CN110707497A - Novel wire harness manufacturing method - Google Patents
Novel wire harness manufacturing method Download PDFInfo
- Publication number
- CN110707497A CN110707497A CN201911038614.8A CN201911038614A CN110707497A CN 110707497 A CN110707497 A CN 110707497A CN 201911038614 A CN201911038614 A CN 201911038614A CN 110707497 A CN110707497 A CN 110707497A
- Authority
- CN
- China
- Prior art keywords
- plug
- wire harness
- welding
- tail
- wire
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a novel wire harness manufacturing method, which belongs to the technical field of wire harness manufacturing and comprises the following steps: the wire speed manufactured by the invention has the advantages of oxidation resistance, strong shock resistance, chemical oil stain corrosion resistance, good sealing performance and flame retardant property, and greatly improves the reliability and safety of national defense equipment in practical application.
Description
Technical Field
The invention belongs to the technical field of manufacturing of wire harnesses, and particularly relates to a novel wire harness manufacturing method.
Background
The wiring harness is a wiring part for connecting each electric appliance in the electric appliance, has a vital function, has higher and higher requirements on the quality, and particularly has the problems of safety and environmental protection.
The wire harness manufactured by the conventional wire harness manufacturing process has the problems of water seepage, corrosion, burning, abrasion and the like, and the leakage or short circuit caused by the water seepage and insulation damage can cause the equipment to work normally or even harm the personal safety.
Disclosure of Invention
The invention aims to: aiming at the problems, the invention provides a novel wire harness manufacturing method which can manufacture a wire harness with oxidation resistance, strong shock resistance, chemical oil stain corrosion resistance, good sealing performance and flame retardant property.
In order to achieve the above object, the present invention adopts the following technical solutions.
A novel wire harness manufacturing method comprises the following steps:
s1, cutting and arranging a plurality of wires;
s2, the conducting wire in the step S1 is bundled and fixed by an insulating tape and then penetrates into a corrugated sleeve, and then a plug and a plug tail accessory penetrate into two ends of a wiring harness;
s3, wire stripping: stripping an insulating layer at the end of the wire, wherein the copper core of the wire is exposed out of the end of the wire;
s4, cleaning: cleaning the welding cup and the end of the lead by dipping wiping cloth in absolute ethyl alcohol to remove an oxide layer or oil stain on the surface of the welding cup and the end of the lead;
s5, tin coating: enameling tin the welding cup on the plug, immersing the inner surface of the welding cup, screwing down the copper core of the lead, and then heating to enamal tin on the lead;
s6, welding: welding the point number of the plug with a lead corresponding to the wire number;
s7, protection of welding spots: enclosing the periphery of the welding spot by using an adhesive tape, pouring the adhesive into the welding spot, and curing at normal temperature;
s8, fastening accessories: fastening the plug and the plug tail accessory;
s9, potting: pouring a pouring sealant into the accessory at the tail part of the plug, and curing at normal temperature;
s10, fixing the end of the corrugated sleeve: winding a silicon rubber tape at the joint of the tail accessory of the plug and the wiring harness for filling, and completing the fixation of the corrugated sleeve and the wiring harness;
and S11, sealing the tail end of the plug tail accessory to obtain the novel wiring harness.
Further, in the step S1, the trimming and trimming of the lead wire reserves 15% of the margin for the lead wire.
Further, the bellows sleeve in the step S2 is a polyamide black bellows.
Further, the inner diameter of the corrugated sleeve is greater than 2/3 times of the outer diameter of the wiring harness, and the length of the corrugated sleeve is 20mm shorter than the length of the wiring harness.
Further, the length of the copper core of the exposed wire in the step S3 is not more than 1mm of the upper edge of the welding cup.
Further, the absolute ethanol in the step S4 is absolute ethanol with a concentration of not less than 99.5%.
