JP4696735B2 - Manufacturing method of bus bar wiring layer - Google Patents

Description

  The present invention relates to a technique for assembling a wiring layer using bus bars.

  In junction boxes used for branch wiring in automobiles, wiring circuits are appropriately configured by bus bars.

  For example, the bus bar is assembled as follows.

  First, the plate-shaped metal member is punched into a wiring pattern shape that constitutes each bus bar. At this time, the bus bars are punched out in such a manner that the bus bars are appropriately connected by a bridge so that the bus bars do not fall apart.

  Next, the end of each bus bar is bent and formed by press bending or the like to form a tab portion. This tab portion is used for connection between bus bars between different layers and connection with other members (external connector or the like).

  Then, the bridge is cut by press cutting or the like so that the bus bars are separated, and then the bus bars are rearranged in a predetermined arrangement and attached to the insulating plate. Thereby, a predetermined bus bar wiring layer is completed.

  Note that Patent Document 1 is given as a prior art document related to the present invention.

JP 2003-197297 A

  However, in the above bus bar assembly technique, the pressing process for bending the tab portion and the like and the pressing process for cutting the bridge are performed separately. For this reason, it is necessary to prepare a separate press apparatus, and a press die expense and equipment cost become large.

  Further, since the bus bars are rearranged in a predetermined arrangement after the bus bars are completely separated by press cutting or the like, the rearrangement work is complicated.

  Therefore, an object of the present invention is to make it possible to manufacture the bus bar wiring layer with a simple manufacturing facility and to easily perform the manufacturing operation.

A method for manufacturing a bus bar wiring layer according to the present invention is a method for manufacturing a bus bar wiring layer having a plurality of bus bars, wherein each bus bar is integrally connected by a first bridge and more than the first bridge. A step of forming a connection bus bar integrally connected by a second bridge that is easy to cut, and a step of simultaneously bending the connection bus bar by the same pressing device and cutting the first bridge And a step of rearranging each of the bus bars while manually dividing the second bridge after the step of bending the connection bus bar and dividing the first bridge. It is a thing.

  In this case, the first bridge may be a portion having a strength that can be divided by a press device, and the second bridge may be a portion having a strength that can be divided manually.

  Further, the second bridge may be formed in a shape in which a hole is formed in a substantially central portion of the plate-like portion.

  Further, the second bridge may be a member in which a groove is formed along the width direction thereof.

  Furthermore, the second bridge may be provided at a position where the adjacent bus bars can be separated by bending in one direction.

According to the bus bar wiring layer manufacturing method of the present invention, the bus bars are integrally connected by the first bridge and connected by the second bridge that is easier to cut than the first bridge. Since it comprises a step of forming a bus bar and a step of bending the connecting bus bar at the same time by the same pressing device and dividing the first bridge, the second bridge is not divided. The cutting work of the first bridge and the bending process for the connecting bus bar can be performed while remaining in the process, and the manufacturing equipment can be reduced. Moreover, in this state, since each bus bar is in a state of being connected by the second bridge, the bus bars can be rearranged while manually dividing the second bridge, and the bus bar is assembled. Can be easily performed.

  In this case, the first bridge is a portion having a strength that can be divided by a press device, and the second bridge is a portion having a strength that can be divided by a manual operation. Then, since each bus bar is in a relatively firmly connected state, it is excellent in portability. Moreover, in the state which divided | segmented the 1st bridge | bridging, the 2nd bridge | bridging can be easily divided | segmented by hand and each bus-bar can be made into a disjointed state.

  Further, when the second bridge is formed in a shape in which a hole is formed in a substantially central portion of the plate-like portion, the bus bars can be connected and held in a relatively stable manner by the second bridge. The second bridge can be easily divided.

  Further, when the second bridge is a member formed with a groove along the width direction, the second bridge can be easily divided along the groove.

  Further, when the second bridge is provided at a position where the adjacent bus bars can be separated by bending in one direction, the adjacent bus bars can be easily separated from each other.

  Hereinafter, the manufacturing method of the connection bus-bar and bus-bar wiring layer which concern on embodiment of this invention is demonstrated.

