WO2021143985A1

WO2021143985A1 - Method for producing a cable harness and device for applying a coating to a branched wire bundle

Info

Publication number: WO2021143985A1
Application number: PCT/DE2021/100049
Authority: WO
Inventors: Dirk Schubert; Paul Heisler; Jörg Franke; Andreas ZIEGMANN; Robert Süß-Wolf
Original assignee: Friedrich-Alexander-Universität Erlangen-Nürnberg
Priority date: 2020-01-17
Filing date: 2021-01-15
Publication date: 2021-07-22
Also published as: DE102020200548A1

Abstract

In the method for producing a cable harness (24), a branched wire bundle (4) is laid using guide elements (5) and then dipped in a dip tank (18) containing a viscous material (M) to form a coating (22). The viscous material (M) is a silicone with a viscosity in the region of 500 mPas to 4000 mPas. With a particular configuration of laying aids (5, 12, 14), it is ensured that the wire bundle (4) is clamped on the assembly board (2) and the coating (22) is formed in the desired manner.

Description

description

The invention relates to a method for producing a cable harness with the features of the preamble of claim 1 and a device for applying a covering to a branched cable harness a dipping process, such a process and such a device can be found in DE 3601 116 C2 or DE 3826989 G2, for example. According to these documents, a branched wiring harness is first fixed to an assembly board. The cable harness consists of several cables, on each of which connectors are arranged at the end. To form a protective sheath that surrounds the cable harness, the branched cable harness is immersed in an immersion bath. In this there is a liquid that adheres to the insulation of the individual cables of the cable harness and then hardens.

According to DE 3601 116 C2, cable ties are provided for fixing the individual lines to one another. This leads to a significantly larger circumference at the parts of the cable tie and thus overall to an increase in the space required for the cable harness in the installation situation. This is particularly disadvantageous when used in a motor vehicle. A so-called overhead conveyor is also provided as an assembly aid, by means of which the cable harness pre-assembled on an assembly board is picked up from the assembly board and then moved to the immersion bath. In contrast, DE 3826989 C2 provides an immersion bath method for attaching a sheath to a branched wiring harness, in which the wiring harness is not removed from the assembly board. Rather, the assembly board is moved to the immersion bath together with the branched wiring harness attached to it, for example with the aid of a robot, and there the wiring harness is immersed in the immersion bath. In order to avoid wetting the plugs attached at the ends with the insulation material of the immersion bath, the mounting board is angled in an L-shape, the plugs being arranged in the angled partial area.

Proceeding from this, the invention is based on the object of specifying an improved method and an improved device for sheathing a branched wiring harness with the aid of an immersion bath for forming a cable set.

The object is achieved according to the invention by a method for the production of a cable harness which has a plurality of lines combined to form a line strand. The cable harness is laid as a branched cable harness with several branches in a desired laying geometry on an assembly board. For this purpose, the individual lines are typically laid along a predefined route. In this case, guide elements are provided along which the individual lines are guided in accordance with the desired routing geometry. Subsequently, that is, after the branched wiring harness has been formed on the assembly board, the wiring harness is immersed in an immersion bath with a viscous material to form a covering specially designed as a protective cover. The line harness is preferably arranged on the mounting board. In particular, the assembly board itself is gripped in order to move the cable harness to the immersion bath. The casing is then formed from the viscous material after curing. According to the invention, a silicone with a (dynamic) viscosity in the range between 500 mPas and 4,000 mPas is used as the viscous material. Investigations have shown that a silicone material of this type is particularly well suited for the production of a sheath for a branched conduit using the immersion bath process.

A particular advantage of using the silicone lies in the fact that it has a highly non-polar character and therefore does not or only hardly adheres to the assembly board or to the guide elements. This leads to the fact that the material does not wet the laying board and the guide elements or at least the material can easily be removed from the cable board and the guide elements or other laying aids and recycled again after it has hardened.

In addition to this favorable property of the silicone as such, the setting of the viscosity is of particular importance. The selected range between 500 mPas to 4,000 mPas achieves, on the one hand, good, complete wetting and preferably also penetration into the spaces between the individual lines, so that a completely closed envelope is formed. At the same time, the selected viscosity ensures that there is sufficient adhesion to the conduit when it is pulled out of the immersion bath. As a result, the formation of dripping noses from the viscous insulation material is at least largely, if not completely, avoided.

After being removed from the immersion bath, the silicone material hardens and forms the protective cover for the cable harness. The cable loom is fixed in a suitable manner via the sheathing. The cable loom provided with the sheathing defines the cable harness.