Further, the last sealing process for the plug tail accessory in step S11 includes the following steps:
(1) at the joint of the corrugated pipe and the tail accessory, 200% of the silica gel self-adhesive tape is stretched from 2/3 of the plug tail accessory to the tail end and wound to the position of 50-60mm of the corrugated pipe in a mode of overlapping 1/2, and then the process is repeated once;
(2) winding a layer of hot melt adhesive tape on a corrugated pipe section which is wound with the silica gel self-adhesive tape, wherein the winding method is that after the corrugated pipe section is stretched by 100 percent, the corrugated pipe section is uniformly wound in an 1/2 overlapping mode
(3) Sleeving a double-wall heat-shrinkable tube on the part wound with the hot-melt adhesive tape in the step (2), performing heat-shrinking treatment by using a hot air gun, setting the temperature to be 150-250 ℃, and uniformly heating the heat-shrinkable tube from the head end to the tail end of the plug around the circumference.
Further, the double-wall heat shrinkable tube in the step (2) is a polyethylene hydrocarbon double-wall heat shrinkable tube.
Further, the diameter of the double-wall heat-shrinkable tube in the step (2) is 2-3mm larger than the outer diameter of the plug.
Furthermore, the corrugated sleeve is sleeved with an identification sleeve.
The invention has the beneficial effects that:
the wire harness produced by the method is well verified on missile loading transport vehicles and heat preservation transport vehicles of a certain series of models, compared with the wire harness produced by the traditional process, the wire harness produced by the method has the advantages of strong oxidation resistance and impact resistance, chemical oil stain corrosion resistance, good sealing performance and flame retardant property, and the reliability and safety of the national defense equipment are greatly improved in practical application.
Drawings
FIG. 1 is a schematic view of a wiring harness configuration of the present invention;
fig. 2 is a schematic view of the plug structure of the present invention.
In the figure, 1-wire harness, 2-welding spot, 3-wire copper core, 4-insulating layer, 5-welding cup, 6-plug tail accessory, 7-plug, 8-marking sleeve, 9-corrugated sleeve, 10-double-wall heat-shrinkable tube, 11-hot-melt adhesive tape, 12-silica gel self-adhesive tape and 13-pouring sealant.
Detailed Description
The technical solution of the present invention is further described below, but the scope of the claimed invention is not limited to the described.
As shown in fig. 1 and 2, a method for manufacturing a novel wire harness 1 includes the following steps:
s1, cutting and arranging a plurality of wires;
s2, the conducting wire in the step S1 is bundled and fixed by an insulating tape and then penetrates into the corrugated sleeve 9, and then the plug 7 and the plug tail accessory 6 penetrate into two ends of the wiring harness 1;
s3, wire stripping: peeling off the insulating layer 4 at the end of the wire, and exposing the copper core 3 at the end of the wire;
s4, cleaning: cleaning the welding cup 5 and the end of the lead by dipping wiping cloth in absolute ethyl alcohol to remove an oxide layer or oil stain on the surface of the welding cup;
s5, tin coating: tin coating is carried out on the welding cup 5 on the plug 7, the inner surface of the welding cup 5 is fully soaked, the copper core 3 of the lead is screwed down, and then the lead is heated to carry out tin coating;
s6, welding: welding the point number of the plug 7 with a lead corresponding to the line number; the welding spot 2 is even and full, the phenomena of insufficient solder and false solder cannot occur, and the thickness is 1.5mm2Welding the lower wire, wherein the set temperature of a constant temperature iron is 280 ℃, the (2.5-4) mm2 wire is welded at 300 ℃, and the temperature is more than 6mm2-10mm2The lead is preferably welded by a 60W-100W electric soldering iron.
S7, protection of welding spot 2: enclosing the periphery of the welding spot 2 by using an adhesive tape, pouring the adhesive into the welding spot, and curing at normal temperature; the dosage of the adhesive is determined according to the size of the plug 7, and the adhesive is cured within 24 hours at normal temperature when the adhesive does not pass through the welding point 2.
