JP4289601B2

JP4289601B2 - Method for manufacturing harness circuit body

Info

Publication number: JP4289601B2
Application number: JP2003067696A
Authority: JP
Inventors: 真史塚本; 満治久保田; 和由矢部
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2003-03-13
Filing date: 2003-03-13
Publication date: 2009-07-01
Anticipated expiration: 2023-03-13
Also published as: JP2004282817A

Description

【０００１】
【発明の属する技術分野】
本発明は、自動車のインストルメントパネル等に配置され、複数のコネクタを複数の電線で相互に接続して電装品等の各補機に分岐接続させるハーネス回路体とその製造方法に関するものである。
【０００２】
【従来の技術】
図１９は従来の車両用のハーネス回路体の一形態、図２０は図１９のＡ−Ａ断面図をそれぞれ示すものである（特許文献１参照）。
【０００３】
図１９において符号６１は自動車のインストルメントパネル内に水平に配設されるリインフォース（補強材）、６２はリインフォース６１の後面側（車室寄り）に配索されたワイヤハーネス（幹線）、図２０の符号６３は同じくリインフォース６１の前面側（エンジンルーム寄り）に配索されたワイヤハーネス（幹線）をそれぞれ示している。
【０００４】
各ワイヤハーネス６２，６３によってインパネ側の計器やスイッチ、オーディオといった電装品や補機への給電や信号の授受やエンジンルーム側の空気調和機等の補機への給電等が行われる。
【０００５】
これら二つのワイヤハーネス６２，６３は図２０の両分岐ボックス６４，６５によって相互に接続され、一方（後面側）の分岐ボックス６４からコネクタ６６と分岐線６７を介して各電装品や補機に接続される。
【０００６】
他方（前面側）の分岐ボックス６５はハウジング内に複数枚の絶縁プレートを縦置きに備え、各絶縁プレートにワイヤハーネスの各電線６３が並列に配置され、各電線６３は圧着端子に接続され、圧着端子の嵌合接続部に一方の分岐ボックス６４の長尺端子のタブ部が適宜貫通接続される。長尺端子は一方の分岐ボックス６４内で電線と接続されつつ、分岐ボックス後端のコネクタ内に位置し、分岐線側のコネクタ６６内の端子と接続される。ワイヤハーネス（幹線）６２，６３と分岐線６７と各分岐ボックス６４，６５とでハーネス回路体６８が構成される。
【０００７】
【特許文献１】
特開２００１−１９１８７０号（第３〜４頁、図１〜図３）
【０００８】
【発明が解決しようとする課題】
しかしながら、上記従来のハーネス回路体にあっては、回路仕様を変更する際に電線や端子の配列を再設計するのが困難であるという問題や、幹線相互の接続や幹線と分岐線との接続構造が複雑化し、部品コストが高くつくという問題、あるいは製造に多くの手間や装置が必要で、製造コストが高くつくといった問題があった。
【０００９】
本発明は、上記した点に鑑み、仕様変更時の回路設計を容易化することができ、また、構成部品を簡素化することができ、さらに、生産を容易に且つ効率良く行うことができるハーネス回路体の製造方法を提供することを目的とする。
【００１０】
【課題を解決するための手段】