In an expedient embodiment, the silicone has a structurally viscous behavior. This is understood to mean that with increasing shear acting on the viscous material (fluid) in the immersion bath, it becomes thinner, that is, less viscous. This is used to the effect that the viscosity is reduced in the immersion bath itself, in that, for example, shear is generated by continuous mixing, for example by stirring, as a result of which the lower viscosity is set in the immersion bath. As soon as the cable harness with the silicone material adhering to it leaves the immersion bath, the viscosity increases so that the silicone becomes thicker, which means that it adheres better and no longer drips off.

As an alternative to the active movement of the material in the immersion bath to generate shear, the structural viscosity is used to the effect that when the cable harness is immersed in or removed from the immersion bath, a shear load occurs locally on the cable harness due to its movement and the viscosity is reduced as a result. The wiring harness is therefore deliberately immersed or removed at a high speed. Good wetting is achieved as a result. At the same time, the viscosity increases after removal, i.e. becomes more viscous, so that, for example, dripping and dripping are avoided.

The previously specified viscosity between 500 mPas and 4,000 mPas relates to a dynamic viscosity in the immersion bath. In the case of using a structurally viscous material, this specified viscosity relates to the viscosity under shear stress, i.e. especially in the state when the material is actively moved in the immersion bath, e.g. by stirring, and shear forces are applied as a result.

The structural viscosity is expediently such that the viscosity differs by a factor of at least 10 or at least 100 between the state under heavy load and when there is no shear load, especially with active movement (thorough mixing) in the immersion bath. A sufficiently strong active movement is therefore provided to generate a sufficiently high shear stress. In the case where no active movement is intended and the structural viscosity is only used by immersing and removing the wiring harness, the differences lie in the viscosity (due to the lower shear stress) below and for example only at a factor of 1.5 to 5.

According to a preferred embodiment, the material is thixotropic, so that the viscosity decreases increasingly with (constant) (shear) stress and increases again increasingly after the stress has ended.

In a preferred development, the viscous material is UV-curing. In principle, there is also the possibility that the material will harden due to the temperature or ambient air alone. In the case of a UV-curing property, the material adhering to the cable harness is preferably irradiated by means of a suitable lighting device using UV light, so that curing or at least hardening takes place as quickly as possible. In order to avoid UV-induced curing in the immersion bath with such a choice of material, the immersion bath is preferably arranged in a dark room. In this context, “dark room” is generally understood to mean that no light, in particular no UV light, penetrates. In a preferred embodiment, curing, especially crosslinking of the material, takes place at room temperature or at elevated room temperature, e.g. up to 80 ° C. The silicone used is therefore in particular a silicone that cross-links at room temperature or at elevated room temperature. This can be a one-component or a two-component system.

In the present case, “silicone” is understood to mean a so-called silicone rubber or a silicone elastomer, which is crosslinked for curing. Addition-curing or condensation-curing silicones are used for the viscous mass. Addition-crosslinking silicones are preferably used, since they do not release any by-products during the crosslinking reaction. Two-component, addition-curing, so-called RTV-2 silicones that cure at room temperature or at elevated room temperature are used in particular. Examples of suitable silicones are, for example, the silicones known under the trade name Elastosil, in particular the classes Elastosil RT or Elastosil P, especially Elastosil RT 602 A / B or Elastosil P 7676 A / B or other comparable silicones. For example, Elastosil P7670 already has a dynamic viscosity of 1800 mPas (without the need for shear stress).

In addition, silicones known under the trade name Semicosil, in particular Semicosil 911 A / B or also Semicosil 924, have proven to be suitable. These are pseudoplastic materials. Semicosil 911 A / B, for example, shows a dynamic viscosity of 8000 mPas depending on the shear stress and a dynamic viscosity of 1600 mPas at a high shear rate. The dyn. The viscosity of Semicosil 924 varies depending on the shear rate / shear stress, for example between 35,000 mPas and 2,000 mPas.

With the help of such a material, the sheathing can be applied to the branched line set in a particularly suitable and reliable manner. The thickness of the cover is adjusted, for example, by several dipping processes. The thickness per immersion process is, for example, in the range between 0.2 mm and 3 mm, especially in the range between 0.5 mm and 1.5 mm.

In addition to the use of a suitable material, the design of the assembly board with the guide elements attached to it for guiding the cable harness is of particular importance for the design of the sheathing and the production of the cable set in the desired laying structure. The further aspects relating to the mounting board described below are basically also independent of the use of the special silicone material and can therefore also be used with other, conventional immersion bath materials.

