JP3114615B2 - Method and apparatus for manufacturing wire harness - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a wire harness used for OA equipment, home electric appliances or internal wiring of automobiles.

[0002]

2. Description of the Related Art Conventionally, wiring harnesses for electrical wiring installed inside OA equipment, home electric appliances or automobiles are conventionally known as shown in FIG.
A plurality of electric wires 1 for connecting the PU, the display device, various switch parts, and the like are bundled in a substantially cylindrical shape, and jigs (not shown) for holding the connector 3 and the electric wires 1 are actually provided. After arranging the electric wire 1 along this, wrapping the adhesive tape 2 for protection around the electric wire 1 and further covering the case of a resin molded product (not shown) After maintaining a certain shape, the OA device, the home electric appliance, the automobile, or the like to be attached is attached so as to correspond to the internal wiring configuration (first conventional example). However, in the first conventional example, at the time of manufacturing,
Since the adhesive tape 2 was wound around the electric wire 1 after the electric wire 1 was manually crawled on such a jig, it took a lot of time to wind the adhesive tape 2 after the electric wire 1 was crawled, Work efficiency was poor.

Accordingly, as shown in FIGS. 11 and 12, for example, a flexible printed wiring (FPC) or the like in which a conductive path 4 is printed in a pattern on a flexible base film 5 and a cover film 6 is laminated thereon. (The second conventional example) is frequently used. However, in the case of a complicated wire harness having a bent portion in the conductive path 4, as shown in FIG. 12, an etching mask is formed for each pattern in a manufacturing process, and punching is performed after forming a pattern on a large-area base film Dk. Since the cutting is performed using a mold, a large-scale apparatus such as an etching apparatus and a cutting apparatus is required. Further, since a large-area base film Dk is used, a large work space is required, and the space efficiency is poor.

Further, as shown in FIG. 13, a plurality of strip-shaped conductors 1 are arranged in parallel in a straight line, and the upper and lower sides thereof are laminated with films 5 and 6, and then bent in accordance with the wiring route (No. 3 conventional examples). With this method, the second
Necessary various devices as in the conventional example can be omitted. However, in the wire harness of the third conventional example, the bent portion 7 is damaged, or as shown in FIG. On the other hand, there has been a problem that the shape of the wire harness is not stable.

[0005] Each strip-shaped conductor 1 may be placed along the wiring route in a shape corresponding to the wiring route and at a predetermined interval with high accuracy. In this case, a time required for adjusting the shape of the strip-shaped conductor 1 is required. And the time efficiency was poor. In addition, the problem of the second conventional example remains unsolved in that a large area film is required according to the routing path.

Accordingly, an object of the present invention is to manufacture a wire harness which can be easily manufactured by using only a simple manufacturing apparatus and can be installed without bending a part of a wiring route having a bent portion. It is an object of the present invention to provide a method and a manufacturing apparatus used for the manufacturing method.

[0007]

Means for Solving the Problems In order to solve the above problems,
In the invention according to claim 1, a plurality of electric wires are placed in a straight line and in parallel on a mounting table, and a processing tool having a step formed with a predetermined gradient is pressed against the electric wires, and each electric wire is provided. By setting slacks having different dimensions, it is possible to easily form a bent portion corresponding to a desired routing path for each wire while improving the space efficiency by arranging the wires in a straight line.

[0008] Further, in order to maintain the dimensional deviation of the slack of the plurality of electric wires in which the slack is set, the electric wires are stuck to the film as they are.

According to a second aspect of the present invention, a mounting table having an opening formed in a part of a top surface is used as the mounting table, and a plurality of electric wires are linearly extended over the opening of the mounting table. By placing the processing tool in the opening and pressing it down while abutting the wire in the opening to set the slack, the bending portion corresponding to the desired routing path for each wire with only extremely easy operation Can be formed.

According to a third aspect of the present invention, there is provided a wire harness manufacturing apparatus for realizing the method according to the first aspect, wherein a wire supply means for supplying a plurality of wires and a wire supply means for supplying the plurality of wires. Line aligning means for aligning the plurality of electric wires in parallel, a mounting table for linearly mounting the plurality of electric wires aligned in parallel by the line aligning means, and pressing against the electric wires on the mounting table. And a slack size adjusting means in which a step for contacting the wires so as to set a slack of a different size is formed at a predetermined gradient.

