JP2017022031A - Terminal mounting method of electric wire, terminal mounting structure, and mounting jig - Google Patents

Abstract

PROBLEM TO BE SOLVED: To accurately connect terminal metal fittings to both terminals of a thick electric wire so that their circumferential mounting positions are made different.SOLUTION: In a process of axially continuously forming a small projection at one part of an outer peripheral surface of an insulating coating of an outer layer of a thick electric wire having a core wire cross section of 8 mmor more during extrusion molding, providing a wire fixing jig where a plurality of fitting grooves fitted with the small projection are recessed in an inner peripheral surface of a mold hole corresponding to the outer diameter of the thick electric wire at predetermined angular intervals in the circumferential direction, and connecting terminal metal fittings to the core wire exposed by peeling off the insulating coating at both terminals of the thick electric wire, after one of the terminal metal fittings is connected to one end of the thick electric wire, the thick electric wire is twisted by a required angle to fit and fix the small projection to one fitting groove selected from the fitting grooves, and then the other of the terminal metal fitting is connected to the other end of thick electric wire in a different direction.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a terminal mounting method, a terminal mounting structure, and a mounting jig for an electric wire. More specifically, the terminal fitting is connected to both ends of a hard-to-bend thick wire that is wired to a vehicle or the like by changing the mounting position in the circumferential direction. is there.

In a vehicle such as an automobile, a thick electric wire having a core wire cross-sectional area of 8 mm ² or more is wired as a power line, a ground line, or the like. As shown in FIG. 5A, the terminal fittings 111 and 112 are connected to both ends of the thick wire 100 with a phase of 90 degrees, and between the devices 110 and 120 as shown in FIG. The thick wire 100 is wired to the terminal 110 and the terminal fitting 111 connected to the lower position of the thick wire 100 is fixed to one device 110, while the thick wire 100 is refracted upward and then refracted sideways. The terminal fitting 112 connected to the lateral position of the other end of the electric wire may be fixed.

The thick wire 100 is rigid with respect to torsion. Therefore, after connecting the terminal fitting 111 to the lower end Y1 with respect to the central axis L1 at one end of the thick wire 100 with a crimping device or a welding device, the thick wire 100 is connected. It is not easy to twist the wire 90 degrees and connect the terminal fitting 112 to one side Y2 of the other end of the thick wire 100 with the crimping device or the welding device.
Therefore, as shown in FIG. 6, two sets of upper and lower wire fixing jigs 150A and 150B are provided, and one end of the thick wire 100 on the terminal connection side is fixed by the electric wire fixing jig 150A or The terminal fitting 111 is connected with a welding device, and then the one end is fixed with the electric wire fixing jig 150A, the thick electric wire 100 is twisted 90 degrees, and the other end of the twisted thick electric wire 100 is connected. The terminal fitting 112 is connected to the other end of the thick electric wire fixed by another electric wire fixing jig 150B and twisted 90 degrees by a crimping device or a welding device.

  Conventionally, in Japanese Patent Application Laid-Open No. 2004-327234, in order to change the direction of the terminal fitting (the mounting position in the circumferential direction) at both ends of the electric wire, the outer surface of the electric wire is marked with a gap along the circumferential direction. By attaching a terminal to a position marked with a different position at both ends of a thick wire, an electric wire that can be attached to both ends by changing the direction of the terminal is provided.

JP 2004-327234 A

  As shown in FIG. 6, when a thick wire is fixed in a twisted state using an electric wire fixing jig, two electric wire fixing jigs 150A and 150B for fixing both ends of the thick electric wire are required. There is a problem that it is expensive and requires a lot of work. Furthermore, when the length of the electric wire is long, an angle shift occurs between both ends, and there is a case where a terminal cannot be connected to both ends with a predetermined angular interval.