S8, fastening accessories: fastening the plug 7 with the plug tail attachment 6;
s9, potting: pouring a pouring sealant 13 into the plug tail accessory 6, and curing at normal temperature; the amount of the potting liquid is preferably not to overflow the plug tail accessory 6, and the potting liquid is cured for 24 hours at normal temperature.
S10, fixing the end of the corrugated sleeve 9: a silicon rubber belt is wound at the joint of the plug tail accessory 6 and the wiring harness 1 for filling, and the corrugated sleeve 9 and the wiring harness 1 are fixed;
and S11, sealing the tail end of the plug tail accessory 6 to obtain the novel wiring harness 1.
And in the step S1, reserving 15% of allowance for the wire in the trimming and tidying process.
The bellows sleeve 9 in the step S2 is a polyamide black bellows. The black polyamide corrugated pipe has the advantages of oxidation resistance, impact resistance, chemical corrosion resistance and flame retardance
The inner diameter of the corrugated sleeve 9 is greater than 2/3 times the outer diameter of the wiring harness 1, and the length is 20mm shorter than the length of the wiring harness 1.
The length of the exposed copper wire core 3 in the step S3 is not more than 1mm of the upper edge of the welding cup 5.
The absolute ethyl alcohol in the step S4 is absolute ethyl alcohol with the concentration not lower than 99.5%.
The step S11 of sealing the end of the plug tail attachment 6 includes the following steps:
(1) at the joint of the corrugated pipe and the tail accessory, the silica gel self-adhesive tape 12 is stretched by 200 percent and is wound to the position of 50-60mm of the corrugated pipe in a mode of overlapping 1/2 from the 2/3 position of the plug tail accessory 6 to the tail end, and then the process is repeated once;
(2) winding a layer of hot melt adhesive tape 11 on a corrugated pipe section which is wound with a silica gel self-adhesive tape 12, wherein the winding method is to uniformly wind the corrugated pipe section in an 1/2 overlapping mode after the corrugated pipe section is stretched by 100 percent;
(3) sleeving the part wound with the hot melt adhesive tape 11 in the step (2) with a double-wall heat shrinkable tube 10, performing heat shrinkage treatment by using a hot air gun, setting the temperature to be 150-250 ℃, and uniformly heating the heat shrinkable tube from the head end to the tail end of the plug 7 around the circumference. The length of the plug is determined according to the diameter of the plug 7, when the diameter of the plug 7 is less than or equal to phi 10, the length of the heat-shrinkable tube is defined as 50mm, and when the diameter is more than phi 10 and less than phi 30, the length of the heat-shrinkable tube is defined as 60 mm; when the diameter is more than phi 30 and less than phi 50, the length of the heat-shrinkable tube is defined as 100 mm.
The double-wall heat shrinkable tube 10 in the step (2) is a polyethylene hydrocarbon double-wall heat shrinkable tube.
The diameter of the double-wall heat shrinkable tube 10 in the step (2) is 2-3mm larger than the outer diameter of the plug 7.
The wire harness 1 manufactured in the above step further includes a marking sleeve 8 sleeved on the corrugated sleeve 9. A white heat-shrinkable tube is sleeved on the corrugated sleeve 9 to serve as a mark, the name mark of the wiring harness 1 is arranged at the position between the wiring harnesses 1, and the identification marks of the plug 7 are respectively arranged at two ends of the wiring harness 1.
