EP0241939B1 - Method for forming wire harness and apparatus for the same - Google Patents

Method for forming wire harness and apparatus for the same Download PDF

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Publication number
EP0241939B1
EP0241939B1 EP87105710A EP87105710A EP0241939B1 EP 0241939 B1 EP0241939 B1 EP 0241939B1 EP 87105710 A EP87105710 A EP 87105710A EP 87105710 A EP87105710 A EP 87105710A EP 0241939 B1 EP0241939 B1 EP 0241939B1
Authority
EP
European Patent Office
Prior art keywords
wires
wire
harness
forming
wavering
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.)
Expired
Application number
EP87105710A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0241939A1 (en
Inventor
Michio Sumitomo Wiring Systems Ltd. Fukuda
Tsutomu Sumitomo Wiring Systems Ltd. Iida
Naoki Sumitomo Wiring Systems Ltd. Kuroda
Nobuyuki Sumitomo Wiring Systems Ltd. Itaya
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Wiring Systems Ltd
Original Assignee
Sumitomo Wiring Systems Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Sumitomo Wiring Systems Ltd filed Critical Sumitomo Wiring Systems Ltd
Publication of EP0241939A1 publication Critical patent/EP0241939A1/en
Application granted granted Critical
Publication of EP0241939B1 publication Critical patent/EP0241939B1/en
Expired legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H01B13/01236—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses the wires being disposed by machine
    • H01B13/01245—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses the wires being disposed by machine using a layout board
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H01B13/01254—Flat-harness manufacturing

