JPH04237653A - Electrical equipment assembling method - Google Patents

Abstract

PURPOSE:To reduce an assembling cost and improve a non-defective rate, reliability and the like in various processes by efficiently performing processes related to the peeling of a covered conductor led out of an electrical equipment and sheathing such as the caulking of a mounted terminal, and combining various tests between the processes. CONSTITUTION:An electrical equipment 31 is assembled through a jig mounting process 11, a line placing process 12, a first outer skin peeling process 13, a second outer skin peeling process 14, an insulation test process 15, a connector terminal mounting process 16, a crimp-style terminal mounting process 17, a shaping process 18 for shaping a second covered conductor 37 and a crimp-style terminal 38 to an electrical equipment body 32, a caulking process 19 for performing the caulking of a protruding part 33 protrusively provided at the electrical equipment body 32 to form a caulked part 34, a resistance value testing process 20 for measuring the resistance value, a jig removing process 21 for removing the electrical equipment 31 from a jig, and an external appearance inspecting process 22 for inspecting the external appearance by visual observation.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] This invention peels off the outer sheaths of a plurality of covered electric wires drawn from electrical components having electronic functions,
It relates to a method for assembling electrical components in which a terminal is attached to the peeled wire portion and the terminal portion is caulked to the main body of the electrical equipment, and more specifically, a method for assembling electrical components such as peeling off the covered wire and caulking the terminal portion. This relates to a method for assembling electrical components that reduces assembly costs by efficiently performing processes related to the exterior, and improves the rate of non-defective products and reliability during the process by incorporating various tests between each process. be.

0002

[Prior Art] In recent years, in order to improve the safety and added value of automobiles, etc., in-vehicle electronic devices (hereinafter referred to as electrical components) having various electronic functions have been installed in such automobiles, etc. It has become.

[0003] These electrical components are required to have sufficient reliability not only in terms of equipment performance but also because they are used in vehicles and are directly related to human life. It must have sufficient resistance to humidity, mechanical vibration, etc.

[0004] Furthermore, the electrical components need to be connected to other electrical components or sensing components inside the vehicle via connectors, etc., and the connection points are required to be solid and highly reliable. .

[0005] For this reason, in general, in consideration of environmental resistance characteristics and electrical reliability, the covered electric wires drawn from the electrical components are made of resin such as vinyl chloride on a core wire having good electrical conductivity such as copper. Alternatively, vinyl electric wires covered and insulated with rubber or the like, and enameled electric wires covered and insulated by baking resin such as enamel on the surface of the core wire can be mentioned.

[0006] The covered electric wire drawn from the electrical component is
By cutting the wire to a predetermined length and peeling off the tip to a predetermined length, a terminal or connector is attached to the peeled wire portion, and electrical connection with other electrical components, etc. is made using the terminal or connector. There is.

[0007]Furthermore, it is often necessary to chassis ground the terminal attached to the covered wire to the electrical component body, and in this case, the terminal is caulked to a protrusion provided on the electrical component body. process is used.

[0008] The caulking process utilizes the plastic flow of metal that occurs when the mating surfaces of two parts are struck.
It is a method of joining, airtight, and watertight, and was used not only for electrical parts, but also for ensuring watertightness at the joints of boiler can bodies and ship hulls before welding became widespread.

[0009] The sheathing of the insulated wires drawn from the electrical components is carried out as described above, and each of the above steps is generally carried out by an independent worker, or even if the process is organized into an assembly line. However, no special efforts were made to improve efficiency and reliability.

0010

[Problem to be Solved by the Invention] However, according to the above-mentioned conventional assembly process for electrical components, each process is not linked, and each process basically relies on the manual labor of the worker. In particular, the work of peeling off the outer sheath of a covered electric wire insulated with enamel or the like requires skill on the part of the worker, and the peeling is time-consuming and difficult, and the terminal attached to the covered electric wire must be caulked to the electrical component body. Since the work uses the plastic flow of metal, it requires heavy loads, and it takes a lot of effort for the worker to do it himself, and the work is dangerous. There was a problem in that it hindered the development of

[0011] Furthermore, in the process of assembling electrical components, work standards are not standardized, and no measures are taken to eliminate potential causes of component failure in each work process. There has been a problem in that the defective factors have an influence on the electrical components, resulting in a decrease in reliability and, further, that it is not possible to ensure the safety of drivers riding in automobiles etc. in which the electrical components are mounted.

