JP3989850B2 - Cable harness and method for manufacturing cable harness - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a cable harness having a configuration in which a first electric wire group and a second electric wire group are connected, and a manufacturing method thereof.
[0002]
[Prior art]
In many cases, a plurality of electric wires (electric cables) for constituting a control circuit of a power machine or the like are bundled and handled as a cable harness. Such a cable harness has a portion that branches from a main line to a branch line according to a circuit configuration. Such a branch of the electric wire group includes an electric wire group that is upstream of the signal flow and an electric wire that is downstream of the signal flow. It is often performed by connecting connectors provided on both sides of the group.
[0003]
Further, when the power machine is a vehicle engine or the like, water splashed during traveling of the vehicle may be applied to the connector, which may cause various adverse effects such as a short circuit (short circuit). For this reason, conventionally, in a cable harness used for a machine that can receive splashes of water, oil, etc. during use, a waterproof connector that is waterproofed by inserting a rubber plug or the like into the connector connection portion is generally used. It is.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 2002-42984
[Problems to be solved by the invention]
However, the number of electric wires that can be attached (that is, connectable) to such a connector is relatively small, and the thickness of the electric wires that can be attached is limited due to the pitch of the electric wire arrangement. It is difficult to be suitable for a cable harness for a large engine in which a large number of electric wires are to be tried and many electric wires having different thicknesses are mixed. Therefore, conventionally, it has been necessary to manufacture a different connector for each type of large engine, and further, there has been a problem that the manufacturing cost becomes very high because it is necessary to perform waterproofing.
[0006]
The present invention has been made in view of such problems, and a cable harness capable of obtaining a high waterproof effect with an inexpensive configuration and easily connecting even a large number of electric wires having different thicknesses and a method for manufacturing the same The purpose is to provide.
[0007]
[Means for Solving the Problems]
To achieve the above object, the cable harness according to the present invention comprises a first wire group comprising a plurality of electric wires, and a second wire group comprising a plurality of wires, an end portion of the first wire group A conductive material that inserts a twisted portion of a core wire exposed at the end of the second electric wire group and a core wire exposed at an end of the second electric wire group, and is compressed from the outside and is crimped onto the twisted portion. A cylindrical crimping member comprising: a rectangular plate-shaped positioning member made of an electrically insulating material provided on the front surface with an attachment portion to which the crimping member crimped onto the twisted portion is attached; It is configured with. And the left-right end part of the positioning member is formed with a pair of left and right extending portions projecting outward in the left-right direction, and the portion where the crimping member is crimped to the twisted portion is attached to the attachment portion In this state, the extending portion protrudes outward in the mold, and the positioning member is attached to the mold, and the electric wires of the first and second electric wire groups are attached to the outside of the mold. The resin is made by encapsulating a resin having an insulating property in the mold as it is.
In addition, the resin which has insulation may be enclosed with the metal mold | die for fixing used for fixing the resin enclosure part to an attachment object in the said mold metal mold | die.
[0008]
A method of manufacturing a cable harness according to the present invention, the first wire group and the second wire group comprising a plurality of electric wires, twisting the core wires to expose at each end comprising a plurality of electric wires The portion where the core wires are twisted together is inserted into a cylindrical crimping member made of a conductive material and is compressed from the outside so that the crimping member is crimped onto the twisted portion, The crimping member crimped onto the twisted portion was attached to a mounting portion formed on the front surface of a rectangular plate-shaped positioning member made of an electrically insulating material, and crimped onto the twisted portion. In a state where the crimping member is attached to the attachment portion, a pair of left and right extending portions formed to protrude left and right at the left and right end portions of the positioning member are protruded outward in the mold. A positioning member is attached in the mold, and an insulating resin is provided in the mold while the electric wires of the first and second electric wire groups are extended to the outside of the mold. Made by sealing.
In addition, the resin having the insulating property may be sealed in a state where a fixing metal fitting used for fixing the resin sealing portion to the mounting target is mounted in the mold die.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. FIG. 2 is a block diagram showing a configuration example of a control system using the cable harness according to the present invention, and includes a plurality of sensors S1, S2, S3,..., Sm, a control unit CU, and a plurality of sensors. , Tn, and the control unit CU and the control objects T1, T2,..., Tn are connected by a cable harness H. When this control system is, for example, an electric control system for an automobile engine, the sensors S1, S2, S3,..., Sm correspond to vehicle speed sensors, throttle opening sensors, water temperature sensors, etc. T2,..., Tn correspond to fuel supply devices, electronic fuel injection devices, exhaust gas control devices, and the like. The control unit CU performs a required calculation based on the detection information input from the sensors S1, S2, S3,..., Sm, outputs a command signal via the cable harness H, and controls the control objects T1, T2, ... Tn is activated.