Claims (10)
1. A novel wire harness manufacturing method is characterized in that: the method comprises the following steps:
s1, cutting and arranging a plurality of wires;
s2, the conducting wire in the step S1 is bundled and fixed by an insulating tape and then penetrates into a corrugated sleeve, and then a plug and a plug tail accessory penetrate into two ends of a wiring harness;
s3, wire stripping: stripping an insulating layer at the end of the wire, wherein the copper core of the wire is exposed out of the end of the wire;
s4, cleaning: cleaning the welding cup and the end of the lead by dipping wiping cloth in absolute ethyl alcohol to remove an oxide layer or oil stain on the surface of the welding cup and the end of the lead;
s5, tin coating: enameling tin the welding cup on the plug, immersing the inner surface of the welding cup, screwing down the copper core of the lead, and then heating to enamal tin on the lead;
s6, welding: welding the point number of the plug with a lead corresponding to the wire number;
s7, protection of welding spots: the periphery of the welding spot is surrounded by adhesive tape, then the adhesive is poured in,
curing at normal temperature;
s8, fastening accessories: fastening the plug and the plug tail accessory;
s9, potting: pouring a pouring sealant into the accessory at the tail part of the plug, and curing at normal temperature;
s10, fixing the end of the corrugated sleeve: winding a silicon rubber tape at the joint of the tail accessory of the plug and the wiring harness for filling, and completing the fixation of the corrugated sleeve and the wiring harness;
and S11, sealing the tail end of the plug tail accessory to obtain the novel wiring harness.
2. The novel wire harness manufacturing method according to claim 1, characterized in that: and in the step S1, reserving 15% of allowance for the wire in the trimming and tidying process.
3. The method as claimed in claim 1, wherein the corrugated sleeve in step S2 is a polyamide black corrugated tube.
4. The novel wire harness manufacturing method according to claim 1, characterized in that: the inner diameter of the corrugated sleeve is greater than 2/3 times of the outer diameter of the wiring harness, and the length of the corrugated sleeve is 20mm shorter than the length of the wiring harness.
5. The novel wire harness manufacturing method according to claim 1, characterized in that: the length of the exposed copper core of the lead in the step S3 is not more than 1mm of the upper edge of the welding cup.
6. The novel wire harness manufacturing method according to claim 1, characterized in that: the absolute ethyl alcohol in the step S4 is absolute ethyl alcohol with the concentration not lower than 99.5%.
7. The novel wire harness manufacturing method according to claim 1, characterized in that: the step S11 of sealing the tail end of the plug tail attachment includes the following steps:
(1) at the joint of the corrugated pipe and the tail accessory, 200% of the silica gel self-adhesive tape is stretched from 2/3 of the plug tail accessory to the tail end and wound to the position of 50-60mm of the corrugated pipe in a mode of overlapping 1/2, and then the process is repeated once;
(2) winding a layer of hot melt adhesive tape on a corrugated pipe section which is wound with the silica gel self-adhesive tape, wherein the winding method is that after the corrugated pipe section is stretched by 100 percent, the corrugated pipe section is uniformly wound in an 1/2 overlapping mode
(3) Sleeving the part wound with the hot melt adhesive tape in the step (2) with a double-wall heat-shrinkable tube, performing heat-shrinkable treatment by using a hot air gun, setting the temperature to be 150-250 ℃, and uniformly heating the heat-shrinkable tube from the head end to the tail end of the plug around the circumference.
8. The novel wire harness manufacturing method according to claim 7, characterized in that: the double-wall heat-shrinkable tube in the step (2) is a polyethylene hydrocarbon double-wall heat-shrinkable tube.
9. The novel wire harness manufacturing method according to claim 7, characterized in that: the diameter of the double-wall heat-shrinkable tube in the step (2) is 2-3mm larger than the outer diameter of the plug.