  First, the connection bus bar will be described. FIG. 1 is a view showing a connected bus bar, FIG. 2 is a view showing a state where a first bridge in the connected bus bar is cut and subjected to a predetermined bending process, and FIG. 3 is a view showing a second bridge in the connected bus bar. It is a figure which shows the state cut | disconnected.

  The connecting bus bar 10 is formed, for example, by punching a conductive plate material such as a metal plate by press working, and a plurality of bus bars 12A, 12B, 12C, 12D, 12E,. 1 bridge 16 and a second bridge 18 connected together in the same manner.

  Each of the bus bars 12A, 12B, 12C, 12D, 12E,... Is a thin strip-like conductive plate-like member, and is formed so as to draw a predetermined wiring pattern. Further, predetermined end portions of the respective bus bars 12A, 12B, 12C, 12D, 12E,... Are bent into a substantially L shape to be formed in the tab portion 13 (see FIG. 2). Each tab portion 13 is used for connection between bus bars between different layers and connection with other members (external connector or the like).

  These bus bars 12A, 12B, 12C, 12D, 12E,... Are separated separately as will be described later, and then rearranged in a predetermined arrangement and assembled to an insulating plate. Each bus bar 12A, 12B, 12C, 12D, 12E,... Is assembled so as to draw a predetermined wiring path on the insulating plate, thereby forming a bus bar wiring layer having a predetermined wiring path. A plurality of such bus bar wiring layers are combined in a stacked manner, and housed and assembled in a predetermined case, whereby a junction box for performing electrical branch wiring or the like in an automobile or the like is manufactured.

  The first bridge 16 integrally connects the bus bars 12A, 12B, 12C, 12D, 12E,. In FIG. 1, four first bridges 16 are appropriately distributed between the bus bar 12A and the bus bar 12B, and one first bridge 16 is provided between the bus bar 12A and the bus bar 12C. The first bridge 16 is provided between the bus bar 12E and the bus bar 12E, and the first bridge 16 is provided between the bus bar 12B and the bus bar 12D. As described above, at least one first bridge 16 is provided between the bus bars 12A, 12B, 12C, 12D, 12E,. The first bridges 16 hold the bus bars 12A, 12B, 12C, 12D, 12E,... In an integrated manner without being separated.

  These first bridges 16 are formed in a shape that is more difficult to cut than the second bridge 18 and has a strength that can be cut by press cutting with a press device. More specifically, the first bridge 16 is formed in a narrow strip shape having a predetermined width. For this reason, the integrated bus bar 10 is in a state before being separated by the first bridge 16, and is not easily broken apart by some impact, and has an integrated strength that can withstand large-scale transportation such as transportation to a remote place. have.

  The second bridge 18 also integrally connects the bus bars 12A, 12B, 12C, 12D, 12E,. 1 and 2, two second bridges 18 are provided between the bus bar 12A and the bus bar 12B, and one second bridge 18 is provided between the bus bar 12B and the bus bar 12C. One second bridge 18 is provided between the bus bar 12E. As described above, at least one second bridge 18 is provided between the bus bars 12A, 12B, 12C, 12D, 12E,. Even in a state where the first bridge 16 is disconnected, the bus bars 12A, 12B, 12C, 12D, 12E,... Are held in an integrated manner without being separated.

  These second bridges 18 are formed more easily than the first bridge 16, and in this case, have a shape having a strength that can be divided manually. More specifically, the second bridge 18 is formed in the shape of a narrow strip that connects the bus bars 12A, 12B, 12C, 12D, 12E,..., And has a hole 18h (here, Round hole). In the state separated by the first bridge 16, the bus bars 12 </ b> A, 12 </ b> B, 12 </ b> C, 12 </ b> D, 12 </ b> E,. When the operator applies a necessary force such as holding the bus bars 12A, 12B, 12C, 12D, 12E,... By the hand and bending them in the thickness direction, the second bridge 18 between them can be easily formed. It is designed to break.