The present invention has been made in view of the above-mentioned circumstances, and reduces assembly costs by efficiently carrying out processes related to the exterior of electrical components, such as peeling off the covered wire and caulking the terminal portions. The present invention provides an assembly process for electrical components in which the rate of non-defective products and reliability during the process are improved by incorporating various tests between each process.

[0013]

[Means for Solving the Problems] In order to achieve the above object, the present invention provides a step of peeling off the outer skin of at least one of a plurality of covered electric wires drawn from an electrical component having an electronic function, and a step of carrying out a withstand voltage insulation test; a step of attaching a connecting terminal to at least one peeled wire portion of the covered electric wire; and a step of caulking at least one connecting terminal of the covered electric wire to the electrical component body; By assembling electrical components from the steps of conducting a resistance value measurement test of the electrical components and performing an external appearance inspection of the electrical components,
This aims to achieve the above objectives.

[0014]

[Operation] In the present invention, by peeling off the outer sheath located at the tip of at least one of a plurality of covered electric wires that have electronic functions and are installed outside of electrical components installed in automobiles, etc. A peeled wire portion is formed in which a conductor portion provided inside the covered wire is exposed.

[0015] A withstand voltage insulation test is performed to confirm the electrical insulation state between the electronic function built into the electrical component and the main body of the electrical component.

[0016] A connection terminal for electrical connection is attached to at least one peeled wire portion of the covered electric wire.

[0017] At least one connection terminal attached to the peeled wire portion of the covered electric wire is caulked to the electrical component body using plastic flow of metal.

A resistance value measurement test is performed to measure the resistance value related to the electronic function built into the electrical component.

By assembling electrical components in the manner described above, it is possible to carry out the assembly process related to the exterior of the electrical components efficiently, and also to improve the yield rate and reliability through various tests set between each process. etc. can be improved.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Examples of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a flowchart showing an embodiment of a method for assembling electrical components according to the present invention, and FIG. 2 is a perspective view showing electrical components assembled according to the embodiment.

As shown in FIG. 2, the electrical component 31 according to the present invention has a built-in electronic function for realizing comfort or safety in an automobile, etc., and also has durability when installed in an automobile, etc. An electrical component main body 32 having a solid structure made of metal or the like to improve environmental characteristics, a first covered electric wire 35 extending from the upper left surface of the electrical component main body 32 through a main body hole, 2-covered electric wire 37 and a columnar protrusion 33 made of metal and protruding from the front side of the electrical component main body 32.

The first covered wire 35 has a structure in which an outer sheath made of vinyl chloride or the like having excellent insulation and environmental resistance is insulated and coated on a core wire having good electrical conductivity such as copper. The two-covered electric wire 37 has a structure in which a similar electric wire is insulated and coated with enamel or the like.

The base end portions of the first covered wire 35 and the second covered wire 37 on the electrical component body 32 side are airtightly connected to the electrical component body 32 by sealing materials 39 and 39' made of synthetic resin, rubber, or the like. The electrical component body 32 is also watertight, so that when the electrical component 31 is mounted on an automobile or the like, the electronic functions built into the electrical component body 32 are protected from the external environment such as humidity.

A connector terminal 36 is attached to the tip of the first covered electric wire 35 and has a terminal portion therein for electrically connecting to other electrical components or electronic functions.

A crimp terminal 38 having a hole on the front side and a crimp portion on the proximal end side is attached to the tip of the second covered electric wire 37. is a protrusion 33 that protrudes from the electrical component main body 32;
The protrusion 33 is fitted into the protrusion 33, and caulking is performed using plastic flow caused by the fact that the protrusion 33 is made of metal.
4 is formed.