According to a fourth aspect of the present invention, there is provided a wire harness manufacturing apparatus for realizing the method according to the second aspect, wherein the processing tool is applied to a part of a top surface of the mounting table and to the electric wire. An opening for setting the slack by pressing down while making contact is formed.

According to a fifth aspect of the present invention, as a wire harness manufacturing apparatus, a film sticking table for sticking a film to the plurality of electric wires in a state where the slack is set is further provided.

[0013]

FIG. 1 is a view showing a wire harness according to one embodiment of the present invention. This wire harness is obtained by arranging a plurality of electric wires 11 in parallel on the same plane at equal intervals and fixing a part of the wires 11 by sandwiching them with two protective films 12. In order to cope with a complicated routing route, all the electric wires 11 are curved in a substantially concentric arc shape with a substantially constant gap from each other in a local portion (hereinafter referred to as a “curved portion”) 13. This curved part 1
3, a protective film may be adhered in the same manner as in the conventional example of FIG. 11, but here, for convenience at the time of manufacture, the protective film is not adhered at the curved portion 13 as shown in FIG. ing. For this reason, each of the electric wires 11 used is covered with an insulating coating. In this embodiment, an example in which four electric wires 11 are installed is shown, but the number is not limited to four as long as the electric wires 11 are arranged in parallel on the same plane at equal intervals.

FIG. 2 is a view showing a state in which the axial direction of each electric wire 11 in the bending portion 13 is changed at a bending angle of 90 °. In the curved portion 13 of the wire harness, since the electric wires 11 (11a to 11d) are spaced apart by a fixed distance w, all the lengths need to be set differently.

Here, when the distance between the wires 11a to 11d is w and the radii of curvature are w, 2w, 3w, and 4w, respectively, the wires 11a to 11d
Lengths L1, L2, L3, L4 are quarter lengths of the circumference for each radius of curvature. Therefore, L1 = (2π · w) / 4 = πw / 2 L2 = (2π · 2w) / 4 = πw L3 = (2π · 3w) / 4 = 3πw / 2 L4 = (2π · 4w) / 4 = 2πw. The deviation of the lengths of the wires 11 adjacent to each other is as follows: L2−L1 = (πw) − (πw / 2) = πw / 2 L3−L2 = (3πw / 2) − (πw) = πw / 2 L4 L3 = (2πw) − (3πw / 2) = πw / 2. As described above, it is necessary to set the length deviation (πw / 2) between the adjacent electric wires 11. As a method, as in the second conventional example, the electric wires 11 are manually set in accordance with the wiring route. Wire 11 using a jig such as a mold.
Although there is a method of adjusting the shape of the above, work efficiency and space efficiency are poor. Therefore, in this embodiment, after the electric wires 11 are installed linearly and in parallel as indicated by the broken lines in FIG.
As shown in FIG. 5, a processing tool 14 (slack dimension adjusting means) having a step 15 having a constant height ( h = πw / 4 ) is used for each constant width (w) of the electric wires 11a to 11d. By pushing down the step 15 of the processing tool 14 to the electric wire 11 and loosening it by a predetermined dimension, each electric wire 1 is turned off as shown by a solid line in FIG.
1a to 11d are adjusted to an appropriate length suitable for the bending portion 13. Each step 15 of the processing tool 14 is
It is formed in a substantially arc-shaped concave shape so as to prevent detachment of 1d.

As a manufacturing apparatus, an apparatus as shown in FIG. 6 is used. The manufacturing apparatus includes a wire supply unit 21 (wire supply means) having a plurality of wire supply drums 20 and supplying the wires 11 simultaneously, and a plurality of supplied wires 1.
1. A line aligning jig 22 (line aligning means) in which a groove 22a for aligning the separation width (w) is formed, and a predetermined connector 23
, A circuit length adjustment unit 25 for adjusting the length of each of the wires 11 (11a to 11d) using the processing tool 14, and a connector pressure contact unit 24 and a circuit length adjustment unit. There is provided a wiring board 27 (film sticking table) for sticking (wiring) the film 12 to the electric wire 11 and protecting the wire 12 between the wire 25 and the circuit length adjusting sections 25.
Here, as shown in FIG.
8, an opening 29 is formed in the center of the top surface of the electric wire 11 for pushing down the processing tool 14 with respect to the electric wire 11 to loosen the electric wire 11. The mounting table 28 and the wiring table 27 of the line alignment jig 22, the connector press contact portion 24, and the circuit length adjusting portion 25 are set at the same height. These may be detachable as independent units, or may be formed as an integral unit.