  Note that a groove may be formed in order to easily divide the second bridge 18. That is, the second bridge 118 shown in FIG. 4 is configured such that a notch 118a (a groove having a substantially V-shaped cross section in this case) is formed in the second bridge 18 as a groove along the width direction thereof. Yes. Further, the second bridge 218 shown in FIG. 5 is formed in the shape of a narrow strip plate connecting the bus bars 12A, 12B, 12C, 12D, 12E,..., And a notch as a groove along the width direction thereof. 218a (here, a groove having a substantially V-shaped cross section) is formed. These notches 118a and 218a are formed, for example, by pressing. The width direction of the second bridges 18, 118, 218 refers to a direction substantially orthogonal to the direction connecting the bus bars 12A, 12B, 12C, 12D, 12E,.

  When two or more second bridges 18 are provided between adjacent bus bars 12A, 12B, 12C, 12D, 12E,..., The second bridges 18 are connected to the adjacent bus bars 12A, 12B, 12C, 12D, 12E,... Are provided at positions that can be divided by bending in one direction. In other words, there may be two or more second bridges 18 between the adjacent bus bars 12A, 12B, 12C, 12D, 12E,..., And the adjacent bus bars 12A, 12B, 12C, 12D, 12E,. Between each, those 2nd bridge | bridging 18 is provided so that it may be located on the straight line L. FIG. 4 and 5, when the notches 118a and 218a are formed, the notches 118a and 218a are also formed so as to extend along the straight line L. 1 and 2, two second bridges 18 are provided so as to be positioned on a straight line L between the bus bar 12A and the bus bar 12B. When the bus bar 12A and the bus bar 12B are bent in the thickness direction, the two second bridges 18 between them are bent and broken, and the bus bar 12A and the bus bar 12B are separated (see FIG. 3). ).

  And after each bus-bar 12A, 12B, 12C, 12D, 12E, ... is isolate | separated, it rearranges suitably and is assembled | attached to an insulating board or a case, and a junction box is manufactured.

  Next, a method for manufacturing the bus bar wiring layer will be described. FIG. 6 is a process diagram illustrating a method for manufacturing the bus bar wiring layer, and FIG. 7 is an explanatory diagram illustrating an example of a manufacturing line for the bus bar wiring layer.

  This connection bus bar 10 is conveyed to the production line shown in FIG. 7, for example. In the production line shown in FIG. 7, a first press device 30, a bus bar temporary placement table 32, a rearrangement stage 34, and a second press device 36 are provided from the upstream side toward the downstream side.

  The 1st press apparatus 30 is an apparatus which presses a board | plate material by applying a pressure between metal mold | dies, and performs the partial cutting | disconnection of the connection bus-bar 10 and a tab bending process by a press process here. More specifically, the first pressing device 30 presses and cuts the first bridge 16 of the connecting bus bar 10 and simultaneously presses predetermined end portions of the bus bars 12A, 12B, 12C, 12D, 12E,. It has a mold that can be bent to form the tab portion 13.

  The bus bar temporary placement table 32 is a table for temporarily placing the connection bus bar 10 that has been partially cut and tab-bent in the connection bus bar 10.

  A pallet is disposed on the rearrangement stage 34, and an insulating plate is disposed on the pallet, and the bus bars 12A, 12B, 12C, and 12D are rearranged in a predetermined arrangement on the insulating plate. , 12E,... Are assembled.

  The 2nd press apparatus 36 is an apparatus which presses a board | plate material by applying a pressure between metal mold | dies. Here, the second pressing device 30 applies pressure to the bus bars 12A, 12B, 12C, 12D, 12E,... Assembled on the insulating plate in a state of being arranged in a predetermined arrangement on the pallet. In addition, the bus bars 12A, 12B, 12C, 12D, 12E,... Are squeezed and the projections for attaching the insulating plates are partially crushed. The work to attach to the insulating plate.

  A method of manufacturing the bus bar wiring layer in this manufacturing line will be described.

  As shown in FIG. 6, when manufacturing a bus bar wiring layer, a connection bus bar 10 formed by punching a conductive plate such as a metal plate by press working or the like is prepared (see FIG. 1). The connection bus bar 10 may be manufactured by equipment in the vicinity of the production line, or may be manufactured by equipment in a remote place. In particular, since the connecting bus bar 10 is connected by the relatively strong first bridge 16, the connecting bus bar 10 has sufficient strength to withstand transport from such a remote place.