10. The novel wire harness manufacturing method according to claim 1, characterized in that: the corrugated sleeve is sleeved with a marking sleeve.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911038614.8A CN110707497B (en) | 2019-10-29 | 2019-10-29 | Wire harness manufacturing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911038614.8A CN110707497B (en) | 2019-10-29 | 2019-10-29 | Wire harness manufacturing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN110707497A true CN110707497A (en) | 2020-01-17 |
| CN110707497B CN110707497B (en) | 2021-08-03 |
Family
ID=69202700
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201911038614.8A Active CN110707497B (en) | 2019-10-29 | 2019-10-29 | Wire harness manufacturing method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN110707497B (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112216443A (en) * | 2020-10-12 | 2021-01-12 | 昆山康玛斯电子科技有限公司 | USB wire harness manufacturing method |
| CN112436309A (en) * | 2020-10-27 | 2021-03-02 | 安徽晨越电子有限公司 | Multi-core electronic wire harness and processing method thereof |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN203759332U (en) * | 2014-04-03 | 2014-08-06 | 四川九洲线缆有限责任公司 | Bundled cable assembly |
| CN105990807A (en) * | 2015-07-06 | 2016-10-05 | 深圳市金达照明有限公司 | Production method of copper core cable soldered and sealed intermediate joint |
| CN208173849U (en) * | 2018-06-07 | 2018-11-30 | 东莞市晴联实业有限公司 | A kind of HDMI connector for being applicable in automatic welding and meeting function of shielding |
-
2019
- 2019-10-29 CN CN201911038614.8A patent/CN110707497B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN203759332U (en) * | 2014-04-03 | 2014-08-06 | 四川九洲线缆有限责任公司 | Bundled cable assembly |
| CN105990807A (en) * | 2015-07-06 | 2016-10-05 | 深圳市金达照明有限公司 | Production method of copper core cable soldered and sealed intermediate joint |
| CN208173849U (en) * | 2018-06-07 | 2018-11-30 | 东莞市晴联实业有限公司 | A kind of HDMI connector for being applicable in automatic welding and meeting function of shielding |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112216443A (en) * | 2020-10-12 | 2021-01-12 | 昆山康玛斯电子科技有限公司 | USB wire harness manufacturing method |
| CN112436309A (en) * | 2020-10-27 | 2021-03-02 | 安徽晨越电子有限公司 | Multi-core electronic wire harness and processing method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| CN110707497B (en) | 2021-08-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN110707497B (en) | Wire harness manufacturing method | |
| CN109742640B (en) | Method for connecting cable and wiring terminal | |
| CN106450807A (en) | Wire joint connection terminal and wire joint connection method | |
| CN105990807A (en) | Production method of copper core cable soldered and sealed intermediate joint | |
| CN105185482B (en) | A kind of preparation method with the outer cable by structure of waterproof | |
| CN204131073U (en) | A kind of 35kV and following cable termination jockey | |
| CN105935824A (en) | Tin soldering process for aluminum enameled wire stator | |
| CN105006304A (en) | Method for making cable with waterproof core wire structure | |
| TWI569551B (en) | A method for producing cables with water resistant core wire structures | |
| CN201243092Y (en) | Sealing device connected through metal conductor | |
| CN114227162B (en) | Hot melting connection process for 25 type passenger car box body and pipeline heat tracing band | |
| CN103944034A (en) | Manufacturing method for cable intermediate joint | |
| CN104037517A (en) | Aluminium wire-contained motor joint and processing method thereof | |
| CN214588141U (en) | Sealing structure and charging device | |
| CN110474464A (en) | The manufacturing method of field frame assembly, motor and field frame assembly | |
| US9633759B2 (en) | Waterproofing structure for insulation-coated electrical wire, and wire harness | |
| CN1251248C (en) | Warm-water crosslinked cable core thermosol end capping process | |
| CN103682931A (en) | Wire joint protection method | |
| CN113437615A (en) | Wiring operation method for production and processing of heat tracing line | |
| CN108963704B (en) | Waterproof treatment method for cable network on carrier rocket | |
| CN207094268U (en) | Novel inserting connection type flexible light band plug | |
| CN218827859U (en) | Durable heating wire structure | |
| CN219980571U (en) | Be applied to shaded pole's power cord, enameled wire connection structure | |
| CN214674612U (en) | Novel welding point protection structure of aluminum wire motor | |
| CN205862820U (en) | A kind of crosslinked polyethylene fusing type insulated cable joint |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |