JP7211924B2 - Wire harness manufacturing method and wire harness - Google Patents

Wire harness manufacturing method and wire harness Download PDF

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JP7211924B2
JP7211924B2 JP2019194085A JP2019194085A JP7211924B2 JP 7211924 B2 JP7211924 B2 JP 7211924B2 JP 2019194085 A JP2019194085 A JP 2019194085A JP 2019194085 A JP2019194085 A JP 2019194085A JP 7211924 B2 JP7211924 B2 JP 7211924B2
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wire harness
metal plate
bent
manufacturing
electric wires
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JP2021068634A (en
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弘樹 後藤
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Yazaki Corp
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Yazaki Corp
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring

Description

本発明は、自動車等の車両に配索されるワイヤハーネスの製造方法及びワイヤハーネスに関する。 TECHNICAL FIELD The present invention relates to a method for manufacturing a wire harness to be routed in a vehicle such as an automobile, and the wire harness.

この種のワイヤハーネスとして、特許文献１（図示せず）に開示されたものがある。このワイヤハーネスは、複数本の電線と、この複数本の電線における保護対象部分を一括して挿通・保護する保護部材としてのパイプを備えている。このワイヤハーネスでは、パイプに複数本の電線を通した後で、その両端末に端子とコネクタをそれぞれ取り付けて端末処理をしている。 A wiring harness of this type is disclosed in Patent Document 1 (not shown). This wire harness includes a plurality of electric wires and a pipe as a protective member that collectively inserts and protects portions to be protected of the plurality of electric wires. In this wire harness, after passing a plurality of electric wires through a pipe, terminal processing is performed by attaching terminals and connectors to both ends of the wires.

特開２０１１－９７６９２号公報JP 2011-97692 A

しかしながら、前記従来のワイヤハーネスでは、複数本の電線の端末処理後にはパイプを挿通することができないため、パイプに複数本の電線を通した後に、複数本の電線の両端末に端子やコネクタを取り付ける必要がある。すなわち、パイプに複数本の電線が組み込まれた状態で電線端末の処理を行う必要があるため、その端末処理時の加工には、広い作業スペースが必要となる。 However, in the conventional wire harness, since the pipe cannot be inserted after the end processing of the plurality of electric wires, terminals and connectors are attached to both ends of the plurality of electric wires after passing the plurality of electric wires through the pipe. need to be installed. That is, since it is necessary to process the ends of the wires in a state in which a plurality of wires are assembled in the pipe, a large work space is required for processing the ends.

本発明は、このような従来技術が有する課題に鑑みてなされたものである。そして、本発明の目的は、電線の端末処理を施した後でパイプ形態が作製可能となって、加工作業スペースの省スペース化及び製造工程の効率化を図ることができるワイヤハーネスの製造方法及びワイヤハーネスを提供することにある。 The present invention has been made in view of the problems of the prior art. Further, an object of the present invention is to provide a wire harness manufacturing method and a method for manufacturing a wire harness, in which a pipe shape can be manufactured after the end of the electric wire is processed, and the processing work space can be saved and the efficiency of the manufacturing process can be improved. To provide a wire harness.

本発明の態様に係るワイヤハーネスの製造方法は、一又は複数本の電線を保護部材で包囲してなるワイヤハーネスの製造方法であって、前記一又は複数本の電線の両端末に端子とコネクタを取り付ける第１工程と、前記両端末に端子とコネクタが取り付けられた前記一又は複数本の電線の保護対象部分を包囲するように前記保護部材としての矩形板状の金属板材を曲げ加工して筒状に形成する第２工程と、前記金属板材の突き合わされた両端縁部の全長を隙間を設けずに該金属板材の長手方向と直交する方向に接合させる第３工程と、前記筒状に曲げ加工して前記一又は複数本の電線の保護対象部分を包囲した前記金属板材を、製造段階で、ワイヤハーネスの配索経路に沿う形状に曲げ加工する第４工程と、を備える。 A method of manufacturing a wire harness according to an aspect of the present invention is a method of manufacturing a wire harness in which one or more electric wires are surrounded by a protective member, and a terminal and a connector are attached to both ends of the one or more electric wires. and bending a rectangular plate-shaped metal plate material as the protective member so as to surround a portion to be protected of the one or more electric wires having terminals and connectors attached to both ends. a second step of forming a cylindrical shape by pressing the metal plate, a third step of joining the entire length of the butted end edges of the metal plate in a direction orthogonal to the longitudinal direction of the metal plate without providing a gap, and the cylinder and a fourth step of bending the metal plate, which has been bent into a shape to surround the portion to be protected of the one or more electric wires, into a shape along the wiring route of the wire harness in the manufacturing stage.

