TWI396851B - Method and detection device for riveting part of wire terminal - Google Patents

Description

Wire terminal riveting portion detecting method and detecting device

The present invention relates to a method and a detection circuit for detecting the quality of a rivet portion of a terminal of a wire, and more particularly to a method for detecting the quality of a terminal rivet portion of each wire in a wire harness used in a vehicle.

With the requirement of environmental protection, the regulations on the exhaust of vehicles have become stricter, and the fuel system of the locomotive has a tendency to switch from the traditional carburetor to the injection fuel system. In order to effectively control the injection fuel system in response to this trend, the normal operation of electronic components such as the sensors and electronic control components is important to the operation of the locomotive, thereby making it possible to connect the fuel systems, sensors and electronics. The quality requirements of the locomotive harness harness for control components have increased, especially for the quality of the wires and their terminals used in the harness system.

6 is a schematic view of a wire harness system of a locomotive. As shown in FIG. 6, the wire harness system 31 of the locomotive 1 is closely related to various terminals of the fuel system, including a throttle opening sensor terminal 32, a fuel injector terminal 36, and The oxygen sensor terminal 37, the ignition coil terminal 35, the temperature sensor terminal 34, the intake pressure sensor terminal 33, and the like. In addition, the harness system 31 is also connected to other terminals for controlling various types of electronic components on the locomotive, such as the rear directional light terminal 21, the tail light terminal 22, the brake light terminal 23, the left handle switch assembly terminal 241, and the front left directional light terminal. 24. Horn terminal 25, headlight terminal 26, ECU terminal 27, front right direction lamp terminal 28, right handle switch assembly terminal 29, and the like. It can be seen from the above that there are many terminals connected to the harness system 31, and the quality of the terminals and the wires has a great influence on the quality of the system.

7 is an enlarged schematic view of a wire terminal used in the wire harness system. As shown in FIG. 7, the wire 211 and the terminal 111 in the wire harness system are not integrally formed. Usually, the terminal 111 is integrated with the rivet portion 311, and is riveted. Since the electric wire 211 and the terminal 111 are connected in a manner, the riveting quality of the caulking portion 311 has a great influence on the signal transmission quality of the riveted electric wire terminal.

In order to ensure the quality of the wire harness system, in addition to the requirements for the wire and the terminal itself to meet the specified specifications and quality, there is no specific detection method and specification for the riveting quality of the rivet portion 311 at the connection between the wire 211 and the terminal 111. However, if the connection quality of the terminal rivet portion 311 of the electric wire 211 is not good, the resistance of the portion may be greatly changed. When the resistance fluctuates greatly, the signal is unstable, and the stability of the entire system is lowered. .

On the other hand, the poor quality of the terminal rivet portion 311 of the electric wire 211 may cause the resistance value to become large at this point, and the power consumption flowing therethrough may increase, and the heat loss may be converted, so that the line temperature rises. It may cause problems such as heat damage to the line or early deterioration of the line. Therefore, in order to avoid the influence of the poor riveting quality of the rivet portion 311, it is necessary to develop a systematic method for the detection of the specification and connection quality of the rivet portion 311 for effective detection.

In the prior art, in order to detect the riveting quality of the riveting portion, there are two detection methods, namely, the peeling force measurement and the metallographic confirmation.

The peeling force is measured by applying a predetermined drawing force to the terminal caulking portion 311 of the riveted electric wire 211 to measure the peeling force of the caulking portion. According to the detected pull-out force that the rivet portion 311 can withstand, the riveting quality is judged.

However, the pull-out force measurement is a destructive test, and the wire terminal used for the pull-out force measurement can no longer be used after being tested, resulting in loss of the wire terminal product.

In addition, the measurement of the detachment force for the rivet quality of the rivet portion 311 does not actually achieve a better accurate effect. The purpose of the rivet quality inspection according to the rivet portion is mainly to prevent the riveting of the rivet portion (not riveted) to cause the above resistance. The fluctuation causes the signal transmission to be unstable and the heat damage that may occur when the signal is transmitted. However, the peeling force measurement confirms the riveting quality by measuring the pulling force of the terminal and the rivet portion 311 of the electric wire 211. (The riveting portion is riveted tightly), and the detachment force that the rivet portion 311 can withstand does not fully represent the electrical specifications and qualities of various aspects, such as the stability of transmitting electronic signals. Therefore, when the peeling force measurement is used, it is possible that, for example, the terminal caulking portion 311 of the electric wire 211 passes the peeling force measurement, but actually does not reach the requirement of fully complying with various types of signal transmission and the like.

Another method for previously measuring the riveting quality of the terminal caulking portion 311 of the electric wire 211 is a metallographic confirmation method in which the terminal caulking portion 311 of the electric wire 211 is potted, cut, and then riveted by cutting using a metallographic analysis apparatus. The section of the portion 311 is confirmed by the metallographic analysis to determine the riveting quality, and FIG. 8 shows a metallographic cross-sectional view of the terminal rivet 311 of the electric wire 211 after cutting.

The metallographic confirmation method provides a more accurate riveting quality inspection by directly performing metallographic confirmation on the rivet portion 311. However, it is a destructive test similarly to the measurement of the pull-out force, and the wire terminal used for the metallographic confirmation method can no longer be used after being tested, resulting in unnecessary loss of the wire terminal.