Definitions

  • This invention relates to an improved method of forming wire harness for use in an automobile, particularly, in a wiring harness assembly placed within a limited space such as a door structure, or ceiling space in a room cabinet.
  • a wiring harness assembly placed within a limited space such as a door structure, or ceiling space in a room cabinet.
  • an apparatus for manufacturing the wiring harness assembly is disclosed, in which insulated wires are placed in a parallel alignment followed by bonding the neigbouring wires so that the wiring harness exhibits a predetermined, desired flattened shape.
  • the wiring harness for motor vehicles is composed of a variety of elements. Those include groups of insulated electric wires, connectors consisting of electrical terminals and plastic housing of connectors, grommet and outer binding materials such as clamps and tapes.
  • a design table with guide-pins is used to manufacture a set of wire harness assembly, in which an approximate length of insulated electric wire with an electrical terminal in its one end portion is wired along a drawing on the table in which the guide-pins stand aside the trail of wire, and desired numbers of wires are set to form a harness configuration.
  • the sets of wires are then bundled together by means of binding materials resulting in a group of an assembled but shapeless wire collection.
  • the US-A-3,699,630 reports on apparatus for use in the manufacture of a wire harness as well as a method for forming this wire harness.
  • a wire dispensing head is controlled to selectively dispense wires from a group of supply spools, laying the wire along predetermined paths according to the desired harness pattern configuration, cutting the wires to conform to the individual path lengths, and securing the wires at respective termination sites.
  • the thus spent wires are cramped together by cramps to form a harness which usually has an almost cylindrical cross section.
  • the US-A-4,071,393 discloses an apparatus for use in the manufacture of a wiring harness of the kind including a plurality of electrically insulated wires having their thermoplastic sheaths fused to a thermoplastic backing tape. Accordingly, the electric insulated wires are directed in a parallel configuration between two cylinders and are covered on the upper and lower side with endless sheaths or strips which are capable to bond to each other.
  • the cylinders press the tape against the wires and at least one of the cylinders is driven so that the wires and the tape are driven between the cylinders as a result of rotation of the cylinder.
  • a hot air blower blows hot air onto the tape and the sheets of the wires immediately before they pass between the cylinders so that when pressure is applied to them by the cylinders the heated surfaces fuse together.
  • none of the above mentioned apparatus and methods for producing wiring harness are providing wiring harness which are capable to be used in technical fields where only a limited space is available, since on the one hand the resulting cylindrical cross section is inadequate, or, on the other hand, further bonding material is applied which further increases the amount of material to be stored in e. g. a door structure.
  • an apparatus for use in the manufacture of the wire harness comprising a wire guide having a wavering element in a wiring head attached to a transversal axis X along longitudinal directions of wires. Further, a wire forming table with a flat surface on the top is provided having a travelling mechanism along the Y-direction, which is perpendicular to the transversal X-axis. Additionally, wire bonding means are provided comprising a wire press mechanism either by thermal fusion or by adhesion while a group of insulated electric wires are led by said wire guide on the forming table in a closed, parallel alignment.
  • the method for forming wire harness comprises the steps of selecting a group of insulated electric wires to be connected to the terminals showing a common connector housing, clamping the starting end portion of each of the selected wires in order, drawing wires out of supplying means and placing the measured and cut wires in a parallel alignment using a wafering wire guide on a forming-table which is able to travel along rails laid in a direction Y perpendicular to the longitudinal axis X, pressing them with a roller or roll mechanism having heating means while disentangling and bonding the neighbouring wires simultaneous either utilizing an adhesive or suitable softing agent or by thermal fusion of the surfaces of insulation of wires, and leading wires through the wafering wire guide while the wire guide moves an X-direction and the forming table shifts in Y-direction achieving two-dimensionally plotted desired harness pattern on the table.
  • the method of forming wire harness of the present invention comprises the steps of selecting a group of the insulated electric wires to be assembled, clamping the starting ends of the wires in order, followed by applying a metallic terminal to each wire end if desired, placing measured and cut wires on a forming table with a program controlled travelling means along the Y axis which is perpendicular to the longitudinal direction of wires X, making a parallel alignment of wires by providing them with a wiring head which consists of a wavering guide and a press mechanism with or without grooves for disentangling wires while the wiring head traces back along axis X, bonding the neighbouring wires as the wiring head proceeds by either thermal fusion of the outer surface of the insulating layer of the wire or utilizing suitable adhesives on the surface of the wire, controlling both the movement of the wiring head along the coordinate X and that of the forming table along the coordinate Y, shaping the wires into any desired flattened harness pattern which is particularly useful for wiring door harness of motor vehicles.
  • Fig. 1 shows steps of forming wire harness of the present invention.
  • Fig 1(A) is a process diagram illustrating the method of the present invention.
  • Fig 1(B) shows a side view illustrating the wire feed.
  • Fig. 1(C) shows a harness pattern formed on the forming table.
  • Fig. 2 shows the apparatus for forming wire harness of the present invention.
  • Fig. 2(A) illustrates a front view of the apparatus of the present invention.
  • Fig. 2(B) illustrates a side view of the wavering wiring head on the forming table with an index roller having grooves being used in the apparatus of the present invention.
  • Fig. 2(C) is an enlarged front view illustrating the wiring head used in the apparatus of the present invention.
  • Fig. 2(D) is an enlarged view illustrating an index roller