前記金属板材を円筒状に曲げ加工することが好ましい。 It is preferable to bend the metal plate into a cylindrical shape.

前記金属板材を楕円筒状に曲げ加工することが好ましい。 It is preferable to bend the metal plate material into an elliptical cylindrical shape.

前記金属板材を扁平な四角筒状に曲げ加工することが好ましい。 It is preferable to bend the metal plate material into a flat square tube shape.

本発明の他の態様に係るワイヤハーネスは、両端末に端子とコネクタが取り付けられた一又は複数本の電線と、前記両端末に端子とコネクタが取り付けられた前記一又は複数本の電線の保護対象部分を包み込むように包囲して保護する保護部材と、を備え、前記保護部材としての矩形板状の金属板材を曲げ加工して筒状に形成した該金属板材の突き合わされた両端縁部の全長が隙間を設けずに該金属板材の長手方向と直交する方向に接合してあると共に配索経路に沿う形状に曲げ加工してある。 A wire harness according to another aspect of the present invention includes one or more electric wires having terminals and connectors attached to both ends, and the one or more electric wires having terminals and connectors attached to both ends. and a protective member that surrounds and protects the portion to be protected in a manner that envelops and protects the portion to be protected. The entire length of the part is joined in a direction orthogonal to the longitudinal direction of the metal plate material without providing a gap, and is bent into a shape along the wiring route.

本発明によれば、電線の端末処理を施した後でパイプ形態が作製可能となって、加工作業スペースの省スペース化及び製造工程の効率化を図ることができるワイヤハーネスの製造方法及びワイヤハーネスを提供することができる。 ADVANTAGE OF THE INVENTION According to the present invention, a wire harness manufacturing method and a wire harness can be manufactured in the form of a pipe after performing terminal processing of electric wires, which can save the working space and improve the efficiency of the manufacturing process. can be provided.

本発明の第１実施形態に係るワイヤハーネスの一例を示す斜視図である。BRIEF DESCRIPTION OF THE DRAWINGS It is a perspective view which shows an example of the wire harness which concerns on 1st Embodiment of this invention. （ａ）～（ｃ）は上記ワイヤハーネスの製造手順を示す斜視図である。(a) to (c) are perspective views showing the manufacturing procedure of the wire harness. （ａ）～（ｃ）は上記ワイヤハーネスの各形態例を示す断面図である。4(a) to 4(c) are cross-sectional views showing respective form examples of the wire harness. FIG. 本発明の第２実施形態に係るワイヤハーネスの一例を示す斜視図である。It is a perspective view which shows an example of the wire harness which concerns on 2nd Embodiment of this invention. （ａ）～（ｃ）は上記第２実施形態に係るワイヤハーネスの製造手順を示す斜視図である。(a) to (c) are perspective views showing the manufacturing procedure of the wire harness according to the second embodiment. （ａ）～（ｃ）は上記第２実施形態に係るワイヤハーネスの各形態例を示す断面図である。(a) to (c) are cross-sectional views showing respective form examples of the wire harness according to the second embodiment. 本発明の第３実施形態に係るワイヤハーネスの一例を示す斜視図である。It is a perspective view which shows an example of the wire harness which concerns on 3rd Embodiment of this invention. （ａ）～（ｄ）は上記第３実施形態に係るワイヤハーネスの製造手順を示す斜視図である。(a) to (d) are perspective views showing the manufacturing procedure of the wire harness according to the third embodiment. （ａ）～（ｄ）は上記第３実施形態に係るワイヤハーネスの各形態例を示す断面図である。(a) to (d) are cross-sectional views showing respective form examples of the wire harness according to the third embodiment. 上記第３実施形態のワイヤハーネスを車体に組付ける状態を示す断面図である。It is sectional drawing which shows the state which assemble|attaches the wire harness of the said 3rd Embodiment to a vehicle body.

以下、図面を用いて本発明の実施形態に係るワイヤハーネス及びその製造方法について詳細に説明する。 A wire harness and a method for manufacturing the same according to embodiments of the present invention will be described below in detail with reference to the drawings.

図１は本発明の第１実施形態に係るワイヤハーネスの一例を示す斜視図である。図２（ａ）～図２（ｃ）はワイヤハーネスの製造手順を示す斜視図である。図３（ａ）～図３（ｃ）はワイヤハーネスの各形態例を示す断面図である。 FIG. 1 is a perspective view showing an example of a wire harness according to a first embodiment of the invention. 2(a) to 2(c) are perspective views showing the manufacturing procedure of the wire harness. 3(a) to 3(c) are cross-sectional views showing examples of the form of the wire harness.

図１に示すように、ワイヤハーネス１０は、両端末１１ａ，１１ｂに端子（図示略）とコネクタ１４が予め取り付けられて端末処理されている一本の電線１１と、この電線１１の保護対象部分を包囲して保護する円筒状の金属板材（保護部材）１５と、を備えている。 As shown in FIG. 1, the wire harness 10 includes a single electric wire 11 having terminals (not shown) and a connector 14 preliminarily attached to both ends 11a and 11b and terminal-treated, and a portion to be protected of the electric wire 11. and a cylindrical metal plate member (protective member) 15 that surrounds and protects the .

図２（ａ）に示すように、金属板材１５は、例えば、アルミニウム製の矩形板状のものを使用しており、この矩形板状のものを円筒状に曲げ加工することで、１本の電線１１を包み込むように包囲している。また、図３（ａ）に示すように、電線１１は、芯線１２と、この芯線１２を覆う絶縁被覆１３と、を有している。尚、円筒状の金属板材１５に包囲される電線１１は、２本以上の複数本でも良い。さらに、金属板材１５は、ステンレス製や銅製の矩形板状のものでも良い。 As shown in FIG. 2A, the metal plate material 15 is, for example, a rectangular plate made of aluminum. It surrounds so that the electric wire 11 may be wrapped. Further, as shown in FIG. 3( a ), the electric wire 11 has a core wire 12 and an insulating coating 13 covering the core wire 12 . Incidentally, the number of electric wires 11 surrounded by the cylindrical metal plate member 15 may be two or more. Furthermore, the metal plate material 15 may be a rectangular plate made of stainless steel or copper.

次に、第１実施形態のワイヤハーネス１０の製造方法を図２（ａ）～（ｃ）に沿って順に説明する。 Next, a method for manufacturing the wire harness 10 of the first embodiment will be described in order along FIGS. 2(a) to 2(c).

まず、図２（ａ）に示すように、電線１１の両端末１１ａ，１１ｂには、端子（図示略）とコネクタ１４を事前に取り付けて端末処理をしておく（第１工程）。 First, as shown in FIG. 2(a), both ends 11a and 11b of the electric wire 11 are attached with terminals (not shown) and connectors 14 in advance, and the ends are treated (first step).

次に、矩形板状の金属板材１５上に、両端末１１ａ，１１ｂにコネクタ１４が取り付けられた一本の電線１１を載せ、図２（ｂ），（ｃ）に示すように、その保護対象部分を包み込んで包囲するように金属板材１５を円筒状に曲げ加工する（第２工程）。 Next, a single electric wire 11 having connectors 14 attached to both ends 11a and 11b is placed on a rectangular metal plate 15, and as shown in FIGS. The metal plate material 15 is bent into a cylindrical shape so as to wrap and surround the portion (second step).

これら第１工程と第２工程により、図３（ａ）に示すように、断面が円環状で両端縁部１５ａ，１５ｂが突き合わされてなる金属板材１５の内部に電線１１を挿通させたワイヤハーネス１０が製造される。そして、図１及び図３（ａ）に示すように、円筒状の金属板材１５の突き合わされた両端縁部１５ａ，１５ｂの全長を、隙間を設けずに金属板材１５の長手方向と直交する方向に溶接等により接合する（第３工程）。なお、図３（ｂ）に示すように、円筒状の金属板材１５の両端縁部１５ａ，１５ｂを下側で重ね合わせてオーバーラップさせても良い。また、図３（ｃ）に示すように、金属板材１５を円筒状に曲げ加工する際に、下側に位置する合わせ端縁部１５ａ，１５ｂが互いに対向するよう隙間を設けて水抜き部１５ｃを形成しても良い。 Through these first and second steps, as shown in FIG. 3(a), a wire harness in which electric wires 11 are passed through a metal plate member 15 having an annular cross section and having both end edges 15a and 15b butted against each other. 10 are produced. Then, as shown in FIGS. 1 and 3A, the entire length of the butted end edges 15a and 15b of the cylindrical metal plate 15 is extended in a direction orthogonal to the longitudinal direction of the metal plate 15 without providing a gap. are joined by welding or the like (third step). In addition, as shown in FIG. 3(b), both end edges 15a and 15b of the cylindrical metal plate 15 may be overlapped on the lower side. Further, as shown in FIG. 3(c), when bending the metal plate material 15 into a cylindrical shape, a gap is provided so that the lower matching edge portions 15a and 15b are opposed to each other, and the drain portion 15c is formed. may be formed.

次に、円筒状に曲げ加工して一本の電線１１の保護対象部分を包囲した円筒状の金属板材１５を、製造段階で、ワイヤハーネス１０の配索経路に沿う形状、例えば、略クランク状に曲げ加工する（第４工程）ことで、図１に示すワイヤハーネス１０が完成する。 Next, in the manufacturing stage, the cylindrical metal plate material 15, which has been bent into a cylindrical shape and surrounds the portion to be protected of one electric wire 11, is formed into a shape, for example, a substantially crank shape, along the wiring route of the wire harness 10. (fourth step), the wire harness 10 shown in FIG. 1 is completed.

この第１実施形態では、一本の電線１１の端末処理を施した後でパイプ形態が作製可能となるため、加工作業スペースの省スペース化及び製造工程の効率化を図ることができる。 In the first embodiment, the pipe shape can be manufactured after the single electric wire 11 is subjected to the terminal treatment, so that the processing work space can be saved and the efficiency of the manufacturing process can be improved.

図４は本発明の第２実施形態に係るワイヤハーネスの一例を示す斜視図である。図５（ａ）～図５（ｃ）はワイヤハーネスの製造手順を示す斜視図である。図６（ａ）～図６（ｃ）はワイヤハーネスの各形態例を示す断面図である。 FIG. 4 is a perspective view showing an example of a wire harness according to a second embodiment of the invention. 5(a) to 5(c) are perspective views showing the manufacturing procedure of the wire harness. 6(a) to 6(c) are cross-sectional views showing examples of the form of the wire harness.

図４に示すように、ワイヤハーネス２０は、両端末２１ａ，２１ｂに端子（図示略）とコネクタ２４が予め取り付けられて端末処理されている３本の電線２１と、各電線２１の保護対象部分を包囲して保護する楕円筒状の金属板材（保護部材）２５と、を備えている。 As shown in FIG. 4, the wire harness 20 includes three electric wires 21, which are terminal-treated in advance with terminals (not shown) and connectors 24 attached to both ends 21a and 21b, and a portion to be protected of each electric wire 21. and an elliptical cylindrical metal plate member (protective member) 25 that surrounds and protects the .

図５（ａ）に示すように、金属板材２５は、例えば、アルミニウム製の矩形板状のものを使用しており、この矩形板状のものを楕円筒状に曲げ加工することで、各電線２１を包み込むように包囲している。また、図６（ａ）に示すように、各電線２１は、芯線２２と、この芯線２２を覆う絶縁被覆２３と、を有している。尚、円筒状の金属板材２５に包囲される電線２１は、一本でも３本以上の複数本でも良い。さらに、金属板材２５は、ステンレス製や銅製の矩形板状のものでも良い。 As shown in FIG. 5A, the metal plate material 25 is, for example, a rectangular plate made of aluminum. It surrounds 21. Moreover, as shown in FIG. 6A, each electric wire 21 has a core wire 22 and an insulating coating 23 covering the core wire 22 . The electric wire 21 surrounded by the cylindrical metal plate 25 may be one or a plurality of three or more. Furthermore, the metal plate material 25 may be a rectangular plate made of stainless steel or copper.

次に、第２実施形態のワイヤハーネス２０の製造方法を図５（ａ）～（ｃ）に沿って順に説明する。 Next, a method for manufacturing the wire harness 20 of the second embodiment will be described in order along FIGS. 5(a) to 5(c).

まず、図５（ａ）に示すように、各電線２１の両端末２１ａ，２１ｂには、端子（図示略）とコネクタ２４を事前に取り付けて端末処理をしておく（第１工程）。 First, as shown in FIG. 5A, terminals (not shown) and connectors 24 are attached in advance to both ends 21a and 21b of each electric wire 21, and the ends are processed (first step).

次に、矩形板状の金属板材２５上に、両端末２１ａ，２１ｂにコネクタ２４が取り付けられた各電線２１を載せ、図５（ｂ），（ｃ）に示すように、その保護対象部分を包み込んで包囲するように金属板材２５を楕円筒状に曲げ加工する（第２工程）。 Next, each electric wire 21 having a connector 24 attached to both ends 21a and 21b is placed on a rectangular plate-like metal plate 25, and as shown in FIGS. The metal plate material 25 is bent into an elliptical cylindrical shape so as to wrap and surround (second step).

これら第１工程と第２工程により、図６（ａ）に示すように、断面が楕円環状で両端縁部２５ａ，２５ｂが突き合わされてなる金属板材２５の内部に各電線２１を挿通させたワイヤハーネス２０が製造される。そして、図４及び図６（ａ）に示すように、楕円筒状の金属板材２５の突き合わされた両端縁部２５ａ，２５ｂの全長を、隙間を設けずに金属板材２５の長手方向と直交する方向に溶接等により接合する（第３工程）。なお、図６（ｂ）に示すように、円筒状の金属板材２５の両端縁部２５ａ，２５ｂを下側で重ね合わせてオーバーラップさせても良い。また、図６（ｃ）に示すように、金属板材２５を楕円筒状に曲げ加工する際に、下側に位置する合わせ端縁部２５ａ，２５ｂが互いに対向するよう隙間を設けて水抜き部２５ｃを形成しても良い。 Through these first and second steps, as shown in FIG. 6(a), a wire in which each electric wire 21 is inserted through a metal plate 25 having an elliptical cross section and having both end edges 25a and 25b butted against each other. A harness 20 is manufactured. Then, as shown in FIGS. 4 and 6A, the entire length of the butted end edges 25a and 25b of the elliptical cylindrical metal plate 25 is perpendicular to the longitudinal direction of the metal plate 25 without providing a gap . It joins by welding etc. in the direction (3rd process). In addition, as shown in FIG. 6(b), both end edges 25a and 25b of the cylindrical metal plate 25 may be overlapped on the lower side. Further, as shown in FIG. 6(c), when bending the metal plate material 25 into an elliptical cylindrical shape, a gap is provided so that the lower matching edge portions 25a and 25b are opposed to each other, and a drain portion is formed. 25c may be formed.

次に、円筒状に曲げ加工して各電線２１の保護対象部分を包囲した円筒状の金属板材２５を、製造段階で、ワイヤハーネス２０の配索経路に沿う形状、例えば、略クランク状に曲げ加工する（第４工程）ことで、図４に示すワイヤハーネス２０が完成する。 Next, in the manufacturing stage, the cylindrical metal plate material 25, which is bent into a cylindrical shape and surrounds the portions to be protected of each electric wire 21, is bent into a shape along the wiring route of the wire harness 20, for example, a substantially crank shape. By processing (fourth step), the wire harness 20 shown in FIG. 4 is completed.

この第２実施形態では、各電線２１の端末処理を施した後でパイプ形態が作製可能となるため、加工作業スペースの省スペース化及び製造工程の効率化を図ることができる。 In the second embodiment, the pipe shape can be manufactured after the end treatment of each electric wire 21 is performed, so that the processing space can be saved and the efficiency of the manufacturing process can be improved.