[0010]
The cable harness H has a configuration in which a plurality of electric wires (electric cables) are bundled, and selectively transmits the command signal output from the control unit CU to the control targets T1, T2,. Therefore, the cable harness H is connected to the control unit CU on the trunk line side (upstream side of the command signal flow) and the branch line side (downstream side of the command signal flow) connected to the control objects T1, T2,. ), And both the wire groups M and B are connected (connected) by the connector J.
[0011]
FIG. 3 shows an example of the configuration of the connector J for connecting both the wire groups M and B. This connection tool J connects nine electric wires m1 to m9 constituting the main wire side electric wire group M and 25 electric wires b1 to b25 constituting the branch side electric wire group B. Specifically, the wires between the main wires m1 to m9 and the branch wires b1 to b25 and the wires are connected to each other as shown in FIG. ), And a plurality of core wire joints obtained by splicing the core wires are sealed with a resin (resin portion 10) having electrical insulation. 1 is a diagram (illustrated by a broken line) in which the resin portion 10 is omitted from FIG.
[0012]
The procedure for connecting the main wire group M and the branch wire group B in the cable harness H will be described. First, as shown in FIG. 4, three electric wires 22, 24, 26 (these are to be connected) The electric wires 22, 24, and 26 correspond to the electric wires that constitute both electric wire groups M and B, and the core wires 22a, 24a, and 26a of the electric wires m1 to m9 and b1 to b25 described above are actually exposed. Twist together (see FIG. 4A). Here, the case where there are three wires to be connected is shown, but the same applies to the case of other numbers. Next, after attaching the cylindrical crimping member 16 made of a conductive material to the twisted core wires 22a, 24a, and 26a (see FIG. 4B), the crimping member 16 is not crimped. The core wires 22a, 24a, and 26a that are crushed and twisted with a tool are crimped (see FIG. 4C). Thereby, the core wires 22a, 24a, and 26a of the three electric wires 22, 24, and 26 are joined in a short circuit state. In addition, in embodiment shown here, the core wire of the electric wires m1-m9 which comprise the electric wire group M of the trunk line side, and the core wire of the electric wires b1-b25 which comprise the electric wire group B of the branch line side are (m1 and b1, b2). , B3), (m2 and b4, b5, b6), (m3 and b7, b8), (m4 and b9, b10), (m5 and b11, b12), (m6 and b13, b14, b15), (m7 And b16, b17, b18, b19), (m8 and b20, b21, b22), and (m9 and b23, b24, b25).
[0013]
Next, the spliced joint and the joint portion (core wire joint portion) of the core wire crimped by the crimping member 16 is a positioner (positioning member) formed in the rectangular plate shape shown in FIGS. 1 and 5. 12 are used for mutual positioning. The positioner 12 is formed with a plurality of core wire attachment holes 14, 14,... Arranged in two horizontal rows in the upper and lower rows and penetrating in the thickness direction. Each member 16 is inserted and attached into these core wire attachment holes 14. FIG. 5 shows only combinations of (m1 and b1, b2, b3), (m5 and b11, b12) and (m7 and b16, b17, b18, b19) among the spliced core wires. This is just an example, and other combinations are similarly attached to the positioner 12. The positioner 12 is used to ensure electrical continuity only between the core wires crimped and connected by the crimping member 16 (the core wire inserted into one core wire mounting hole 14 and the other core wire mounting hole 14 are inserted. In order to prevent electrical conduction with the core wire), it is necessary to be made of an electrically insulating material such as a resin having an electrically insulating property.
[0014]
When the core wires thus crimped are inserted into the core wire attachment holes 14, 14,... Of the positioner 12 and positioned relative to each other, the positioner 12 with the core wires attached thereto is not shown in the mold mold. The positioner 12 is positioned in the mold. When the positioner 12 is positioned in the mold, the molten resin is injected into the mold, cured, and hardened. That is, the core wire joint is resin-sealed with an insert mold. At this time, the positioner 12 is resin-sealed together with the core wire joining portion. However, as shown in FIGS. 1, 3, and 5, the positioner 12 is formed to protrude laterally on both the left and right sides. Extending portions 12a and 12a are provided, and the ends of these extending portions 12a and 12a project outside the mold die in a state where the mold dies are closed. It is possible to perform resin sealing after the positioning of the positioner 12 is reliably performed.