The guide elements are designed so that the cable harness - apart from its end areas - is at a first level relative to the mounting board. sets or is led. The wiring harness generally has a plurality of ends which are preferably located in connector housings and which, in particular, are arranged within the connector housing relative to the mounting board at a second level and in particular are fixed on the mounting board. By arranging the ends or the connector housing at a different, in particular lower, height level (in relation to the mounting board) than the rest of the wiring harness, it is possible to only wet the wiring area at the first height level with the viscous material during the immersion process Do not wet the ends / connector housings located on the second level. This is controlled by a suitable immersion depth in the immersion bath. In a first variant, the plug housings are therefore not also immersed in the viscous material of the immersion bath.

The assembly board is generally preferably a simple, flat board that spans a two-dimensional plane. Conventional assembly boards are therefore used. A particular advantage of laying the wire harness at different levels, in particular arranging the wire ends at a lower height, is that the wire harness as a whole is not only routed within a two-dimensional plane, but also in three dimensions and thus has areas which are typically curved. Overall, the dimensions of the branched wiring harness arranged on the assembly board - in relation to a projection onto the assembly board - are smaller than when they are laid within a two-dimensional plane. This makes it possible to make the cable board more compact overall.

In a preferred development, at least one deflection element is provided, which is arranged between a guide element and one end of the cable harness, that is to say specifically between a guide element and a connector housing. The Umienkeiement leads the cable harness at a (middle) height between the first and the second height level, ie it supports the cable harness from a support position that is between the two height levels. By arranging an additional deflection element, the line strand defined between the two height levels out. This results in the best possible adaptation to the desired course of the line harness. Without such deflection elements, there would be an abrupt deflection, for example kinking, which would be quasi “frozen” after the covering has been applied and hardened. Under certain circumstances, this would lead to an undesirable final geometry of the cable set and, for example, make it more difficult to bring the respective ends (connector housing) of the finished cable set into the desired installation positions in the later installation of the cable set.

In a preferred development, the deflecting element supports the cable harness at several height positions. There is therefore successive routing at different height positions over a certain section area of the line harness, so that the transition between the two height levels is as smooth as possible.

In a preferred embodiment, the at least one support position of the deflecting element is also adjustable. In particular, the at least one height position of the Umienkeiementes on which the Umienkeiement guides the line strand can be adjusted.

In one embodiment variant, the deflection element is designed, for example, with a movable, in particular pivotable deflection arm on which the guide line is supported, in particular rests. This deflection arm forms the support position. In particular, it can be locked in various swivel or angular positions. The deflection element is specifically designed as a foldable deflection fork. In addition to a fork-shaped deflecting arm, this generally has a holding arm attached to the mounting board, to which the deflecting arm is movably attached.

According to a preferred embodiment of the deflecting element, it is designed in such a way that it guides the line strand in an arc. For this purpose, the deflecting element preferably has an in particular curved guide channel. This guide channel is, for example, open on one side and shaped like a guide channel. Alternatively, the guide channel! Formed closed, but can preferably be opened so that the wiring harness can be inserted.

In order to avoid wetting of the ends, especially the connector housing, with the insulating material of the immersion bath, the ends of the cable harness, especially the connector housing, are not immersed in the immersion bath, ie in the viscose material, in a preferred embodiment.

As an alternative or in addition to this, the ends, especially the connector housings, are protected by a protective hood, which is preferably reusable, against wetting with the viscose material during the immersion process. By using a protective hood, the sheath can therefore be brought up to the connector housing in the desired manner and specifically, for example, in such a way that the material of the sheath automatically seals the connector housing.

According to a further variant, there is finally the possibility of also immersing the ends, especially the connector housings, in the viscous material of the immersion bath, at least a little so that the viscous material deliberately penetrates the connector housing at least partially. In this way it is achieved, for example, that in a connection area, that is to say in the area where the line section enters the connector housing, a reliable sealing of the sheath from the connector housing takes place. Complete immersion of the plug housing is, however, preferably avoided here too, in order to avoid wetting of contacts or stripped end regions located inside the plug housing with the insulating material. In an expedient embodiment, it is also provided that the line strand is tensioned on the assembly board. In particular, this avoids a loose, undefined hanging down of the cable harness, which is typically immersed overhead in the immersion bath. With conventional mounting boards, they are Guide elements, also referred to as laying aids, are often designed in the manner of upwardly open forks, which therefore only support the cable harness in the direction of the cable board. For the immersion process, the cable board must be fed to the immersion bath upside down, i.e. with the wiring harness in front. Without the tensioning measures, the cable harness would sag downwards, which would lead to an undesirable, undefined geometry (arched sagging), which would also be fixed in an undesirable manner after the material has hardened. By tensioning the cable loom it is generally achieved that the cable loom is guided in a defined manner at a desired height level without the cable loom sagging.

