JP3092438B2 - Manufacturing method of wire harness - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION This invention relates to manufacturing <br/> method for producing Waiyahane scan, and more particularly, a number of the wires is laid on the wiring board, the part by pressing joint connector The present invention relates to a wire harness assembled by conducting electric wires and a method of manufacturing the wire harness.

[0002]

2. Description of the Related Art Generally, a wire harness is an electric wiring system having a large number of electric wires. In an assembling process, an electric wire is placed on a plate-shaped jig called a drawing board. And various electrical components and exterior components including a press-fit joint connector are mounted on the drawing board.

[0003] In particular, when a large-scale wire harness is manufactured, a plurality of unit wire bundle assemblies called temporary binding circuits are manufactured, and they are electrically connected to each other by a press-fit joint connector in a process called a main binding process. Is widely adopted (for example, Japanese Utility Model Laid-Open No. 61-1).
17465). When connecting some wires among the wires constituting the wire harness to the press-fit joint connector, as shown in FIG. There is known a type in which an electric wire W to be formed is projected in a loop shape and the U-turn portion 102 is connected by a press-fit joint connector. In the following description of the present specification, of the U-turn unit 102,
A portion that protrudes the longest from the wire bundle 101 (a portion indicated by reference numeral 102A in FIG. 10) is called a loop end.

As a technique for connecting the U-turn part 102 by a press-fit joint connector, for example,
It is disclosed in JP-A-9-1119580. In the configuration of the publication, as shown in FIG.
The loop end 102A is positioned on the press-fit joint connector 110 and connected to the press-fit joint connector 110 in a known manner.

However, in this configuration, it is difficult to position the loop end 102A at a predetermined position of the press-fit joint connector 110 due to the wire W being stretched or pulled. As a result, the U-turn portion 102 often deviates from the original setting position, and a stable press-contact structure cannot be obtained, resulting in a large variation in quality.

To solve such a problem, a configuration disclosed in Japanese Patent Application Laid-Open No. 3-165476 has been proposed. In the configuration of the publication, as shown in FIG. 12, a pair of wiring jigs 121 and 122 is used to stretch a U-turn portion 102 in parallel with a wire bundle 101 serving as a main line, and further, a positioning member 123 is provided. Using each U-turn part 10
The second loop end 102A is connected to the press-fit joint connector 110.
It is positioned above.

[0007] In the configuration of FIG. 12, the wire W is less susceptible to the influence of the wire W being stretched or pulled.
1, 122 and the U-turn portion 102
Therefore, it is necessary to position each U-turn part 102 by laying out, so that there is a problem that the positioning process takes time and effort. In addition, since the wiring jigs 121 and 122 are provided, it is necessary to secure a space for wiring on the drawing board. was there.

Further, as a configuration for solving such a problem, a configuration disclosed in JP-A-63-259977 is also known. In the configuration of the publication, as shown in FIG. 13, the press-connecting joint connector 110 is placed on the cantilever jig 124 and positioned.
2 is inserted from the free end of the cantilever jig 124 to the outer periphery of the press-fit joint connector 110 and the mounting portion 124A of the cantilever jig 124, and each U-turn portion 102 is connected to the press-fit joint connector 110.

In the configuration shown in FIG. 13, since the intermediate portion between the loop end 102A of each U-turn portion 102 and the wire bundle 101 is connected to the press-connecting joint connector 110, the loop end is grasped and the U-turn portion 102 is connected to the press-connecting joint connector. 11
It becomes possible to position at zero. As a result, the electric wire W
In addition to making it less susceptible to the effects of wire stretching and tension (see the same publication, page 3, upper right column, lines 9 to 12), the wiring jigs 121 and 122 in FIG. 12 can be eliminated. become.

However, in the configuration shown in FIG.
Since the mounting portion 124A of the cantilever jig 124 is also inserted into the 02, the work of arranging the U-turn portion 102 on the crimping joint connector 110 and removing the crimping joint connector 110 after the crimping from the cantilever jig 124. There was a problem that work became difficult and workability deteriorated. The present invention has been made in view of the above problem, it is possible to perform the pressure work in a compact space, Waiyahane scan that can stabilize the high quality workability
The purpose of the present invention is to provide a manufacturing method.