図７は本発明の第３実施形態に係るワイヤハーネスの一例を示す斜視図である。図８（ａ）～図８（ｄ）はワイヤハーネスの製造手順を示す斜視図である。図９（ａ）～図９（ｄ）はワイヤハーネスの各形態例を示す断面図である。図１０はワイヤハーネスを車体に組付ける状態を示す断面図である。 FIG. 7 is a perspective view showing an example of a wire harness according to a third embodiment of the invention. 8(a) to 8(d) are perspective views showing the manufacturing procedure of the wire harness. 9(a) to 9(d) are cross-sectional views showing examples of the form of the wire harness. FIG. 10 is a cross-sectional view showing how the wire harness is assembled to the vehicle body.

図７に示すように、ワイヤハーネス３０は、両端末３１ａ，３１ｂに端子（図示略）とコネクタ３４が予め取り付けられて端末処理されている３本の電線３１と、各電線３１の保護対象部分を包囲して保護する四角筒状の金属板材（保護部材）３５と、を備えている。 As shown in FIG. 7, the wire harness 30 includes three electric wires 31 whose ends are previously attached with terminals (not shown) and connectors 34 at both ends 31a and 31b, and a portion to be protected of each electric wire 31. and a rectangular cylindrical metal plate member (protective member) 35 that surrounds and protects the .

図８（ａ）に示すように、金属板材３５は、例えば、アルミニウム製の矩形板状のものを使用しており、この矩形板状のものを扁平な四角筒状に曲げ加工することで、各電線３１を包み込むように包囲している。また、図９（ａ）に示すように、各電線３１は、芯線３２と、この芯線３２を覆う絶縁被覆３３と、を有している。尚、円筒状の金属板材３５に包囲される電線３１は、図９（ｄ）に示すように、一本でも良く、３本以上の複数本でも良い。さらに、金属板材３５は、ステンレス製や銅製の矩形板状のものでも良い。 As shown in FIG. 8A, the metal plate material 35 is, for example, a rectangular plate made of aluminum. It surrounds so that each electric wire 31 may be wrapped. Moreover, as shown in FIG. 9A, each electric wire 31 has a core wire 32 and an insulating coating 33 covering the core wire 32 . The electric wire 31 surrounded by the cylindrical metal plate 35 may be one as shown in FIG. 9(d), or may be three or more. Furthermore, the metal plate material 35 may be a rectangular plate made of stainless steel or copper.

次に、第３実施形態のワイヤハーネス３０の製造方法を図８（ａ）～（ｄ）に沿って順に説明する。 Next, a method for manufacturing the wire harness 30 of the third embodiment will be described in order along FIGS. 8(a) to 8(d).

まず、図８（ａ）に示すように、各電線３１の両端末３１ａ，３１ｂには、端子（図示略）とコネクタ３４を事前に取り付けて端末処理をしておく（第１工程）。 First, as shown in FIG. 8(a), both ends 31a and 31b of each electric wire 31 are attached with terminals (not shown) and connectors 34 in advance and subjected to terminal processing (first step).

次に、矩形板状の金属板材３５上に、両端末３１ａ，３１ｂにコネクタ３４が取り付けられた各電線３１を載せ、図８（ｂ），（ｃ）に示すように、その保護対象部分を包み込んで包囲するように金属板材３５を楕円筒状に曲げ加工する（第２工程）。この際、図８（ｂ）に示すように、まず、金属板材３５の他方の端縁部３５ｂを直角に曲げ加工する。次に、図８（ｃ）に示すように、金属板材３５の一方の端縁部３５ａを直角に２回曲げ加工する。 Next, each electric wire 31 having a connector 34 attached to each end 31a, 31b is placed on a rectangular metal plate 35, and as shown in FIGS. The metal plate material 35 is bent into an elliptical cylindrical shape so as to wrap and surround (second step). At this time, as shown in FIG. 8B, first, the other edge portion 35b of the metal plate 35 is bent at a right angle. Next, as shown in FIG. 8(c), one edge portion 35a of the metal plate 35 is bent twice at right angles.