To tension the cable loom, fixation units are preferably provided which grip the cable loom in the region of its ends and exert a certain amount of tensile stress on the cable loom. The line ends, especially the connector housings themselves, are usually arranged / received directly on the assembly board, for example in corresponding receptacles. The fixing unit is preferably arranged directly on such a (plug) receptacle. The fixing unit preferably has a clamping element for gripping the cable loom in a clamping manner, as well as an adjusting mechanism so that the clamped cable loom can be moved / pulled, for example, approximately in the direction of the assembly board in order to exert a certain tension on the cable loom. The wiring harness is therefore tensioned by means of the fixing unit, in particular in the direction of the assembly board. The particular advantage of the arrangement of the fixing unit is that no force is exerted on the connector itself, that is, the cable end rests in the connector without force and, for example, no tensile stress is exerted on the electrical contacts in the connector. Clamping and power transmission only takes place on the lines themselves.

As an alternative or in addition, the height of the guide elements for tensioning the line section can be or are adjusted. In this execution Fixing units are preferably also provided, but these are designed, for example, as simple clamping units without an adjustment mechanism for forming the tension.

As explained above, immersion takes place overhead, which can lead to sagging of the cable loom. In order to avoid this or at least to limit it, in a preferred embodiment the cable harness is supported by two adjacent guide elements, once in the direction of the mounting board and once in the direction facing away from the cable board. Several, in particular all, guide elements are preferably designed alternately in such a way that once the support to the mounting board and once the support takes place in the direction facing away from the front of the mounting board. This means that a “pushing” and a “pulling” guide element are provided alternately. The first pushes the wiring harness away from the mounting board, the second pulling the wiring harness towards the mounting board.

In a preferred embodiment, in particular, exactly two different types of guide elements are provided, which are arranged alternately. This particularly concerns the pushing and pulling guide elements described above.

As an alternative to two differently designed types of guide elements, there is also the possibility of providing only one type of guide element which, for example, has a transverse arm on which the line section rests. When laying a respective line, it is then guided once above and once below such a cross arm.

In a preferred embodiment it is provided that the pushing as well as the pulling guide element guide the cable harness at different heights, that is to say support it at different heights, pushing once and pulling once. Preferably in such a way that the wiring harness adopts a (slightly) undulating course. As a result, overall tensioning of the line section is achieved and sagging is avoided. In an expedient further development, at least some of the guide elements are changed in their position during immersion and / or after the conduit section has been immersed in the immersion bath. In particular, this takes place in that the guide elements vibrate. A suitable (vibration) drive is provided for this. According to a first variant, this acts on the entire cable board, so that the entire cable board is exposed to vibrations. According to a second alternative, the drive is assigned to a single guide element or a group of guide elements, so that these are moved individually and independently of the assembly board, in particular vibrate.

In general, the movement of the guide elements means that there is a relative movement between the cable harness and the guide element. As a result, the point of contact of the cable harness on the guide element is shifted and also enables this point of contact to be wetted with the viscous material in the immersion bath. By this measure it is achieved that the envelope is completely formed and no non-wetted contact points remain. So there is a complete and full-surface wetting with the viscous material.

Another advantage of the movement - in the case of the use of structurally viscous or thixotropic materials - is to be seen in the fact that the movements generate a shear load on the material, making it thinner.

Moving the guide elements outside of the immersion bath also has the advantage that excess material adhering to the guide elements is thereby at least partially shaken off. In an expedient embodiment, the arrangement of tapes in defined, discrete areas is provided for fixing the individual lines to one another, that is, the individual lines are each “punctually” wrapped in a tape at several positions. A full-surface banding or a spiral conveying moderate wrapping is not provided. The arrangement of a tape has the particular advantage that it is hardly bulky and therefore does not increase the size significantly. At the same time, it fixes the cable bundle, that is to say the individual cables of the cable harness, to one another in the most compact way possible

As an alternative to tapes, the individual lines are preferably fixed by means of a spiral thread or an adhesive. This is applied to the individual lines in the manner of a primer, for example by spraying or painting. For example, the lines are individually pretreated with the adhesive.

The tape is expediently arranged at least and preferably exclusively in the area of the guide elements. As a result, the entire area of the bundle of lines is encased as much as possible. If there is no wetting in the area of the guide elements, especially at the points of contact of the line strand on the guide element, the bundle of lines is at least surrounded by the tape there.

In an expedient embodiment, the immersion process takes place with the exclusion of light. The wetting with the viscous material therefore takes place in the dark, i.e. especially without UV light. After removal from the immersion bath, the assembly board with the wiring harness attached to it is expediently transferred to a chamber, where it is irradiated with light, especially with UV light. The object is also achieved according to the invention by a device with the features of claim 22. The advantages and preferred embodiments cited with regard to the method can also be applied to the device in a corresponding manner. For this purpose, the device comprises a mounting board for fixing the cable harness, which has several guide elements for guiding the cable harness at a first height level. Furthermore, one or more of the following elements are provided: - Fixing units, which are designed to fix the ends of the cable loom and to exert tension on the branched cable loom,

- At least one deflection element for guiding and supporting the line strand at a height between the first height level and a height level which is defined by the mounting board itself and

- At least one (vibration) drive for at least one guide element, which is set up and controlled in such a way that the at least one guide element is moved during a dipping process in the dipping process. A respective drive is preferably a respective one

Guide element or a group of guide elements jointly assigned.

