JP2020087500A - Wire harness and method for manufacturing wire harness - Google Patents

Abstract

To provide a wire harness easily laid on a narrow space without increasing costs.SOLUTION: A wire harness 410 comprises: a plurality of electric wires 401; a first connector 400a and a second connector 400b connected to the electric wires; a first binding member 402a binding the electric wires so as to form a first bent part 431 in which the electric wires are bent in one direction from the first connector; a second binding member 402b binding the electric wires so as to form a second bent part 432 in which the electric wires are bent in the same direction from the second connector; and a third binding member binding the electric wires between the first binding member and the second binding member. The first binding member binds the plurality of electric wires so that a wire length of the outermost electric wire in the first bent part among the plurality of electric wires is longer than that of the innermost electric wire, and the second binding member binds the plurality of electric wires so that a wire length of the outermost electric wire in the second bent part among the plurality of electric wires is longer than that of the innermost electric wire.SELECTED DRAWING: Figure 7

Description

The present invention relates to a wire harness and a method for manufacturing the wire harness.

2. Description of the Related Art In recent years, in the electric appliance market, there has been a demand for multifunctionality while maintaining miniaturization and body size. Electrical appliances generally use a sheet metal frame to maintain the strength of the housing, and a portion touched by the user is covered with a resin material or the like so as not to come into contact with burrs on the cut end surface of the sheet metal. The consumable unit and the regular replacement unit included in the electric appliance may have the same configuration. For example, in a copying machine (image forming apparatus), a fixing unit that fixes a toner image on a recording material by heat and pressure corresponds to a regular replacement unit. The fixing unit is fixed to the sheet metal frame of the copying machine so as to withstand the pressure applied during fixing. The sheet metal frame is a portion touched by a user or a serviceman, and is therefore covered with a resin cover. Copiers are also required to be downsized. If the space of the electric wire path of the heater that generates heat or the electric wire path of the drive unit that applies pressure is narrow, the electric wire is caught between the sheet metal frame and the cover due to scattering of the electric wire (hereinafter referred to as wire catching), short circuit or Quality problems such as disconnection may occur.

Generally, in order to maintain quality, a method of binding a plurality of electric wires by a binding member to prevent the plurality of electric wires from scattering and to suppress a space required for mounting a wire harness (hereinafter referred to as a mounting space) is adopted. However, if the electric wire is bent and laid in the longitudinal direction of the connector, the electric wire is bent in the vicinity of the connection part to the connector, which causes an unnecessary electric wire length (hereinafter referred to as extra length). There is a concern that line biting may occur due to excess length. Therefore, there has been proposed a method of maintaining quality by forming a guide of a resin material along the bent shape of the electric wire and integrating the electric wire and the guide (Patent Document 1).

JP, 2014-89845, A

However, when the electric wire is protected by the guide, it is difficult to insert the guide where the mounting space of the wire harness is limited. In addition, if the electric wire and the guide are integrated, the manufacturing cost of the wire harness increases due to the guide.
Therefore, the present invention provides a wire harness that can be easily laid in a narrow space without increasing the cost.

A wire harness according to an embodiment of the present invention is
Multiple wires,
A first connector connected to the first end of the plurality of electric wires,
A second connector connected to a second end of the plurality of wires opposite to the first end,
When the plurality of electric wires are viewed from the first connector, the plurality of electric wires are formed so as to form a first bent portion in which the plurality of electric wires are bent in one direction in the longitudinal direction of the first connector. A first binding member for binding,
When the plurality of electric wires are viewed from the second connector, the plurality of electric wires are bent in the same direction as the one direction of the first bending portion in the longitudinal direction of the second connector. A second binding member that binds the plurality of electric wires so as to form a bent portion,
A third binding member for binding the plurality of electric wires between the first binding member and the second binding member,
Equipped with
The first binding member, by binding the plurality of electric wires so that the line length of the outermost electric wire in the first bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. Maintaining the shape of the first bend,
The second binding member, by binding the plurality of electric wires so that the line length of the outermost electric wire in the second bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. It is characterized in that the shape of the second bent portion is maintained.

According to the present invention, it is possible to provide a wire harness that can be easily laid in a narrow space without increasing the cost.

FIG. 3 is a sectional view of the image forming apparatus. FIG. 3 is a block diagram of a control unit of the image forming apparatus. FIG. 3 illustrates a fixing device. Explanatory drawing which shows the wire harness manufacturing method by a reference example. The figure which shows the wire harness by the reference example bent in Z shape. Explanatory drawing which shows the wire harness manufacturing method by a present Example. The figure which shows the positional relationship of a connector, a pile, and a binding member, and the some electric wire of the connector vicinity. The figure which shows the wire harness by a present Example. The figure which shows the positional relationship of a connector, a pile, and a binding member, and the some electric wire of the connector vicinity.

(Image forming device)
FIG. 1 is a sectional view of the image forming apparatus 100. As shown in FIG. 1, the image forming apparatus 100 is a tandem type intermediate transfer type full-color printer in which image forming units 1 a, 1 b, 1 c, and 1 d are arranged along the downward surface of the intermediate transfer belt 3. The separation roller 8 separates the recording material P drawn out from the recording material cassette 4 sheet by sheet and conveys the recording material P to the registration roller 9. The registration roller 9 receives the recording material P in a stopped state and makes it stand by, and conveys the recording material P to the secondary transfer portion T2 in synchronization with the toner image on the intermediate transfer belt 3.

The image forming units 1a, 1b, 1c, and 1d have substantially the same configuration except that the colors of toners used in the developing devices 51a, 51b, 51c, and 51d are different from yellow, magenta, cyan, and black. The image forming unit 1d will be described below as a representative. The subscripts a, b, c, and d of the reference numerals represent yellow, magenta, cyan, and black, respectively, but the subscripts a, b, c, and d of the reference numerals in the image forming unit are omitted unless necessary. To do. The image forming unit 1 is assembled into a replacement unit (process cartridge) including the photosensitive drum 10. In the photosensitive drum 10, a photosensitive layer having a negative charging polarity is formed on the outer peripheral surface of an aluminum cylinder. The photosensitive drum 10 is rotated at a predetermined process speed by receiving a driving force from a driving motor (not shown). The photosensitive drum 10 is charged to a uniform negative potential by the charging roller 41 incorporated in the image forming unit 1. The exposure device 6 scans a laser beam, which is ON/OFF modulated according to the scanning line image data in which a black separated color image is developed, by a rotating polygon mirror to form an electrostatic latent image on the surface of the charged photosensitive drum 10. The electrostatic latent image formed on the surface of the photosensitive drum 10 is subjected to reversal development into a toner image by attaching toner by the developing device 51 incorporated in the image forming unit 1. The primary transfer roller 2 presses the intermediate transfer belt 3 to form a primary transfer portion T between the photosensitive drum 10 and the intermediate transfer belt 3. By applying a positive DC voltage to the primary transfer roller 2, the negative toner image carried on the photosensitive drum 10 is primarily transferred to the intermediate transfer belt 3 passing through the primary transfer portion T.

The intermediate transfer unit 20 is arranged above the image forming unit 1. The intermediate transfer unit 20 integrally includes the intermediate transfer belt 3, a support mechanism that supports the intermediate transfer belt 3, and a drive mechanism that rotates the intermediate transfer belt 3. The intermediate transfer unit 20 is a replacement unit that can be attached to and detached from the image forming apparatus 100. The intermediate transfer belt 3 is supported by being stretched over a tension roller 27, a belt driving roller 26, a secondary transfer inner roller 25, and primary transfer tension rollers 28 and 29. The intermediate transfer belt 3 is rotated by the belt driving roller 26 in the direction indicated by the arrow R2. The intermediate transfer belt 3 is an endless belt member that does not expand or contract. The intermediate transfer unit 20 also includes a density sensor 80 that detects the density of the toner image on the intermediate transfer belt 3. The intermediate transfer unit 20 has primary transfer rollers 2a, 2b, 2c, 2d arranged corresponding to the image forming units 1a, 1b, 1c, 1d, respectively. The primary transfer rollers 2a, 2b, 2c, 2d are biased by springs (not shown) toward the photosensitive drums 10a, 10b, 10c, 10d, respectively. The primary transfer rollers 2a, 2b, 2c, 2d bring the intermediate transfer belt 3 into contact with the photosensitive drums 10a, 10b, 10c, 10d to form the primary transfer portions Ta, Tb, Tc, Td.

The inner secondary transfer roller 25 stretches the inner surface of the intermediate transfer belt 3 and contacts the outer intermediate transfer belt 3 with the outer secondary transfer roller 22 to form a secondary transfer portion T2. The inner secondary transfer roller 25 is provided in the intermediate transfer unit 20. The secondary transfer outer roller 22 is provided in the main body 30 of the image forming apparatus 100. The secondary transfer outer roller 22 is applied with a positive DC voltage from a power source (not shown) and forms a transfer electric field with the secondary transfer inner roller 25 connected to the ground potential.

The fixing device 5 has a fixing roller 5a provided with a fixing heater 211 and a pressure roller 5b. The pressure roller 5b is pressed against the fixing roller 5a to form a heating nip. The recording material P is nipped by a heating nip and conveyed, and is heated and pressed to melt the toner image and fix the toner image on the surface of the recording material P to form a full-color image. The recording material P on which the full-color image is formed is discharged onto the discharge tray 7 by the discharge roller 11.

(Controller unit)
FIG. 2 is a block diagram of the control unit 200 of the image forming apparatus 100. The control unit 200 centrally controls the image forming apparatus 100. The control unit 200 drives each load in the image forming apparatus 100, collects and analyzes information of the sensors 214, performs image control, and exchanges data with the operation unit 202, that is, a user interface. The control unit 200 has a CPU 201a, a ROM 201b, and a RAM 201c. The control unit 200 further includes an AD converter 203, a high voltage control unit 205, a motor control unit 207, a DC load control unit 208, a sensor interface (hereinafter referred to as sensor IF) 209, an AC driver 210, and an image control unit 220. The control unit 200 includes an operation unit 202, a thermistor 204, a high voltage unit 206, motors 212 including a drive motor (not shown) that drives the photosensitive drum 10, and a clutch/solenoid (hereinafter referred to as CL/SL) 213 as a DC load. Electrically connected to. The control unit 200 is also electrically connected to the sensors 214 such as a photo interrupter and a micro switch, the fixing heater 211, and the image forming unit 1. The operation unit 202, the thermistor 204, the high voltage unit 206, the motors 212, the CL/SL 213, the sensors 214, the fixing heater 211, and the image forming unit 1 are provided in the image forming apparatus 100.

The CPU 201a executes the image forming sequence according to the program stored in the ROM 201b. The RAM 201c temporarily or permanently stores rewritable data during execution of the image forming sequence. The RAM 201c also stores a high voltage setting value of the high voltage control unit 205, various data described later, and image formation command information input from the operation unit 202. The RAM 201c is supplied with power from a battery (not shown) and can retain data even when the image forming apparatus 100 is powered off.

The user sets information such as a copy magnification and a density setting value via the operation unit 202. The operation unit 202 displays the state of the image forming apparatus 100 such as the number of images formed, information indicating whether or not an image is being formed, the occurrence of a jam, and the location of a jam. The operation unit 202 further accepts an input of adjustment such as registration position adjustment and density adjustment by a serviceman, if necessary, and displays a guide for initialization operation when the image forming apparatus 100 is installed or when the developing device 51 is replaced. And accepts the start of operation.

The control unit 200 drives the motors 212 and the CL/SL 213 to convey the recording material P, and monitors the conveyance operation of the recording material P based on the detection result of the sensors 214. The CPU 201a puts the signals from the sensors 214 into a detectable state via a sensor IF 209 including a pull-up/pull-down circuit (not shown) and a filter circuit (not shown), and acquires the signals. The CPU 201a controls the motors 212 by the motor control unit 207 based on the signals from the sensors 214. The CPU 201a drives the CL/SL 213 by the DC load control unit 208. The CPU 201a inputs a high voltage control signal to the high voltage unit 206 by the high voltage controller 205. The high voltage unit 206 applies a high voltage to the charging roller 41, the developing device 51, the primary transfer roller 2 and the secondary transfer inner roller 25, respectively.

The CPU 201a controls the fixing heater 211 by the AC driver 210 to heat the fixing roller 5a. The fixing roller 5a is provided with a thermistor 204 that detects the temperature of the fixing heater 211. The resistance value of the thermistor 204 changes according to the temperature change of the fixing roller 5a. The AD converter 203 converts the resistance value of the thermistor 204 into a voltage value, and then outputs the temperature data as a digital value to the CPU 201a. The CPU 201a controls the AC driver 210 based on the temperature data to bring the temperature of the fixing roller 5a to a predetermined temperature. The image control unit 220 processes the image data input from the outside and outputs it to the image forming unit 1.

(Fixing device)
FIG. 3 is a diagram showing the fixing device 5. As shown in FIG. 3A, the fixing device 5 is provided with electric wires 302 and 309 for supplying AC power and electric wires 303 and 305 for transmitting a control signal. The electric wire 302 supplies AC electric power to the fixing heater 211. The electric wire 303 transmits a signal for detecting the resistance value of the thermistors 204a, 204b, 204c, 204d to the CPU 201a. The fixing heater 211 and the thermistors 204a-204d are regular replacement units. The electric wires 302 and 303 are connected to relay connectors 308 and 306, respectively, in order to facilitate the service work of taking out the fixing heater 211 or the thermistors 204a-204d from the fixing device 5 at the time of regular replacement. The serviceman removes the electric wire 303 from the relay connector 306 and then replaces the thermistors 204a, 204b, 204c, and 204d. Also, the service person replaces the fixing heater 211 after removing the electric wire 302 from the relay connector 308.

The electric wire 302 is connected to the electric wire 309 via the relay connector 308. The electric wire 309 is connected to the connector 300. The electric wire 303 is connected to the electric wire 305 via a relay connector 306. The electric wire 305 is connected to the connector 300. The electric wires 303 and 305 are housed in the guide 304 so as not to go out of the guide 304. The guide 304 is made of a resin material and is formed integrally with the exterior cover 301. The connector 300 is connected to a connector (not shown) provided on the main body 30 of the image forming apparatus 100. The connector 300 is held by the exterior cover 301. The connector 300 is attachable to and detachable from the exterior cover 301. When inserting or removing the electric wire 305 or 309 into or from the connector 300, the outer cover 301 is removed. FIG. 3B is an explanatory diagram of a structure inside the exterior cover 301. When the outer cover 301 is removed, the sheet metal frame 311 can be seen. The sheet metal frame 311 is in contact with the exterior cover 301. In FIG. 3B, the outer cover shape 307 and the electric wire 305 on the inner side of the outer cover 301, which cannot be seen from the outside, are shown by dotted lines. The electric wire 305 and the electric wire 309 are connected to the connector 300.

(Electrical wire)
The electric wire 305 is connected to the connector 300 and the relay connector 306. The electric wire 305 is bent in the vicinity of the connector 300 and the vicinity of the relay connector 306 to have a Z-shape. Since the outer cover 301 holds and fixes the position of the connector 300, the outer cover shape 307 inside the outer cover 301 makes the outer cover 301 thick and strong as shown by a dotted line in FIG. 3B. Is formed. The electric wire 305 is laid so as to pass through the inside of the outer cover shape 307, and extends from the connector 300 through the through hole 310 provided in the outer cover 301 to the outside of the outer cover 301. The electric wire 305 includes a plurality of electric wires. When the electric wires 305 in the outer cover shape 307 are scattered when the outer cover 301 is connected to the sheet metal frame 311, the scattered electric wires are sandwiched between the outer cover 301 and the sheet metal frame 311 to cause a short circuit or disconnection. I have something to do. When the electric wire 305 is short-circuited or broken, the detected value of the resistance value of the thermistor 204 becomes abnormal, and a high temperature error or a low temperature error of the fixing heater 211 occurs. When an error occurs in the temperature detected by the fixing heater 211, the operation of the image forming apparatus 100 is stopped and downtime occurs. Guides can be used to prevent the wires 305 from spattering. However, it is difficult to use the guide because the space of the outer cover shape 307 through which the electric wire 305 is passed is small. Further, if the electric wire 305 is prevented from being scattered by using a tape winding or a tube, the cost will be increased.

(Wire harness manufacturing method by reference example)
FIG. 4 is an explanatory diagram showing a wire harness manufacturing method according to a reference example. FIG. 4A is a diagram showing a plurality of electric wires 501 cut into a uniform length. Usually, the electric wires 501 whose number matches the number of pins of the connectors 500a and 500b are cut into a uniform line length. FIG. 4B is a diagram showing a plurality of electric wires 501 whose both ends are connected to the connectors 500a and 500b, respectively. Both ends of the cut electric wire 501 are pressed or crimped to the connectors 500a and 500b, respectively. The plurality of electric wires 501 are connected to the respective ends of the connectors 500a and 500b to form a wire harness 510. The wire harness 510 is in a state where electrical continuity is established between the connector 500a and the connector 500b.

FIG. 4C is a diagram showing the wire harness 510 placed on the workbench 600. A wire harness type 610 is created in advance on the workbench 600. The wire harness mold 610 is linearly formed. The wire harness type 610 is created such that the piles 505a and 506a are arranged near the connection portion of the electric wire 501 with the connector 500a, and the piles 505b and 506b are arranged near the connection portion of the electric wire 501 with the connector 500b. ing. The position of the wire harness 510 is fixed by the piles 505a, 506a, 505b and 506b. On the workbench 600, attachment positions 511a, 511b, and 511c of the binding members 502a, 502b, and 502c attached to the electric wire 501 are marked.

First, as shown in FIG. 4C, the connectors 500a of the wire harness 510 are fitted into the piles 505a and 506a arranged on the workbench 600, and the connectors of the wire harness 510 are fitted to the piles 505b and 506b arranged on the workbench 600. Insert 500b. Next, the binding members 502a, 502b and 502c are respectively arranged at the attachment positions 511a, 511b and 511c marked on the workbench 600, and the binding members 502a, 502b and 502c are connected to the electric wire 501 as shown in FIG. 4D. Attach to. Next, the wire harness 510 is removed from the workbench 600. FIG.4(e) is a figure which shows the wire harness 510 to which the binding members 502a, 502b, and 502c were attached. Finally, the conduction between the connector 500a and the connector 500b is confirmed, and the wire harness 510 is packed.

Normally, as shown in FIG. 4E, the electric wires 501 are bundled by using the binding members 502a, 502b and 502c such as tie wraps (registered trademark), Insulock (registered trademark), binding bands, tapes, etc. Hold down. As a result, the mounting space for the wire harness 510 is reduced. In order to further reduce the mounting space of the wire harness 510, the electric wire 501 is bent in the longitudinal direction of each of the connectors 500a and 500b in the vicinity of the connection portion with the connectors 500a and 500b to form the wire harness 510 into a Z shape. FIG. 5 is a diagram showing a wire harness 510 according to a reference example that is bent in a Z shape. The shape of the wire harness 510 bent into the Z shape shown in FIG. 5 corresponds to the shape of the electric wire 305 shown in FIG. 3B. As shown in FIG. 4E, the lengths of the plurality of electric wires 501 from the connector 500a to the binding member 502a are uniform, and the lengths of the plurality of electric wires 501 from the connector 500b to the binding member 502b are also uniform. .. When the wire harness 510 is bent into a Z shape as shown in FIG. 5, the distance between the connector 500a and the binding member 502a and the distance between the connector 500b and the binding member 502b inside the bent portion are shortened. As a result, extra length is generated in the electric wires 503a and 503b inside the bent electric wires 501, and the electric wires 503a and 503b inside are loosened. If the extra length of the inner wires 503a and 503b is large, the wires 503a and 503b are sandwiched between the sheet metal frame 311 and the outer cover 301 (wire catching occurs), and problems such as short circuit and disconnection occur.

(Wire harness manufacturing method according to this embodiment)
The method for manufacturing the wire harness according to this embodiment will be described below. This embodiment provides a wire harness manufacturing method for solving the problem of the wire harness 510 according to the reference example while suppressing cost increase. FIG. 6 is an explanatory view showing the wire harness manufacturing method according to the present embodiment. FIG. 6A is a diagram showing a plurality of electric wires 401 cut into a uniform length. The electric wires 401, the number of which corresponds to the number of pins of the connectors 400a and 400b, are cut into a uniform length. FIG. 6B is a diagram showing a plurality of electric wires 401 whose both ends are connected to the connectors 400a and 400b, respectively. Both ends of the plurality of cut electric wires 401 are pressed or crimped to the plurality of pins of the connectors 400a and 400b, respectively. A first end 401a of the plurality of electric wires 401 is connected to a connector (first connector) 400a, and a second end 401b opposite to the first end 401a of the plurality of electric wires 401 is a connector (second connector). The connector) 400b is connected to form the wire harness 410. The wire harness 410 is in a state where electrical continuity is established between the connector 400a and the connector 400b.

FIG. 6C is a diagram showing the wire harness 410 arranged on the workbench 700. In order to improve the mass productivity of the wire harness 410 and to manufacture the wire harness of stable quality, the wire harness mold 710 is prepared in advance on the workbench 700. The wire harness mold 710 is formed in a shape that follows the mounting shape (Z shape) of the wire harness 410 shown in FIG. The wire harness type 710 is created such that the stakes 405a and 406a are arranged in the vicinity of the connection portion of the electric wire 401 with the connector 400a, and the stakes 405b and 406b are arranged in the vicinity of the connection portion of the electric wire 401 with the connector 400b. ing. The wire harness type 710 is made so that the piles 404a and 404b are arranged at positions inside the respective portions where the electric wire 401 is bent in order to bring the shape of the wire harness 410 closer to the mounting shape shown in FIG. 6(e). Has been done. The position of the wire harness 410 is fixed by the piles 404a, 404b, 405a, 405b, 406a, and 406b, and the wire harness 410 is Z-shaped. On the work table 700, respective attachment positions 711a, 711b and 711c of the binding members 402a, 402b and 402c attached to the electric wire 401 are marked. By arranging the binding members 402a, 402b, and 402c at the attachment positions 711a, 711b, and 711c marked on the work table 700, the work of attaching the binding members 402a, 402b, and 402c to the electric wire 401 at predetermined positions becomes easy.

First, as shown in FIG. 6C, the connectors 400a of the wire harness 410 are fitted into the piles 405a and 406a arranged on the workbench 700, and the connectors of the wire harness 410 are inserted into the piles 405b and 406b arranged on the workbench 700. Insert 400b. The position of the electric wire 401 is adjusted by the piles 404a and 404b. FIG. 7 is a diagram showing a positional relationship between the connector 400b, the pile 404b, and the binding member 402b and a plurality of electric wires 401 near the connector 400b. The pile 404b is arranged so as to be in contact with the extension line 407 of the electric wire 411 that is pressed or crimped to the innermost (right side in FIG. 7) pin of the connector 400b among the plurality of electric wires 401 or in the vicinity of the extension line 407. .. The distance H from the connector 400b to the pile 404b is preferably set so that the wire harness 410 has a shape close to the mounting shape. The angle θ formed by the electric wire 411 and the connector 400b with the intersection 422 of the extension line 407 and the upper end surface of the connector 400b as the center is set to π/2 (hereinafter, expressed in the radian method, the unit is rad). The positional relationship among the connector 400a, the pile 404a, and the binding member 402a is the same as in FIG.

Here, when the distance W from the position of the electric wire 409 pressed or crimped to the outermost pin (left side in FIG. 7) of the connector 400b among the plurality of electric wires 401 to the extension line 407 of the electric wire 411 is equal to the distance H ( Consider W=H). The length of the electric wire 409 from the connector 400b to the bundling member 402b closest to the connector 400b is defined as the line length L1. The length of the electric wire 411 from the connector 400b to the bundling member 402b closest to the connector 400b is defined as a line length L2. Generally, there is a radius of curvature as a method of digitizing bending. Assuming that the distance W is equal to the distance H and that the electric wire 409 is a perfectly circular shape without bending, the radius of curvature is W (line length L1/angle θ=(1/2πW)/(1/2π)=W ). The radius of curvature represents bending of the electric wire 409 having a radius of the distance W, and is W regardless of the number of pins and the size of the connector 400b.

As the radius of curvature increases, the bending becomes looser. When the radius of curvature is larger than the distance W, the bending degree becomes loose and it becomes difficult to save the mounting space of the wire harness 410. In this embodiment, when a plurality of electric wires 401 are bent, a difference (hereinafter referred to as a line length difference) is provided between the wire length L1 of the electric wire 409 and the wire length L2 of the electric wire 411. The bending degree of the electric wire 409 pressed or crimped to the outermost pin (left side in FIG. 7) of the connector 400b is represented by a distance W which is a radius of curvature. However, the bending degree of the electric wire 411 pressed or crimped to the innermost pin (right side in FIG. 7) of the connector 400b cannot be represented by the radius of curvature. Therefore, the degree of bending of the electric wire 411 is represented by the value of the ratio of the line length difference between the line length L1 and the line length L2. The value of the ratio of the line length difference is expressed as a percentage by dividing the value obtained by subtracting the line length L2 from the line length L1 by the line length L1 and multiplying by 100.

Line length difference ratio value=(line length L1−line length L2)/line length L1×100 [%]

The value of the ratio of the line length differences in the example shown in FIG. 7 is as follows.
Ratio value of line length difference=(1/2πW-H)/(1/2πW)×100
=(1/2πW-W)/(1/2πW)×100
=(1-2/π)×100
Since π is the circumference ratio, the value of the ratio of the line length difference is 36.3% regardless of the number and size of the pins of the connector 400b. At this time, it is assumed that the electric wire 409 has a neat and perfectly circular shape without bending.

The ratio value of the line length difference is 0 when there is no line length difference and the electric wire 401 is not bent. As the value of the line length difference ratio increases, the degree of bending becomes tighter. Increasing the value of the ratio of line length differences is the same as decreasing the radius of curvature. When the value of the ratio of the wire length difference is smaller than 36.3%, the bending condition becomes loose and it becomes difficult to save the space for mounting the wire harness 410. The tolerance of the attachment position 711b of the binding member 402b closest to the connector 400b is 5 mm. Therefore, the wire length of the electric wire 401 from the connector 400b to the bundling member 402b may have a manufacturing variation of up to 5 mm. From the above, in order to reduce the mounting space of the wire harness 410, the binding member 402b closest to the connector 400b should have a line length difference ratio value of 36.3% or more and a line length difference of more than 5 mm. It is advisable to set the attachment position 711b of.

On the other hand, in the wire harness 510 according to the reference example shown in FIG. 5, the line length difference between the line length L1 and the line length L2 is nominally 0. However, manufacturing variations occur in the respective wire lengths of the plurality of electric wires 501 from the connector 500b to the binding member 502b. An example of actually measured values of the line lengths of the plurality of electric wires 501 from the connector 500b to the binding member 502b of the wire harness 510 according to the reference example is shown below. The distance W is 15 mm. The average value of the line length difference is 0.6 mm. The value obtained by multiplying the standard deviation of the line length difference by 3 is 1.2 mm. The average value of the ratio values of the line length difference is 1.1%.

The procedure for attaching the binding members 402a, 402b, and 402c to the wire harness 410 according to this embodiment will be described below. First, as shown in FIG. 6C, the connectors 400a of the wire harness 410 are fitted into the piles 405a and 406a arranged on the workbench 700, and the connectors of the wire harness 410 are inserted into the piles 405b and 406b arranged on the workbench 700. Insert 400b. The wire harness 410 is arranged on the workbench 700 along a wire harness mold 710 created in advance, and is bent into a mounting shape (Z shape) as shown in FIG.

When the plurality of electric wires 401 are viewed from the connector (first connector) 400a, the first bent portion 431 is formed so that the plurality of electric wires 401 can be bent in one direction (rightward in this embodiment) in the longitudinal direction D1 of the connector 400a. Form. The pile 404a is arranged inside the first bent portion 431 so as to maintain the bent shape of the first bent portion 431. Using the pile 404a as a fulcrum, the wire lengths of the plurality of electric wires 401 are adjusted so that the innermost electric wire 409 in the first bent portion 431 of the plurality of electric wires 401 does not have an extra length. When the plurality of electric wires 401 are viewed from the connector (second connector) 400b, the plurality of electric wires are oriented in the same direction (rightward in this embodiment) as one direction of the first bent portion 431 in the longitudinal direction D2 of the connector 400b. Form a second bend 432 in which 401 is bent. The pile 404b is arranged inside the second bent portion 432 so as to maintain the bent shape of the second bent portion 432. Using the pile 404b as a fulcrum, the line lengths of the plurality of electric wires 401 are adjusted so that the innermost electric wire 411 in the second bent portion 432 of the plurality of electric wires 401 does not have extra length.

After adjusting the wire length, before binding the plurality of electric wires 401 by the binding member (third binding member) 402c, the binding member (first binding member) 402a is aligned with the attachment position 711a marked on the workbench 700. Is attached as shown in FIG. The first bent portion 431 is formed on the plurality of electric wires 401 between the connector (first connector) 400a and the binding member (first binding member) 402a. A binding member for maintaining the shape of the first bent portion 431 such that the outermost electric wire 411 in the first bent portion 431 of the plurality of electric wires 401 is longer than the innermost electric wire 409 in length. A plurality of electric wires 401 are bound together by 402a. By attaching the bundling member 402a closest to the connector 400a to the electric wire 401, an extra length is unlikely to be generated between the connector 400a and the bundling member 402a, and the line length is optimized.

Before binding the plurality of electric wires 401 by the binding member (third binding member) 402c, the binding member (second binding member) 402b is shown in FIG. 6D in accordance with the mounting position 711b marked on the workbench 700. Install as shown in. The second bent portion 432 is formed on the plurality of electric wires 401 between the connector (second connector) 400b and the binding member (second binding member) 402b. In order to maintain the shape of the second bent portion 432 so that the line length L1 of the outermost electric wire 409 in the second bent portion 432 of the plurality of electric wires 401 is longer than the line length L2 of the innermost electric wire 411. The plurality of electric wires 401 are bound by the binding member 402b. The outermost electric wire 411 in the first bent portion 431 becomes the innermost electric wire 411 in the second bent portion 432. The innermost electric wire 409 in the first bent portion 431 becomes the outermost electric wire 409 in the second bent portion 432. As a result, excess length is unlikely to occur in the wire length of the plurality of electric wires 401. Furthermore, by attaching the bundling member 402b closest to the connector 400b to the electric wire 401, an extra length is less likely to occur between the connector 400b and the bundling member 402b, and the line length is optimized.

In this way, by attaching the binding members 402a and 402b on the side closer to the connectors 400a and 400b to the electric wire 401 before the binding member 402c in the central portion, the bent shape of the wire harness 410 is as shown in FIG. 6(e). The mounting shape can be maintained. Finally, the binding member 402c is attached to the electric wire 401 at the attachment position 711c in order to prevent the electric wire 401 from being scattered between the binding members 402a and 402b. That is, after binding the plurality of electric wires 401 by the binding member (first binding member) 402a and the binding member (second binding member) 402b, the other binding member (third binding member) of the plurality of binding members is bound. A plurality of electric wires 401 are bound by a member) 402c.

In this embodiment, the electric wire 401 connected from the one connector 400a to the other connector 400b is bound by the three binding members 402a, 402b and 402c. However, the number of binding members is not limited to three, and the electric wires 401 may be bound by three or more binding members such as four and five. Even when three or more binding members are used, the binding member closest to the connectors 400a and 400b is attached to the electric wire 401 before the other binding members. According to this embodiment, the wire harness 410, which is a single harness, can be manufactured in a shape close to the mounting shape, and the mounting space of the wire harness 410 can be suppressed. It is possible to solve the quality problem due to the scattering of the electric wires 401 due to the excess length. With respect to the space saving of the mounting space of the wire harness 410, the quality of the bundled wire can be maintained without increasing the cost. According to this embodiment, it is possible to provide the wire harness 410 that can be easily installed in a narrow space without increasing the cost.

(Multi harness)
The wire harness 410 according to the present embodiment is a single harness in which one connector 400b is connected to one connector 400a. Next, a multi-harness for connecting a plurality of connectors to one connector will be described. FIG. 8 is a diagram showing a wire harness 810 according to this embodiment. As shown in FIG. 8A, the wire harness 810 has two connectors 800a in one connector 800c by a plurality of electric wires (a plurality of first electric wires) 801a and a plurality of electric wires (a plurality of second electric wires) 801b. And 800b is a connected multi-harness. A connector (second connector) 800a is connected to the connector (first connector) 800c by a plurality of electric wires 801a, and a connector (third connector) 800b is connected to the connector 800c by a plurality of electric wires (a plurality of different electric wires) 801b. It is connected.

In the wire harness 810, as shown in FIG. 8B, the electric wires 801a and 801b are respectively bent into the mounting shape (Z shape). The binding members 802a, 802b, 802c and 802d arranged near the connectors 800a, 800b and 800c are attached to the electric wires 801a and 801b before the other binding members 802e and 802f. The positional relationship between the connector 800a and the binding member 802a and the positional relationship between the connector 800b and the binding member 802b are the same as those in FIG.

With reference to FIG. 9, the attachment position of the binding member 802d attached to the plurality of electric wires 801a extending from the connector 800c to the branch destination connector 800a will be described. FIG. 9 is a diagram showing a positional relationship between the connector 800c, the pile 804, and the binding member 802d and a plurality of electric wires 801a near the connector 800c. The pile 804 is arranged so as to come into contact with the extension line 807 of the electric wire 811 that is pressed or crimped to the innermost pin (right side in FIG. 9) of the connector 800c among the plurality of electric wires 801a or in the vicinity of the extension line 807. .. The distance H from the connector 800c to the pile 804 may be set so that the wire harness 810 has a shape close to the mounting shape. The positional relationship between the connector 800c and the bundling member 802c is the same as in FIG.

Here, when the distance W from the position of the electric wire 809 pressed or crimped to the pin on the center side (outside the bend) of the connector 800c among the plurality of electric wires 801a to the extension line 807 of the electric wire 811 is equal to the distance H (W =H). The length of the electric wire 809 from the connector 800c to the binding member 802d closest to the connector 800c is defined as the line length L1. The length of the electric wire 811 from the connector 800c to the bundling member 802d closest to the connector 800c is defined as the line length L2. Similar to the single harness wire harness 410 shown in FIG. 7, the effective attachment position of the binding member 802d for suppressing the mounting space of the wire harness 810 is such that the value of the wire length difference ratio is 36.3% or more, and The line length difference may be set to be larger than 5 mm. Further, the attachment position of the binding member 802c to the electric wire 801b extending from the connector 800c to the opposite branch destination connector 800b may be set in the same manner.