上記目的を達成するために、本発明の請求項１に係るハーネス回路体の製造方法は、並列に配置され、分岐線を接続可能な複数のコネクタと、該複数のコネクタのうちの所要のコネクタの所要の端子の露出した圧接部に圧接されてコネクタ並び方向に延びる幹線とを備え、該幹線が、該コネクタの上面に沿って略コの字状に屈曲して配置された電線屈曲部を有し、該電線屈曲部が、コネクタ並び方向の真直部分と、該真直部分の両端側で屈曲したコネクタ嵌合方向の真直部分とを有し、該コネクタ並び方向の真直部分が該コネクタを相互に連結し、該コネクタ嵌合方向の真直部分が前記圧接部に圧接され、さらに、該圧接部を覆うカバーを備えて構成されるハーネス回路体を製造する方法であって、対向する一対の成形型の櫛歯部で前記幹線を略コの字状に屈曲させ、該一対の成形型の櫛歯部に横櫛を挿入して該横櫛に前記電線屈曲部を保持させ、該一対の成形型を開き、該横櫛を前記カバーに貫通させて該カバーの溝に該電線屈曲部を係合させ、該横櫛を抜き取り、該カバーを前記コネクタの圧接部に押し付けて該電線屈曲部を該圧接部に接続させることを特徴とする。
上記構成により、幹線を構成する各電線を所要のコネクタの所要の端子に接続することで、種々の回路仕様に対応した分岐用回路が簡単に構成される。コネクタや端子といった構成部品は共通使用される。また、電線が屈曲部でコネクタの端子に接続されることで、コネクタを除く部分で幹線が長手方向に真直に位置し、幹線の延長方向とコネクタの配列方向とが一致し、ハーネス回路体の構成が簡素化・スリム化すると共に、幹線の所要の位置にコネクタが配置され、分岐線との接続位置が最適化される。
【００１１】
また、電線を端子の圧接部に圧接することで、電線接続が容易に且つ効率的に行われる。複数の圧接部の並び方向に対して直交する方向で電線屈曲部が接続される。
また、電線屈曲部がコネクタの外面に沿って位置することで、コネクタ嵌合方向への電線屈曲部の突出がなくなり、電線配索構造及び全体構造が簡素化・スリム化される。各コネクタは電線屈曲部で相互に連結される。電線屈曲部をＵ字状に折り返しつつ各コネクタを重ね合わせてブロック化することもできる。
【００１２】
また、カバーで端子と電線の接続部が絶縁・保護される。
また、一対の成形型を閉じることで、電線（幹線）が成形型の外観略コの字状の櫛歯部で略コの字状に屈曲変形（成形）される。各成形型の櫛歯部によって電線は矩形波状に屈曲成形される。櫛歯部を閉じた状態で横櫛を櫛歯部の間すなわち櫛歯部を構成する各ブレード間の隙間に挿入することで、電線の屈曲形状が横櫛によって維持される。従って成形型を開いても横櫛が電線屈曲部を保持して電線の屈曲形状が正確に維持される。次いでカバーに横櫛を貫通することで、横櫛間の電線屈曲部がカバーの溝に移行されて係合保持される。横櫛をカバーから抜き取ることで、複数のカバーと複数の電線との仮組立体が構成される。このカバーをコネクタの圧接部に被せつつ強く押し付けることでカバー内の電線が圧接部に圧接接続され、ハーネス用回路体が形成される。カバーは電線圧接部を外部から絶縁保護する。
【００１３】
請求項２に係るハーネス回路体の製造方法は、請求項１記載のハーネス回路体の製造方法において、所要の長さ・位置に前記櫛歯部を有する複数枚の前記成形型を重ね合わせて、並列に配置した複数本の前記幹線を同時に屈曲成形することを特徴とする。
上記構成により、複数対の成形型で複数本の電線が各電線の所要屈曲形状に屈曲成形される。請求項１記載の横櫛は複数枚の成形型の櫛歯部を貫通して各電線の屈曲部を保持する。
【００１４】
請求項３に係るハーネス回路体の製造方法は、請求項１又は２記載のハーネス回路体の製造方法において、前記櫛歯部として少なくとも各一対の加圧リブを用いることを特徴とする。
上記構成により、各成形型の各一対の加圧リブの先端で電線（幹線）が剪断方向に屈曲されつつ対向方向の加圧リブの間でリブ長手方向に挟まれるように成形される。
【００１５】
請求項４に係るハーネス回路体の製造方法は、請求項３記載のハーネス回路体の製造方法において、前記加圧リブは複数の支持杆にスペーサと共に挿通して組み付けられ、少なくとも該加圧リブと該スペーサと該支持杆とで前記成形型を分解可能に構成したことを特徴とする。