To avoid adhesion between the viscous material for the covering (silicone) and the individual elements of the device, such as guide elements, deflection elements, mounting board, receptacles for the plug, etc., at least some of these elements, preferably all of these elements, are in a preferred embodiment , provided with a suitable non-stick coating. Alternatively, they are made of a suitable material. In particular, the (surface) material of these elements is selected in such a way that the viscous material of the immersion bath does not wet it, so that the viscous material virtually rolls off.

Some of the configurations and variants described above are viewed as independently inventive concepts, which are therefore viewed as inventive in themselves, regardless of the specially selected silicone material. The filing of divisional applications on these aspects remains reserved.

This applies in particular to the following concepts according to claims 7, 8, 14, 15, 17, 18, i.e. the features of these claims, in combination with the features of the preamble of claim 1, are viewed as independently inventive:

- the guidance / arrangement of the ends of the cable harness on a first height level that is closer to the assembly board than a second height level, on which the wiring harness is guided (claim 7), especially in combination with a flat mounting board

- the arrangement and design of the deflection elements (claims 8-11),

- the tensioning of the cable harness (claim 14) with the preferred developments according to claims 15-17,

- the design and arrangement of the guide elements as pushing and pulling guide elements in an alternating arrangement (claim 17),

- the movement / vibration of the guide elements during immersion (claim 18).

Exemplary embodiments of the invention are explained in more detail below with reference to the figures. These each show in schematic, simplified representations:

Fig. 1 is a side view of a mounting board with attached wiring harness, which is immersed in an immersion bath,

2 shows a representation similar to FIG. 1 in a second variant, FIG. 3 shows a plan view of the mounting board shown in FIG. 2 with a branched wiring harness attached to it, FIG. 4 shows an end view of the mounting board according to FIG. 3, FIG. 5 shows a Side view of the mounting board according to FIG. 3,

6A to 6C show different design variants for a deflecting element as well

7 shows a detail of a line strand wrapped at points with a tape in the area of a guide element.

In the figures, parts that have the same effect are shown with the same reference numerals.

In FIGS. 1 to 5, a mounting board 2 is shown in each case, on which a branch line 4 is arranged. The mounting board 2 is also generally referred to as an installation board or cable board. In the present case it is a two- dimensional, flat and therefore simply designed board. The line strand 4 generally has several individual electrical lines, in particular cores, which are combined to form a line bundle.

A plurality of guide elements 5 are arranged on the mounting board 2, which guide the line strand 4 along a desired, predetermined laying geometry, that is to say along the desired branched structure. This branched structure can be seen in particular from the plan view according to FIG. 3. In general, the branched line strand 4 has a plurality of sub-strands starting from a main strand, which are typically arranged at an acute or also at a right angle to the main strand. As a result of the branched structure, the cable loom 4 forms several ends 6, to each of which a connector housing, hereinafter referred to as connector 8 for short, is attached in the exemplary embodiment.

In the exemplary embodiment 2 receptacles 10 are arranged on the mounting board, each receiving the connector 8.

In the area of the respective ends 6, fixing units 12 are furthermore arranged, which each grip the line strand 4 in an end area directly in front of the plug 8, in particular in a clamping manner, and thus hold it. The fixing units 12 are preferably designed to exert a tensile stress on the cable loom 4, so that the latter is tensioned as a whole. Via the guide elements 5, the wiring harness 4 is guided at a distance from the mounting board 2 at a first height level N1, at least except for the end regions near the connector 8. In contrast, the ends 6 and the plugs 8 are arranged on a - relative to the mounting board 2 - lower, second height level N2. In particular, the plugs 8 are arranged directly on the mounting board 2.

In addition, deflection elements 14 are provided, each of which guides the cable loom 4 in the end area to a plug 8. In particular, they convey Deflection elements 14 between the two height levels N1, N2, ie the deflection elements 14 support the cable harness at at least one height position between the two height levels N1, N2.