[0027] The crimp portion on the proximal end side of the crimp terminal 38 may be equipped with a protective member for protecting the crimp portion and the peeled wire portion of the inserted second covered wire 37. .

Next, a method 25 for assembling electrical components involves assembling the electrical components 31 as described above by subjecting the first covered wire 35 and second covered wire 37 drawn from the electrical component main body 32 to various processes. will be explained with reference to FIG.

Each step of the method 25 for assembling electrical components according to this embodiment is carried out on an assembly line using conveyor chains, etc., and includes a second skin peeling step 14, a caulking step 19, and an insulation testing step 15, which will be described later. It is assumed that approximately one worker is involved in each process except for the resistance value test process 20.

The method 25 for assembling electrical components includes a step of peeling off the outer skin of at least one of a plurality of covered wires drawn from an electrical component having an electronic function, and a step of conducting a withstand voltage insulation test of the electrical component. A step of attaching a connection terminal to at least one peeled wire portion of the covered electric wire, a step of caulking at least one connection terminal of the covered electric wire to the electrical component body, and a resistance value measurement test of the electrical component. The electrical component 31 is assembled through each step.

(First step) In the jig mounting step 11, the electric component 31 having a built-in electronic function and having the first covered wire 35 and the second covered wire 37 is placed on the assembly line. It is mounted on a component mounting jig that is generally required when

[0032] The component mounting jig is capable of arbitrarily mounting various types of electrical components 31, and has a structure that allows workers involved in this process to easily mount the electrical components 31. A plurality of electrical components 31 can be mounted as necessary.

(Second Step) In the line mounting step 12, the component mounting jig on which the electrical component 31 is mounted is mounted on a transfer chain constructed on the assembly line.

(Third step) In the first outer skin peeling step 13, the outer skin is peeled off at a predetermined interval from the tip of the first covered electric wire 35 drawn from the substantially rear upper surface of the electrical component 31. , exposing the internal core wire.

In this step, the first covered wire 35
However, in view of the fact that it has a thick outer sheath made of vinyl chloride, etc., and that the core wire diameter is relatively large, it is common to use a sheath stripper for insulated wires that can be operated at hand. .

(Fourth step) In the second outer sheathing step 14, the outer sheath is peeled off at a predetermined interval from the tip of the second covered electric wire 37 that is drawn from the upper surface of the electrical component 31 on the near side. , exposing the internal core wire.

In this step, the second covered wire 37
However, the applicant filed an application for utility model registration in Utility Model Application No. 918 of 1993, considering that the coated wire has a thin outer covering made of enamel or the like and has a relatively small core wire diameter. It is preferable to apply a coating stripping device of.

[0038] The automatic peeling device includes a drive unit installed above the conveyor chain of the assembly line, a rotary end that is rotationally driven by the drive unit and is provided with a peeling blade hole, the drive unit and It has an installation height adjustment mechanism that makes it possible to adjust the installation height of the rotating end, and the tip of the second covered electric wire 37 is inserted into the stripping blade hole of the rotating end, and the drive unit rotates. The outer cover of the second covered electric wire 37 is peeled off by rotationally driving the end portion.

(Fifth step) In the insulation test step 15, the first covered wire 35 and the second covered wire 37 from which the outer skin has been peeled are
In order to detect the electrical insulation state between at least one of the electrical component body 32 and the electrical component main body 32 formed of a good conductor such as metal, a high voltage is applied between the two.

[0040] Judgment by this test is carried out using a dedicated withstand voltage insulation testing device, and a buzzer or a warning light is used to alert the operator to products with poor insulation.

Further, for electrical contact with the peeled wire portion of the first covered wire 35 or the second covered wire 37, for example, a contact plate or the like is provided above the conveyor chain in the assembly line, and the peeled wire is connected to the contact plate. In addition, for electrical contact with the electrical component body 32,
For example, a conveyance chain is interposed via the component mounting jig.