  Further, in Patent Document 1, the outer surface of the electric wire is marked with an angular interval. However, in a thick electric wire, even if it is twisted to the required mark position, a return occurs due to rigidity, and the required mark position is reached. It is difficult to connect the terminal fittings accurately. Therefore, even if the outer surface of the electric wire is marked, the thick electric wire needs to be fixed in a twisted state. In this case, both ends need to be fixed as described above. There is a problem that one electric wire fixing jig is required.

  SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and a method for attaching a terminal of an electric wire that can be connected to both ends of a thick electric wire that is difficult to twist by changing the attachment position in the circumferential direction with a simple jig and a simple attachment method. It is an object of the present invention to provide a mounting structure provided by the method and a mounting jig used in the mounting method.

In order to solve the above-mentioned problems, the present invention is an extrusion molding of the insulation coating by continuously providing a small projection in the axial direction at one location on the outer peripheral surface of the insulation coating of the outer layer of a thick wire having a core wire cross-sectional area of 8 mm ² or more. Sometimes set up and
An electric wire fixing jig is provided in which a plurality of fitting grooves of the small protrusions are provided at predetermined intervals in the circumferential direction on the inner peripheral surface of the mold cavity corresponding to the outer diameter of the thick wire,
In the step of connecting the terminal fitting to the core wire exposed by peeling off the insulation coating at both ends of the thick electric wire, after connecting the terminal fitting to one end of the thick electric wire, A terminal connection method for a thick wire by twisting and fitting the small protrusion into one fitting groove selected from the fitting grooves, and connecting the terminal fitting to the other end of the thick wire by changing the direction. Is provided.

The small protrusion provided on the outer surface of the thick electric wire has a semicircular cross section with a diameter of 0.8 to 2.0 mm, and the fitting groove provided in the electric wire fixing jig is recessed in a semicircular cross section. It is preferable to provide 2 to 4 fitting grooves provided in the jig.
For example, four fitting grooves provided in the wire fixing jig are provided at intervals of 90 degrees.
The electric wire fixing jig is composed of an upper mold and a lower mold, and the upper mold is fitted to the lower mold and then the upper mold is fitted to the upper mold and the upper mold is clamped. It is said.

  According to the terminal connection method of the thick wire of the present invention, since the single wire fixing jig that can fix the end of the thick wire to which the terminal fitting is connected in the required direction is used, the thick wire is twisted. It is only necessary to fix with the electric wire fixing jig in the state, and it is not necessary to fix the two electric wire fixing jigs, and it is not necessary to fix both ends to the electric wire fixing jig in a twisted state. At the same time, the cost can be reduced.

The connection between the both ends of the thick wire and the terminal fitting is performed by welding the core wire exposed at both ends to the terminal fitting by resistance welding or ultrasonic welding, crimping with a barrel provided on the terminal fitting, and pressure welding provided on the terminal fitting. You may connect by any method of press contact with a blade.
In the case of a thick electric wire having a core wire cross-sectional area of 8 mm ² or more, it is preferable to connect the core wire and the terminal fitting by welding from the viewpoint of electrical connection reliability. Therefore, it is preferable that the electric wire fixing jig is installed on the side surface of the welding apparatus, the thick electric wire is twisted and fixed with the electric wire fixing jig, and the core wire and the terminal fitting are welded and connected with the welding apparatus.

Furthermore, this invention provides the terminal connection structure of the thick wire formed with the said terminal connection method.
When it is necessary to make the attachment position of the circumferential direction of the terminal metal fitting connected to the both ends of the length direction of a thick electric wire differ in the terminal attachment structure of this invention, the terminal metal fitting can be accurately connected to the predetermined position. Thus, for example, the terminal fitting is connected upward to the lower position of one end of the thick wire, the terminal fitting is connected to the other end in a twisted state, and the terminal fitting is thickened while the thick wire is returned to a straight line. When connected to the side of the electric wire sideways, the terminal fitting at one end of the thick electric wire is fixed upward to one device, the thick electric wire is twisted and refracted upward, and then refracted sideways. The terminal fitting connected to the other end of the thick wire can be fixed to the other device without difficulty. At that time, the terminal metal fitting is fixed upward to the other device, but the terminal metal fitting is connected in a sideways state when viewed from the one end side fixed first.