[0011]

[Means for Solving the Problems]

[0012] Configuration of 請 Motomeko 1 described, to produce a subassembly circuit including a U-turn portion protruding from the wire bundle into a loop, U
In the method of manufacturing a wire harness in which a turn end of a loop end that protrudes most from a wire bundle and an intermediate portion between the wire bundle and the wire bundle are pressed, a temporary binding circuit is manufactured on a drawing board at the time of completion.
The above-mentioned U-turn part which is arranged in a product form and needs to be electrically connected
The, while aligning grip the loop ends, U Tha
To the wire temporary fixing part of the crimp joint connector.
On the top side of the insulation displacement joint connector,
After temporarily fixed in a reciprocating posture in a direction intersecting with the connector,
A method for producing a wire harness which is characterized that you press the pressure contact joint connector by a press machine.

[0013]

According to the structure of the present invention, it is possible to temporarily fix the U-turn portion to the wire temporary fixing portion of the press-fit joint connector while performing positioning by grasping the loop end. At this time, since the U-turn portion is open in the vertical direction,
The turn portion is temporarily fixed in a state where portions other than the wire temporary fixing portion of the press-fit joint connector are opened. In this state, U
By pressing both intermediate portions of the turn portion to the press-connecting joint connector in a known manner, the both intermediate portions are pressed against the press-connecting joint connector.

[0014]

Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a schematic exploded perspective view showing a main part of a wire harness WH according to a preferred embodiment of the present invention, and FIG.
FIG. 3 is a configuration diagram showing a temporary binding circuit X2 forming H.
FIG. 4 is a configuration diagram of a temporary binding circuit Y2 constituting the wire harness WH together with the temporary binding circuit X2 of FIG. 2, and FIG. 4 is configured by combining the temporary binding circuits X2 and Y2 of FIG. 2 and FIG. It is a lineblock diagram of a wire harness WH.

The wire harness WH in the present embodiment
Combines the temporary binding circuit X2 shown in FIG. 2 and the temporary binding circuit Y2 shown in FIG. 3, and as shown in FIG. 1 and FIG.
It is connected to one wire bundle assembly by a press-fit joint connector 20. As described above, when a plurality of temporary tying circuits X2 and Y2 are manufactured in advance and a desired tying circuit is combined to manufacture the wire harness WH, the wire harness WH which is a complex combination of complicated wiring systems is manufactured. By designing the wire harness WH for each system, it is possible to achieve sharing.

First, referring to FIG. 1, a press-fitting joint connector 20 according to the present embodiment includes a cover 21 and a holder 22 made of resin, and a press-fitting fitting 2 made of a conductive material.
3 is provided. The cover 21 is a molded product having a U-shaped cross section, and includes a substantially rectangular top plate 21A and a top plate 21A.
Side plate portions 21B respectively extended on the longitudinal side portions of
End plate 21 extended to side plate 21B and top plate 21A
C is integrally provided.

On the inner surface of the top plate 21A, there are provided a large number of pressing pieces 21D which hang downward. Pressing piece 21D
Is for pushing U-turn portions U1 to U5 of the electric wire W into the press-fitting fitting 23 in the electric wire W press-fitting step described later. Although not specifically shown, each pressing piece 21D
Has a groove for avoiding interference with the blade 23A of the press fitting 23 described later, and has a pressing surface along the arc of the electric wire W.

Each of the side plate portions 21B is connected to the top plate portion 21A.
A concave portion 21E formed along the longitudinal direction is provided at the lower portion. Indents 21F are formed in the recess 21E at predetermined intervals in the longitudinal direction. The indent 21F is for pushing the electric wire W downward. The end plate 21C includes a projection 21G and a locking projection 2.
1H is integrally provided.

Next, the holder 22 has a substantially rectangular main body portion 22A facing the top plate portion 21A of the cover 21 in plan view.
And two holding member groups 22B and 22C arranged side by side along the longitudinal direction of the main body 22A. Each of the holding piece groups 22 </ b> B and 22 </ b> C is erected in a large number in a row in the longitudinal direction, and forms a temporary fixing portion 202 for temporarily fixing the electric wire W to be pressed against the press fitting 23.

The holding piece groups 22B, 22C define a holding space D1 for holding the electric wire W therebetween. Also,
One holding piece group 22B and another holding piece group 22C have a holding space D1 facing each other in the width direction of the main body 22A. Each of the holding piece groups 22B and 22C includes a large number of holding pieces 202.
A. Each of the holding pieces 202A is a columnar body having a rectangular cross section, and a substantially arrowhead-shaped projection 202B is formed at the tip thereof. Then, one protrusion 202
B and another protrusion 202 adjacent to the one protrusion 202B.
Introducing space D that introduces the electric wire W into the holding space D1 between itself and B.
2 is divided.

An inclined surface 202 is provided above each projection 202B.
D is formed, and the electric wire W is guided into the introduction space D2 by the inclined surface 202D. FIG.
, 22H is a jaw. This jaw 22H is formed by a concave portion 21E formed in each side plate 21B of the cover 21.
A receiving surface H1 for receiving the lower surface of the cover 21 and an engaging portion H2 for engaging the outer surface of the side plate portion 21B continuously with the receiving surface H1. The cover 21 is positioned vertically by the receiving surface H1. The locking portion H2 prevents the side plate portion 21B from expanding at the time of pressurization.

The press fitting 23 is a well-known one formed of a conductive plate. The press fitting 23 holds the core wire of the electric wire W in a state where a covering portion of the electric wire W is cut, and electrically connects the press fitting 23 with the electric wire W. The purpose of this is to make a proper connection. In the press-connecting joint connector 20 described above, the U-turn portions U1 to U5 formed in the temporary binding circuits X2 and Y2 shown in FIGS.

Each of the temporary tying circuits X2 and Y2, as is conventionally known, cuts the electric wire by measuring it to a predetermined length, strips the coverings at both ends of the cut electric wire, and exposes the exposed electric wires. It is assembled by crimping terminal fittings to the core wires at both ends of the electric wire and inserting the crimped terminal fittings into predetermined connector housings 1 to 10. For example, the temporary binding circuit X2 illustrated in FIG. 2 includes a wire bundle 101 that forms a trunk by bundling a plurality of wires W, and five connector housings 1 to 5 that are connected to predetermined wires W branched from the wire bundle 101.
have. The five connector housings 1 to 5 are respectively a connector housing 1 for a hazard switch, a connector housing 2 for coupling to another wiring harness WH group, a connector housing 3 for a junction box, and a connector housing 4 for a defogger switch.
And a connector housing 5 for an overhead light lighting control unit.

On the other hand, a temporary tying circuit Y2 shown in FIG. 3 is composed of a wire bundle 101 which forms a trunk by bundling a plurality of wires W, and five connector housings 6 connected to predetermined wires W branched from the wire bundle 101. 10 to 10. The connector housings 6 to 10 are respectively a connector housing 6 for an air purifier switch, a connector housing 7 for an overdrive changeover switch, a connector housing 8 for a shock absorber control switch, a connector housing 9 for an automatic transmission power changeover switch, and air. It is a connector housing 10 for a purifier body.

In each of the temporary binding circuits X2 and Y2, U-turn portions U1 to U5 are formed in which portions to be connected by the press-connecting joint connector 20 are expanded in a loop shape at the time of final binding. Such U-turn parts U1 to U5 are, in particular,
If the electric wire is automatically wired by an automatic wiring machine, it can be easily formed. This is because, when wiring is performed by an automatic wiring machine, wiring pins may be planted in accordance with the U-turn parts U1 to U5, and wiring may be performed so that electric wires are hung on the wiring pins. It is. An automatic wiring machine for automatically wiring electric wires to manufacture a temporary binding circuit is disclosed in, for example, Japanese Patent Application No. 4-155349 and Japanese Utility Model Application No. 4-43.
No. 609, Japanese Patent Application No. 4-163046, Japanese Patent Application No. 4-24
No. 8300) may be used. Other automatic wiring machines may be used.