これら第１工程と第２工程により、図９（ａ）に示すように、断面が扁平な四角環状で両端縁部３５ａ，３５ｂが上端側角部で突き合わされてなる金属板材３５の内部に各電線３１を挿通させたワイヤハーネス３０が製造される。そして、図７及び図９（ａ）に示すように、扁平で四角筒状の金属板材３５の上端側角部で突き合わされた両端縁部３５ａ，３５ｂの全長を、隙間を設けずに金属板材３５の長手方向と直交する方向に溶接等により接合する（第３工程）。なお、図９（ｂ）に示すように、円筒状の金属板材２５の両端縁部３５ａ，３５ｂを下側で重ね合わせてオーバーラップさせても良い。また、図９（ｃ）に示すように、金属板材２５を楕円筒状に曲げ加工する際に、下側に位置する合わせ端縁部３５ａ，３５ｂが互いに対向するよう隙間を設けて水抜き部３５ｃを形成しても良い。 Through these first and second steps, as shown in FIG. 9(a), a metal plate 35 having a flat square annular cross-section and both end edges 35a and 35b butted against each other at upper corners is formed inside each of the metal plates 35. A wire harness 30 through which the electric wire 31 is inserted is manufactured. Then, as shown in FIGS. 7 and 9(a), the entire length of both edge portions 35a and 35b, which are butted against each other at the upper end side corners of a flat square tubular metal plate 35, is covered without providing a gap. 35 are joined by welding or the like in a direction orthogonal to the longitudinal direction (third step). In addition, as shown in FIG. 9(b), both end edges 35a and 35b of the cylindrical metal plate member 25 may be overlapped on the lower side. Further, as shown in FIG. 9(c), when bending the metal plate material 25 into an elliptical cylindrical shape, a gap is provided so that the lower matching edge portions 35a and 35b are opposed to each other, and a drain portion is formed. 35c may be formed.

次に、円筒状に曲げ加工して各電線３１の保護対象部分を包囲した扁平で四角筒状の金属板材３５を、製造段階で、ワイヤハーネス３０の配索経路に沿う形状、例えば、略クランク状に曲げ加工する（第４工程）ことで、図７に示すワイヤハーネス３０が完成する。 Next, in the manufacturing stage, a flat square tubular metal plate material 35, which is cylindrically bent and surrounds the portions to be protected of each electric wire 31, is formed into a shape, for example, a substantially cranked shape along the wiring route of the wire harness 30. By bending into a shape (fourth step), the wire harness 30 shown in FIG. 7 is completed.

この第３実施形態では、各電線３１の端末処理を施した後でパイプ形態が作製可能となるため、加工作業スペースの省スペース化及び製造工程の効率化を図ることができる。 In the third embodiment, the pipe shape can be manufactured after the end treatment of each electric wire 31 is performed, so that the processing work space can be saved and the efficiency of the manufacturing process can be improved.

また、図１０に示すように、車体フロア１の床下２に第３実施形態のワイヤハーネス３０を配索する場合には、蓋４で閉塞される扁平で断面凹状の収容ボックス３内に、扁平で薄形四角形状のワイヤハーネス３０を収容することができる。この収容ボックス３内でワイヤハーネス３０は回ることがない。尚、収容ボックス３は、両側のフランジ部３ａ，３ａがボルト５で止められている。 Further, as shown in FIG. 10 , when wiring the wire harness 30 of the third embodiment under the floor 2 of the vehicle body floor 1 , a flat wire harness 30 is placed in the storage box 3 that is closed by the lid 4 and has a flat cross-sectional concave shape. , the thin rectangular wire harness 30 can be accommodated. The wire harness 30 does not turn inside the storage box 3. - 特許庁The storage box 3 is fixed with bolts 5 at the flange portions 3a, 3a on both sides.

以上、本実施形態を説明したが、本実施形態はこれらに限定されるものではなく、本実施形態の要旨の範囲内で種々の変形が可能である。 Although the present embodiment has been described above, the present embodiment is not limited to these, and various modifications are possible within the scope of the gist of the present embodiment.

すなわち、前記各実施形態によれば、筒状に曲げられた金属板材の内部に一本又は３本の電線を包み込むように包囲させたが、２本又は４本以上の電線を包み込むように包囲させても良い。 That is, according to each of the above-described embodiments, one or three electric wires are wrapped inside the cylindrically bent metal plate material, but two or four or more electric wires are wrapped so as to be wrapped. You can let me.