  Furthermore, the present invention comprises an upper die and a lower die, and includes a die hole corresponding to the outer diameter of the electric wire in a state where the upper die and the lower die are clamped, and 2 on the inner peripheral surface of the die hole. There is provided an electric wire fixing jig provided with a plurality of semicircular fitting grooves at predetermined angular intervals in the circumferential direction and continuous in the length direction.

  It is preferable to provide four fitting grooves with an opening cross-sectional diameter of 1.0 to 2.5 mm and spaced by 90 degrees. Thus, when four fitting grooves are provided, they are provided at the top and bottom vertex positions and the left and right end positions, and the arc grooves provided at the lower end of the upper mold and the upper end of the lower mold are combined at the left and right end positions. It is trying to become.

  The electric wire fixing jig is preferably used when connecting a terminal fitting to the end of the thick wire, but an electric part such as a terminal fitting is required at an intermediate position in the length direction of the electric wire or at the end of the electric wire. It can also be suitably used for mounting in the direction.

  According to the terminal connection method of the thick wire of the present invention, since the single wire fixing jig that can fix the end of the thick wire to which the terminal fitting is connected in the required direction is used, the thick wire is twisted. It is only necessary to fix with the electric wire fixing jig in the state, and it is not necessary to fix the two electric wire fixing jigs, and it is not necessary to fix both ends to the electric wire fixing jig in a twisted state. In addition, there is an advantage that the cost can be reduced.

The thick electric wire of embodiment of this invention is shown, (A) is a perspective view, (B) is sectional drawing, (C) is a perspective view which shows the state which changed the direction of the terminal metal fitting to the both ends of the thick electric wire, and was connected. (D) is a perspective view which shows the state which twists a thick electric wire and connects a both-ends terminal metal fitting to an apparatus. An electric wire fixing jig is shown, (A) is a sectional view in the state where the upper and lower molds are opened, and (B) is a perspective view in the mold closed state. It is the schematic which shows the positional relationship of the said electric wire fixing jig and an ultrasonic welding apparatus. (A) (B) (C) is drawing which shows the process of connecting a terminal metal fitting to the both ends of a thick electric wire. (A) (B) is a perspective view which shows a prior art example. 6 is a diagram illustrating a conventional method.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
At one end in the length direction of the thick wire 1 shown in FIGS. 1 (A) and 1 (B) consisting of a power supply line or ground wire arranged in the automobile, as shown in FIG. 1 (C), the center of the thick wire 1 The first terminal fitting 2A is connected upward at a lower position with respect to the axis L1, and the second terminal fitting 2B is connected laterally on the side surface with respect to the central axis L1 at the other end in the length direction. As shown in FIG. 1 (D), the first terminal fitting 2A is bolted to a conductor 4A such as a bus bar of the first device 3A and the thick electric wire 1 is horizontally wired in the automobile. The second terminal fitting 2B at the other end of the thick wire 1 is refracted upward, and the second terminal fitting 2B at the other end of the thick wire 1 is bolted to a conductor 4B such as a bus bar of the second device 3B. .

The thick wire 1 has a core wire 1a having a cross-sectional area of 8 mm ² or more, and the outer periphery of the core wire 1a is covered with an insulating coating 1b made of an insulating resin. The insulating coating 1b is extruded on the outer peripheral surface of the core wire 1a. It is provided by molding. One small protrusion 1c is provided on the outer peripheral surface of the insulating coating 1b continuously in the length direction along the central axis L1 during extrusion. The small protrusion 1c has a semicircular cross section and a diameter d1 of 0.8 to 2.0 mm, which is 1.0 mm in this embodiment. The core wire 1a of the thick wire 1 is composed of a large number of strands of strands, and is composed of a copper-based metal or an aluminum-based metal.