In this embodiment, the U-turn parts U1 to U5
From the middle of the wire bundle 101 serving as a trunk line,
01 protrudes in one direction crossing the longitudinal direction. If this configuration is adopted, only the wires W to be pressed by the press-connecting joint connector 20 can be easily selected.
The operation of sorting the electric wires W is easy and reliable, and the productivity is improved.

Next, main binding is performed in which a predetermined number of temporary binding circuits are assembled and connected in a finished product form (see FIG. 4). In this binding, the temporary binding circuits X2 and Y2 are assembled in a finished product form, and the U-turn units U1 to U5 are short-circuited in a predetermined combination. In this embodiment, the U-turn part U1 of the temporary binding circuit X2 and the temporary binding circuit Y2
The U-turn part U3, the two U-turn parts U4, U4 formed in the temporary binding circuit X2, and the U-turn part U2 of the temporary binding circuit X2 and the U-turn part U5 of the temporary binding circuit Y2 are respectively combined and described above. It is short-circuited by the press-fit joint connector 20. IDC connector 20
When the wires are short-circuited with each other using the U-turn part U1
In some cases, predetermined wires of a plurality of temporary binding circuits X2, Y2 are short-circuited to each other, as in the case of short-circuiting connection between U and U3, or one temporary binding is made to short-circuit the U-turn portions U4, U4. In some cases, a plurality of wires constituting a circuit are short-circuited.

The operation of assembling the temporary binding circuits X2 and Y2 into a completed product form and performing the final binding is performed manually. A board 210 shown in FIGS. 5A and 5B is used to assemble a predetermined number of temporary binding circuits X2 and Y2 for the final binding. On the drawing board 210, a plurality of circuit holders 220 are arranged in advance according to the finished product form. The operator holds a predetermined number of temporary binding circuits in the holder 220, thereby assembling the predetermined number of temporary binding circuits into a finished product form.

The drawing board 210 also defines a press space 230 for attaching a press-fit joint connector. Further, the drawing board 210 is provided with a press-fitting joint connector stand 240 arranged adjacent to the press space 230. Press space 2
30 and the press-fit joint connector stand 240 are shown in FIG.
As shown in FIG. 5 (A), they may be arranged in the left-right direction, and may be arranged in plural sets in the length direction (left-right direction) of the drawing board 210. Alternatively, as shown in FIG. The press space 230 and the press-connecting joint connector base 240 may be arranged vertically, and a plurality of sets may be arranged in the lateral direction.

FIG. 6 is a perspective view showing an example of the press-connecting press 30 provided in the press space 230 and an example of the press-joint connector base 240. Pressing press machine 30 for mounting press-fit joint connector 20
Is a hook 3 attached to the tip of a wire 31 suspended from a beam (not shown) on the ceiling and capable of moving up and down.
It is hung on two. The press-contact press 30 is provided with a vertically long support plate 33 and a hydraulic press cylinder 34 attached to the support plate 33, and below the hydraulic press cylinder 34, a pressing member 35 vertically moved by the hydraulic press cylinder 34. Is provided. A depression 36 is formed on the lower surface of the pressing member 35, and the cover 21 of the press-connecting connector 20 can be set in the depression 36. The pressing press machine 30 further includes a support plate 33.
A positioning guide plate 37 extending horizontally from the support plate 33 is fixed below the support plate 33.

On the other hand, a plurality of pillars 41, for example, two pillars 41 are erected on the surface of the binding board 210, and the two pillars 41 are provided.
The press-fit joint connector stand 240 is attached to the upper end of the connector. A positioning projection 43 for setting the holder 22 of the press-connecting connector 20 is formed on the upper surface of the connector base 240. Further, on the lower surface of the connector stand 240, a positioning guide plate 37 of a press-contact press machine is provided.
And a positioning guide 44 which is engaged with the projection. When attaching the press-connecting connector 20, the positioning guide plate 37 is engaged with the positioning guide 44, and the hydraulic press cylinder 34 is operated in this state. Then, the pressing plate 35 is lowered by the hydraulic press cylinder 34, and the lid or the blade set on the pressing plate 35 is fitted to the holder 22 of the press-connecting connector 20.

