JP2012240057A - Method of welding wire conductor part and wiring harness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of welding wire conductor part allowing flat joining of even many wires.SOLUTION: The wires 7 are installed flat side by side on the same plane of a stage 3. In this case, the wire conductor parts 9 are sandwiched by a jig that the adjacent wire conductor parts 9 are in contact with each other. Leading ends of the wire conductor parts 9 are arranged in order along a relative moving direction of a later described laser. Ends (joints) of the wire conductor parts 9 are arranged to overhang a groove 5. In this state, the laser 11 which is a high energy density beam is radiated. In this case, a laser beam radiation shaft 12 of the laser 11 is set at a predetermined position apart from ends of the wire conductor parts 9. The stage 3 is moved in a direction that wires 7 are installed side by side while radiating the laser 11, or the laser beam is line-radiated using a galvanoscanner from a remote device. That is, a laser 11 radiating position is shifted relative to the stage 3 (the wires 7).

Description

  The present invention relates to a method for welding a wire conductor and a wire harness capable of manufacturing a flat wire harness including a concentrated joint of a large number of wires.

  A wire harness used for an automobile or the like is used by joining a plurality of electric wires. For such joining of the wires, for example, the insulation coating of each of the plurality of wires is peeled off to expose the core wires, and the ends of the core wires are aligned and overlapped, and the core wires are sandwiched in this state. There is a method of joining core wires by resistance welding or ultrasonic joining (Patent Document 1).

JP 2000-188018 A

  However, the conventional method as disclosed in Patent Document 1 needs to sandwich an electric wire between an electrode for resistance welding or an anvil and a horn for ultrasonic bonding. Therefore, there is a limit to the number of wires to be connected. Moreover, since it is difficult to join the electric wires to be joined in a flat state, it is difficult to wire the joined wire harness in a narrow region.

  This invention is made | formed in view of such a problem, and it aims at providing the welding method of the electric wire etc. which can be joined flat even if it is many electric wires.

  In order to achieve the above-described object, the first invention is a state in which a plurality of wire conductor portions from which the insulation coating of the end portion of the wire is peeled are provided on the same surface, and the adjacent wire conductor portions are in contact with each other. Then, irradiation is performed while relatively moving a high energy density beam along the direction in which the electric wire conductor portion is provided from one end side in the direction in which the electric wire conductor portion is provided to the other end side. A method for welding an electric wire conductor, characterized by melting and integrating the tip.

  The plurality of electric wires include different electric wire diameters, and when the electric wire conductor portions are provided on the same surface, the electric wires are arranged so that the electric wire diameters are reduced from the thicker ones to the end portions on the thicker electric wire diameter side. The high energy density beam may be irradiated along the direction in which the wire conductor portion is provided from the end of the wire having a small diameter.

  When the wire conductor portions are provided on the same plane, the tips of the plurality of wire conductor portions are arranged obliquely with respect to the relative movement direction of the high energy density beam with respect to the wire conductor portions, and from the end portions of the wire conductor portions. From the end of the side where the distance to the irradiation axis of the high energy density beam is long to the end of the side where the distance from the end of the wire conductor to the irradiation axis is short, the height is increased along the direction in which the wire conductor is provided. You may irradiate an energy density beam.

  When the wire conductor portions are provided on the same surface, the ends of the respective wire conductor portions may be arranged in the same direction, and when the wire conductor portions are provided on the same surface, adjacent to each other. The end portions of the matching wire conductor portions may be opposed to each other, and may be arranged in a staggered manner so as to overlap substantially perpendicular to the longitudinal direction.

  The high energy density beam may be either a laser or an electron beam.

  According to the first invention, adjacent electric wire conductors are brought into contact with each other and irradiated while relatively moving a high energy density beam from one end side to the other end side in the side-by-side direction, Since the tip of the electric wire is fused and integrated, even if the number of electric wires increases, the reliability of bonding is not affected. Therefore, in principle, there is no limit on the number of wires to be connected.