(Sixth Step) In the connector terminal mounting step 16, a connector terminal 36 for connection with other electrical components or electronic functions is mounted on the peeled wire portion of the first covered wire 35.

[0043] The attachment is generally performed by crimping the peeled wire portion of the first covered wire 35 to the terminal installed inside the connector terminal 36 using a special crimping tool or by soldering. It is.

(Seventh step) In the crimp terminal mounting step 17, a crimp portion of a crimp terminal 38 having a hole on the front side and a crimp portion on the proximal end side is attached to the peeled wire portion of the second coated wire 37. is inserted, and the crimping portion is further crimped together with the peeling line portion using a dedicated crimping tool.

(Eighth Step) In the shaping step 18, the second covered wire 37 with the crimp terminal 38 attached thereto is attached to a protrusion 33 made of metal that protrudes from the upper surface of the electrical component main body 32 on the near side. The crimp terminal 38 is fitted into the hole, and the second covered wire 37 and the crimp terminal 38 are shaped so that they do not protrude from the electrical component main body 32.

(Ninth step) In the crimping step 19, the protrusion 33 into which the crimp terminal 38 is fitted is pressed from above,
Utilizing the plastic flow caused by the protrusion 33 being made of metal, the crimp terminal 38 is inserted into the electrical component main body 3 via the protrusion 33.
A caulking portion 34 is formed by caulking 2.

In this process, in view of the need to press the protruding portion 33 from above with a tremendous force and the danger involved, the applicant of the present application filed the application in 1997.
It is preferable to apply a crimping device that has been registered as a utility model in No. 9.

The automatic moving device includes a pressing part that is installed above the conveyor chain of the assembly line and supplies a strong pressing force, and a positioning part of the protruding part 33 into which the crimp terminal 38 is inserted. a positioning section that performs the positioning, a fixing section that fixes the electrical component 31 and the component mounting jig after the positioning, and a fixing section that prevents pressure from being applied to the conveying chain when the protruding section 33 is pressed by the pressing section. When the electrical component 31 mounted on the component mounting jig reaches a predetermined position by the conveying chain, the positioning part performs positioning, and the The position of the crimp terminal 38 is fixed by the fixing part, the conveying chain is avoided from receiving the pressing force by the pressing force avoiding part, and then the protruding part 33 is pressed by the pressing part, and the crimp terminal 38 is attached to the electrical component. It is adapted to be caulked to the main body 32.

This means that the second covered wire 37 is electrically connected to the electrical component main body 32 via the crimp terminal 38.

(10th step) The resistance value testing step 20 detects the electrical resistance value present in, for example, the second covered wire 37, that is, the electrical component main body 32, and the connector terminal 36 of the first covered wire 35. In order to do this, a current is passed between the two.

[0051] Judgment by this test is carried out using a dedicated resistance value measurement test device, and if the resistance value does not meet the specifications, a buzzer or warning light is used to make the operator aware of it. There is.

Further, electrical contact to the second covered electric wire 37 can be made using a conveyor chain or the like via the electrical component main body 32, and further, the
Electrical contact to the connector terminal 6 can be made by bringing a contact into contact with a terminal portion provided inside the connector terminal 36.

[0053] For electrical contact when a crimp terminal similar to that of the second covered wire 37 is attached to the peeled wire portion of the first covered wire 35, the insulation test step 15 is performed.
Similarly, it is also possible to provide a contact plate or the like above the conveyor chain in the assembly line, and to make contact between the contact plate and the crimp terminal.

(Eleventh process) In the jig removal process 21, when the above assembly process is completed and the results of various tests conform to predetermined standards, the jig removal process 21 removes the component mounting jig from the conveyor chain in the assembly line. At the same time, the electrical component 31 is removed from the component mounting jig.

(Twelfth Step) In the appearance inspection step 22, the electrical components 31 assembled by the above assembly steps are
The connector terminal mounting process 16 and the crimp terminal mounting process 17
The operator visually inspects mechanical tests in each process such as the caulking process 19 and the like.

