JP5750290B2 - Wire harness forming jig and method of manufacturing wire harness - Google Patents

Description

The present invention is lower cost with reduced number of parts to reduce the manufacturing time and installation time, and, formed form jig of the wire harness to prevent the electric wire is longer than necessary, and, the wire The present invention relates to a method for manufacturing a harness.

  Various electronic devices and electrical components are mounted on automobiles and the like. A wire harness that transmits power from a power source such as a battery or a control signal from a control device is electrically connected to the electronic device or electrical component. The wire harness is routed in a vehicle along a vehicle body panel of an automobile or the like, and has a desired three-dimensional shape in which appropriate portions are bent in a desired direction along the surface of the vehicle body panel.

  The wire harness includes a plurality of electric wires, a connector attached to an end of the plurality of electric wires and fitted to the electronic device, and a wire harness tube that accommodates the electric wires and protects the electric wires. I have. The wire harness tube is formed in a cylindrical shape, and concave grooves extending in the circumferential direction and convex stripes extending in the circumferential direction are alternately arranged in the longitudinal direction so that the outer surface has a bellows shape. It is formed and has flexibility.

  Since such a wire harness has a shape in which the flexible wire harness tube having flexibility described above is bent in a desired direction at the appropriate location described above, the wire harness tube is generally provided with a protector or a wiring. A clip is provided (see, for example, Patent Document 1 and Patent Document 2).

JP 2011-10474 A JP 2003-9345 A

  However, the general wire harness described in Patent Document 1 requires a mounting operation for attaching the protector to the above-described wire harness tube, and it takes time and labor to manufacture the wire harness. There was a problem that the time was prolonged.

  Moreover, since such a wire harness is expensive for the protector, there is a problem that the cost of the wire harness increases.

  In addition, since the general wire harness described in Patent Document 2 and the like has a plurality of wiring clips attached to the wire harness tube described above, it is necessary to perform an attaching operation to attach a plurality of wiring clips. There is a problem that it takes time and labor for the mounting work and a problem that the time required for manufacturing the wire harness is prolonged.

  Moreover, since such a wire harness is expensive for a plurality of wiring clips, there is a problem that the cost of the wire harness increases.

  In addition, since the wire harness is bent again when the wire harness is actually routed in an automobile, there is a problem that the time required for attaching the wire harness becomes longer. there were.

  In addition, since the wire harness is bent again when the wire harness is actually routed in an automobile, the wire harness is connected so that the connector can be securely fitted to a desired electronic device. There has been a problem that it has to be slightly longer than the minimum desired length.

The present invention aims to solve this problem. That is, the present invention is lower cost with reduced number of parts to reduce the manufacturing time and installation time, and, molding jig wire harness scan to prevent wire is longer than necessary, and, the It aims at providing the manufacturing method of a wire harness.

In order to solve the above-mentioned problems and achieve the object, the invention described in claim 1 is characterized in that at least one electric wire and a concave groove and a convex formed in a cylindrical shape with a thermoplastic resin and extending in the circumferential direction. And a protective member in which strips are alternately arranged in the longitudinal direction and the outer surface is formed in an accordion shape, and a molding jig for molding a wire harness in which the protective member containing the electric wire is bent at an appropriate place. In the tool, the forming jig includes a support portion that bends the protection member in the bent direction of the appropriate portion and supports the protection member, and the support portion includes the protection portion on the support portion. When the member is supported, the concave groove and the convex strip located outside the appropriate portion of the protective member in the bent direction are exposed and the heat of the heating means is exposed to the concave groove and the convex strip. A notch that conveys and a locking projection that locks into the groove , Is provided with a molding jig of the wire harness, characterized in that the appropriate position of the protective member is bent so as to restore not the direction.

According to the second aspect of the present invention, at least one electric wire, a cylindrical groove made of a thermoplastic resin, and concave grooves and ridges extending in the circumferential direction are alternately arranged in the longitudinal direction. A manufacturing method for manufacturing a wire harness according to claim 1 , comprising: a protective member having a bellows-shaped surface, wherein the protective member containing the electric wire is bent at an appropriate location . Using a jig, the concave groove and the ridge located outside the appropriate portion of the protective member in the bent direction are heated by a heating means to be plastically deformed, and the appropriate portion of the protective member is A method of manufacturing a wire harness, wherein the wire harness is bent so as not to be restored in a direction.