In addition, the metallographic phase confirms that special equipment with high price is required for cutting and metallographic analysis. Therefore, the inspection is usually sent to a special analyst, and the time from glue filling, cutting, metallographic analysis to obtaining test results is long. It requires a high detection cost and a long detection time, which is a test method that can be easily used by non-common operators. In the metallographic analysis, the metallographic analysis practitioners did not tend to have a certain standard in the detection of metallographic analysis, but they have different testing standards. Therefore, the results of metallographic analysis performed by different operators There may be cases where the results are different. Table 1 shows an example of the detection of the metallographic phase of the riveting portion by the metallographic confirmation method, which uses the detection criteria of the relationship between the specific dimension values of the three metallographic sections of A, B, and C and the material thickness, and is detected. The three specific dimensions of the terminal rivet parts A, B, and C must meet the standards listed in Table 1 to meet the required riveting quality of the rivet joint.

As described above, the detection process of the pull-out force measurement or the metallographic confirmation is complicated, especially the metallographic confirmation, and the special manufacturer needs to perform the glue filling, cutting, and metallographic analysis on the riveting portion, so neither of the two detection methods can be used for the wire terminal. Direct inspection in the production process, so that even if there are defective products in the production process, it can not be detected immediately, and it is necessary to wait for the completion of the entire production batch to be tested, resulting in the inability to immediately discover the process problems to immediately improve the process. Therefore, the defect rate cannot be effectively reduced.

In addition, either the pull-out force measurement or the metallographic confirmation is the direct detection and only the terminal crimping portion 311 itself of the electric wire 211 is detected. Therefore, if the wire main-line portion has a broken portion of the core wire, it cannot be detected.

For the above-mentioned problems in the determination of the pull-out force and the metallographic confirmation of the riveting quality of the riveting portion, the industry and users have long hoped to obtain an effective improvement solution. The present invention is a novel solution to the inventors' problems in the above-mentioned prior art method of detecting the riveting of electric wire terminals, and after painstaking consideration and long-term commitment to research and development. That is, an object of the present invention is to provide a method and a detection circuit for detecting the riveting quality of a rivet portion of a terminal of a wire which can be easily, quickly, and at low cost.

After the wire terminal is riveted, if the resistance of the rivet portion changes due to the bending of the wire, and the fluctuation is large, it indicates that the rivet portion is not properly tightened, and there is a gap between the core wires of the rivet portion, so when the wire is When the line is twisted, the core wire of the wire is pulled and moved, and the resistance value changes greatly.

When there is a gap in the core wire of the riveting portion, in addition to the above, the resistance value of the wire line will fluctuate greatly, and the overall resistance value will also become large, and the large resistance value will cause heat loss of the wire and large voltage drop of the wire line. And problems such as heat damage.

Therefore, the inventors have painstakingly thought that the relationship between the crimping portion of the electric wire terminal and the electric resistance thereof can be easily detected by detecting the caulking portion of the electric wire terminal without using a destructive method such as metallographic detection.

Specifically, the invention of claim 1 is a method for detecting a terminal riveting portion of an electric wire, wherein the method is for detecting an electric wire having a terminal and a terminal riveting portion at one end, wherein the method includes: a static resistance measuring step, When the electric wire is in a static state, the two ends of the electric wire are connected by a resistance meter, and the resistance value is measured, and the measured resistance value is a static resistance value; the dynamic resistance measuring step is connected by a resistance meter. In the state in which both ends of the electric wire are bent, the electric resistance value of the electric wire in the state of being dynamically bent is measured, and the maximum and minimum values of the measured electric resistance values are compared with the static The resistance value of the difference between the resistance values is greater than the dynamic resistance value; the resistance change rate calculation step is such that the larger of the static resistance value and the dynamic resistance value is a numerator, and the smaller is a denominator, and the ratio is calculated. And using the ratio as the resistance change rate; and the resistance change rate determining step, when the calculated resistance change rate is less than a reference value, determining the electric power of the electric wire The resistance change rate is acceptable.

According to the above configuration of the present invention, the electric wire whose electric resistance change rate is judged to be qualified can be judged by changing the electric resistance change rate of the electric wire without damaging the electric wire, and the riveting state of the electric wire can be confirmed, and whether the core portion of the electric wire main body is broken can be confirmed. section. Moreover, the invention can be directly detected in the production process, so that it is easy to ensure that the variation of the resistance of the riveting portion of the electric wire falls within the required range, so that the harness system using the electric wires can avoid the problem of system instability.

The invention of claim 2 is the invention of claim 1, wherein the electric wire has a bending angle of more than 90 degrees.

According to the above configuration of the present invention, the electric wire which is judged to be qualified when the bending angle is larger than 90 degrees can be surely required to be a wire function which requires a large angle of bending in the wire harness system.

The invention of claim 3 is the invention of claim 1, wherein the reference value is 1.5.

According to the above-described configuration of the present invention, it is possible to ensure an electric wire having a riveting quality equivalent to that confirmed by the metal phase, with the electric wire judged to be a qualified electric wire with a reference value of 1.5.