  • a process layout for forming a wire harness for use in a automobile door harness is explained. It is composed of a wire-forming table (2) having a travelling mechanism along the Y axis which is perpendicular to a longitudinal direction X of a group of insulated electric wires to be assembled, and of a wiring head (3) having a wavering mechanism and a press means with or without grooves for wires equipped with heating means.
  • the wiring head (3) suspends over the wire-forming table (2) and is movable along the axis X, and thus the table (2) and the wiring head (3) constitute a X-Y plotting element.
  • a wire supply (4) In front of the wire-forming table (2) are located in front of the wire-forming table (2) are located a wire supply (4), a clamp (5) which is able to turn toward a terminal crimp machine (7), and a cutting machine (6).
  • wire-carrier (8) having a clamp mechanism for holding the starting ends of wires A, insulation remover (9), terminal crimper 7 and applicator for connector housing (11), both applicable to the terminating ends B, and terminal supplier (12).
  • a group of wires (1) is selected for a set of wiring harness to be assembled. The selection is usually made among the wires which share a common connector within total harness structure.
  • the wires are drawn out of a wire supply (4) and are held properly by a wire clamp means (5) which is able to turn into a direction perpendicular to the longitudinal direction X of the wires where a terminal crimp element including a wire-insulation remover and a terminal crimper (7) with a terminal feeder (12) are located.
  • the destined wire ends (B) which are on the opposite side of the staring wire ends (A), is shifted toward Y2 and Y3 direction along axis Y.
  • the wire ends (B) are subject to extra steps including insulation removal at (9), terminal crimping at (7), and a connector housing is attached at (11), and thus flat wire harness is obtained.
  • the starting ends A of the wires are crimped with terminals, and then lead along the X axis while the A ends are held by the clamp (5) until it reaches a cutter (6).
  • a wire carrier (8) proceeds to the cutter (6) and holds the wire end A, and the clamp (5) moves back to the original position along axis X while wires are brought to a table end portion (13) where the wire ends A are fixed.
  • Each of the wires is measured by means of dancer-roller passway (14) in length according to their anticipated distance in an assembled harness on the table (2) and is cut by the cutter (6).
  • Fig. 1 (C) illustrates a harness pattern formed by the method of the present invention.
  • a wiring head (3) having a wavering mechanism and a press means suspends over the wires on the table (2).
  • the wiring head (3) comes down to the table (2) and touches the wire-surfaces in its press means such as a guiding roll (20) with or without grooves for wires.
  • the wires (1) are disentangled and simultaneously the neighbouring wires are bonded together by either thermal fusion in the surfaces of their insulation or by using an adhesive.
  • the corner portions R1 and R2 are formed by moving the wiring head (3) and the forming-table (2) into X and Y directions, respectively, according to a programmed design for an anticipated harness pattern.
  • Preferred embodiment of the present invention of forming wire harness is that a both-sided adhesive tape having larger width than that of the actual harness pattern to be traced is placed on the wire-forming table (2) along the passage or wires before the wires are lead on the table (2) through wire-guide (3).
  • the tape sticks to the wire surfaces and is useful as a substrate for maintaing the wires (1) on the predetermined position in a parallel alignment until the neighbouring wires become bonded.
  • the tape can be removed after the harness has been formed in a pattern.
  • a flat harness with integrating unit pattern can be formed, in which a number of branches are included in a single pattern.
  • a complexed flat harness is provided by integration of unit harness elements which consist of a group of wires as described in the present invention.
  • FIG. 2 An apparatus for achieving the same object of forming a flat harness with parallel wire alignments is described referring to Fig. 2.
  • the Figure illustrates a front view of the device.
  • To the wire-forming table (2) are equipped two guide rails (17A) and (17B) along which the wire-forming table (2) can be slidably moved in a direction of the Y axis.
  • 16A is a rotatable driving rod located in the middle and underneath the table (2).
  • 16B is also a rotatable driving rod to which the hanger (18) of wiring head (3) is attached.
  • the rod is literally the X coordinate and is parallel to the longitudinal wire direction.
  • the wavering wiring head (3) and three rollers (20), (21A) and (21B) are attached to the head portion of the hanger (18).
  • the roller (20) is an indexing roller whose course is directed by a computer program, and the other two are rollers for disentangling the wires (1) into a parallel alignment between each other.
  • the latter rollers (21A) and (21B) have spaced grooves for wires and are equipped with heating means which are useful for bonding neighbouring wires by thermal fusion. The latter two rollers follow the trail of the former roller (20).
  • the wires (1) are introduced into a hollow pipe (23) and are drawn to the forming-table (2) and are disentangled and bonded together as the three rollers (20), (21A) and (21B) pass over them.
  • index roller (20) has completed its programmed tracing around an desired harness pattern, the wires (1) on the forming table (2) are aligned in parallel showing formed flat pattern of wire harness.
  • the wires (1) are lead into their common longitudinal direction X by moving the wiring head (3) which is driven by rotating the driving rod (16B) and also wires (1) are directed toward the Y direction by travelling of the forming table (2).
  • the wires (1) are lead into their common longitudinal direction X by moving the wiring head (3) which is driven by rotating the driving rod (16B) and also wires (1) are directed toward the Y direction by travelling of the forming table (2).
  • a flat, two dimensionally plotted wire harness is provided.
  • an accurate harness pattern is achieved.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Supply And Installment Of Electrical Components (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Insulated Conductors (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
EP87105710A 1986-04-18 1987-04-16 Method for forming wire harness and apparatus for the same Expired EP0241939B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP61090596A JPS62246205A (ja) 1986-04-18 1986-04-18 ワイヤハーネスの成形方法とその成形方法のための成形装置
JP90596/86 1986-04-18
CA000554961A CA1328732C (en) 1986-04-18 1987-12-21 Method of forming wire harness and apparatus for the same

