JPS6053410B2 - Wire harness manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a wire harness.

Wire harnesses are generally constructed by combining a large number of electric wires, providing branch lines to the main line, and connecting connectors to each of these lines. Because it requires a great deal of labor and time to manufacture, it has traditionally been difficult to use various automatic wiring methods. A method is proposed.

However, in principle, these methods first cut the wires to a predetermined length and route them between each connector, so while they have the advantage of being able to automate the entire process up to the installation of the connectors, The problem was that it took a long time to manufacture, and productivity was low.

The present invention has been made to improve the above-mentioned drawbacks, and it is possible to simultaneously route and cut electric wires, and when cutting the electric wires, the terminal portions of the electric wires are connected at appropriate intervals by bridges. By fixing the arrangement and making it extremely easy to connect connection terminal fittings and attach connectors, we aim to reduce the time and labor required for wire harness manufacturing as a whole and provide a low-cost wire harness. It is something to do. An embodiment of the present invention will be described with reference to the drawings. In FIG. 1A, 1 is a workbench, on which a plurality of wiring locking pins 2 and a wiring table 3 are arranged in advance at predetermined positions.

Reference numeral 4 denotes a bridge placed on the wiring table 3, and as shown in FIG. They are formed protrudingly at regular intervals, and are cut and used as appropriate depending on the number of wires to be wired.

Reference numeral 8 denotes a wire that has been routed, and a programmed automatic machine, that is, a cooperation mechanism between a wiring head equipped with a wire clamping jig and the wiring table 3, sequentially places the wire on the wiring table 3 on the bridge 4. The terminals of each electric wire 8 are cut off from the bridge 4 leaving a predetermined length 1, and are routed to connect each wiring table 3. , wire harness A is obtained.

When the wiring is completed, a tape 9 is wound around the branch part of each electric wire 8 and temporarily fixed.

As a result, as shown in FIG. 2, each electric wire 8 is routed with a predetermined wiring interval and number of wires according to the product spacing, and is connected to the bridge 4 by leaving a predetermined length 1 from each end. As a result, wire harnesses B are obtained which are arranged and fixed in an orderly manner with constant intervals.

Although this wire harness B is a semi-finished product, it is automatically routed with the desired wiring spacing and number of wires, and the terminals of each wire are arranged and fixed in an orderly manner by a bridge, leaving a predetermined length. Therefore, at the stage before moving on to the next process such as connecting the connecting terminal fittings and connectors to the terminal part,
It is extremely advantageous for storage, transportation, etc.

In FIG. 3, the wire harness C is obtained by removing the insulation from the terminal portion of each electric wire 8 fixed by the bridge 4, removing the insulation coating using a terminal fitting attachment device, and crimping the connecting terminal fitting 10. be.

The terminal portion of each electric wire 8 constituting this wire harness C is as follows:
Since they are arranged and fixed in an orderly manner by the bridge 4, a plurality of connection terminal fittings 10 can be crimped and connected at the same time, and as shown in FIG. There is no need to insert the wires one by one, and they can be easily inserted and installed at the same time. After inserting the connection terminal fitting 10 into the connectors 11,
Remove bridge 4 if necessary.

FIG. 5 is a schematic perspective view of a wiring device used for carrying out the present invention. A shaft 14 is provided, and a wiring head 15 is movably provided on the Y-axis 14.

The X-axis 12 and Y-axis 14 are each rotated by four motors,
By appropriately setting the amount of rotation, the wiring head 15
The wire 8 held by the wiring head 15 can be carried to any position between the wiring tables 3 arranged on the workbench 1. Reference numeral 16 denotes a control device, in which the entire wiring process is programmed (NC-controlled) using tape.

Reference numeral 17 denotes a wire reel station, and each wire 8 whose insulation coating is color-coded is connected to the wiring head 15 via a tension reducing capstan 18 which is rotated in the wire feeding direction by a motor (not shown). .

FIG. 6 is a side view of the wiring head 15, with a wiring jig 24 at the top of the wiring head main body 19, and a hood lamp jig 4 at the bottom.
5 are provided so as to be able to rise and fall, respectively, and to be freely rotatable with respect to predetermined positions.

An annular wiring jig mounting base 21 is rotatably provided in the wiring head main body 19 by a plurality of guide rollers 20, and the mounting base 21 is connected to a regulating rotation motor 2 of a servo motor or the like 7.
It is connected to 2.

Wiring jig elevation guide pipes 23 are provided on the wiring jig mounting base 21 at predetermined intervals, a plurality of wiring jigs 24 are inserted, and the wiring jig 24 is held at a predetermined height using the knob pins 25. I'm saving it. Each wiring jig 24 is connected with a different color electric wire 8 from the front reel station 17, but the rotation of the wiring jig mounting base 21 linked to the regulation rotation motor 22 allows the wiring jig 24 to be connected to any wiring jig 24. can be selectively positioned at a predetermined position P (Fig. 7).