  Then, the connecting bus bar 10 is set in the first press device 30 and predetermined end portions of the bus bars 12A, 12B, 12C, 12D, 12E,... At the same time, the first bridge 16 is cut (partially cut). As a result, the bus bars 12A, 12B, 12C, 12D, 12E,... Are integrally connected by the second bridge 18 (see FIG. 2, the cut portion is indicated by a broken line in FIG. 2). It is taken out from the press device 30 and temporarily placed on the bus bar temporary placement table 32.

  Each bus bar 12A, 12B, 12C, 12D, 12E,... That is connected by the second bridge 18 is handed over to the operator, and is broken at each second bridge 18 by the operator's manual work. While being rearranged in a predetermined arrangement, it is assembled to an insulating plate placed on a pallet (see FIG. 3, a broken portion by manual work is shown by a broken line in FIG. 3). In addition, each bus bar 12A, 12B, 12C, 12D, 12E,... In the form of the connecting bus bar 10 is appropriately changed in consideration of waste of materials while being based on an arrangement assembled on an insulating plate. Arranged in position. Therefore, after all the bus bars 12A, 12B, 12C, 12D, 12E,... Are separated, the bus bars 12A, 12B, 12C, 12D, 12E,. .. Can be easily and quickly rearranged into a predetermined arrangement while dividing 12A, 12B, 12C, 12D, 12E,... One by one.

  And each bus-bar 12A, 12B, 12C, 12D, 12E, ... assembled | attached to the insulating plate in the state arranged in the predetermined arrangement | sequence on the pallet is set to the 2nd press apparatus 36. FIG. Then, caulking, thermal crushing, or the like is performed, and the bus bars 12A, 12B, 12C, 12D, 12E,... And the insulating plate are attached, and the bus bar wiring layer is completed.

  The completed bus bar wiring layer is transported to the next process line and used as a junction box assembly part or the like.

  FIG. 8 is a process diagram showing a method of manufacturing a bus bar wiring layer as a reference example, and FIG. 9 is an explanatory diagram showing an example of a bus bar wiring layer manufacturing line as the reference example.

  That is, let us consider a case where the second bus 18 is not provided in the connection bus bar 10 and the bus bars 12A, 12B, 12C, 12D, 12E,. In this case, the above-described tab bending and the bus bars 12A, 12B, 12C, 12D, 12E,... Due to the breakage of the first bridge 16 cannot be performed in the same work process by the same pressing device. If the bus bars 12A, 12B, 12C, 12D, 12E,... Fall apart while the tab is bent, the bus bars 12A, 12B, 12C, 12D, 12E,. This is because inconveniences such as remaining on the mold occur.

  For this reason, as shown in FIG. 9, in the production line, a press device 30A for bending the tab and a press device 30B for dividing each bus bar 12A, 12B, 12C, 12D, 12E,. It is necessary to prepare each separately. Then, as shown in FIG. 8, it is necessary to divide each bus bar 12 </ b> A, 12 </ b> B, 12 </ b> C, 12 </ b> D, 12 </ b> E,... .

  In this case, the bus bars 12A, 12B, 12C, 12D, 12E,... For this reason, each operator needs to rearrange each of the bus bars 12A, 12B, 12C, 12D, 12E,. For this reason, in the example described as a reference example, more molds and pressing devices are required than in the manufacturing method described with reference to FIGS. 6 and 7, and the bus bars 12A, 12B, 12C, 12D, It can be seen that the rearrangement work of 12E,.

  Furthermore, in the example shown in FIGS. 6 and 7, it is sufficient to prepare one type of pallet dedicated to the second press device 20. On the other hand, in the reference example, a pallet or the like for moving the bus bars 12A, 12B, 12C, 12D, 12E,. Depending on the number of items to be rearranged and the request for the production cycle, it is necessary to prepare more types of pallets.