The invention according to any one of the first to third aspects, further comprising the step of applying a voltage step of connecting each of the two ends of the electric wire in series with a power source. The power source applies a voltage and a current to the detecting wire; and the measuring temperature obtaining step is: measuring a temperature of the terminal riveting portion of the wire as a measuring temperature in a state in which the power source applies a voltage and a current to the wire; The resistance value judging step is performed by adding a temperature to the measured temperature of the terminal riveting portion of the wire, and then summing the test temperature. If the test temperature is less than a predetermined temperature, determining the resistance of the wire The value is acceptable.

As described above, the riveting quality of the terminal caulking portion of the electric wire is poor, which may cause problems such as heat damage of the electric wire. With respect to these problems, according to the above configuration of the present invention, when the electric wire is used, the actual electric line is loaded and energized. The current flows through the possible heat generation on the wire line, and the temperature generated by the current is detected, and it can be judged whether the terminal riveting portion of the wire causes heat damage in actual use. According to the present invention, it is possible to easily, quickly and inexpensively detect whether or not the riveted portion of the electric wire meets the requirement for preventing heat generation.

The invention of claim 4, wherein the adjusted temperature is an absolute value of a difference between 40 ° C and an ambient temperature during measurement, and the predetermined temperature is 70 ° C.

According to the above configuration of the present invention, the absolute value of the difference between the ambient temperature at 40 ° C and the measurement temperature is determined as the temperature at which the temperature is determined to be 70 ° C as the predetermined temperature, and it is ensured that the steel wire is qualified as the metal phase. Riveted quality wire.

The invention of claim 4, wherein the maximum value of the temperature measured when the temperature measured by the terminal crimping portion of the electric wire is substantially stabilized is the above-mentioned electric wire Measure the temperature.

According to the above configuration of the present invention, the maximum value of the temperature measured by the temperature measured by the terminal crimping portion is substantially stabilized as the above-mentioned measurement temperature of the electric wire, and it is possible to further ensure the same riveting as the metal phase. Quality wire.

The invention of any one of items 1 to 3, wherein the wire length is 100 mm to 200 mm.

According to the present invention, when the electric wire has a length of 100 mm to 200 mm, the bending of the electric wire and the measurement of the electric resistance can be performed more conveniently.

The invention of claim 8 is a method for detecting a terminal riveting portion of a wire, wherein the method detects a plurality of wires each having a terminal and a terminal riveting portion at one end, wherein the method comprises the steps of: from the plurality of wires The wire is sampled by at least two or more wires to be tested; and the at least two or more wires to be tested sampled are respectively detected by the detection method of any one of items 4 to 6; Calculating an average value of the test temperatures of the at least two or more of the to-be-detected wires measured; the overall quality judging step is that the resistance change rate of the at least two or more wires to be detected is qualified and the resistance is When the value is acceptable, if the maximum value of the test temperatures of the at least two or more wires to be detected is less than the sum of the average value and the correction value, it is determined that the riveting quality of the riveting portion of the plurality of wires is qualified. .

According to the present invention, by sampling at least two test wires from a plurality of wires, and detecting the sampled test wires by the detection methods of the fourth to sixth inventions of the present invention, it is quick, simple and low-cost. The entire wire of the plurality of wires is detected.

According to the present invention, in the detection of the riveting quality of the terminal riveting portion of the plurality of electric wires, only a low-cost and ubiquitous device such as a resistance tester, a constant voltage source, a constant current source, and a thermometer can be used for detection, and neither need to be taken off. The force measurement equipment for pull force measurement does not require high-priced metallographic analysis equipment for metallographic confirmation, so the test can be completed at a very low cost.

Moreover, the detection method of the invention does not require complicated wiring, force measurement, or complicated steps such as metallographic confirmation cutting and metallographic analysis, so it has convenient and rapid effects.

Moreover, in the present case, the test time required to calculate the resistance or temperature for the riveting quality determination step is short, and the required number of detections can be completed in a short time.

Moreover, the accuracy of the detection effect obtained by detecting the resistance or the temperature is high, because the resistance or temperature of the terminal riveting portion of the electric wire is directly detected, instead of determining the riveting quality of the riveting portion by the pulling force or the like, the peeling quality can be avoided. It may occur in the pull force measurement that is determined by the pull-out force but whose electrical specifications do not meet the required specifications.

Further, in the above invention, in detecting the electric resistance or detecting the temperature, the object to be detected includes the main body of the electric wire in addition to the caulking portion, so that the quality of the core wire of the electric wire portion can be ensured, and the prior art can be prevented from being pulled out. In the force measurement and metallographic confirmation, only the problem of the riveting quality of the caulking portion can be confirmed.

In addition, as shown in the above invention, in the invention of the present invention, it is not necessary to perform the destructive detection such as the removal of the terminal riveting portion of the tested electric wire or the cutting of the metal phase, so that all the tested wire terminals can be used normally. The wire terminal cost lost in the testing of the prior art riveting portion can be reduced.

The invention of claim 9 is the invention of claim 6, wherein the correction value of the above-mentioned temperature average value is 3 °C.

According to the present invention, it is possible to ensure that the riveted portion of the electric wire which is judged to have passed the level of the metal phase confirmation.

According to a tenth aspect of the present invention, there is provided a device for detecting a terminal riveting portion of a wire for detecting an electric wire having a terminal and a terminal riveting portion at one end, wherein the detecting circuit comprises: a resistance meter, It is connected in series with the riveting portion and the other end of the electric wire, and can measure the static state and the resistance value in the dynamic state of the electric wire, and output the measured results separately; and the judging circuit receives the electric resistance meter The measured resistance values of the electric wires in the static state and the dynamic state are measured, and the resistance values are calculated and compared to determine whether the resistance change rate of the electric wires is acceptable.