As described above, the method 25 for assembling electrical components related to the exterior of the electrical components 31 is configured.

However, according to method 25 for assembling electrical components, a work index can be obtained by standardizing the assembly process, and the process of stripping the outer covering of each coated wire, crimping process, etc. can be carried out efficiently and steadily. As a result, it becomes possible to improve the non-defective product rate and reliability regarding the assembly.

[0058] Further, in the method 25 for assembling electrical components, by standardizing the assembly process, it is possible to reduce the number of workers compared to the number of workers that were conventionally required, thus promoting reductions in personnel costs. I can do it.

Furthermore, the method 25 for assembling electrical components includes:
By mixing various tests between each process, the test status is perceived by the workers engaged in the work, so parts that do not meet the tests are excluded by the workers, which reduces the probability of defective products being mixed in. can be significantly reduced.

[0060] In this embodiment, the explanation has been made on the assumption that the number of covered wires to be assembled for the exterior of the electrical component 31 is two, but the invention is not limited to this, and even if there are three or more covered wires, the assembly process can still be carried out. This can be handled flexibly by increasing the number arbitrarily.

Further, similarly to the above, there may be a plurality of caulking portions, and furthermore, there may be a plurality of locations where connector terminals are attached.

[0062]

[Effect of the invention] The method for assembling electrical components according to the present invention is as follows:
Since it is configured as described above, it has the following effects.

(1) a step of peeling off the outer skin of at least one of a plurality of covered electric wires drawn from an electrical component having an electronic function; and a step of conducting a withstand voltage insulation test of the electrical component;
A step of attaching a connection terminal to at least one peeled wire portion of the covered electric wire, a step of caulking at least one connection terminal of the covered electric wire to the electrical component body, and a resistance value measurement test of the electrical component. Electrical components are assembled from a process and a process of performing an external appearance inspection of the electrical components.

[0064] This makes it possible to standardize the assembly process of the electrical components, obtain work indicators, and perform the sheathing process and caulking process of various covered electric wires efficiently and reliably. Therefore, it has an excellent effect of being able to improve the non-defective product rate and reliability regarding the assembly.

(2) Furthermore, by standardizing the assembly process, it is possible to reduce the number of workers compared to what was previously required, which is an excellent advantage in that it is possible to promote a reduction in personnel costs. have an effect.

(3) Furthermore, by mixing various tests between each process, the test status is perceived by the workers engaged in the work, so parts that do not meet the tests are excluded by the workers. Therefore, it has the excellent effect of greatly reducing the probability of defective products being mixed together.

[Brief explanation of the drawing]

[Figure 1] Flowchart showing an example of the method for assembling electrical components

[Figure 2] A perspective view showing electrical components assembled according to the same example.

[Explanation of symbols]

11 Jig mounting process 12 Line mounting process 13 First outer skin peeling process 14 Second skin peeling process 15 Insulation test process 16 Connector terminal installation process 17 Crimp terminal installation process 18 Shaping process 19　　　　Caulking process 20 Resistance value test process 21 Jig removal process 22 Appearance inspection process 25 How to assemble electrical parts 31 Electrical parts 32　　　Electrical parts body 33 Protruding part 34 Caulking part 35 First covered wire 36 Connector terminal 37 Second covered wire 38 Crimp terminal 39 Seal material

Claims (1)

[Claims] 1. A step of peeling off the outer skin of at least one of a plurality of covered electric wires drawn from an electrical component having an electronic function, a step of performing a withstand voltage insulation test of the electrical component, and a step of peeling off the outer skin of at least one of the plurality of covered electric wires drawn from an electrical component having an electronic function. a step of attaching a connecting terminal to one peeled wire portion, a step of caulking at least one connecting terminal of the covered electric wire to the electrical component main body, a step of performing a resistance value measurement test of the electrical component, and a step of performing a resistance value measurement test of the electrical component; A method for assembling electrical components, comprising a step of performing an external appearance inspection, and assembling the electrical components.