If the term “height levels” is used here, this is generally understood to mean a height range which extends over a (tolerance) range, for example +/- 20% or +/- 10% of a specified target height of the respective Corresponds to height levels N1, N2 or 1-5 cm or 1-3 cm. In FIG. 1, a (vibration) drive 16 is assigned to each guide element 5 by way of example. This is arranged in particular at the foot of a respective guide element 5 and is able to set the respective guide element 5 in motion, in particular vibrations. The movement can take place in different linear directions, be formed by superimposing several linear directions or also by a rotating movement or by superimposing linear and rotating motion sequences. In a simplest embodiment variant, only a lifting movement, that is to say a linear movement perpendicular to the mounting board 2, is carried out. As an alternative or in addition to this, a movement is carried out parallel to the mounting board.

1 and 2 show a situation in which the assembly board 2 with the wiring harness 4 arranged thereon is immersed upside down, that is, with the wiring harness 4 in front, in an immersion bath 18 which is filled with a viscous material M. This is especially silicone, which has a viscosity (dynamic viscosity) in the range between 500 mPas and 4,000 mPas.

A unit 20 for mixing or circulating the viscous material M is also contained within the immersion bath 18. The unit 20 is designed in such a way that the viscous material M is set in motion within the immersion bath 18, so that different layers of the viscous material M within the immersion bath 18 experience a shear load relative to one another, so that partial areas of the viscous material M within the Immersion bath relative are moved towards each other. The unit 20 is, for example, a circulating device, a stirring device or some other suitable device. The viscous material M is in particular a structurally viscous material, so that the viscosity of the material M within the immersion bath 18 is reduced by the forced shear stress, so that the viscous material M in the immersion bath 18 is thinner. As a result of this measure, the viscous material M penetrates very well into the spaces between individual lines of the line section. When the cable loom 4 is removed from the immersion bath 18, the shear stress is eliminated and the viscosity increases, so that good adhesion of the viscous material M to the cable loom 4 is promoted.

The adhering viscous material M then hardens and forms a solid envelope 22, which is indicated by a dashed line in FIGS. 3 and 7 by way of example. The cable loom 4 provided with the sheath 22 forms - together with the plugs 8 attached to it - a (finished) cable harness 24, which is also referred to as a cable set. This is then removed from the mounting board 2 and is. Preferably, but not necessarily, further assembly steps are carried out, for example fastening clips are attached. The cable harness 24 is then ready for further transport / installation in an intended installation location. In particular, the cable harness 24 is a cable harness 24 for a motor vehicle, which is therefore subsequently installed in a motor vehicle. The process and the method for producing the cable harness 24 are as follows:

The cable harness 24 generally consists of the branched wiring harness 4, which is surrounded by the sheath 22 in the manner of a (thin) cable jacket, and the plugs 8 fastened to the ends 6 at each end. These are electrical contact plugs for electrical connection with other cables or parts of a motor vehicle electrical system. In a first step, the individual lines of the wiring harness 4 are laid on the assembly board 2 along the desired laying structure with the help of laying aids, namely in particular with the help of the guide elements 5, the deflection elements 14 and the fixing units 12. This is done either manually or automatically or partially automated. The individual lines are generally already pre-assembled at the end with contact elements such as contact sockets or contact pins. The multiple lines are further bundled in a suitable manner, specifically tied with the aid of a tape 26 (cf. FIG. 7, for example). Preferably, only punctual banding takes place here. The plugs 8 are then typically attached.

After the completion of the preassembled wiring harness 4 in this way, it initially remains on the assembly board 2. This is gripped, for example, with the aid of an adjusting device, specifically with the aid of a robot, and guided to the immersion bath 18. It is rotated (by 180 °), for example, so that the conduit 4 is immersed upside down in the immersion bath 18.

Subsequently, the assembly board 2 with the cable harness 4 is removed and the adhering viscous material M hardens, so that the casing 22 is formed. For this purpose, UV curing in particular is provided in order to promote the fastest possible curing. The material M is therefore in particular a UV-curing material. For this purpose, the immersion bath 18 itself is preferably arranged in a darkroom in order to avoid premature curing. Conversely, after being removed from the immersion bath 18, the assembly board 2 is guided into or through a lighting station in which suitable (UV) lighting elements are arranged. The curing takes place in particular at ambient temperature (room temperature) or at elevated room temperature up to, for example, 80 ° C. The steps of immersion and curing can be carried out several times in succession in order to produce a desired thickness of the casing 22. Complete curing is not required between two dipping processes. The cable harness 24 should largely be manufactured in the desired routing geometry in which it is later routed at the place of use, for example in the motor vehicle. Furthermore, the aim is, in particular, to have a covering 22 that is as continuous as possible without missing or free spaces. In order to achieve this, different measures are provided on the mounting board 2, which are explained in more detail below. In particular, this relates to the special design of the laying aids used. In the present case, “laying aids” are understood to mean in particular the guide elements 5, the deflection elements 14 and the fixing units 12. According to a first aspect, the cable loom 4 is tensioned at the assembly width 2 and / or guided in such a way that the cable loom does not sag, if possible, and the cable loom 4 is guided within the first height level N1. In the first embodiment variant according to FIG. 1, the guide elements 5 are initially designed in the manner of forks, that is to say generally in the manner of guide elements into which the individual lines can simply be inserted from above. The wiring harness 4 is therefore supported from below (from the mounting board side). In order to avoid sagging in this case, the fixing units 12 are specifically provided in this embodiment variant, which exert tensile stress and are designed to be suitable for this purpose. In particular, they have a clamping arm with which the cable loom 4 is gripped in the end area. Furthermore, this clamping arm can be adjusted so that the cable loom 4 is pulled, for example, in the direction of the mounting board 2 in order to apply the desired tension.