[0015]
Thus, in this cable harness H, the core wire joint portion of the electric wire is sealed with resin (resin portion 10), and there is no room for moisture to enter the joint portion of the core wire, so that a high waterproof effect is obtained. It is possible to prevent various harmful effects such as a short circuit from occurring when water or oil enters the connection portion. In addition, since the molding of the resin portion 10 can be performed at a low cost, the manufacturing cost of the cable harness H is equivalent to two electric wires (here, the electric wire group M on the main line side and the electric wire group B on the branch line side) as in the past. However, it can be made much cheaper than the structure that is joined via the connector. Further, as can be seen from the above description, in the present cable harness H, even when there are a large number of wires to be connected, or even when wires having different thicknesses are mixed, these cable harnesses H Since it can be easily connected without being limited by the conditions, when the cable harness H is applied to a control system for a large engine having a large number of electric wires and a large number of wires, a particularly great effect can be obtained.
[0016]
Moreover, in this cable harness H, it is also possible to equip the resin part 10 with an attached part. 1 and 3 show an example in which a cylindrical fixing metal fitting 18 for fixing the resin portion 10 to a predetermined location on the vehicle body is attached. The fixing metal fitting 18 is attached to the resin portion 10 simultaneously with the molding of the resin portion 10 by placing it in the mold in advance when insert molding the core wire joint portion of the electric wire as described above. Alternatively, a hole for attaching the fixing metal fitting 18 may be formed at the time of molding and may be attached by screwing or the like after molding.
[0017]
FIG. 6 shows another embodiment of the connector J of the cable harness H according to the present invention (shown as connector J ′ in FIG. 6). The connector J 'according to this embodiment is different in the configuration of the positioner (reference numeral 12'). That is, in this positioner 12 ', instead of the plurality of holes (core wire attachment holes 14) provided in the above-described positioner 12, a core wire extending in the upper and lower rows in the horizontal direction and penetrating in the thickness direction is provided. An attachment groove 14 'is formed. In this case, the core wire of the spliced wire is inserted into the core wire mounting groove 14 ′ while being crimped by the crimping member 16. In the configuration in which the core wire joint portion is inserted into the core wire attachment groove 14 ′ and positioned as described above, the positioning can be performed more freely than in the case of the above-described positioner 12 in which the core wire joint portion is inserted into the core wire attachment hole 14. The degree can be increased.
[0018]
The preferred embodiments of the present invention have been described so far, but the scope of the present invention is not limited to those shown in the above-described embodiments. For example, in the above-described embodiment, an electric control system for an automobile engine is shown as an example to which the cable harness according to the present invention is applied. However, the present invention is not limited to such an electric control system for an automobile engine. The present invention can be applied to any cable harness that constitutes a circuit. Moreover, the shape of the resin part 10, the arrangement of the electric wires with respect to the resin part 10 (how to attach the core wire), etc. are completely free, and are not limited to the above examples.
[0019]
In the above-described embodiment, both the wire groups to be connected (corresponding to the trunk-side wire group M and the branch-side wire group B in the above example) are connected to the connector J (or connector J ′). However, this is only an example, and both electric wire groups may have a configuration extending in different directions with respect to the connection tool. Moreover, the fixing metal fitting 18 attached to the resin part 10 is not limited to a cylindrical thing like the above-mentioned example, Other shapes may be sufficient. In addition, instead of the fixing bracket for fixing the resin portion 10 at a predetermined position, or in addition to the fixing bracket, a bracket used for other applications such as a bracket for supporting other components. It is also possible to attach to the resin part 10. In addition, the cable harness and the manufacturing method thereof according to the present invention are not only connected for branching the branch-side wire group from the trunk-side wire group as shown in the above embodiment, but also between unbranched wires. It can also be applied to connection, that is, extension of a group of wires.