上記構成により、治具部品であるスペーサや加圧リブを共通使用し、治具部品の組み付けを各電線の屈曲形態に応じて変更して、種々の形態に成形型を組み立てることができ、種々の回路仕様（形態）に容易に且つ迅速に対応することができる。
【００１６】
請求項５に係るハーネス回路体の製造方法は、請求項１〜４の何れか１項に記載のハーネス回路体の製造方法において、前記電線の圧接後に前記複数のコネクタを重ね合わせてコネクタブロックとすることを特徴とする。
上記構成により、複数のコネクタブロックと各コネクタブロックを連結接続する複数の電線（幹線）とでハーネス回路体が構成される。同形状のコネクタ同士を重ね合わせて一つのコネクタブロックとすることが好ましい。コネクタブロックによって分岐線側のコネクタが高さ方向に並列に配置接続される。
【００２５】
【発明の実施の形態】
以下に本発明の実施の形態を図面に基づいて詳細に説明する。
図１〜図２は、本発明に係るハーネス回路体の一実施形態を示すものである。
【００２６】
このハーネス回路体１は、並列に配置された複数のコネクタ２と、各コネクタ２の上壁面の基端側に配設されたカバー３と、各カバー３の下側で各コネクタ２の端子４（図２）に接続されて各コネクタ間を接続する複数本の電線（幹線）５とを備えたものである。各コネクタ２には分岐線側のコネクタ６が嵌合接続され、分岐線７は各種電装品やＥＣＵといった補機にコネクタ８で接続される。
【００２７】
図２の如くハーネス回路体１のコネクタ２は、合成（絶縁）樹脂で薄型に形成された雌型のハウジング９と、ハウジング９の上壁（壁部）１０の外面に垂直に突出した圧接部１１を含む前記端子４とで構成され、端子４は圧接部１１に続いてハウジング９の嵌合室１３内に突出した水平なタブ部１２を有する。嵌合室１３に分岐線側の雄型のコネクタ６（図１）が挿入され、タブ部１２と分岐線側の雌型の端子（図示せず）とが相互に接続される。分岐線７とそのコネクタ６とを含めてハーネス回路体と称してもよい。
【００２８】
各コネクタ２において圧接部１１は等ピッチで複数並列に配置され、左右端の圧接部１１の外側においてハウジング９から一体にカバー３に対する係止片１４が突設されている。各係止片１４は外向きの係止突起を有している。圧接部１１は左右一対の圧接歯の間のスロットに絶縁被覆電線５を圧入して絶縁被覆を切裂させつつ電線芯線部を接続させるものである。圧接部１１がハウジング９の上面１０から垂直に突出したことで、ハウジング上に電線収容スペースが確保されている。各圧接部１１の並び方向は電線（幹線）５の長手方向に等しい。
【００２９】
図１の如く電線５は略コの字状に屈曲した状態で各コネクタ間に接続される。すなわちコネクタ２の並び方向に延長された電線５は、ハウジング９の基端外側でほぼ直角に屈曲されて（５ａの部分）ハウジング９の上面に沿って短い距離で真直に延び（この部分５ｂが圧接される）、ハウジング上で再度屈曲されて（５ｃの部分）隣のコネクタ２に向けて延び、隣のハウジング９の上面で屈曲されて（図１の５ｄの部分）ハウジング基端側に向けて短く真直に延び（この部分５ｅが圧接される）、ハウジング基端外側で再度屈曲されて隣のハウジング又は所要のハウジングに向けて又は幹線と平行に延びている。ワイヤハーネスの幹線を構成する複数の電線５は水平方向に並列に配置され、コネクタ２の基端外側で圧接部１１の垂直面と平行に延びている。どのコネクタ２のどの端子４にどの電線５を圧接するかは、回路仕様によって適宜設定される。
【００３０】
図２の如くカバー３は合成（絶縁）樹脂でハウジング９の幅と同程度の長さに形成され、下側に電線挿通用の複数の溝１５を等ピッチで並列に有し（溝１５は隣接する突部１６の間に形成されている）、溝１５に連通して圧接部１１に対する挿入空間を有し、溝間の突部１６の上側において細長の貫通孔１７を等ピッチで並列に有し、左右端にコネクタ側の係止片１４に対する可撓性の係合枠片１８を有している。貫通孔１７については後述するが、後述の電線位置決め部材（横櫛）を用いなければ貫通孔１７は特に必要はない。