As an alternative or in addition to this, there is also the possibility of adjusting the height of the guide elements 5 after the cable strand 4 has been fixed by means of the fixing units 12 in order to apply the tension.

In the embodiment variant shown in FIG. 2, the line strand 4 is guided alternately “pulling” and “pushing” through the guide elements 5. This is understood to mean that the wiring harness 4 alternates from the guide Rungs elements 5 is pulled once in the direction of the assembly width 2 and once pushed away from the mounting board 2. In particular, this means that the cable loom 4 is laid in an approximately wave-like manner, with adjacent guide elements 5 for this purpose guiding the cable loom 4 at two different heights h1, h2, but within the first height level N1.

In the exemplary embodiment in FIG. 2, this is achieved by two different types of guide elements 5. One type is designed, for example, in the manner of an upwardly open fork (with an opening oriented away from the assembly board), as has already been described for FIG. 1. The other type of guide elements 5 is formed, for example, in the manner of a ring eyelet through which the individual lines of the line strand 4 are guided.

The ring eyelet is preferably designed in such a way that it can be opened in order to enable the lines to be inserted. Alternatively, this second type of guide element 5 is designed to be open, the opening being oriented in the direction of the assembly board 2. For example, the guide element 5 is designed in the manner of a hook open towards the mounting board 2 (hook bent in a U-shape).

Another aspect is to be seen in the as complete as possible wetting of the line section 4 with the viscous material M. In order to ensure this also in the area of the guide elements 5, the drive 16 described above is provided. As a result, the cable loom 4 moves relative to the respective guide element 5, so that a support point is changed and is wetted with the material M by a continuous one Forming envelope 22.

As explained above, the individual lines of the cable loom 4 are combined, that is to say banded, at individual discrete points with the aid of a tape 26. This is shown, for example, in FIG. 5 or also in FIG. 7. It is specifically provided that the tape 26 is provided at least also or exclusively in the area of the guide elements 5. On the one hand, this ensures protection of the lines during assembly and laying. In addition, the tape 26 ensures a continuous covering. The tape 26 is it is a conventionally used tape 26 which is only of a small thickness so that the tape 26 is hardly applied.

Another aspect can be seen in the specially designed deflection elements 14. Since the plugs 8 are arranged at the lower level N2 than the rest of the wiring harness 4, these plugs 8 typically have to be brought back to a different height level after they have been manufactured. In order to ensure a smooth and homogeneous transition between the two height levels N1, N2, which enables easy subsequent bending, the deflection elements 14 are initially designed in such a way that they guide and support the conduit 4 at a medium height level , which is arranged between the first height level N1 and the second height level N2. It is specifically provided that a support takes place at several different height positions or also a continuous support over a certain height range. In general, the respective deflecting element 14 is preferably designed in such a way that the cable loom 4 is guided along an arc between the first height level N1 to the second height level N2, in particular is guided without kinks. Examples of the design of the deflecting elements 14 are shown in FIGS. 6A to 6C:

According to FIG. 6A, the deflecting element 14 has a plurality of support arms which, in the exemplary embodiment, are each designed as forks and which define different support levels. The individual contact surfaces of these support arms run along an imaginary arcuate line. The support arms are expediently adjustable relative to one another so that, for example, the angle between two adjacent support arms and / or the length of a respective support arm can be adjusted. In the simplest embodiment variant, a vertically leveled main arm and only one further support arm branching off from it are provided. Preferably, a total of more than two, for example three or even more, support arms are provided. In the embodiment variant according to FIG. 6B, the deflecting element 14 has a guide channel which is open on one side, for example upward, and which extends in particular in an arc shape. The wiring harness 4 can simply be inserted into this (from above). The guide channel extends in particular over an angular range of, for example, at least 45 ° or also at least 60 °. In the exemplary embodiment, it extends over 90 °. The guide channel itself is held by a holding structure of the deflecting element 14.