  According to the invention described in claim 1, the wire harness is provided with the plastic deformation portion by heating the groove and the ridge located outside the bent direction of the appropriate portion of the protective member. The elastic strain that the outside of the appropriate portion of the protective member in the bent direction has the plastic strain before heating, and the appropriate portion of the protective member is held in a shape bent in a desired direction. Is done. For this reason, it is not necessary to bend the protective member in a desired direction with a protector or a wiring clip as in a conventional general wire harness. Therefore, the attachment work which attaches a protector and a wiring clip to a wire harness becomes unnecessary, the manufacturing time of a wire harness is shortened, and the expense concerning the said wire harness is held down.

  In addition, since the plastic harness is provided on the outer side of the appropriate portion of the protective member in the bent direction, the wire harness has the plastic deformable portion on the inner side of the appropriate portion of the protective member in the bent direction. Since the plastic deformation portion is longer than the case where it is provided, the bending of the appropriate portion of the protective member is more firmly formed.

  In addition, since the wire harness is held in a shape in which the appropriate portion of the protective member is bent in a desired direction, it is not necessary to bend the wire harness again when the wire harness is actually attached to the automobile. For this reason, the time required for the work of attaching the wire harness is reduced.

  Moreover, since it is not necessary to bend a wire harness again when actually attaching a wire harness to a motor vehicle, it can prevent that an electric wire becomes unnecessarily long.

According to the first aspect of the present invention, the wire harness forming jig is provided with a support portion for bending the protective member in an appropriately bent direction and supporting the protective member, and the support. Since the concave groove and the ridge located outside the bent direction of the appropriate portion of the protective member are exposed at the portion, and a notch portion through which the heat of the heating means is transmitted is provided. The bent direction can be accurately set to a desired direction, and the plastic deformation portion can be easily formed at the appropriate place by the heating means. Therefore, the wire harness forming jig can easily form a wire harness bent in a desired direction.

  Further, the wire harness forming jig is provided with a locking projection that locks in the concave groove of the protective member, so that the protective member can be reliably restricted from moving in the longitudinal direction. it can. For this reason, positioning of a protection member comes to be performed correctly and the positional accuracy of the position which provides an appropriate position in a protection member improves.

According to the second aspect of the present invention, in the method for manufacturing the wire harness, the groove and the ridge located outside the bent direction of the appropriate portion of the protective member are heated and plastically deformed by the heating means. Therefore, it is possible to easily and quickly manufacture a wire harness in which appropriate portions of the protective member are bent in a desired direction. Moreover, since components such as a protector and a wiring clip are not used, an inexpensive wire harness can be manufactured with a small number of components.

It is explanatory drawing which shows the structure of the motor vehicle provided with the wire harness concerning one Embodiment of this invention. It is a perspective view of the wire harness of the motor vehicle shown in FIG. It is a perspective view which shows the electric wire and linear corrugated tube of the wire harness shown in FIG. It is a perspective view which shows the state which accommodated the electric wire in the corrugated tube shown in FIG. It is IV-IV arrow sectional drawing in FIG. It is II-II arrow sectional drawing in FIG. It is a perspective view of a jig for forming a wire harness according to an embodiment of the present invention. It is a perspective view which shows the state which has arrange | positioned the corrugated tube in the jig | tool for shaping | molding the wire harness shown in FIG. It is explanatory drawing which shows the state which supported the corrugated tube with the jig | tool for wiring.

Hereinafter, embodiments of the present invention will be described with reference to FIGS.
As shown in FIG. 1, a wire harness 10 according to an embodiment of the present invention is routed in a vehicle 1 such as a hybrid vehicle or an electric vehicle that can run by the driving force of a motor 3. In the illustrated example, a hybrid vehicle is shown as the vehicle 1.

  The automobile 1 is a vehicle that travels by the driving force of two driving sources of an engine 2 and a motor 3. The motor 3 is supplied with power from a battery 5 as an electronic device via an inverter 4 as an electronic device. In the illustrated example, the engine 2, the motor 3 and the inverter 4 are provided on the vehicle interior front side 6 of the automobile 1, and the battery 5 is provided on the vehicle interior rear side 7 of the automobile 1.