At this time, the binding members 802a, 802b, 802c and 802d close to the connectors 800a, 800b and 800c are bound before the other binding members 802e and 802f to maintain the bent shape of the electric wires 801a and 801b. As a result, the wire harness 810 is maintained in a shape close to the mounting shape. Finally, the binding members 802e and 802f are attached to the electric wires 801a and 801b in order to suppress the scattering of the electric wires 801a and 801b between the binding members 802a, 802b, 802c and 802d. According to this embodiment, it is possible to manufacture the wire harness 810 which is a multi-harness in a shape close to the mounting shape, and to suppress the mounting space of the wire harness 810. It is possible to solve the quality problem due to the scattering of the electric wires 801 due to the excess length. With respect to the space saving of the mounting space of the wire harness 810, the quality of the bundled wire can be maintained without increasing the cost. According to this embodiment, it is possible to provide the wire harness 810 that can be easily laid in a narrow space without increasing the cost.

400a, 400b, 800a, 800b, 800c... Connector 401, 801a, 801b... A plurality of electric wires 402a-402c, 802a-802f... Bundling member 410, 810... Wire harness 431... First Bent portion 432... second bent portion L1... outermost wire length of the bent portion L2... innermost wire length of the bent portion

Claims (9)

Multiple wires,
A first connector connected to the first end of the plurality of electric wires,
A second connector connected to a second end of the plurality of wires opposite to the first end,
When the plurality of electric wires are viewed from the first connector, the plurality of electric wires are formed so as to form a first bent portion in which the plurality of electric wires are bent in one direction in the longitudinal direction of the first connector. A first binding member for binding,
When the plurality of electric wires are viewed from the second connector, the plurality of electric wires are bent in the same direction as the one direction of the first bending portion in the longitudinal direction of the second connector. A second binding member that binds the plurality of electric wires so as to form a bent portion,
A third binding member for binding the plurality of electric wires between the first binding member and the second binding member,
Equipped with
The first binding member, by binding the plurality of electric wires so that the line length of the outermost electric wire in the first bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. Maintaining the shape of the first bend,
The second binding member, by binding the plurality of electric wires so that the line length of the outermost electric wire in the second bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. A wire harness, characterized in that the shape of the second bent portion is maintained. The difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the first bent portion is larger than 5 mm,
The wire harness according to claim 1, wherein a difference between the wire length of the outermost electric wire and the wire length of the innermost electric wire in the second bent portion is larger than 5 mm. The difference between the line length of the outermost electric wire in the first bent portion and the line length of the innermost electric wire, the line length of the outermost electric wire in the second bent portion and the most The wire harness according to claim 2, wherein the difference between the wire lengths of the inner wires is substantially the same. A value obtained by dividing the difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the first bent portion by the line length of the innermost electric wire is 36.3% or more. Yes,
A value obtained by dividing the difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the second bent portion by the line length of the innermost electric wire is 36.3% or more. The wire harness according to claim 2, wherein the wire harness is provided. A third connector,
A number of different wires,
Further equipped with,
The first connector is connected to the first ends of the plurality of different electric wires,
The said 3rd connector is connected to the 2nd end part opposite to the said 1st end part of these other some electric wire, The any one of Claim 1 thru|or 4 characterized by the above-mentioned. Wire harness. A plurality of electric wires, a first connector connected to first ends of the plurality of electric wires, and a second connector connected to a second end of the plurality of electric wires opposite to the first end. And a first bent portion in which the plurality of electric wires are bent in one direction in the longitudinal direction of the first connector when the plurality of electric wires are viewed from the first connector. A first binding member that binds a plurality of electric wires, and the one direction of the first bent portion in the longitudinal direction of the second connector when the plurality of electric wires are viewed from the second connector, Between a second binding member that binds the plurality of electric wires so as to form a second bent portion in which the plurality of electric wires are bent in the same direction, and between the first binding member and the second binding member A third binding member for binding the plurality of electric wires together, and a method for manufacturing a wire harness comprising:
Before binding the plurality of electric wires by the third binding member, the line length of the outermost electric wire in the first bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. Binding the plurality of electric wires by the first binding member to maintain the shape of the first bent portion,
Before binding the plurality of electric wires by the third binding member, the line length of the outermost electric wire in the second bent portion of the plurality of electric wires is longer than the line length of the innermost electric wire. Binding the plurality of wires by the second binding member to maintain the shape of the second bent portion,
A method comprising: Bundling the plurality of electric wires by the first binding member makes the difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the first bent portion larger than 5 mm. Including bundling the plurality of electrical wires,
By bundling the plurality of electric wires with the second binding member, a difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the second bent portion becomes larger than 5 mm. 7. The method of claim 6, including bundling the plurality of electrical wires. Before binding the plurality of electric wires by the first binding member and the second binding member, the wire length of the outermost electric wire and the wire length of the innermost electric wire in the first bent portion. Arranging the wire harness on the workbench so that the difference between the wire length of the outermost wire and the wire length of the innermost wire in the second bent portion is substantially the same. The method of claim 7, further comprising: Bundling the plurality of electric wires by the first binding member means that the difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the first bent portion is the innermost. Bundling the plurality of electric wires so that the value divided by the wire length of the electric wire of 3 is 36.3% or more,
Bundling the plurality of electric wires by the second binding member means that the difference between the line length of the outermost electric wire and the line length of the innermost electric wire in the second bent portion is the innermost. 9. The method according to claim 7, further comprising bundling the plurality of electric wires so that a value of the electric wires divided by the wire length becomes 36.3% or more.

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