Next, a method of manufacturing a wire harness using the above-described processing tool 14 and manufacturing apparatus will be described.

First, the electric wires 11 are respectively supplied from the plurality of electric wire supply drums 20 of the electric wire supply section 21 and the line aligning jig 2 is provided.
The wire 11 is placed on the upper surface of the connector press-contact portion 24, the mounting table 28 of the circuit length adjusting portion 25, and the wiring board 27 while setting the predetermined separation width w of the wire 11 through the second groove 22 a. And parallel to each other.

Next, as shown in FIG. 5, with respect to the electric wires 11 (11a to 11d) extending over the central opening 29 of the mounting table 28,
The steps 15 of the processing tool 14 are brought into contact with each other, and the wires 11a to 11d are loosened by a dimension corresponding to the steps 15 by being pressed down by a predetermined dimension. At this time, the electric wire 11 is supplied from each electric wire supply drum 20 by the slackened size. In addition,
The processing tool 14 may be automatically pushed down using an electrically controlled lifting device, or may be pushed down manually by an operator.

Thereafter, the predetermined film 12 is adhered to the wire 11 from above the wiring board 27 and fixed thereto, and the predetermined connector 2
3 are pressed to complete the wire harness shown in FIG.

In the bending portion 13, for example, as shown in FIGS. 7 and 8, when it is desired to change the axial direction of each wire 11 at a bending angle of, for example, 45 °, the separation width of each wire 11a to 11d is represented by w, When the radii of curvature are w, 2w, 3w, and 4w, respectively, the electric wires 11a to 11d in the bending portion 13 are formed.
Since the lengths L1, L2, L3, and L4 are 八 of the circumference of each radius of curvature, L1 = (2π · w) / 8 = πw / 4 L2 = ( 2π · 2w) / 8 = πw / 2 L3 = (2π · 3w) / 8 = 3πw / 4 L4 = (2π · 4w) / 8 = πw, and the deviation of the length of the wires 11 adjacent to each other is L2- L1 = (πw / 2)-(πw / 4) = πw / 4 L3-L2 = (3πw / 4)-(πw / 2) = πw / 4 L4-L3 = (πw)-(3πw / 4) = πw / 4, so that the step 1 of the processing tool 14 corresponds to the deviation.
The height ( h ) of 5 may be set. Specifically, assuming that the gradient of the step 15 of the processing tool 14 when the bending angle ε of each electric wire 11 at the bending portion 13 is 90 ° is θ (FIG. 4), FIG.
When the bending angle ε of each wire 11 is 45 ° as shown in FIG. 9, the gradient of the step 15 of the processing tool 14 is set to θ / 2 as shown in FIG. Thus, for the bending angle ε of the electric wire 11,
The gradient of the step 15 of the processing tool 14 may be set to (θ × ε / 90 °).

As described above, after the electric wires 11a to 11d are placed in a straight line, the processing tool 14 having the step 15 is connected to the electric wire 1a.
With only a very easy operation such as pressing down on the wire 1, each of the wires 11 a to 11 d can be adjusted by loosening it to an appropriate length suitable for the bending portion 13. And can be installed without bending as in the third conventional example.

In the case where there are three or more curved portions 13, a circuit length adjusting portion 25 may be added in accordance with the number of the curved portions 13. When the distance between the bending portions 13 is changed in the case where there are a plurality of bending portions 13, the distance between the connector press contact portion 24 and the circuit length adjusting portion 25 may be changed and designed.

In FIG. 1, the electric wire 1 in which the slack is set is shown.
1 is arranged on the same plane, but it is a matter of course that three-dimensionally bending may be applied for wiring.

[0025]

According to the first aspect of the present invention, a plurality of electric wires are placed linearly and in parallel on a mounting table, and a processing tool having a step formed at a predetermined gradient is pressed against the electric wires. Since different sizes of slack are set for each electric wire, it is possible to easily form a bent portion corresponding to a desired wiring route for each electric wire while improving the space efficiency by arranging the electric wires linearly. .

Further, since a plurality of slack-set electric wires are adhered to the film as they are, the dimensional deviation of the slack can be maintained.

According to the second aspect of the present invention, a mounting table having an opening formed in a part of the top surface is used, and a plurality of electric wires are linearly and parallelly extended over the opening of the mounting table. The slack is set by pressing down the processing tool in the opening while abutting the wire on the electric wire, so that a bent portion corresponding to a desired wiring path can be formed for each electric wire only by an extremely easy operation.