  Also, compared to ultrasonic welding and resistance welding, the wires can be joined in a completely flat state, so the thickness of the connecting portion (the direction perpendicular to the direction in which the wire conductor portion is installed) is thicker than the maximum wire diameter. Never become. In addition, it is possible to ensure the bonding strength in a smaller processing area compared to ultrasonic welding, and the welding state is not affected by the current resistance value unlike resistance welding.

  In addition, when joining wires with different wire diameters, the wire diameters are sequentially arranged from thick to thin, and a high energy density beam such as a laser is irradiated from the thick wire diameter side in order toward the welding direction. A sufficient amount of molten metal in the conductor portion can be allowed to flow, and the wires can be reliably joined together.

  Also, if the tips of the wires are arranged diagonally and the wires are joined by irradiating the high energy density beam from the long side to the short side from the end of the wire conductor to the beam spot of the high energy density beam, Since the welding is performed from the side with a large amount of molten metal in the wire conductor portion to the side with a small amount of molten metal, sufficient molten metal in the wire conductor portion can be flowed sequentially toward the welding direction, and the wires can be reliably joined together. it can.

  Moreover, in this invention, the direction of the electric wires joined may be the same direction, and the direction which opposes may be sufficient as it. That is, the wires can be reliably joined regardless of the direction of the wires.

  According to a second aspect of the present invention, a plurality of wire conductor portions from which the insulation coating of the end portions of the wires is peeled off are provided on the same surface, and the ends of the adjacent wire conductor portions are continuous by a high energy density beam. The wire harness is characterized by being melted and integrated.

  According to the second invention, it is possible to obtain a wire harness in which a number of electric wires are joined flat.

  ADVANTAGE OF THE INVENTION According to this invention, even if it is many electric wires, the welding method of the electric wire conductor part etc. which can be joined flat can be provided.

Schematic which shows the welding apparatus 1. FIG. The figure which shows the joint state of the electric wire 7. FIG. The figure which shows the state in which the electric wire 7 is joined. The figure which shows the other attachment state of the electric wire. The figure which shows the state which arrange | positions the electric wire from which thickness differs. The figure which shows the state which joins the electric wire from which thickness differs. The figure which shows the other attachment state of the electric wire. The figure which shows the wire harness 15. FIG. The figure which shows the wire harness 20. FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing the welding apparatus 1, FIG. 2 (a) is a plan view showing a state where the electric wires 7 are provided, and FIG. 2 (b) is a perspective view showing a state where the electric wires 7 are provided. The welding apparatus 1 includes a stage 3 and a laser irradiation unit. The stage 3 is a part where the electric wire 7 is installed and held, and a groove 5 is formed in part. The stage 3 is movable relative to the laser irradiation part in the direction in which the grooves 5 are formed.

The electric wire 7 is configured by covering the outer periphery of the electric wire conductor portion 9 with an insulating coating. A predetermined range of the insulation coating is removed from the end of the electric wire 7, and the electric wire conductor 9 is exposed. In addition, the electric wire conductor part 9 is a stranded wire in which, for example, a single wire or a plurality of strands made of copper or aluminum is combined, and generally has a size of about 0.13 to 5.0 cm ² .

  The electric wire 7 is provided flat on the same surface of the stage 3. At this time, the wire conductor portions 9 are fixed with a jig or the like (not shown) so that the adjacent wire conductor portions 9 are in contact with each other. Moreover, the front-end | tip of the electric wire conductor part 9 is arrange | positioned and aligned along the relative movement direction of the laser mentioned later. Further, the end portion (joining portion) of the electric wire conductor portion 9 is disposed so as to protrude from the groove 5.

  In this state, a laser 11 that is a high energy density beam is irradiated (in the direction of arrow A in the figure). At this time, the laser beam irradiation axis 12 of the laser 11 is set to a predetermined position from the end of the electric wire conductor 9. In a state where the laser 11 is irradiated, the stage 3 is moved in the direction in which the electric wires 7 are provided (in the direction of arrow B in FIG. 1). Alternatively, a galvano scanner may be used to irradiate the laser beam with a remote device. That is, the irradiation position of the laser 11 moves relative to the stage 3 (electric wire 7) (in the direction of arrow C in the figure).