Reference numeral 26 denotes a lifting unit that raises and lowers the wiring jig 24 at a predetermined position P, and 27 denotes a motor that drives a capstan 33 of the wiring jig 24, which will be described later.

As shown in FIG. 8, the wiring jig 24 is provided with a connecting bar 30 that engages with the lifting unit 26 on the outside of a cylinder 29 with a wire insertion hole 28 inside, and a connection bar 30 that engages with the lifting unit 26.
At the top of the capstan head 31 and wire check device 3 are installed.
5, a nozzle 38 for wiring the electric wire is provided at the lower part. The capstan 31 is provided with a wheel 32 driven by the motor 27 on the outside, a capstan 33 pivotally attached to the wheel 32 inside, and a wire loosening prevention piece 34 facing the lower part of the capstan 33. .

Further, the wire check device 35 is provided with a check claw 36 inside which is biased by a spring, and has a wire guide 36 at the upper end.
It consists of 7. The electric wire wiring nozzle 38 is formed of a coil spring, and when a certain tension is applied to the wiring jig 24 while running, it bends in the opposite direction to the running direction, and returns to its original state when the tension is released when the running is stopped. It is preferable to use a material that has a certain degree of elasticity and can straighten the bending of the wire being wired. FIG. 9 is a side view of the elevating and rotating device for the clamp jig 45, in which numeral 39 indicates the clamp jig body, and the actuator 40
It is installed so that it can be raised and lowered freely.

41 is an annular clamp jig mounting board that also serves as a pulley.
It is rotatable relative to the clamp jig main body 39 and is provided at a position where its center coincides with the axis of the wiring jig 24 at the predetermined position P.

Reference numeral 42 denotes a regulating rotation motor for controlling the direction of the clamp jig 45, 43 a timing pulley thereof, and 44 a belt connecting the clamp jig mounting board 41 and the timing pulley 43.

Therefore, the clamp jig 45 can be rotated to a desired position about the wiring jig 24 by driving the regulating rotation motor 42, and can be moved up and down by the actuator 40. FIG. 10 is an enlarged side view of the clamp jig 45. The clamp jig 45 includes, in order from the front, a front end clamp plate 46, a wire end insertion guide plate 47 with built-in springs, a cutting blade 48, and a rear end. The guide plate 47 and the cutting blade 48 slightly protrude from the lower surfaces of the front and rear end clamp plates 46 and 49 and are provided to be perpendicular to each other.

This front terminal clamp plate 46 and rear terminal clamp plate 49
and are provided at symmetrical positions with respect to the cutting blade 48. FIG. 11 is a perspective view of the wiring table 3, with a nozzle guide pin 50 at the upper front end,
A nozzle guide groove 54 is provided at the rear end, and a bridge placement groove 51 for sequentially placing the bridge 4 in the middle;
A wire clamp claw 52 and a cutting blade contact surface 53 are provided, and fitting holes 55 for a separately used jig are provided on both sides of the bridge mounting groove 51. Note that 56 is a release screw for the wire clamp claw 52. Nozzle guide pin 5
0. The nozzle guide groove 54 and the like are increased or decreased according to the number of wires to be wired, and are used to guide the wiring nozzle 38 of the wiring jig 24 during wiring, and the wire clamp claw 52 is It is responsible for holding the electric wires during wiring, and can only hold down the electric wires that are being inserted.

Figure 12 shows the wiring table 3, the wiring jig 2, and the clamp jig 4.
5, at the starting point of the wiring (FIG. 12A), the bridge 4 is placed in advance in the bridge mounting groove 51 of the wiring table 3-1, and the bridge 4 and the nozzle are The wiring nozzle 3 of the wiring jig 24 is placed between the guide pins 50.
8 is bent and makes contact, and the end portion (length 1) of the wire 8 exposed from the tip is slightly bent and attached to the wire clamp claw 5.
It is located two meters above.

In this state, when the clamp jig 45 is pushed down, the wire end insertion guide plate 47, which protrudes from the lower surface of the front end clamp plate 46, comes into contact with the end of the wire 8, as shown in the opening of FIG.

Therefore, the wire 8 is guided to the center of the wire clamp claw 52, then steadily pressed by the front end clamp plate 46 and held between the clamp claws 52, and at the same time positioned between the clamping pieces 6, 6'' of the bridge 4. That is, at the starting point of the wire, even if the wire exposed from the tip of the wiring nozzle 38 is slightly bent, the wire end insertion guide plate 47
The front end clamp plate 46 is securely locked onto the wiring table 3-1 by the cooperative mechanism.