According to the present invention, the riveting quality of the terminal riveting portion of the plurality of electric wires can be achieved only by the resistance detecting meter and the simple judging circuit, and the force measuring device for measuring the pulling force is not required, and the high price of the metal phase confirmation is not required. Metallographic analysis equipment makes it quick and easy to perform tests directly in the production process at a very low cost. Further, the electric wire change rate of the electric wire can be judged without damaging the electric wire, and the riveted state of the electric wire can be confirmed, and at the same time, it can be confirmed whether or not the wire portion of the main body of the electric wire has a broken portion.

The invention of claim 10, wherein the determining circuit is such that the larger of the static resistance value and the dynamic resistance value is a numerator, and the smaller one is a denominator, and the ratio is calculated. The ratio is taken as the resistance change rate, and when the calculated resistance change rate is equal to or lower than the reference value, it is judged that the resistance change rate of the electric wire is acceptable.

According to the above configuration of the present invention, it is possible to easily and effectively ensure that the fluctuation of the electric resistance of the rivet portion of the electric wire falls within the required range, so that the harness system using the electric wires can avoid the problem of system instability.

The invention of claim 12 is the invention of claim 11, wherein the reference value is 1.5.

According to the above-described configuration of the present invention, it is possible to ensure an electric wire having a riveting quality equivalent to that confirmed by the metal phase, with the electric wire judged to be a qualified electric wire with a reference value of 1.5.

According to a thirteenth aspect of the invention, there is provided a device for detecting a terminal rivet portion of a wire, which is for detecting a wire having a terminal and a terminal rivet at one end, and has a detecting circuit, wherein the detecting circuit includes: a power source; The two ends are respectively connected in series to the terminal of the electric wire and the other end of the electric wire; a thermometer is connected to the riveting portion of the electric wire, measuring the temperature of the riveting portion, and outputting the measured temperature value; and judging a circuit that receives the temperature of the riveting portion measured by the thermometer and determines a temperature from a maximum value of the measured temperature when the measured temperature reaches a stable state, and determines the above according to the measured temperature Whether the resistance value of the wire is acceptable.

According to the above configuration of the present invention, the riveting quality of the terminal riveting portion of the plurality of electric wires can be detected only by the power source, the thermometer, and the simple judging circuit, and the force measuring device for measuring the pull-out force is not required, and the metal phase is not required to be expensive. Metallographic analysis equipment makes it quick and easy to perform inspections at a very low cost.

The invention of claim 11, wherein the power source is connected to one end of the opposite side of the riveting portion of the electric wire via a copper plate; and the terminal of the one end of the riveting portion of the electric wire has the above After the terminals corresponding to the terminals are connected to each other, the other end of the electric wire having the corresponding terminal is connected to the power source via a copper plate; and the terminal riveting portion of the wire having the corresponding terminal is filled with solder to fill the core between the riveting portions. gap.

According to the above configuration of the present invention, the copper plate can be used as a fixture for measuring temperature, and the temperature can be measured more conveniently, and the electric wire to be measured is connected to the electric wire having the corresponding terminal, and then connected to the copper plate via the copper plate. The power supply can prevent the heat of the riveting portion of the wire to be measured from being dissipated to the copper plate and affect the accuracy of the detection result. The riveting portion of the wire with the corresponding terminal is filled with the solder to prevent the riveting quality of the riveting portion from affecting the detection result.

The invention of claim 15 is the invention of claim 13 or claim 14, wherein the determining circuit adds the adjusted temperature to an adjusted temperature, and if the sum of the measured temperature and the adjusted temperature is less than a predetermined temperature, Then, it is judged that the resistance value of the wire is acceptable.

According to the above configuration of the present invention, it is possible to effectively detect whether or not the rivet portion of the electric wire meets the requirement for preventing heat generation.

The invention of claim 16 is the invention of claim 15, wherein the adjusted temperature is an absolute value of a difference between 40 ° C and an ambient temperature during measurement, and the predetermined temperature is 70 ° C.

According to the above configuration of the present invention, the absolute value of the difference between the ambient temperature at 40 ° C and the measurement temperature is determined as the temperature at which the temperature is determined to be 70 ° C as the predetermined temperature, and it is ensured that the steel wire is qualified as the metal phase. Riveted quality wire.

Embodiments of the present invention will be described in detail below with reference to the drawings.

The first embodiment of the present invention is an embodiment of a resistance detecting circuit. 1 is a schematic view showing a first embodiment of a detecting circuit 100 for a wire terminal crimping portion used in the detecting method of the present invention. As shown in FIG. 1, the detecting circuit 100 has a riveting portion 30 and a riveted terminal 10. The detecting circuit 100 includes the length L of the to-be-detected electric wire 20, which may be between 100 mm and 200 mm. The detecting circuit 100 includes a resistance meter 40 connected to the riveting portion 30 and the other end of one end of the electric wire 20 to be inspected. The resistance meter 40 performs the measurement of the static state of the electric wire 20 and the dynamic state, and outputs the measured results separately; and the judging circuit 50 receives the electric wire 20 measured by the electric resistance meter 40 in a static state. And the respective resistance values in the dynamic state, and the respective resistance values are calculated and compared to determine whether the resistance change rate of the crimping portion 30 of the electric wire 20 is acceptable, and the result is output.