Next, the operation of this embodiment will be described.
As described above, the temporary binding circuits X2 and Y2 are collected in a finished product form and placed on the drawing board 210. Here, the locations of the wires that need to be electrically connected in the predetermined number of temporary binding circuits are U-turn portions U1 to U5. Therefore, the temporary binding circuits X2, Y assembled on the drawing board 210
2, the U-turn parts U1 to U5 protrude from
The turn sections U1 to U5 are connected to the press-fit joint connector base 240.
May be set to the press-connecting joint connector 20 set at the first position.

As described above, since the electric wires W which need joint processing in the temporary binding circuit constitute the U-turn sections U1 to U5, the joint processing can be performed at a position outside the temporary binding circuits X2 and Y2. . As a result, this U
Turn parts U1 to U5 can be easily press-welded joint connector 2
The crimping press connector 30 can be used to easily attach the crimping joint connector 20 to a required location and short-circuit the wires.

Next, the corresponding U-turn portions U1 to U5 are temporarily fixed to the holder 22. With reference to FIG. 1, in the present embodiment, of the U-turn portions U <b> 1 to U <b> 5, an intermediate portion between the loop end UL most protruding from the wire bundle 101 and the wire bundle 101 and the press-connecting joint connector 20 are pressed. Therefore, the U-turn parts U1 to U5 are connected to the press-fitting joint connector 2 while performing positioning by grasping the loop end UL.
Thus, it is possible to temporarily fix the wire to the wire temporary fixing portion 202. At this time, the U-turn portions U1 to U5 are located on the upper surface side of the press-connecting joint connector 20.
Reciprocating in the direction A intersecting with U-turn section U1-U
5 is a wire temporary fixing portion 20 of the pressure welding joint connector 20.
Temporarily fixed with parts other than 2 open. In this state, the U-turn parts U1 to U5 are
When the U-turn portions U1 to U5 are sandwiched between the cover 21 and the holder 22 by pressing both intermediate portions of the cover 21 to the press-connecting joint connector 20, the cover 21 is moved within a range where the cover 21 is restricted by the flange portion 22H. As a result of the pressing piece 21 </ b> D dropping by impact, the covering portion of the electric wire W of the U-turn portions U <b> 1 to U <b> 5 is cut by the terminal fitting 23, and the terminal fitting 23 comes into contact with the core wire of the electric wire W, so that the press fitting 2
3 and the electric wire W are electrically connected. Both intermediate portions are pressed against the press-connecting joint connector 20.

FIGS. 7 to 9 show a main binding step of a temporary binding circuit according to another embodiment of the present invention.
FIG. 8 is a wiring diagram of the thus-tied wire harness WH.
Temporary binding circuit X3 constituting wire harness WH in FIG.
FIG. 9 is a wiring diagram of another temporary binding circuit Y3 connected to the temporary binding circuit X3 of FIG. As shown in these figures, in the wire harness WH of FIG. 7, U-turn portions U6 and U7 are formed at the end of the wire bundle 101 serving as a main line. In addition, each of the temporary binding circuits X3 and Y3 includes a separated end W1 obtained by cutting off the end of the electric wire W. The U-turn portions U6 and U7 are short-circuited by one press-connecting joint connector 20. In addition, FIG.
In FIG. 9, reference numerals 11 to 14 denote connector housings connected to predetermined electric wires W.

As shown in this embodiment, the U-turn portion may not only protrude from the middle of the wire bundle 101, but also protrude from the end of the wire bundle 101 serving as a trunk line. Further, the press-connecting joint connector 20
Not only the U-turn portion but also the pressure contact including the separated end portion W1 may be used. As described above, according to the present embodiment, the U-turn portions U1 to U7 are temporarily fixed and pressed in a state where the portions other than the wire temporary fixing portions 202 of the press-connecting joint connector 20 are opened, and are press-contacted. The attachment and detachment of the connector 20 is facilitated, and the workability is improved. In addition, since the U-turn portions U1 to U7 can be temporarily fixed to the press-connecting joint connector 20 while performing the positioning by grasping the loop end UL, the electric wire can be straightened without using a special wiring jig. It is possible to prevent the influence of tension or the like.