FIG. 12C shows the end point of the wiring, and the wiring table 3-2 is placed opposite the wiring table 3-1.

Further, the wiring nozzle 38 of the wiring jig 24 bends into contact with the nozzle guide groove 54, and the electric wire 8 exposed from its tip is passed through the wiring locking pin 2 and the nozzle guide pin 50. It is stretched linearly between the wiring table 3-1. Therefore, the wire 8 is connected to the wire clamp claw 52 and the bridge 4.
are aligned with the centers of the clamping pieces 6, 6''. In this state, when the clamp jig 45 is pushed down, the electric wire 8 is steadily pressed against the rear terminal clamp plate 49. It is held between the clamp claws 52 and is simultaneously cut by the cutting blade 48 leaving the end portion (length 1) on the cutting blade contact surface 53. Next, the clamp jig 45 is If it is rotated by the operation of (see Fig. 9) and positioned directly behind the wiring jig 24, it will return to the starting position of the wiring, as in the case of Fig. 12A.

FIG. 13 schematically shows the wiring process using the wiring jig 24, the clamp jig 45, and the wiring table 3.

71 Position a specific wiring jig 24 at a predetermined position P by the regulating rotation motor 22 (hereinafter referred to as 1 wiring jig selection)
, the wiring jig 24 is lowered to the rear of the wiring table 3-1 by driving the lifting unit 26 (hereinafter referred to as 1 wiring jig lowering).

(Fig. 13 A) 2 Wiring jig 24 on x axis 12 and Y axis 14
(hereinafter referred to as RXY axis travel), the wiring jig 24 is positioned at the starting position of the wiring (see Fig. 12A), and the clamp jig 45 is lowered and raised by driving the actuator 40 ( Below 1. Lowering the clamp jig,
The end of the wire 8 (length I) is placed on the wiring table 3-
1 (see Figure 12), capstans 18 and 33 for reducing the tensile force of the electric wire are simultaneously driven (hereinafter referred to as 1 capstan drive).

(Figure 13) The wiring jig 24 is moved toward the wiring table 3-2 while the electric wire 8 is stretched by 3rXY-axis travel.

(FIG. 13C) Position the fourth wiring jig 24 at the end point of the wiring (see FIG. 12C) with respect to the wiring table 3, and lower and raise the first clamp jig to lower the wire 8. to lock and cut. Next, the 1-clamp drive is stopped. (13th
In Figure D), the wiring between the wiring tables 3-1 and 3-2 is completed.

5r By moving the XY axes, the wiring jig 24 is moved to the wiring table 3-2.
The clamp jig 45 is positioned directly behind the wiring jig 24 by driving the regulating rotation motor 42.

That is, clamp jig direction control is performed. (Figure 13 E)
6r By traveling on the XY axes, the wiring jig 24 is moved to another preset wiring table), and the original wiring jig 24 is raised by the driving of the lifting unit 26; Retained.

7 Next, similarly to 1, another specific wiring jig 24 is selected, 1 wiring jig is lowered, and 2 and 3 are sequentially selected.
By repeating step 7, the desired wire harness A as shown in Figure 1A is obtained! Ru.

FIG. 14 shows the entire device for removing the coating and attaching terminal fittings to the end portions of the wires in the wire harness B. Reference numeral 69 denotes a wire holder having a wire guide pin 70, and an auxiliary clamp 71 can be opened and closed with respect to the pin 70. It is arranged to hold the electric wire.

72 is a wire sheath removal/cutting device provided opposite to the wire holder 69, which includes a pair of sheath removal/cutting blades 73, 7;
4, and the blades 73 and 74 are provided so as to be movable toward and away from each other in the direction in which they face each other and in the direction of the wire holder 69.

75 is a clamp for the auxiliary clamp 71.

A terminal crimping device 76 has a lower crimping die 77 and an upper crimping die 78 driven by a hydraulic press ram 79. The crimping device 76 is configured to be slidably movable behind the wire holder 69. 80 is a terminal feeding guide that includes upper and lower terminal feeding claws 81 and 82; 83 is a terminal transfer cylinder that moves together with the terminal crimping device 76;
84 is a chain terminal connecting a large number of terminals, and 85 is a terminal feed adjustment piece.

FIG. 15 schematically shows the steps of removing the coating from the end portion of the wire, cutting it, and attaching the terminal fitting.

i The electric wire 8 fixed to the bridge 4 with the end portion (length 1) left is placed on the electric wire holder 69 and clamped and fixed by the electric wire guide pin 70 and the auxiliary clamp 71. (1st
Figure 5 a) i Remove the pair of coatings and approach the wire holder 69 side with the cutting blades 73 and 74 open.