【００３１】
図２において各電線５は例えば昇降式の圧接ブレードといった治具（図示せず）で圧接部１１に圧接され、その後、カバー３を装着して圧接部１１を外部から絶縁させる。あるいは、カバー３の溝１５に予め各電線５をセットした後、圧接部１１に向けてカバー３を装着することで、各電線５を圧接部１１に圧接させることも可能である（これについては後述する）。
【００３２】
また、接続部として圧接部１１に限らず圧着やハンダ付けや溶接等の手段で端子４の露出した接続部に電線５を接続することも可能である。但し、圧着の場合は電線５の中間部を皮剥きしたり、ハンダ付けや溶接の場合は多くの工数や大きな装置を必要とするので、圧接がベストである。また、上記コネクタ２として、圧接部１１に続く雌型の端子（図示せず）を収容した雄型のコネクタ（図示せず）を使用し、分岐線側のコネクタ６（図１）を雌側のコネクタとすることも可能である。
【００３３】
上記ハーネス回路体１は例えば自動車のインストルメントパネルの内側や裏側（エンジンルーム寄りの部分等）に配索される。インストルメントパネル以外に車両のフロアや各種パネル等に配索することも可能である。
【００３４】
図３は、ハーネス回路体の各コネクタに電線を配索する方法の一形態を示すものである。図１の形態と同じ構成部分には同じ符号を付して詳細な説明を省略する。
【００３５】
このハーネス回路体１９は三つの嵌合室１３を並列に有するコネクタ２１と、四つの嵌合室１３を並列に有するコネクタ２０と、多数（例えば１２）の嵌合室（図３では後側にあるので見えない）を有する長尺のコネクタ２２とを備えたものである。
【００３６】
作業台上に長尺のコネクタ２２と他の短尺のコネクタ２０，２１とを背中合わせに配置（固定）し、自動配索機２３のノズル２４から電線５を一筆書きで各コネクタ２０，２１，２２の上面に順に吐出配索していく。自動配索機２３は矢印の如くＸＹ方向すなわちコネクタ長手方向と長手直交方向（コネクタ嵌合方向）とにノズル２４を交互に動かしながら、電線５をコネクタ上で略コの字状（矩形波状）に配索し、各コネクタ間では電線５を小ピッチの波形（５ｆの部分）に配索して幹線部を構成する。なお、コネクタの数や長さが小さな場合は、各コネクタを幹線長手方向に並列に配置して上記自動配索機２３の二次元方向の移動により電線５を配索してもよい。
【００３７】
図４は、各コネクタに電線を配索する方法の他の形態を示すものであり、上各コネクタ２０〜２２を移動テーブル上で長手方向に並列にセットし、移動テーブル（図示せず）の上方に一つ又は複数の上記自動配索機２３のノズル２４をコネクタ長手直交方向に移動自在に配置し、移動テーブルすなわちコネクタ２０〜２２を矢印の如くコネクタ長手方向（Ｘ方向）に移動しつつノズル２４から電線５をコネクタ長手方向に所要長さで配索した後、ノズル２４をコネクタ長手直交方向（Ｙ方向）に移動して電線５を圧接部１１上に配索し、再度移動テーブル（コネクタ）をＸ方向に移動して電線５を矩形波状に配索していく。
【００３８】
複数の自動配索機２３を使用することで、複数本の電線５を同時に所要形状に配索することができ、一つの自動配索機２３を用いる場合よりも生産性が向上する。各自動配索機２３の移動はＹ方向のみであるから自動配索機同士の干渉の心配がない。移動テーブル上でコネクタ２０〜２２のみを長手方向に移動（駆動）させるようにすることも可能である。また、長手方向の作業スペースが少ない場合は、コネクタ２０〜２２を移動テーブルに図３の如く背中合わせに配置して、一列目のコネクタ２０，２１に電線５を配索した後、移動テーブルを戻し、且つ自動配索機２３をコネクタ横断方向に大きく移動させて二列目のコネクタ２２に電線を配索することも可能である。
【００３９】