  FIG. 3 is a diagram illustrating a state in which the electric wire 7 is joined. First, as shown to Fig.3 (a), when the laser 11 is irradiated from one edge part (upper part of a figure) of the attachment direction of the electric wire 7, the edge part of the electric wire conductor part 9 will be fuse | melted. Under the present circumstances, it welds one after another, retreating the front-end | tip position of the electric wire conductor part 9 toward the reverse direction to a front end side by the wet of molten metal, surface tension, and the heat conduction of adjacent electric wire conductor parts. That is, while the molten metal flows in the direction of adjacent electric wires (downward in the figure), the molten metal is integrated and solidified to form the welded portion 13.

  When the laser 11 is sequentially irradiated to the vicinity of the end portion of the electric wire conductor portion 9 and moved to the other end portion (downward in the drawing) of the electric wire 7 side by side, all the electric wires are welded, 13 is formed. That is, with the relative movement of the laser, the molten metal sequentially flows in the direction of the adjacent electric wires and is reliably integrated at the welded portion 13.

  In addition, about the number of the electric wires joined, etc., it is not restricted to the illustrated example. In the present invention, as long as the relative movement between the laser 11 and the electric wire 7 provided is possible, theoretically, unless the electric wire is extremely thick and cannot be melted to obtain a desired electric wire weld with laser energy. There is no limit to the number of wires to be joined.

  Further, the distance from the tip of the wire conductor portion 9 to the laser beam irradiation axis 12 of the laser 11 (distance from the tip of the wire conductor portion 9 to the arrow C in FIG. 2A) is in a state where the laser output is appropriate. For example, the outer diameter of the wire conductor portion 9 may be about 1/3 to 3 times. This is because if the distance is too short, the amount of molten metal is reduced, and if the distance is too long, there is a possibility that unmelted part of the wire may be generated, such as wire spillage.

  FIG. 4 is a diagram illustrating another example of the method for joining the electric wires 7. In the present invention, a wire harness can be configured by joining a large number of electric wires in an arbitrary direction and joining them flat.

  In the example shown in FIG. 4A, the electric wires 7 are arranged in a staggered pattern on the same plane so as to face each other. At this time, the ends of the wire conductor portions 9 are arranged so as to wrap with respect to the relative movement direction C of the laser. In addition, the electric wire conductor part 9 is fixed with the jig etc. which abbreviate | omitted illustration so that the electric wire conductor parts 9 may contact reliably.

  In this state, as shown in FIG. 4 (b), by sequentially irradiating the wrap portion of the wire conductor portion 9 with laser, the tips of all the wire conductor portions 9 are melted and integrated.

  Moreover, as shown in FIG. 5, the electric wires 7a, 7b, and 7c from which the diameter of an electric wire differs can also be joined. The electric wire conductors 9a, 9b, and 9c of the electric wires 7a, 7b, and 7c are thickest in the electric wire conductor 9a, and then become thinner in the order of the electric wire conductor 9b and the electric wire conductor 9c.

  In such a case, as shown in FIG. 5, the electric wires are provided side by side in order of increasing electric wire diameter. In the example shown in the figure, the electric wire conductor 9a (the electric wire 7a) having the largest electric wire diameter, the electric wire conductor portion 9b (the electric wire 7b) having the largest electric wire diameter, and the electric wire conductor portion 9c (the electric wire 7c) having the smallest electric wire diameter in this order. Is attached. In addition, an electric wire is pinched | interposed from both ends (up-down and left-right direction of a figure) with the jig etc. which abbreviate | omitted illustration so that adjacent electric wire conductor part 9a, 9b, 9c may contact. At this time, as shown in FIG. 5B, the upper surface of all the wire conductor portions 9a, 9b, 9c is included with respect to the focal depth of the laser 11. That is, it is desirable that the positions of the upper surfaces of the wire conductor portions 9a, 9b, and 9c be arranged so that the laser output density with respect to the upper surface matches.