Therefore, according to the present embodiment, the pressure welding operation can be performed in a compact space, and the workability is high and the quality can be stabilized. The method of manufacturing the wire harness WH described above only shows one embodiment of the present invention, and the present invention is not limited to the described embodiment. In the description of the embodiment, for the sake of simplicity of description and illustration, only two temporary binding circuits are used for the actual binding. However, when manufacturing the actual wire harness WH, many temporary binding circuits are assembled. In many cases, this unity is done.
Even in such a case, the wire harness WH can be manufactured using the manufacturing method according to the present invention.

In the manufacturing method of the present invention, the production of a plurality of electric wire units including the step of cutting and stripping, the stripping step and the terminal crimping step and the production of the temporary binding circuit using the plurality of electric wire units are performed by an automatic machine. It may be performed, or may be performed manually by an operator in some cases. In addition, the present invention can be variously modified within the scope described in the claims.

[0039]

As described above, according to the present invention,
The U-turn portion is temporarily fixed and pressed in a state in which a portion other than the wire temporary fixing portion of the press-connecting joint connector is opened, so that attachment and detachment of the press-connecting joint connector is facilitated and workability is improved. In addition, it is possible to temporarily fix the U-turn part to the press-fit joint connector while performing positioning by holding the loop end. It becomes possible to prevent.

Therefore, according to the present invention, the pressure welding operation can be performed in a compact space, and there is a remarkable effect that the workability is high and the quality can be stabilized.

[Brief description of the drawings]

FIG. 1 is a schematic exploded perspective view showing a main part of a wire harness according to a preferred embodiment of the present invention.

FIG. 2 is a configuration diagram illustrating a temporary binding circuit that configures the wire harness.

FIG. 3 is a configuration diagram of a temporary binding circuit forming the wire harness together with the temporary binding circuit of FIG. 2;

FIG. 4 is a configuration diagram of a wire bundle assembly configured by combining the temporary binding circuits of FIGS. 2 and 3;

FIG. 5 is a diagram showing a configuration example of a drawing board required for a main binding step in the method of manufacturing a wire harness according to the embodiment.

FIG. 6 is a perspective view showing an example of a press-contact press machine provided in a press space and an example of a press-joint connector base.

FIG. 7 is a wiring diagram of a wire harness according to another embodiment of the present invention.

FIG. 8 is a wiring diagram of a temporary binding circuit forming the wire harness of FIG. 7;

FIG. 9 is a wiring diagram of another temporary binding circuit connected to the temporary binding circuit of FIG. 8;

FIG. 10 is a schematic exploded perspective view showing a main part of a conventional wire harness.

FIG. 11 is a schematic exploded perspective view showing a main part of another conventional wire harness.

FIG. 12 is a schematic exploded perspective view showing a main part of still another conventional wire harness.

FIG. 13 is a schematic exploded perspective view showing a main part of still another conventional wire harness.

[Explanation of symbols]

 Reference Signs List 20 press-welding joint connector 101 wire bundle 202 temporary fixing portion U1 U-turn portion U2 U-turn portion U3 U-turn portion U4 U-turn portion U5 U-turn portion U6 U-turn portion U7 U-turn portion UL Loop end WH Wire harness

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-63-259977 (JP, A) JP-A-59-8289 (JP, A) JP-A-57-136782 (JP, A) JP-A-60-1985 37682 (JP, A) JP-A-60-65482 (JP, A) JP-A-59-119580 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01R 4/24 H01R 43 / 01

Claims (1)

(57) [Claims] 1. A temporary binding circuit including a U-turn portion protruding in a loop form from a wire bundle is manufactured, and of the U-turn portion, an intermediate portion between a loop end of the U-turn portion most protruding from the wire bundle and the wire bundle is press-contacted. In the method of manufacturing a wire harness , a temporary tying circuit is arranged on a drawing board in a finished product form, and the U-turn portion that needs to be electrically connected is gripped by a loop end.
The U-turn part intersects with the crimping joint connector on the upper surface side of the crimping joint connector with respect to the wire temporary fixing part of the crimping joint connector while performing alignment.
After temporarily fixed in a posture back and forth in the direction, by pressing machine
Method of manufacturing a wire harness for a press joint connector, wherein pressure to Rukoto.