  The wire harness 10 of this embodiment electrically connects the battery 5 and the inverter 4 to each other, and supplies power from the battery 5 to the inverter 4 or from the inverter 4 to the battery 5. The wire harness 10 is routed on the lower surface of the vehicle body frame 8 as a vehicle body panel. When the wire harness 10 is routed on the lower surface of the vehicle body frame 8, the location 10a (two locations in the illustrated example) is appropriately oriented in a desired direction (corresponding to a direction bent when routed in the vehicle 1). It is bent.

  As shown in FIG. 2, the wire harness 10 includes at least one electric wire 11 (two in the illustrated example), two connectors 12, and a harness tube (hereinafter referred to as a corrugated tube) as a cylindrical protective member. 13.

  As illustrated in FIGS. 5 and 6, the electric wire 11 includes a conductive core wire 16 and an insulating covering portion 17. The core wire 16 is formed by twisting a plurality of conductive strands. The strand is made of a conductive metal such as copper or a copper alloy. Moreover, the core wire 16 may be comprised with one strand. The covering portion 17 is made of a synthetic resin such as a polyvinyl chloride resin. The covering portion 17 covers the core wire 16.

  As shown in FIG. 3, the connector 12 includes a connector housing 18 and a terminal fitting 19. The connector housing 18 is made of an insulating synthetic resin and has a box shape. The terminal housing 19 is accommodated in the connector housing 18. Further, the connector housing 18 is provided with a lock arm 18a for fitting to the connector provided in the battery 5 or the inverter 4 described above.

  The terminal fitting 19 is made of a conductive sheet metal and is attached to the end of the electric wire 11. The terminal fitting 19 is electrically connected to the core wire 16, that is, the electric wire 11, and is connected to the terminal fitting of the connector provided in the battery 5 or the inverter 4 described above.

  The corrugated tube 13 is made of a thermoplastic resin as a synthetic resin such as an insulating hard polyvinyl chloride resin. As shown in FIGS. 1 and 2, the corrugated tube is formed so that the connector housing 18 is slightly exposed at both ends of the electric wires 11 attached to both ends, that is, slightly shorter than the entire length of the wire harness 10. Has been. The wire harness 10 is formed slightly shorter than the entire length.

  As shown in FIG. 3, the corrugated tube 13 is formed in a cylindrical shape having an oval cross section. In addition, as shown in FIG. 5, the corrugated tube 13 has grooves 14 extending in the circumferential direction and ridges 15 extending in the circumferential direction that are alternately arranged in the longitudinal direction, and the outer surface is bellows-like. And the entire thickness is uniform. In addition, the corrugated tube 13 may be provided with a slit extending along the longitudinal direction, and the corrugated tube 13 may be elastically deformed so as to expand the slit, and the electric wire 11 may be accommodated in the corrugated tube 13.

  As shown in FIG. 6, the corrugated tube 13 is formed by heating a plurality of concave grooves 14 and a plurality of convex strips 15 that are located outside the desired portion 10a described above in the desired direction. Is provided.

  The plastic deformation portion 13a is formed by plastic deformation of the corrugated tube 13 located outside the desired direction in an arc shape. The plastic deformation portion 13a receives heat generated from an electric heater such as a dryer or a halogen heater as a heating means and is heated to a temperature at which the plurality of grooves 14 and the plurality of ridges 15 are softened. Is formed by being cooled and cured.

  In the present embodiment, as shown in FIG. 7, the plastic deformation portion 13 a described above is formed at an appropriate location 10 a of the corrugated tube 13 by a wire harness forming jig 21 that bends the wire harness 10 in a desired direction. Yes.

  The wire harness forming jig 21 includes a support portion 21 a that is formed in a concave groove shape and that accommodates and supports the corrugated tube 13. The support portion 21a is formed by being bent from the center portion in the desired direction of the appropriate portion 10a described above. The support portion 21a is formed in a plate shape and is bent from the center portion along the desired direction, and is erected from one end inside the desired direction in the width direction of the bottom plate portion 22. The side wall part 24, the side wall part 25 erected from the outer end in the desired direction in the width direction of the bottom plate part 22, and the wiring board erected from the back surface of the bottom plate part 22 and not shown. And a plurality of (two in the illustrated example) column portions 28. The wire harness forming jig 21 is made of a synthetic resin such as a thermosetting resin or a heat resistant resin, or a heat resistant material such as a metal.

  The bottom plate portion 22 is formed in a width that accommodates the long-axis side of the corrugated tube 13 having an oval cross section. The bottom plate portion 22 is formed with a linear portion 22a that linearly accommodates and supports the corrugated tube 13 extending in front of the appropriate portion 10a and rearward of the appropriate portion 10a.