(Fig. 15) Beat opposite coating removal, cutting blade 73,
74 and lightly pinch the electric wire 8 from above and below (0 points)
, and retreat to the coating removal position (01 point).

(Fig. 15 C) In the above cases i and 2, the electric wire 8 is neatly partitioned by the electric wire guide pin 70 and is pressed down by the sheath removal and cutting blades 73 and 74 approaching from above and below, so that the end portion thereof is bent. Even if it is attached, it will be held securely.

At the Iv coating removal position (point 01), only the coating is cut by the upper and lower coating removal and cutting blades 73 and 74, and the wire is retreated to the wire cutting position (point 02).

That is, the conductor portion of the electric wire 8 is exposed between points 01 and 02. (FIG. 15 D) ■ At the wire cutting position (point 02), the wire 8 is cut by the upper and lower sheath removal and cutting blades 73 and 74, and the sheath removal blades 73 and 74 retreat.

Therefore, each electric wire 8 is cut from the bridge 4 at a fixed position, and the tips thereof are all aligned. (FIG. 15E) ■ The terminal crimping device 76 moves behind the wire holder 69.

At the same time, the chain terminal 84 is also moved according to the number of electric wires 8 by the terminal feed claws 81 and 82. (Proceed to FIG. 15) ■ By driving the hydraulic breath ram 79, the connection terminal fittings 10 are swaged to the end portions of the respective electric wires 8, and the terminal swage device 76 is retreated to its original position. At this time, the moving distance of the crimping device 76 is (Σ), but the terminal feed claw 82 is moved by the terminal feed adjustment piece 85?
? Therefore, the connecting terminal fittings 10 are sent to the next crimping process in correspondence to (Σ one tile (four pieces in the figure)).

Thereafter, steps I, ii, .

Next, by attaching connectors to each part of the connection terminal fitting 10, a completed wire harness D as shown in FIG. 4 is obtained. As described above, in the present invention, a plurality of wiring tables are arranged in advance on a workbench with product intervals, and bridges for storing electric wires at appropriate intervals are removably placed on each wiring table. Then, the wire is locked to one wiring table by the wiring head and engaged between the pair of clamping pieces of the bridge, and then routed toward the other wiring table, and the electric wire is routed to the other wiring table. 1 of the wiring table, and engages between the pair of clamping pieces of the bridge to cut the wire, and then successively routes the wire between the desired wiring tables, and connects the terminal part of the wire to the The structure is such that, while the electric wire is held at an appropriate distance via the bridge, the coating is removed from the end of the wire, the terminal fitting is crimped to the end, and the end terminal fitting is attached to the connector. This makes it extremely easy to connect the connecting terminal fittings and attach connectors, thereby shortening the overall manufacturing time and increasing productivity.

[Brief explanation of the drawing]

1 to 4 are explanatory diagrams showing the wire harness assembly process, FIG. 5 is an overview perspective view of the wiring device, FIG. 6 is a side view of the wiring head 15, and FIG. 7 is an illustration of the wiring head 15. 8 is a partial sectional view of the wiring jig 24, FIG. 9 is a side view of the elevating and rotating device for the clamp jig 45, FIG. 10 is an enlarged side view of the clamp jig 45, and FIG. The figure is a perspective view of the wiring table 3, and FIG. 12 shows the wiring table 3, wiring jig 24, and clamp jig 5.
Fig. 13 is a clear diagram of the wiring process, Fig. 14 is a perspective view showing removal of the wire sheathing, terminal fittings attached, and the entire device, Fig. 15 is a diagram showing the removal of the sheathing, cutting, and It is an explanatory view of a terminal metal attachment process. 1... Workbench, 3... Wiring table, 4...
...Bridge, 8...Electric wire, 10...
...Connection terminal fitting, 11...Connector, 15.
... Wiring head, 72 ... Wire sheath removal and cutting device, 76 ... Terminal tightening device.

Claims (1)

[Claims] 1. Arrange multiple wiring tables in advance on a workbench with product intervals, and removably place bridges for storing electric wires at appropriate intervals on each wiring table, and place the electric wires on the wiring head. After the electric wire is locked to one wiring table and engaged between the pair of clamping pieces of the bridge, the wire is routed toward another wiring table, and the wire is connected to the other wiring table. At the same time, the wires are cut by being engaged between the pair of clamping pieces of the bridge, and then the wires are sequentially routed between the desired wiring tables, and the terminal portions of the wires are passed through the bridge at appropriate intervals. A method of manufacturing a wire harness, which comprises removing the coating from the terminal end of the wire, crimping a terminal fitting to the terminal end, and attaching the terminal fitting to a connector while the wire is held in the same position.