A second embodiment of the present invention is an embodiment of a temperature detecting circuit. 2 is a schematic view showing a second embodiment of the detecting circuit 200 of the electric wire terminal caulking portion 30 used in the detecting method of the present invention; as shown in FIG. 2, the detecting circuit 200 has a riveting portion 30 and a riveted terminal 10; The detecting wire 20 is detected, and the length L of the wire 20 can be between 100 mm and 200 mm. The detecting circuit 200 can include, for example, a constant voltage constant current power source 70, and the two ends thereof are respectively connected to the terminal 10 of the electric wire 20 and the electric wire 20 At the other end, a certain voltage and a constant current are applied to the electric wire 20. In the present embodiment, a DC voltage of 12 V and a DC current 10A are applied; a thermometer 60 is connected to the riveting portion 30 of the electric wire 20, and the temperature of the riveting portion 30 is measured. And outputting the same; and the judging circuit 50 receives the temperature value of the riveting portion 30 measured by the thermometer 60, wherein the temperature reaches a maximum value obtained after the temperature is stabilized (there is still a little after the temperature reaches a stable state) Change, so take the maximum value) to measure the temperature and determine whether the measured temperature is qualified. For example, the judging circuit 50 may add the adjustment temperature to obtain the test temperature, and when the test temperature is less than a predetermined pass temperature, it is judged that the resistance value of the riveting portion 30 of the electric wire 20 is acceptable.

The third embodiment of the present invention is also an embodiment of a temperature detecting circuit. 3 is a schematic view showing a third embodiment of the detecting circuit 300 of the electric wire terminal caulking portion 30 used in the detecting method of the present invention. As shown in FIG. 3, the detecting circuit 300 includes a riveted portion 30 and a riveted terminal. The detection line 10 is detected by the electric wire 20, and the length L of the electric wire 20 can be between 100 mm and 200 mm. The detection circuit 300 includes a constant voltage constant current power source 70, and one end of the electric wire 20 opposite to the riveting portion 30 is connected via a copper plate 12 One end of the power source 70 is connected, and the terminal 10 of the electric wire 20 has a terminal 101 corresponding to the terminal 10 (if the terminal 10 is a male terminal, the terminal 101 is a female terminal; if the terminal 10 is a female terminal, the terminal 101 is a male terminal) The electric wire 201 having the terminal 101 is further connected to the other end of the power source 70 via the copper plate 13, and the riveting portion 301 of the electric wire 201 and the terminal 101 is filled with solder to compensate for the possible gap therein; the thermometer 60 is connected to the electric wire 20 The staking portion 30 measures the temperature of the staking portion 30 and outputs it; and the judging circuit 50 receives the temperature value of the rivet portion 30 measured by the thermometer 60, wherein the temperature value obtained by stabilizing the temperature is the highest. Value (there will still be stable after the temperature reached due to small changes, it takes on its maximum) is equal to the temperature measurement, the temperature measurement is determined to be acceptable. For example, the judging circuit 50 may add the adjusted temperature value to obtain the test temperature. When the test temperature is less than a predetermined acceptable temperature, it is determined that the resistance value of the riveting portion 30 of the electric wire 20 is acceptable.

In the detecting circuit 300, the copper plates 12 and 13 are used as the fixture for temperature measurement, and when the terminal 10 is directly clamped to the copper plate 13, the heat flows to the copper plate 13 and is absorbed, causing measurement error, so The terminal 10 and the copper plate 13 are separated by a wire 201. Further, in order to prevent the caulking quality of the caulking portion 301 of the electric wire 201 from affecting the detection result, the caulking portion 301 of the electric wire 201 is filled with solder to ensure the caulking quality of the caulking portion 30 for inspection. In addition, when the harness system on the vehicle is actually used, the terminal 10 is often used in conjunction with a corresponding terminal 101, so that the measurement method can be closer to the actual use situation, and a more accurate result is obtained.

In addition, the detecting device for the terminal riveting portion of the electric wire according to the above embodiments of the present invention may include the detecting circuit 100 of the first embodiment and the detecting circuit 200 of the second embodiment, or may include the detecting circuit as in the first embodiment. 100 and detection circuit 300 as in embodiment 3.

The electric wire to be tested 20 is obtained by sampling in the electric wire produced by the electric wire production process, and the electric wires produced in the process parts of the beginning, middle and end of the electric wire production process batch may be separately sampled, detected, and Test results and adjust the process in real time to increase production yield.

The fourth embodiment of the present invention is also an embodiment relating to a combined resistance detecting method and a temperature detecting method. Fig. 4 is a flow chart showing the steps of the method for detecting the terminal rivet portion of the electric wire according to the fourth embodiment of the present invention. In the flowchart of the step of Fig. 4, a flow chart showing the steps of the detection method using the detection method used in the detection circuit of the first embodiment and the detection method used in the detection circuit of the second embodiment is shown. Specifically, in step S101, the electric wire 20 having the terminal 10 and the terminal caulking portion 30 is placed in a substantially linear state, and the caulking portion 30 and the other end of the electric wire 20 are connected by the electric resistance meter 40. The resistance value is measured. The measured resistance value is a static resistance value Rs, wherein the length of the wire 20 can be between 100 mm and 200 mm.