  The side wall portion 24 is erected from one end of the bottom plate portion 22 in the desired direction and is formed over the entire length of the bottom plate portion 22 in the longitudinal direction. The side wall portion 24 is formed with an extension amount longer than the short axis side of the cross-sectional oval shape of the corrugated tube 13.

  The side wall portion 25 is erected from one end of the bottom plate portion 22 outside the desired direction, and at the center portion, that is, the portion located outside the desired direction, of the appropriate portion 10a of the corrugated tube 13. A notch 27 is provided to expose the plurality of grooves 14 and the plurality of ridges 15 located outside the desired direction. The side wall portion 25 is formed with the same extension amount as the side wall portion 24.

  The notch 27 transmits heat generated from the heating means described above to the plurality of grooves 14 and the plurality of ridges 15 located outside the desired direction of the appropriate portion 10a of the corrugated tube 13. An area where the plastic deformation portion 13a is formed is opened.

  The locking projection 29 is provided on one end side of the support portion 21a, and is provided continuously with the upper surface of the bottom plate portion 22 and the opposing surface where the side wall portion 24 faces the side wall portion 25, and is formed in an L shape. Has been. The locking projection 29 is formed to protrude with a protruding amount that enters the concave groove 14 of the corrugated tube 13.

  Hereinafter, assembly of the wire harness 10 configured as described above will be described. First, as shown in FIG. 3, terminal fittings 19 are attached to both ends of the electric wire 11, and the terminal fitting 19 attached to one end is accommodated in the connector housing 18. As shown in FIG. 4, after the other end of the electric wire 11 is inserted into the corrugated tube 13 extending linearly, the terminal fitting 19 attached to the other end is accommodated in the connector housing 18. . Thus, the electric wire 11 is accommodated in the linear corrugated tube 13.

  Next, as shown in FIG. 8, the corrugated tube 13 is mounted on a wire harness forming jig 21 mounted on the wiring board, and the corrugated tube 13 is bent in the desired direction described above. Subsequently, hot air of a dryer is blown onto the plurality of grooves 14 and the plurality of ridges 15 exposed from the notches 27 of the wire harness forming jig 21. At this time, the hot air of the dryer is blown until the thermoplastic resin constituting the corrugated tube 13 is softened and the plurality of grooves 14 and the plurality of ridges 15 exposed from the notches 27 are deformed.

  Next, the dryer is switched to air blowing, and the plurality of grooves 14 and the plurality of ridges 15 exposed from the notches 27 are cooled and hardened. Then, the appropriate portion 10a of the corrugated tube 13 is bent in the desired direction and the non-recoverable state described above.

  Next, the corrugated tube 13 is removed from the wire harness forming jig 21. And the other appropriate location 10a is formed by repeating the procedure mentioned above, and the wire harness 10 is assembled.

  As described above, the wire harness 10 includes the plurality of concave grooves 14 in which the electric wires 11 are accommodated in the linear corrugated tube 13 and located outside the desired direction of the appropriate portion 10a of the linear corrugated tube 13. The plurality of ridges 15 are heated to form a plastically deformed portion 13a, and the appropriate portion 10a is bent and assembled in the desired direction so as not to be restored.

  The wire harness 10 assembled in this way is attached to the automobile 1 by the connector 12 being fitted to the connector of the battery 5 or the inverter 4 described above and the corrugated tube 13 being attached to the lower surface of the vehicle body frame 8. Routed.

  In addition, as shown in FIG. 9, the wire harness 10 bends the corrugated tube 13 of the location 10a appropriately in the desired direction described above by a plurality of ties 31 to 34 erected on the wiring board, The plurality of concave grooves 14 and the plurality of ridges 15 positioned outside in the desired direction may be heated with a dryer or the like to form the plastic deformation portion 13a. At this time, the corrugated tube 13 is bent in the desired direction by the ties 32 and 33 provided on the inner side in the illustrated example, and the corrugated tube 13 is linearly supported by the ties 31 and 34 provided on the outer side. To do. The tying members 31 to 34 are provided with a column part standing on the wiring board, and a U-shaped part provided at the tip of the columnar part and formed in a U-shape and supporting the corrugated tube 13 and the electric wire 11. And.