  In this state, the laser 11 is directed from the end on the side of the wire conductor 9a (wire 7a) having the largest wire diameter toward the end on the side of the wire conductor 9c (wire 7c) having the smallest wire diameter (see FIG. Middle arrow C direction), the laser 11 is relatively moved, and the respective electric wires are welded and integrated.

  FIG. 6 is a diagram illustrating a state in which the electric wire is welded by relatively moving the laser 11 from the electric wire conductor portion 9a side toward the electric wire conductor portion 9b. When the laser conductor 11 is irradiated to the wire conductor portion 9a having a large wire diameter, the end portion of the wire conductor portion 9a is melted. Under the present circumstances, it welds one after another by the wetting of molten metal, surface tension, and the heat conduction of adjacent electric wire conductor parts. In the example shown in the figure, the melted wire conductor portion 9a flows in the direction of the adjacent wire conductor portion 9b (in the direction of arrow D in the figure).

  That is, with the relative movement of the laser, the molten metal sequentially flows in the direction of the adjacent electric wires and is reliably integrated. In particular, since more molten metal can flow in the moving direction of the laser 11, the interface between the electric wires can be more reliably integrated.

  In addition, such a joining method is applicable also when joining an electric wire to zigzag arrangement | positioning, as shown in FIG. That is, an electric wire may be provided so that more molten metal can flow from the side where welding is started to the side where welding is ended.

  The same effect can be obtained by joining electric wires having the same diameter. FIG. 7 shows a method for efficiently flowing molten metal as described above with respect to the electric wire 7 having the same diameter.

  First, as shown in FIG. 7A, the electric wires 7 are provided on the same plane. At this time, the end of the electric wire conductor portion 9 is disposed so as to be inclined with respect to the joining direction (movement path of the laser beam spot of the laser). That is, with respect to the direction in which the electric wires 7 are provided, the electric wire conductor portion 9 is disposed so that the tip of the electric wire conductor portion 9 is inclined (stepped) by an angle E. In addition, an electric wire is inserted | pinched from both ends (up-down direction of a figure) with the jig etc. which abbreviate | omitted illustration so that adjacent electric wire conductor parts 9 may contact reliably.

  In this state, as shown in FIG. 7B, the laser 11 (not shown) sequentially moves relative to the vicinity of the tip of the wire conductor portion 9 (in the direction of arrow C in the figure). At this time, the laser 11 is connected from the laser beam irradiation shaft 12 to the tip of the electric wire conductor 9 from the end portion (upper side in the drawing) where the distance F1 from the laser beam irradiation shaft 12 to the tip of the electric wire conductor portion 9 is long. Relative movement is made toward the end (lower side in the figure) on the side where the distance Fn is short.

  By doing in this way, the melting allowance of the electric wire conductor part 9 to which the laser 11 is first irradiated becomes F1, and the most metal amount is melted. As the laser 11 moves, the molten metal successively flows to the adjacent electric wires one after another. Therefore, the electric wire interface can be more reliably integrated.

  Here, the arrangement angle E of the electric wires is appropriately set according to the number and diameter of the electric wires to be joined. For example, both F1 and Fn may be appropriately set so as to fall within the above-described melting allowance (1/3 to 3 times the wire diameter), and the effect of the present invention can be obtained if it is about 5 °. Can do. In addition, even if it does not arrange | position a front-end | tip diagonally, if fixation of an electric wire is enough, it is possible to join electric wire conductors reliably.

  As mentioned above, according to this invention, many electric wires can be integrated reliably. Further, since the electric wires are joined in a flat state in a state where they are arranged on a plane, it is possible to arrange a narrow area.

  Moreover, according to this invention, the connection direction of an electric wire is arbitrary. Therefore, the electric wires can be joined in a zigzag shape in opposite directions, or can be joined in one direction.

  Moreover, when connecting electric wires of different thicknesses, a larger amount of molten metal can be contributed to welding by arranging the thick electric wires from the thin electric wires and welding from the thick electric wire side. For this reason, electric wires can be integrated more reliably.

  In addition, by arranging the wire tip to be inclined with respect to the moving direction of the laser and performing welding from the side with the longer melting allowance toward the shorter side, more molten metal can be contributed to the welding. . For this reason, electric wires can be integrated more reliably.