In the step S102, the electric resistance of the electric wire 20 in the state of being dynamically bent is measured while the electric wire 20 is bent to 90 degrees or more in a state where the electric wires are connected to each other by the electric resistance meter, and The resistance value of the difference between the maximum value Rdmax and the minimum value Rdmin of the measured resistance values and the static resistance value Rs is larger than the dynamic resistance value Rd.

In step S103, the larger of the static resistance value Rs and the dynamic resistance value Rd is a numerator, and the smaller one is a denominator, and the ratio is calculated, and the ratio is calculated as the resistance change rate RC.

In step S104, when the calculated resistance change rate RC is equal to or lower than the reference value, it is determined that the resistance change rate of the electric wire 20 is acceptable. In this embodiment, the reference value is set to 1.5.

In step S104, the reference value for determining whether or not the resistance change rate is acceptable is set to 1.5, because the statistical result of the detection result by the inventors of the present invention is found to be a qualified electric wire when the reference value is 1.5. The riveting quality is almost the same as that of the wire confirmed by the metallographic phase. Therefore, the best detection result can be obtained by setting the reference value to 1.5.

In step S105, both ends of the electric wire 20 are connected in series with the power source 70, and the power source 70 applies a direct current constant voltage of 10 V and a direct current constant current 12A to the electric wire 20 to be detected.

In step S106, in a state where the power source 70 applies a voltage of 10 V and a current 12A to the electric wire 20, the temperature of the terminal caulking portion 30 of the electric wire 20 is measured, and the temperature measured by the terminal caulking portion 30 of the electric wire 20 is measured. The maximum value among the temperatures measured until the stabilization is reached is the measured temperature Tm of the terminal rivet portion 30 of the electric wire 20.

In step S107, the measured temperature Tm of the terminal rivet portion 30 of the electric wire 20 is added to the adjustment temperature Tr to obtain a test temperature Tt, and if the measured temperature Tm is the sum of the adjusted temperature Tr (ie, the test temperature) When Tt) is less than a predetermined comparison temperature Tc, it is judged that the electric resistance value of the electric wire 20 is acceptable. In the present embodiment, the comparison temperature Tc is set based on a maximum temperature that can be tolerated by the PVC coating material of the electric wire 20.

Specifically, in the present invention, in step S107, it is considered that the terminal rivet portion 30 of the electric wire 20 may be used under various ambient temperatures, so that a possible maximum use ambient temperature can be assumed and used as a correction parameter. For example, it can be assumed that the terminal rivet portion 30 of the electric wire 20 is most likely to be used in an external environment of 40 ° C. Therefore, in order to correct the value measured in the indoor environment, the measured temperature Tm measured in step S106 is substituted. Corrected in (1) to obtain a test temperature value Tt.

Test temperature = measurement temperature + (maximum use ambient temperature - test ambient temperature) Equation (1)

Next, it is further determined whether the test temperature Tt is lower than a comparison temperature Tc (that is, the highest temperature that the terminal rivet portion 30 of the electric wire 20 is desired to tolerate). In the present invention, the comparison temperature at which the test temperature is acceptable is set to 70 ° C. This is because the PVC coating material of the electric wire generally causes heat damage at 70 ° C or higher, so the present invention uses 70 ° C as the comparative temperature. If the test temperature Tt is smaller than the comparison temperature Tc, it is judged that the resistance value of the electric wire 20 is acceptable.

In step S108, if it is determined in step S104 that the resistance change rate of the electric wire 20 is acceptable, and it is determined in step S107 that the electric resistance value of the electric wire 20 is acceptable, it is determined that the riveting quality of the terminal caulking portion 30 of the electric wire 20 is acceptable.

[Test Example 1]

According to the procedure described in the above embodiment 4, resistance detection and temperature detection were performed for two wire samples A and B at room temperature 25.3 ° C, respectively, and the detection results are shown in Table 2.

Among them, in the resistance detection, the static resistance value measured for the sample A is 3.7 Ω, and the dynamic resistance value is 8.2 Ω, so the resistance change rate of the sample A is 8.2/3.7=2.2, which is greater than the reference value of 1.5; In the test, the measured temperature Tm was 95 ° C, and the test temperature Tt in the use environment corrected to 40 ° C was 109.7 ° C. The value of this test temperature Tt is greater than the comparison temperature Tc 70 °C. Therefore, it is judged that the resistance change rate and the resistance value of the sample A are unqualified, so that the quality of the terminal rivet portion of the sample A is judged to be unacceptable.

On the other hand, in the resistance detection, the static resistance value measured for the sample B is 2.4 Ω, and the dynamic resistance value is 3.5 Ω, so the resistance change rate of the sample B is 3.5/2.4=1.45, which is less than the reference value of 1.5; In the temperature measurement, the measured temperature Tm was 42.5 ° C, and the test temperature Tt in the use environment corrected to 40 ° C was 57.2 ° C. Since the value of the test temperature Tt is less than the comparison temperature Tc 70 ° C, it is judged that the resistance change rate and the resistance value of the sample B are both acceptable, so that the quality of the terminal riveting portion of the sample B is judged to be acceptable.