  According to the present embodiment, in the wire harness 10, the concave groove 14 and the ridge 15 located outside the bent portion of the appropriate portion 10 a of the corrugated tube 13 are heated to form the plastic deformation portion 13 a. Therefore, the elastic strain that the outside of the appropriate portion 10a of the corrugated tube 13 in the bent direction has the plastic strain before heating, and the appropriate portion 10a of the corrugated tube 13 is bent in the desired direction. The shape is held. For this reason, it is not necessary to bend the corrugated tube 13 in a desired direction with a protector or a wiring clip as in a conventional general wire harness. Therefore, the attachment work which attaches a protector and a clip for wiring to the wire harness 10 becomes unnecessary, the manufacturing time of the wire harness 10 is shortened, and the expense concerning the said wire harness 10 is held down.

  Moreover, since the plastic harness 13a is formed on the outside of the corrugated tube 13 in the bent direction of the appropriate portion 10a of the corrugated tube 13, the wire harness 10 is bent in the appropriate direction of the appropriate portion 10a of the corrugated tube 13. Since the plastic deformation portion 13a can be made longer than when the plastic deformation portion 13a is formed on the inner side, the bending of the appropriate portion 10a of the corrugated tube 13 is more firmly formed.

  Further, since the wire harness 10 is held in a shape in which the appropriate portion 10a of the corrugated tube 13 is bent in a desired direction, it is almost necessary to bend again when the wire harness 10 is actually attached to the automobile. Absent. For this reason, the time concerning the installation work of the wire harness 10 is shortened.

  Moreover, since the wire harness 10 does not need to be bent again when actually attaching the wire harness 10 to the motor vehicle 1, it can prevent that the electric wire 11 becomes unnecessarily long. The required length refers to the length of the routing path for connecting electronic devices such as the battery 5 and the inverter 4 mounted on the automobile 1.

  Moreover, since the wire harness 10 does not fix these to each other without winding an adhesive tape such as a wire harness tape around the outer periphery of the corrugated tube 13 and the electric wire 11, the corrugated tube 13 and the electric wire 11 are relatively fixed to each other. The position is not restricted. For this reason, when the portion 10a is appropriately bent in the desired direction described above, even if the wire 11 has a surplus length, the bend of the wire 11 at the portion 10a is appropriately adjusted as appropriate. Can absorb.

  In addition, the wire harness 10 may connect electronic devices other than the battery 5 and the inverter 4, that is, may be used for signal transmission, and may include more electric wires 11 than the two in the illustrated example.

  In addition, embodiment mentioned above only showed the typical form of this invention, and this invention is not limited to embodiment. That is, various modifications can be made without departing from the scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Automobile 10 Wire harness 10a Appropriate location 11 Electric wire 13 Harness tube, corrugated tube (protective member)
13a Plastic deformation part 14 Concave groove 15 Convex strip 21 Jig for forming 21a Support part 27 Notch part 29 Locking protrusion

Claims (2)

Protective member which is formed in a cylindrical shape with at least one electric wire and a thermoplastic resin, and in which outer grooves and ridges extending in the circumferential direction are alternately arranged in the longitudinal direction and the outer surface is formed in a bellows shape In a forming jig for forming a wire harness in which the protective member containing the electric wire is bent at an appropriate place,
The molding jig includes a support portion that bends the protective member in a bent direction of the appropriate portion and supports the protective member, and
When the protective member is supported on the support portion, the support portion exposes the concave groove and the protruding line that are located outside the appropriate portion of the protective member in the bent direction, and A notch for transmitting heat of the heating means to the concave groove and the ridge, and a locking projection for locking to the concave groove,
A jig for forming a wire harness, wherein the appropriate portion of the protective member is bent so that it cannot be restored in the direction. Protective member which is formed in a cylindrical shape with at least one electric wire and a thermoplastic resin, and in which outer grooves and ridges extending in the circumferential direction are alternately arranged in the longitudinal direction and the outer surface is formed in a bellows shape And a manufacturing method for manufacturing a wire harness in which the protective member containing the electric wire is bent at an appropriate place,
Using the wire harness forming jig according to claim 1, the concave groove and the ridge located on the outer side in the bent direction of the appropriate portion of the protective member are heated by a heating means to be plastically deformed. The wire harness manufacturing method is characterized in that the appropriate portion of the protective member is bent so that it cannot be restored in the direction.

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