In the embodiment variant according to FIG. 6C, an arcuate, continuous guide similar to FIG. 6B is again shown, this being designed instead of the open guide channel in the manner of a closed, but preferably laterally opening, channel.

List of reference symbols

2 Mounting board N1 first height level

4 branched wiring harness N2, second level

5 guide elements M viscous material

6 end h1, h2 height

8 plugs

10 shots

12 fuser units

14 deflection element

16 drive

18 immersion bath

20 unit

22 wrapping

24 wiring harness

26 tape

Claims

Expectations

1. A method for producing a cable harness (24) which has several lines combined to form a cable harness, the cable harness ver being a branched cable harness (4) with several branches in a desired routing geometry on a mounting board (2) - is laid and guided by guide elements (5) in accordance with the laying geometry, with the cable harness (4) then being placed in an immersion bath (18) with a viscous material (18) to form a sheath (22) for the cable harness (4). M) is immersed for the envelope (22) and the material (M) then hardens, characterized in that a silicone with a viscosity in the range between 500 mPas and 4000 mPas is used as the viscous material (M).

2. The method according to claim 1, characterized in that the viscous material (M) has a structurally viscous behavior and a shear load is applied to the viscous material (M) in the immersion bath (18).

3. The method according to any one of the preceding claims, characterized in that the viscous material (M) in the immersion bath (18) is subjected to a shear wash by in particular continuous mixing.

4. The method according to any one of the preceding claims, characterized in that the silicone is UV-curing.

5. The method according to any one of the preceding claims, characterized in that the silicone is a silicone which cross-links at room temperature or at an elevated room temperature of up to 80 ° C.

6. The method according to any one of the preceding claims, characterized in that an addition-crosslinking, two-component silicone is used as the silicone.

7. The method according to any one of the preceding claims, characterized in that the guide elements (5) guide the wiring harness (4) relative to the mounting board (2) at a first height level (N1) and that the wiring harness (4) has several ends (6) which are fixed relative to the mounting board (2) at a second height level (N2).

8. The method according to any one of the preceding claims, characterized in that at least one deflection element (14) is provided which is arranged between a guide element (5) and one end (6) and that the line bundle is at a height between the first height level (N1) and the second height level (N2) leads to at least one support position.

9. The method according to the preceding claim, characterized in that the deflecting element (14) supports the bundle of lines at several height positions (h1, h2).

10. The method according to any one of the two preceding claims, characterized in that the support position of the deflecting element (14) is adjustable.

11. The method according to any one of claims 8 to 10, characterized in that the deflecting element (14) guides the cable harness (4) in an arc shape and for this purpose preferably has a curved guide channel.

12. The method according to any one of the preceding claims, characterized in that the ends (6) are not also immersed in the immersion bath (18).

13. The method according to any one of the preceding claims, characterized in that the ends (6) are protected by an in particular reusable protective hood from wetting with material (M) during the immersion process.

14. The method according to any one of the preceding claims, characterized in that the cable loom (4) is tensioned.

15. The method according to any one of the preceding claims, characterized in that the ends (6) are each held by means of a fixing unit (20) and the cable loom (4) are tensioned with the aid of the fixing units (12).

16. The method according to any one of the two preceding claims, characterized in that guide elements (5) are adjusted in their height (h1, h2) for tensioning the bundle of lines.

17. The method according to any one of the preceding claims, characterized in that two adjacent guide elements (5) support the cable harness (4) once in the direction of the mounting board (2) and once in the direction away from the mounting board (2), this being preferably different - Some types of guide elements (5) are provided and / or adjacent guide elements (5) guide the cable harness (4) at different heights (h1, h2).

18. The method according to any one of the preceding claims, characterized in, that at least some of the guide elements (5) are changed in their position during the immersion and / or after the line strand (4) has been immersed in the immersion bath (18).

19. The method according to the preceding claim, characterized in that the at least part of the guide elements (5) vibrates.

20. The method according to any one of the preceding claims, characterized in that in the region of the guide elements (5) the line strand (4) is wrapped by a tape (26).

21. The method according to any one of the preceding claims, characterized in that the immersion process takes place with the exclusion of light.

22. Device for applying a sheath to a branched line section by means of a dipping process, in particular for carrying out the process according to one of the preceding claims, with a

Mounting board (2) for fixing the cable loom (4), which has several guide elements (5) for guiding the cable loom (4) at a first height level (N1) and which also has one or more of the following elements: - Fixing units for fixing from the ends (6) of the cable loom (4) on the mounting board (2) and for tensioning the cable loom (4) at least one deflection element (14) for guiding and supporting the cable loom (4) at a height between the first height level (N1) and the mounting board (2) - at least one drive for at least one guide element (5) in order to move it during a dipping process during the dipping process.