The terminal fittings 2 (2A, 2B) at both ends connected to the core wire 1a exposed from both ends of the thick wire 1 are bolted terminals made of copper-based metal, and the core wire 1a is connected to one side of the flat substrate 2c. And a bolt hole 2h is provided on the other side of the substrate 2c.
The core wire 1a and the terminal fitting 2 may be connected by crimping with a barrel provided on the terminal fitting 2, or may be connected by pressure using a press-contact blade provided on the terminal fitting 2.

  As described above, the terminal fittings 2 </ b> A and 2 </ b> B connected to both ends are connected by changing the direction by 90 degrees at both ends of the thick wire 1. The terminal fittings 2A and 2B at both ends are connected by the method shown in FIG. 3 using the wire fixing jig 10 shown in FIG.

  The wire fixing jig 10 includes a metal upper mold 11 and a lower mold 12, and the upper mold 11 and the lower mold 12 have semicircular mold holes 11a and 12a, respectively, as shown in FIG. Thus, it is set as the mold hole 13 corresponding to the outer diameter of the thick wire 1 with the upper and lower molds clamped. Four fitting grooves 15 (15A to 15D) having a semicircular cross section are provided on the inner peripheral surface of the mold cavity 13 continuously in the length direction at intervals of 90 degrees in the circumferential direction.

The fitting groove 15 has a diameter d2 of an opening cross section of 1.0 to 2.5 mm, and in this embodiment, the fitting groove 15 has a size of 1.1 mm that can fit the small protrusion 1c having a diameter of 1.0 mm of the thick wire 1. .
The four fitting grooves 15 </ b> A to 15 </ b> D are provided with a fitting groove 15 </ b> A at the upper vertex position of the upper mold 11, and provided with a fitting groove 15 </ b> C at the lower vertex position of the lower mold 12. A circular arc groove 15x of 90 degrees is provided at the lower end of 11 and the upper end of the lower mold 12, and semicircular fitting grooves 15B and 15D are also provided. As shown in FIG. 3, one wire fixing jig 10 is installed on the side of the ultrasonic welding apparatus 20.

  Next, using the ultrasonic welding apparatus 20 and the wire fixing jig 10, a method of connecting the terminal fittings 2 </ b> A and 2 </ b> B to the both ends of the thick wire 1 with the attachment directions being different by 90 degrees in the step shown in FIG. 4. Will be explained.

First, as shown in FIG. 4 (A), the electric wire is fixed in a state where the small protrusion 1c is positioned at the upper apex at a position close to the peeled end of the insulating coating 1b at one end in the length direction of the thick wire 1. The thick wire 1 is inserted into the mold hole of the lower die 12 of the jig 10 to cover the upper die 11, and the small protrusion 1c of the thick wire 1 is fitted into the fitting groove 15A of the upper die 11, and this state The mold is clamped to hold and fix the direction of the thick wire 1.
Subsequently, as shown in FIG. 3, the terminal fitting 2 </ b> A is welded to the core wire 1 a exposed by the ultrasonic welding apparatus 20. Thereby, the terminal fitting 2 </ b> A is connected upward to one end of the thick wire 1 at the lower position. The small protrusion 1c provided on the thick wire 1 is located at the upper vertex.

  Then, as shown to FIG. 4 (B), it reverses in the length direction of this thick electric wire 1, and the other end side of a length direction is arrange | positioned at the electric wire fixing jig 10 and the ultrasonic welding apparatus side. The thick wire 1 is twisted at a required angle (90 degrees in this embodiment), and as shown in FIG. 4C, the thick wire is inserted into the 90-degree arc groove 15x at the left end of the lower mold 12 of the wire fixing jig 10 in the drawing. The small protrusion 1c of the electric wire 1 is inserted, and then the upper mold 11 is fitted, and the upper and lower molds are clamped in a state where the small protrusion 1c is fitted in the fitting groove 15D to peel off the thick wire 1. Fix the vicinity of the edge.

