thermal deformation (similar high temperature pressure)
According to high temperature pressure method of testing, test temperature is 150 ± 2 DEG C, and under the load specified in following table, distortion is all no more than 25%.
2.5, thermal endurance
Wire samples 609.6mm, process 7 days (168h) at 158 ± 2 DEG C after, electric wire is all by the withstand voltage test of regulation, and insulating barrier does not all occur that obvious color changes.
3, low temperature resistant:
3.1, cold bend(ing)
Test according to test method, insulating barrier does not all have crackle, and insulated wire all can bear withstand voltage test upon bending.
3.2, cold shock
Test according to following test method, insulating barrier does not all have visible crackle, and after taking out from low-temperature test chamber, insulated wire all can bear withstand voltage test.
4, environment resistant:
4.1, heat-resisting oiliness
The termination of electric wire is peeled off 50.8mm and to be placed in ASTM the 1st, 2 and No. 3 oil 150 ± 2 DEG C and to continue 96 hours, and the increase of the diameter of wire is all no more than 40%.Insulating barrier does not all have crackle, breaks or minute crack, and electric wire is all by the withstand voltage test of regulation.
4.2, hot oil aging
Immersed by insulated sample in ASTM No. 2 oil product, the minimum recorded for 18 hours at 121 DEG C ± 2 DEG C constant temperature is as follows:
| Wire gauge | 18AWG，16AWG |
| Hot strength retention rate/% | 60 |
| Percentage elongation retention rate/% | 60 |
4.3, fuel oil resistance and mineral oil performance
Center 1 foot section of 2 feet of long electric wires is exposed in following environment after 96 hours at 25 ± 5 DEG C of temperature, and the increase of the diameter of wire is all no more than 10%.
Mineral spirits based on naphtha and commercial grade fuel oil-#2.
4.4, ozone resistants
Except ozone concentration is 0.03%(300/1000000ths) and test temperature be except 90 DEG C ± 2 DEG C, expose 24 hours after insulating barrier all there is no crackle.
5,75 DEG C of salt water tests:
After 10ft (3.048m) long loop sample exposes 120 hours in the saline solution of 75 DEG C ± 2 DEG C, electric wire is all by withstand voltage test.
6, testing vertical flammability:
Vertical type burn test results is as follows:
Within the time of having a rest in 15 seconds, the flame of use extinguishes within 3 seconds.
After the 5th time and last use flame, be no more than to the firing duration of sample 3 seconds.
High-power locomotive multiple-limb prepared by the present invention controls the requirement that the length of wire harness and core number all reach four-cycle diesel, effectively overcomes various shortcoming of the prior art and tool high industrial utilization.
Above-described embodiment is illustrative principle of the present invention and effect thereof only, but not for limiting the present invention.Any person skilled in the art scholar all without prejudice under spirit of the present invention and category, can modify above-described embodiment or changes.Therefore, such as have in art usually know the knowledgeable do not depart from complete under disclosed spirit and technological thought all equivalence modify or change, must be contained by claim of the present invention.
Claims (6)
1. high-power locomotive controls a preparation method for wire harness with multiple-limb, comprises the steps:
1) insulated wire cores, braided wires are extruded; The material of the insulating barrier of insulated wire cores is selected from Kynoar;
2) insulated wire cores of step 1 gained is carried out irradiation technique; Irradiation technique adopts high frequency high voltage electron accelerator and integrated coordinated signals bundle lower device to carry out irradiation, and irradiation dose is 9 ~ 15Mrad;
3) branch's welding is carried out after the insulated wire cores of step 2 gained being cut;
4) by step 3 gained insulated wire cores bunchy, and the braided wires of step 1 gained is used to carry out outer braid:
5) at end mounting terminal and the connector of each core;
In described step 1, the braided wires of gained is that nylon yarn surface is extruded PVDF and made, and nylon yarn is as draught line;
In described step 4, weave and woven to backbone direction by branch, trunk branch count is more than 70%, and branch line count is more than 75%.
2. a kind of high-power locomotive multiple-limb as claimed in claim 1 controls the preparation method of wire harness, it is characterized in that, in described step 1, described Kynoar is crosslinked Kynoar.
3. a kind of high-power locomotive multiple-limb as claimed in claim 1 controls the preparation method of wire harness, it is characterized in that, in described step 1, insulated wire cores adopts tinned copper wire.
4. a kind of high-power locomotive multiple-limb as claimed in claim 1 controls the preparation method of wire harness, it is characterized in that, in described step 1, and the insulated wire cores 16AWG electric wire of gained or 18AWG electric wire.
5. a kind of high-power locomotive multiple-limb as claimed in claim 1 controls the preparation method of wire harness, and it is characterized in that, in described step 3, the concrete grammar of branch's welding manner is: first branch is welded smooth with soldering, and reusable heat contracting conduit insulate.
6. the high-power locomotive multiple-limb as described in claim as arbitrary in claim 1-5 controls the application of preparation method in high-power locomotive multiple-limb control wire harness preparation field of wire harness.
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| CN201210553693.8A CN103065723B (en) | 2012-12-19 | 2012-12-19 | A kind of high-power locomotive multiple-limb controls the preparation method of wire harness |
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| CN201210553693.8A CN103065723B (en) | 2012-12-19 | 2012-12-19 | A kind of high-power locomotive multiple-limb controls the preparation method of wire harness |
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| CN103489520B (en) * | 2013-09-28 | 2015-12-23 | 四川新蓉电缆有限责任公司 | A kind of slip-off preventing pays the preparation method of copper core cable in advance |
| CN103825160A (en) * | 2014-03-03 | 2014-05-28 | 浙江钻豹电动车有限公司 | Production technology of electric vehicle master control line |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1170210A (en) * | 1996-05-20 | 1998-01-14 | 矢崎总业株式会社 | Method and apparatus of manufacturing wiring harness |
| CN1551427A (en) * | 2003-05-09 | 2004-12-01 | 住友电装株式会社 | Line pencil manufacturing method and manufacturing device |
| CN1589485A (en) * | 2001-10-12 | 2005-03-02 | 矢崎总业株式会社 | Wire recycling method |
| CN1866411A (en) * | 2006-06-20 | 2006-11-22 | 广州凯恒特种电线电缆有限公司 | Radiation crosslinking modified ethylene-tetrafluoroethylene insulated wire cable |
| CN102103908A (en) * | 2010-12-30 | 2011-06-22 | 安徽鑫科新材料股份有限公司 | Method for producing heat-resistant environmentally-friendly thermoplastic elastic body sheathed flexible cable |
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2012
- 2012-12-19 CN CN201210553693.8A patent/CN103065723B/en not_active Expired - Fee Related
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1170210A (en) * | 1996-05-20 | 1998-01-14 | 矢崎总业株式会社 | Method and apparatus of manufacturing wiring harness |
| CN1589485A (en) * | 2001-10-12 | 2005-03-02 | 矢崎总业株式会社 | Wire recycling method |
| CN1551427A (en) * | 2003-05-09 | 2004-12-01 | 住友电装株式会社 | Line pencil manufacturing method and manufacturing device |
| CN1866411A (en) * | 2006-06-20 | 2006-11-22 | 广州凯恒特种电线电缆有限公司 | Radiation crosslinking modified ethylene-tetrafluoroethylene insulated wire cable |
| CN102103908A (en) * | 2010-12-30 | 2011-06-22 | 安徽鑫科新材料股份有限公司 | Method for producing heat-resistant environmentally-friendly thermoplastic elastic body sheathed flexible cable |
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