  In the manufacturing method of the connection bus bar and the bus bar wiring layer configured as described above, each bus bar 12A, 12B, 12C, 12D, 12E,... Is divided into the first bridge 16 and the second bridge 16 that is easier to divide. And the step of forming the connection bus bar 10 integrally connected to each other, and the step of bending the connection bus bar 10 and separating the connection bus bar 10 by the first bridge 16. Therefore, the first bridge 16 can be detached and the connecting bus bar 10 can be bent simultaneously by the same pressing device 30 while leaving the second bridge 18 unbroken, which is relatively simple. Can be manufactured at manufacturing facilities. In this state, the bus bars 12A, 12B, 12C, 12D, 12E,... Are connected by the second bridge 18, so that the second bridge 18 is divided and the bus bars 12A, 12B are separated. , 12C, 12D, 12E,... Can be rearranged while being separated one by one. Therefore, the assembly work of each bus bar 12A, 12B, 12C, 12D, 12E,. be able to.

  In addition, since the first bridge 16 is a portion having a strength that can be divided by a press device, and the second bridge 18 is a portion having a strength that can be divided by a manual operation, the form of the connecting bus bar 10 In this case, the bus bars 12A, 12B, 12C, 12D, 12E,... Are connected relatively firmly via the first bridge 16, and are excellent in portability such as transport to a remote place. Moreover, in the state where the first bridge 18 is separated, the second bridge can be easily divided by hand, so that the work of rearranging while being divided by the manual work can be easily performed.

  Further, since the second bridge 18 is formed in a shape in which a hole 18h is formed at a substantially central portion of the plate-like portion, each bus bar 12A, 12B, 12C, 12D, 12E, ... are held in a connected state. Therefore, each of the bus bars 12A, 12B, 12C, 12D, 12E,... Can be connected and held by the second bridge 18 in a relatively stable manner, and the manual cutting can be facilitated. it can.

  Further, when two or more second bridges 18 are provided between adjacent bus bars 12A, 12B, 12C, 12D, 12E,..., Each second bridge 18 is connected to each adjacent bus bar 12A, 12B, 12C. , 12D, 12E,... Can be separated by bending them in one direction, so that adjacent bus bars 12A, 12B, 12C, 12D, 12E,.

It is a figure which shows the connection bus-bar which concerns on embodiment. It is a figure which shows the state which performed the predetermined bending process while cut | disconnecting the 1st bridge | bridging in a connection bus bar same as the above. It is a figure which shows the state which cut | disconnected the 2nd bridge | bridging in a connection bus bar same as the above. It is a figure which shows the modification of a 2nd bridge | bridging. It is a figure which shows the other modification of a 2nd bridge | bridging. It is process drawing which shows the manufacturing method of a bus-bar wiring layer. It is explanatory drawing which shows an example of the manufacturing line of a bus-bar wiring layer. It is process drawing which shows the manufacturing method of the bus-bar wiring layer as a reference example. It is explanatory drawing which shows an example of the manufacturing line of the bus-bar wiring layer as a reference example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Connection bus bar 12A, 12B, 12C, 12D, 12E Bus bar 13 Tab part 16 1st bridge 18 2nd bridge 18h Hole 30 Press apparatus 34 Rearrangement stage 36 Press apparatus

Claims (5)

A method of manufacturing a bus bar wiring layer having a plurality of bus bars,
Forming each of the bus bars integrally connected by a first bridge and a connected bus bar integrally connected by a second bridge that is easier to cut than the first bridge;
Simultaneously bending the connecting bus bar by the same pressing device and cutting the first bridge;
Bending the connecting bus bars and rearranging the bus bars by manually cutting the second bridges after the step of dividing the first bridges ;
A method of manufacturing a bus bar wiring layer comprising: It is a manufacturing method of the bus-bar wiring layer according to claim 1,
The first bridge is a portion having a strength that can be divided by a press device,
The method of manufacturing a bus bar wiring layer, wherein the second bridge is a portion having a strength that can be divided manually. A method of manufacturing a bus bar wiring layer according to claim 1 or 2,
The method for manufacturing a bus bar wiring layer, wherein the second bridge is formed in a shape in which a hole is formed in a substantially central portion of a plate-like portion. It is a manufacturing method of the bus-bar wiring layer in any one of Claims 1-3,
The method for manufacturing a bus bar wiring layer, wherein the second bridge is a member in which a groove is formed along a width direction thereof. It is a manufacturing method of the bus-bar wiring layer in any one of Claims 1-4,
The method of manufacturing a bus bar wiring layer, wherein the second bridge is provided at a position where the adjacent bus bars can be separated by bending in one direction.

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