The results of the above-described detection by the detection method of Example 4 of the present invention are compared with the results of the confirmation of the metallographic confirmation method. Samples A and B were subjected to metallographic confirmation to detect the riveted portion. The cross-sectional view for metallographic analysis is shown in Fig. 5. The cross section of the metallographic analysis for sample A has a large gap between the core wires of the caulking portion. Judging by the conventional metallographic detection standard, the judgment result is unsatisfactory, and the gap of the riveting portion of the sample B is small, and the judgment result is qualified after judging by the conventional metallographic detection standard. As a result of the comparison of the detection results, it is understood that the detection method of the present invention can reliably detect the caulking quality of the terminal caulking portion 30 of the electric wire 20 more efficiently, simply, and at low cost instead of the detection method such as metallographic confirmation.

In addition, in the embodiment in which the resistance detecting method and the temperature detecting method are combined, it is not necessary to perform the temperature detecting method after performing the resistance detecting method, and the resistance detecting method may be performed after performing the temperature detecting method, as long as the above-mentioned respective methods are used. The detection circuit of the embodiment is judged by the judgment method of each embodiment, and the effect of the present invention can be obtained.

Further, in the embodiment of the present invention, regarding the temperature detecting method, sampling detection can be performed for a plurality of electric wires 20, and the quality of the entire electric wires 20 can be judged by the following method. In other words, a plurality of wires, for example, three wires 20 are sampled, and the three wires 20 are subjected to the above-described resistance change rate detection and the resistance value detection in the fourth embodiment, and are judged to be qualified, and then the three wires are taken. The maximum value Tmax of each test temperature Tt (the measured temperature plus the value after adjusting the temperature) is compared with the sum of the average value Ta of each test temperature Tt and a specific correction value, such as the maximum value Tmax is smaller than the average value Ta When the sum of the specific correction values is used, it can be judged that the riveting quality of the entire electric wire 20 is acceptable. The above-mentioned specific correction value is obtained after the painstaking research and development of the present invention, and the quality of the detection is the best when the correction value is 3 °C. For example, for the three wires 20, the measured temperatures are respectively measured at 51, 49, and 53 ° C, and the average value is calculated as 51 ° C, and the largest of the measured temperatures is At 53 ° C, this value is less than the sum of the average value of 51 ° C and the correction value (3 ° C) of 54 ° C, so that the riveting quality of the riveted portion of the plurality of wires is judged to be acceptable.

In the detection method of the above embodiment of the present invention, although the temperature is detected after detecting the resistance of the riveting portion, the actual detection may be performed after the temperature is detected first, without affecting the detection effect. .

As described above, the technical contents and technical features of the present invention are disclosed above, and those skilled in the art can still make various substitutions and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of the present invention should be construed as being limited by the scope of the appended claims

1. . . locomotive

10, 101, 111. . . Terminal

12, 13. . . Copper plate

20, 211, 201. . . wire

twenty one. . . Rear direction light terminal

twenty two. . . Tail light terminal

twenty three. . . Brake light terminal

twenty four. . . Front left direction lamp terminal

241. . . Left handle switch assembly terminal

25. . . Speaker terminal

26. . . Headlight terminal

27. . . ECU terminal

28. . . Front right direction lamp terminal

29. . . Right handle switch assembly terminal

30, 301, 311. . . Riveting

31. . . Harness system

32. . . Throttle opening sensor terminal

33. . . Intake pressure sensor terminal

34. . . Temperature sensor terminal

35. . . Ignition coil terminal

36. . . Fuel injector terminal

37. . . Oxygen sensor terminal

40. . . Resistance meter

50. . . Judging circuit

60. . . thermometer

70. . . power supply

100, 200, 300. . . Detection circuit

1 is a schematic view showing a detecting circuit of a terminal riveting portion of a wire to which the present invention is applied;

2 is a schematic view showing another embodiment of a detecting circuit of a terminal riveting portion of a wire to which the present invention is applied;

3 is a schematic view showing another embodiment of a detecting circuit of a terminal riveting portion of a wire to which the present invention is applied;

4 is a flow chart showing a method for detecting a terminal riveting portion of a wire to which the present invention is applied;

Figure 5 is a metallographic analysis diagram of the wire detected by the method for detecting the terminal riveting portion of one of the wires of the present invention;

Figure 6 is a schematic view of a wire harness system of a locomotive;

Figure 7 is a schematic view showing a portion of a wire terminal used in a wire harness system of a locomotive; and

Fig. 8 is a view showing the result of the metallographic confirmation of the prior art wire terminal crimping portion.