１０，２０，３０ ワイヤハーネス
１１，２１，３１ 電線
１１ａ，１１ｂ，２１ａ，２１ｂ，３１ａ，３１ｂ 両端末
１４，２４，３４ コネクタ
１５，２５，３５ 金属板材（保護部材）
１５ａ，１５ｂ、２５ａ，２５ｂ、３５ａ，３５ｂ 両端縁部 10, 20, 30 wire harness 11, 21, 31 electric wire 11a, 11b, 21a, 21b, 31a, 31b both terminals
14, 24, 34 Connector
15, 25, 35 Metal plate material (protective member)
15a, 15b, 25a, 25b, 35a, 35b both end edges

Claims (8)

一又は複数本の電線を保護部材で包囲してなるワイヤハーネスの製造方法であって、
前記一又は複数本の電線の両端末に端子とコネクタを取り付ける第１工程と、
前記両端末に端子とコネクタが取り付けられた前記一又は複数本の電線の保護対象部分を包囲するように前記保護部材としての矩形板状の金属板材を曲げ加工して筒状に形成する第２工程と、
前記金属板材の突き合わされた両端縁部の全長を隙間を設けずに該金属板材の長手方向と直交する方向に接合させる第３工程と、
前記筒状に曲げ加工して前記一又は複数本の電線の保護対象部分を包囲した前記金属板材を、製造段階で、ワイヤハーネスの配索経路に沿う形状に曲げ加工する第４工程と、
を備えるワイヤハーネスの製造方法。 A method for manufacturing a wire harness in which one or more electric wires are surrounded by a protective member,
a first step of attaching terminals and connectors to both ends of the one or more electric wires;
A rectangular plate-shaped metal plate serving as the protection member is bent into a cylindrical shape so as to surround the portion to be protected of the one or more electric wires having terminals and connectors attached to both ends thereof. 2 steps;
a third step of joining the entire length of the butted end edges of the metal plate in a direction orthogonal to the longitudinal direction of the metal plate without providing a gap;
a fourth step of bending the metal plate, which has been bent into a cylindrical shape to surround the portion to be protected of the one or more electric wires, into a shape along the wiring route of the wire harness in the manufacturing stage;
A method of manufacturing a wire harness comprising: 前記金属板材を円筒状に曲げ加工する請求項１に記載のワイヤハーネスの製造方法。 2. The method of manufacturing a wire harness according to claim 1, wherein the metal plate material is bent into a cylindrical shape. 前記金属板材を楕円筒状に曲げ加工する請求項１に記載のワイヤハーネスの製造方法。 2. The method of manufacturing a wire harness according to claim 1, wherein the metal plate material is bent into an elliptical cylindrical shape. 前記金属板材を扁平な四角筒状に曲げ加工する請求項１に記載のワイヤハーネスの製造方法。 2. The method of manufacturing a wire harness according to claim 1, wherein the metal plate material is bent into a flat rectangular tubular shape. 両端末に端子とコネクタが取り付けられた一又は複数本の電線と、
前記両端末に端子とコネクタが取り付けられた前記一又は複数本の電線の保護対象部分を包み込むように包囲して保護する保護部材と、
を備え、
前記保護部材としての矩形板状の金属板材を曲げ加工して筒状に形成した該金属板材の突き合わされた両端縁部の全長が隙間を設けずに該金属板材の長手方向と直交する方向に接合してあると共に配索経路に沿う形状に曲げ加工してあるワイヤハーネス。 one or more electric wires having terminals and connectors attached to both ends;
a protective member that encloses and protects the portion to be protected of the one or more electric wires having terminals and connectors attached to both ends;
with
A rectangular metal plate serving as the protective member is bent into a cylindrical shape, and the entire length of the butted end edges of the metal plate is in a direction perpendicular to the longitudinal direction of the metal plate without providing a gap. A wire harness that is joined and bent into a shape that follows the wiring route. 前記金属板材を円筒状に曲げ加工してなる請求項５に記載のワイヤハーネス。 6. The wire harness according to claim 5, wherein the metal plate material is bent into a cylindrical shape. 前記金属板材を楕円筒状に曲げ加工してなる請求項５に記載のワイヤハーネス。 6. The wire harness according to claim 5, wherein the metal plate material is bent into an elliptical cylindrical shape. 前記金属板材を扁平な四角筒状に曲げ加工してなる請求項５に記載のワイヤハーネス。 6. The wire harness according to claim 5, wherein the metal plate material is bent into a flat rectangular tubular shape.
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