Publications (2)

Publication Number Publication Date
EP0241939A1 EP0241939A1 (en) 1987-10-21
EP0241939B1 true EP0241939B1 (en) 1991-07-03

Family

ID=25671640

Family Applications (1)

Application Number Title Priority Date Filing Date
EP87105710A Expired EP0241939B1 (en) 1986-04-18 1987-04-16 Method for forming wire harness and apparatus for the same

Country Status (4)

Country Link
EP (1) EP0241939B1 (enrdf_load_stackoverflow)
JP (1) JPS62246205A (enrdf_load_stackoverflow)
CA (1) CA1328732C (enrdf_load_stackoverflow)
ES (1) ES2023376B3 (enrdf_load_stackoverflow)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NO914870L (no) * 1990-12-13 1992-06-15 Claude Ricard Fremgangsmaate og anordning for automatisk fremstilling avtrelignende ledningsbunter
FR2670619B1 (fr) * 1990-12-13 1994-01-07 Ricard Claude Procedes et dispositifs pour fabriquer automatiquement des faisceaux, de fils conducteurs ou de fibres optiques, comprenant plusieurs branches et derivations.
JP2942983B2 (ja) * 1995-05-25 1999-08-30 モレックス インコーポレーテッド 電線結束装置
US6582013B1 (en) * 1999-11-09 2003-06-24 Autonetworks Technologies, Ltd. Vehicular ceiling assembling structure, a unit assembly used for the same, a frame member used for the same, and a vehicular ceiling assembling method

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3699630A (en) * 1970-12-31 1972-10-24 Hughes Aircraft Co System for ordered dispensing of wire and the like
GB1458214A (en) * 1973-04-04 1976-12-08 Rists Wires & Cables Ltd Wiring harness disc player
GB1550115A (en) * 1975-05-23 1979-08-08 Lucas Industries Ltd Apparatus for use in the manufacture of a wiring harness
JPS5339587A (en) * 1976-09-22 1978-04-11 Hayashi Hamono Seisakushiyo Yu Rotary grinding stone
JPS6022335B2 (ja) * 1977-07-21 1985-06-01 キヤノン株式会社 フイルムカウンタ
JPS5841517U (ja) * 1981-08-11 1983-03-18 株式会社フジクラ フラツトケ−ブルの製造装置
JPS598004A (ja) * 1982-07-07 1984-01-17 Hitachi Ltd フエイル・セ−フ回路
JPS60117580A (ja) * 1983-11-29 1985-06-25 日本圧着端子製造株式会社 自動圧接機
GB8412827D0 (en) * 1984-05-18 1984-06-27 Molex Inc Terminated wires into electrical connectors
US4607430A (en) * 1984-11-13 1986-08-26 Westinghouse Electric Corp. Method and apparatus for high density wire harness manufacture

Also Published As

Publication number Publication date
JPH0580767B2 (enrdf_load_stackoverflow) 1993-11-10
ES2023376B3 (es) 1992-01-16
EP0241939A1 (en) 1987-10-21
JPS62246205A (ja) 1987-10-27
CA1328732C (en) 1994-04-26

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