10. . . Terminal

20. . . wire

30. . . Riveting

40. . . Resistance meter

50. . . Judging circuit

100. . . Detection circuit

Claims (16)

A method for detecting a terminal riveting portion of a wire, the method for detecting a wire having a terminal and a terminal riveting portion at one end, wherein the method comprises: a static resistance measuring step, wherein the wire is in a resting state, and the resistor is Connect the two ends of the electric wire, measure the resistance value, and measure the resistance value as a static resistance value; the dynamic resistance measurement step is to connect the two ends of the electric wire with a resistance meter to make the electric wire Bending, measuring the resistance value of the wire when it is dynamically bent, and making the absolute value of the difference between the maximum value and the minimum value of the measured resistance value and the static resistance value is dynamic a resistance value; a resistance change rate calculation step, wherein the larger of the static resistance value and the dynamic resistance value is a numerator, and the smaller one is a denominator, and the ratio is calculated, and the ratio is used as a resistance change rate; and the resistance change rate The determining step determines that the resistance change rate of the electric wire is acceptable when the calculated resistance change rate is equal to or less than a reference value. A method of detecting a terminal rivet of a wire of claim 1, wherein the wire has a bending angle greater than 90 degrees. A method of detecting a terminal riveting portion of a wire of claim 1, wherein said reference value is 1.5. The method for detecting a terminal riveting portion of a wire according to any one of claims 1 to 3, further comprising the step of applying a voltage step of connecting the two ends of the electric wire in series with a power source, wherein the power source is used for the detection Applying a voltage and a current to the electric wire; measuring a temperature obtaining step of measuring a temperature of the terminal riveting portion of the electric wire as a measuring temperature in a state in which the power source applies a voltage and a current to the electric wire; and determining a resistance value step And adding the adjusted temperature to the measured temperature of the terminal riveting portion of the wire, and then summing it to the test temperature. If the test temperature is less than a predetermined temperature, the resistance value of the wire is judged to be acceptable. The method for detecting a terminal riveting portion of the electric wire of claim 4, wherein the adjusted temperature is an absolute value of a difference between an ambient temperature of 40 ° C and the measurement, and the predetermined temperature is 70 ° C. The method for detecting a terminal riveting portion of a wire according to claim 4, wherein a maximum value of the temperature measured by the terminal riveting portion of the electric wire is substantially stabilized as the above-mentioned measuring temperature of the electric wire . The method for detecting a terminal riveting portion of a wire according to any one of claims 1 to 3, wherein the wire length is 100 mm to 200 mm. A method for detecting a terminal riveting portion of a wire, wherein the method detects a plurality of wires each having a terminal and a terminal riveting portion at one end, wherein the method comprises the steps of: sampling at least two or more samples from the plurality of wires to be detected a wire; the at least two or more of the to-be-detected wires to be sampled are respectively detected by the detecting method of any one of claims 4 to 6, and the average calculating step is to calculate the at least two or more of the measured The average of the test temperatures of the wires to be tested; and the overall quality determining step, wherein at least two or more of the above-mentioned at least two of the wires to be tested have a resistance change rate and a resistance value is acceptable When the maximum value of each of the test temperatures of the to-be-detected electric wires is less than the sum of the average value and the correction value, it is determined that the riveting quality of the riveting portions of the plurality of electric wires is acceptable. The method for detecting a terminal riveting portion of a wire of claim 8, wherein the correction value of the above temperature average value is 3 °C. A detecting device for a terminal riveting portion of a wire, which is used for detecting an electric wire having a terminal and a terminal riveting portion at one end, and has a detecting circuit, wherein the detecting circuit includes: an electric resistance meter, and the riveting portion of the electric wire and The other end is connected in series, and the static state of the electric wire and the electric resistance in the dynamic state are measured, and the measured results are respectively output; and the judging circuit receives the electric wire measured by the electric resistance meter in a static state and Each of the resistance values in the dynamic state is calculated and compared to determine whether the resistance change rate of the electric wire of the electric wire is acceptable. The detecting device for the terminal riveting portion of the wire of claim 10, wherein the judging circuit is such that the larger of the static resistance value and the dynamic resistance value is a numerator, and the smaller one is a denominator, and the ratio is calculated and the ratio is used as the ratio When the calculated resistance change rate is equal to or lower than the reference value, the resistance change rate of the electric wire is judged to be acceptable. A detecting device for a terminal riveting portion of a wire of claim 11, wherein said reference value is 1.5. A detecting device for a terminal riveting portion of a wire, which is used for detecting an electric wire having a terminal and a terminal riveting portion at one end, and has a detecting circuit, wherein the detecting circuit includes: a power source, and two ends thereof are respectively connected in series to the electric wire The terminal and the other end of the electric wire; a thermometer connected to the riveting portion of the electric wire, measuring a temperature of the riveting portion, and outputting the measured temperature value; and a judging circuit receiving the thermometer The temperature value of the riveting portion is measured as the maximum value of the temperature measured when the measured temperature reaches the steady state, and the resistance value of the electric wire is judged to be acceptable based on the measured temperature. The apparatus for detecting a terminal riveting portion of a wire according to claim 13, wherein the power source is connected to one end of the opposite side of the riveting portion of the electric wire via a copper plate; and the terminal of the one end of the riveting portion of the electric wire corresponds to the terminal After the wires of the terminals are connected to each other, the other end of the electric wire having the corresponding terminal is connected to the power source via a copper plate; and the terminal riveting portion of the wire having the corresponding terminal is filled with solder to fill the core between the riveting portions. gap. The detecting device of the terminal riveting portion of the wire of claim 13 or 14, wherein the determining circuit adds the adjusted temperature to the measured temperature, and if the sum of the measured temperature and the adjusted temperature is less than a predetermined temperature, determining The resistance value of the wire is acceptable. The apparatus for detecting a terminal staking portion of a wire of claim 15, wherein the adjusted temperature is an absolute value of a difference between an ambient temperature of 40 ° C and the measured temperature, and the predetermined temperature is 70 ° C.