  Subsequently, the core wire 1a is welded to the terminal fitting 2B with an ultrasonic welding apparatus. Thereby, the terminal fitting 2B is connected to the thick wire 1 at the other end of the thick wire 1 in a state where the small protrusion 1c is positioned at the left vertex position (a state where the thick wire 1 is linear). . The terminal fittings 2A and 2B connected to both ends are connected to a position 90 degrees away from the thick wire 1, and when the terminal fitting 2B is set to the lower position, the terminal fitting 2A is connected to a lateral position on one side. Therefore, as shown in FIG. 1C, when the terminal fitting 2A is connected to one end of the thick wire 1 in a downward position upward, the terminal fitting 2B is placed sideways on one side of the other end of the thick wire 1. Connected.

  In the step of connecting the terminal fitting 2B to the other end of the thick wire 1, when the small protrusion 1c of the thick wire 1 is fitted into the fitting groove 15B on the right side of the wire fixing jig 10, the terminal fitting is obtained. 2B can be connected laterally to the side position opposite to that shown in FIG.

  As described above, in the present invention, the small protrusions 1c are continuously provided in the length direction on the outer surface of the thick electric wire 1, and the fitting grooves in which the small protrusions 1c can be fitted while the thick electric wire 1 is twisted. By using the electric wire fixing jig 10 provided with the terminal fittings, it is possible to connect the terminal fittings to the both ends of the thick electric wire 1 with different mounting positions in the circumferential direction. Thus, it is only necessary to install one electric wire fixing jig adjacent to a connection device such as an ultrasonic welding device, so that the cost of the connection equipment can be reduced and the number of operations can be simplified.

  In the above embodiment, the terminal fitting is fixed to the end of the thick wire by ultrasonic welding, but resistance welding may be used. Furthermore, a terminal metal fitting may be provided with a barrel for crimping connection, or a pressure contact blade may be provided for pressure connection.

1 Thick wire 1a Core wire 1b Insulation coating 1c Small protrusion 2 (2A, 2B) Terminal fitting
DESCRIPTION OF SYMBOLS 10 Electric wire fixing jig 11 Upper mold | type 12 Lower mold | type 15 (15A-15D) Fitting groove | channel 20 Ultrasonic welding apparatus

Claims (4)

A small protrusion is provided at the time of extrusion of the insulation coating in one place on the outer peripheral surface of the insulation coating of the outer layer of the thick wire having a core wire cross-sectional area of 8 mm ² or more, and
An electric wire fixing jig is provided in which a plurality of fitting grooves of the small protrusions are provided at predetermined intervals in the circumferential direction on the inner peripheral surface of the mold cavity corresponding to the outer diameter of the thick wire,
In the step of connecting the terminal fitting to the core wire exposed by peeling off the insulation coating at both ends of the thick electric wire, after connecting the terminal fitting to one end of the thick electric wire, A terminal connection method for a thick wire by twisting and fitting the small protrusion into one fitting groove selected from the fitting grooves, and connecting the terminal fitting to the other end of the thick wire by changing the direction. .   The small protrusion provided on the outer surface of the thick electric wire has a semicircular cross section with a diameter of 0.8 to 2.0 mm, and the fitting groove provided in the electric wire fixing jig is recessed in a semicircular cross section. The method for connecting terminals of a thick wire according to claim 1, wherein 2 to 4 fitting grooves are provided in the jig.   The terminal connection structure of the thick electric wire formed by the terminal connection method of Claim 1 or Claim 2.   It consists of an upper mold and a lower mold, and has a mold hole corresponding to the outer diameter of the electric wire in a state where the upper mold and the lower mold are clamped, and two or more semicircular shapes on the inner peripheral surface of the mold hole An electric wire fixing jig having fitting grooves provided at predetermined angular intervals in the circumferential direction and continuous in the length direction.

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