[0020]
【The invention's effect】
As described above, in the cable harness according to the present invention , the crimping member is crimped onto the portion where the core wires exposed at the ends of the first and second electric wire groups are twisted together, and the crimped portion is In a state where the positioning member is attached to the attachment portion of the positioning member, the left and right extending portions of the positioning member are attached so as to protrude outward in the mold, and the wires of the first and second electric wire groups are attached to the outside of the mold. Because it is made by encapsulating an insulating resin in the mold while maintaining the extended state , a high waterproof effect is obtained with an inexpensive configuration, and even many wires with different thicknesses can be easily connected Is possible. For this reason, it is suitable as a cable harness for a control system of a large-sized engine in which the thickness of electric wires is various and the number thereof is large.
[0021]
Moreover, the manufacturing method of the cable harness according to the present invention twists the core wires exposed at the ends of the first and second electric wire groups, and crimps a crimping member on the twisted portion. The crimping member thus crimped is attached to the mounting portion formed on the front surface of the positioning member, and with the crimping member attached to the mounting portion in this manner, the left and right end portions of the positioning member are projected outwardly from the left and right. The formed pair of left and right extending portions are protruded outward in the mold, and a positioning member is attached in the mold, and each electric wire of the first and second electric wire groups is extended to the outside of the mold. In this state, it is configured such that an insulating resin is sealed in the mold. According to such a method for manufacturing a cable harness, it is possible to easily connect even a large number of electric wires having different thicknesses. Moreover, the cable harness obtained by this manufacturing method has a high waterproof effect although it is an inexpensive structure.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an example of a connector for connecting a main line side electric wire group and a branch line side electric wire group in a cable harness according to the present invention.
FIG. 2 is a block diagram showing a configuration of a control system to which the cable harness according to the present invention is applied.
FIG. 3 is a perspective view showing an appearance of the connection tool.
FIG. 4 is a diagram showing, in the order of (A), (B), and (C), the procedure of splice joining between the core wire of the electric wire constituting the main wire group and the core wire of the electric wire constituting the branch wire side. It is.
FIG. 5 is a perspective view showing a positioner constituting the connection tool.
FIG. 6 is a perspective view showing another embodiment of the structure of the connection tool.
[Explanation of symbols]
H Cable harness M Main wire group (first wire group)
B Branch-side wire group (second wire group)
J connector 10 resin part 12 positioner (positioning member)
14 Core wire mounting hole 16 Crimping member 18 Fixing bracket

Claims (4)

A first wire group consisting of a plurality of wires;
A second wire group consisting of a plurality of wires;
A portion in which the core wire exposed at the end portion of the first electric wire group and the core wire exposed at the end portion of the second electric wire group are twisted together and inserted and the twisted portion compressed from the outside A cylindrical crimping member made of a conductive material that is crimped onto
A rectangular plate-shaped positioning member made of an electrically insulating material provided on the front surface with an attachment portion capable of attaching the crimping member crimped onto the twisted portion;
A pair of left and right extending portions protruding outward in the left and right directions are formed on the left and right ends of the positioning member,
With the portion where the crimping member is crimped to the twisted portion attached to the attachment portion, the extending portion protrudes outward in the mold, and the positioning member is placed in the mold die. While being attached, each of the electric wires of the first and second electric wire groups is made to extend outside the mold die, and is made by encapsulating an insulating resin in the mold die. And cable harness.   2. The resin according to claim 1, wherein an insulating resin is sealed in a state where a fixing metal fitting used for fixing a resin sealing portion to an attachment target is mounted in the mold. Cable harness. A second wire group comprising a first wire group and a plurality of wires comprising a plurality of electric wires, twisting the core wires to expose at each end,
Inserting the twisted portions of the core wires into a cylindrical crimping member made of a conductive material and compressing the crimped member on the twisted portion by compressing from the outside,
The crimping member crimped onto the twisted portion is attached to an attachment portion formed on the front surface of a rectangular plate-shaped positioning member made of an electrically insulating material,
With the crimping member crimped onto the twisted portion attached to the attachment portion, a pair of left and right extending portions formed on the left and right end portions of the positioning member projecting outward are molded. The positioning member is attached in the mold by protruding outward in the mold,
A cable harness characterized by being made by encapsulating an insulating resin in the mold while keeping the electric wires of the first and second electric wire groups extended to the outside of the mold. Production method. 4. The cable according to claim 3, wherein the insulating resin is enclosed in a state where a fixing metal fitting used for fixing a resin enclosure portion to an attachment target is attached in the mold. A method for manufacturing a harness.

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