  As mentioned above, although embodiment of this invention was described referring an accompanying drawing, the technical scope of this invention is not influenced by embodiment mentioned above. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the technical idea described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.

  For example, the connection method of the electric wires is not limited to the examples shown in FIGS. Moreover, the connection methods shown in FIGS. 2 to 7 can be appropriately combined. For example, the joining method of the electric wire from which thickness differs, and the joining method of the electric wire by diagonal arrangement | positioning of an electric wire edge part can also be combined.

  As the high energy density beam, not only a laser but also an electron beam or the like can be applied.

  Moreover, it can use as shown in FIGS. 8-9 as a wire harness containing the concentration joint manufactured by the above-mentioned various embodiment of this invention. For example, the wire harness 15 shown in FIG. 8 is formed by bifurcating a wire harness that is once formed entirely flat in two directions and bending the welded portion 13 in two directions substantially perpendicularly. The wire conductor portion 9 is provided with an insulating coating, a cap, etc., not shown. For this reason, the welded wire conductor portion 9 is formed in a flat shape, and each branched portion is a flat portion 17. For this reason, it is possible to lay a narrow part.

  Further, the wire harness 20 shown in FIG. 9 is formed in such a manner that the wire harness once formed as a whole is branched in two directions, and one side is bent about 180 ° with respect to the welded portion 13. Even if it does in this way, while the welded electric wire conductor part 9 is formed flat, the site | part branched respectively becomes the flat part 17. FIG. For this reason, it is possible to lay a narrow part.

DESCRIPTION OF SYMBOLS 1 ......... Welding apparatus 3 ......... Stage 5 ......... Groove 7 ......... Wire 9 ......... Wire conductor part 11 ......... Laser 12 ......... Laser beam irradiation axis 13 ......... Welding parts 15 and 20 ……… Wire harness 17 ………… Flat part

Claims (7)

A plurality of wire conductor portions from which the insulation coating at the end of the wire is peeled off are provided on the same surface,
In a state where the adjacent wire conductor parts are in contact with each other, a high energy density beam is applied along the direction in which the wire conductor part is provided from one end side in the direction in which the wire conductor part is provided to the other end side. Irradiating while moving relatively, and melting and integrating the tip of the wire conductor portion. The plurality of wires includes different wire diameters,
When arranging the electric wire conductors on the same surface, arrange them so that the electric wire diameter becomes thicker than the thicker one,
2. The electric wire conductor according to claim 1, wherein a high energy density beam is irradiated along the direction in which the electric wire conductor portion is provided from an end portion having a larger electric wire diameter to an end portion having a smaller electric wire diameter. Part welding method. When arranging the wire conductor portion on the same plane, the tips of the plurality of wire conductor portions are arranged obliquely with respect to the relative movement direction of the high energy density beam with respect to the wire conductor portion,
From the end portion on the side where the distance from the end portion of the electric wire conductor to the laser beam irradiation axis of the high energy density beam is long to the end portion on the side where the distance from the end portion of the electric wire conductor portion to the laser beam irradiation axis is short, The welding method for a wire conductor part according to claim 1 or 2, wherein a high energy density beam is irradiated along a direction in which the wire conductor part is provided.   When arranging the said electric wire conductor part on the same surface, it arrange | positions so that the edge part of each electric wire conductor part may face in the same direction, The Claim 1 characterized by the above-mentioned. Welding method for wire conductors.   2. When the wire conductor portions are provided on the same plane, the ends of adjacent wire conductor portions face each other and are arranged in a staggered manner so as to overlap substantially vertically in the longitudinal direction. The welding method of the electric wire conductor part in any one of Claim 3.   6. The method for welding an electric wire conductor according to claim 1, wherein the high energy density beam is one of a laser and an electron beam.   A plurality of wire conductor portions from which the insulation coating at the ends of the wires is peeled off are provided on the same surface, and the tips of the adjacent wire conductor portions are continuously melted and integrated by the high energy density beam. A wire harness characterized by that.

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