According to the third aspect of the present invention, an electric wire supply means for supplying a plurality of electric wires, a line aligning means for aligning the plurality of electric wires supplied from the electric wire supply means in parallel, and A mounting table for mounting a plurality of aligned electric wires in a straight line, and a step for pressing against the electric wires on the mounting table and setting a slack of a different size for each electric wire to have a predetermined gradient. Since the apparatus has the slack size adjusting means formed by the above, the method according to claim 1 can be easily realized.

According to the fourth aspect of the present invention, an opening is formed in a part of the top surface of the mounting table for setting the slack by pushing down the processing tool while making contact with the electric wire. Item 2 can be easily realized.

According to the fifth aspect of the present invention, a film sticking table for sticking a film to a plurality of electric wires in a state where slack is set is further provided, so that the film can be stuck easily. This has the effect.

[Brief description of the drawings]

FIG. 1 is a plan view showing a wire harness according to one embodiment of the present invention.

FIG. 2 is a diagram showing a state in which a bending angle of each electric wire is set to 90 ° in a bending portion of the wire harness according to the present invention.

FIG. 3 is a view showing an electric wire whose length is adjusted by a processing tool.

FIG. 4 is a front view showing a processing tool for manufacturing the wire harness of FIGS. 1 and 2;

FIG. 5 is a perspective view showing the operation of adjusting the length of the curved portion of the electric wire using the processing tool according to the present invention.

FIG. 6 is a plan view showing a manufacturing apparatus of the present invention.

FIG. 7 is a plan view showing another example of the wire harness according to the present invention.

FIG. 8 is a diagram showing a state where the bending angle of each electric wire is set to 45 ° in the bending portion of the wire harness according to the present invention.

FIG. 9 is a front view showing a processing tool for manufacturing the wire harness of FIGS. 7 and 8;

FIG. 10 is a perspective view showing a first conventional wiring harness for electric wiring.

FIG. 11 is a partially cutaway perspective view showing a second conventional wiring harness for electric wiring.

FIG. 12 is a plan view showing a manufacturing process of a wiring harness for electric wiring according to a second conventional example.

FIG. 13 is a view showing a state where a wire harness of a third conventional example is bent.

FIG. 14 is a diagram showing a state in which a bent portion of the wire harness of FIG. 14 has been elastically restored.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 (11a-11d) Electric wire 12 Film 13 Bending part 14 Processing tool 15 Step 20 Electric wire supply drum 21 Electric wire supply part 22 Alignment jig 22a Groove 23 Connector 24 Connector press contact part 25 Circuit length adjustment part 27 Wiring table 28 Mounting table 29 opening

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) H01B 13/00 H01B 13/012 H05K 13/06

Claims (5)

(57) [Claims] A first step of mounting a plurality of electric wires in a straight line and in parallel on a mounting table; and a processing tool having a step formed at a predetermined gradient is pressed against the electric wires so that each of the electric wires is pressed. Manufacturing a wire harness, comprising: a second step of setting a slack having a different size to a plurality of wires; and a third step of attaching a film so as to avoid an area where the slack is set over the plurality of electric wires. Method. 2. The method for manufacturing a wire harness according to claim 1, wherein the mounting table has an opening formed in a part of a top surface thereof, and wherein in the first step, a plurality of electric wires are provided. Is placed linearly and in parallel so as to span the opening of the mounting table, and in the second step, the slack is set by pushing down the processing tool in the opening while contacting the processing tool with the electric wire. A method for manufacturing a wire harness, comprising: 3. An electric wire supplying means for supplying a plurality of electric wires, a line aligning means for aligning the plurality of electric wires supplied from the electric wire supplying means in parallel, and a plurality of said lines aligned in parallel by the line aligning means. A mounting table for mounting the wires in a straight line, and a step for pressing against the wires on the mounting table and setting a slack of a different size for each of the wires to form a step with a predetermined gradient. An apparatus for manufacturing a wire harness, comprising: a slack dimension adjusting means. 4. The apparatus for manufacturing a wire harness according to claim 3, wherein the slack is set by pressing down the processing tool on a part of a top surface of the mounting table while contacting the processing tool with the electric wire. An apparatus for manufacturing a wire harness, wherein an opening is formed. 5. The wire harness manufacturing apparatus according to claim 3, further comprising: a film sticking table for sticking a film to the plurality of electric wires in a state in which the slack is set. Wire harness manufacturing equipment.