図３，図４の各形態において、テーブル上に電線位置決め用のピン等（図示せず）を突出させておいてもよい。電線５を一つの圧接部１１上に配索した後、すぐにその圧接部１１に圧接ブレード等で圧接してもよい。自動配索機２３に圧接ブレードやその駆動手段を一体的に設けることも可能である。また、ノズル２４から電線５を圧接部１１に仮圧入して位置決めを行わせてもよい。この場合、ノズル２４は上下方向にも移動可能としてもよい。
【００４０】
図３，図４では自動配索機２３のノズル側の部分のみを図示しているが、実際の自動配索機は少なくとも電線５を送り出す回転ローラや、ノズル２４を含むヘッド部をＸＹ方向に移動させるレール部等を含むものである。また、コネクタの形態は図１に示す一つの嵌合室１３のコネクタ１を用いたり混載したりすることも回路仕様に応じて適宜行われる。
【００４１】
図５〜図６は上記自動配索機２３を用いずに電線を予めコの字（矩形）状に屈曲させるための治具及び方法の一実施形態を示すものである。
【００４２】
図５（ａ）（ｂ）の如く水平な電線５は上下一対の成形型２５，２６の垂直な各加圧リブ（加圧歯）２７によってコの字状に屈曲成形される。すなわち、上側の加圧リブ２７は下側の加圧リブ２７よりも内側に位置し、上下の加圧リブ２７の先端で電線５が剪断方向に押されてほぼ直角に屈曲しつつ、上下の加圧リブ２７の間に電線５が挟まれるようにして垂直に位置する。これにより電線５がコの字状に屈曲変形される。屈曲部の屈曲点を符号５ａ，５ｃ，５ｄ，５ｇで示す。符号５ｂ，５ｅは圧接される部分である。なお、後述する屈曲形状を維持する横櫛やピンを用いることも可能である。
【００４３】
図６の如く上側の成形型２５と下側の成形型２６とはそれぞれ横長の基台２８に複数の櫛歯状の水平な支持杆２９を等ピッチで並列に設けたベース３０と、各支持杆２９に上側から挿入されるスリット３１を有する複数のスペーサ３２と、所定の支持杆２９に先端側から挿入される孔部３３を板部３４に形成すると共に板部３４から断面矩形状の前記加圧リブ２７を突出させて成る加圧部材３５とで構成される。
【００４４】
加圧リブ２７は電線一本について上下各一対使用し、二本の電線５を並列に配置して同時に屈曲させるには上下各二対の加圧リブ２７を配置し、複数本（ｎ本）の電線５を同時に屈曲させるには上下各ｎ対の加圧リブ２７を配置する。その場合、各加圧リブ２７の位置は各電線５の屈曲位置や屈曲長さによって異なるから、所要の支持杆２９に加圧部材３５をセットすることになる。
【００４５】
スペーサ３２は加圧リブ２７の位置を決める（固定する）ための部材として作用する。加圧リブ２７を所望の位置に容易に且つ迅速に配置することができるから、回路仕様の変更に迅速に対応して各電線５の屈曲形態を正確に得ることができる。上下の成形型２５，２６は加圧部材２５を上下反転させるだけで全て同じものを共通使用できる。
【００４６】
なお、加圧リブ２７の先端や側面に電線保持用の溝を設けることも有効である。また、スペーサ３２のスリット３１を加圧部材３５と同様の孔部に代えることも可能である。また、電線５を垂直又は水平に配置し、上下の成形型２５，２６を左右の成形型として用いることも可能である。
【００４７】
図７〜図１５は、本発明に係るハーネス回路体の製造方法の一実施形態を示すものである。
【００４８】
このハーネス回路体の製造方法は、図７の成形型５２，５３を用いて図８の複数本の並列な電線５を図９の如く屈曲成形し、次いで図１０の如く横櫛（サイドフォーマないし形状維持部材）３９を成形型５２，５３に挿通させて図１１の如く各電線５の屈曲形状を維持させ、図１２の如くカバー３を横櫛３９に挿通させて、電線５をカバー内に装填させ、図１３の如く横櫛３９を外してカバー３と電線５との仮組付体４０を形成させ、前記図１の如くカバー３をコネクタ２に組み付けつつ電線５をコネクタ２の圧接部１１に圧接し、図１４の如く不要な電線部分５ｊを切断除去して所要の回路を形成した後、図１５の如く形状の同じ隣接のコネクタ２同士を重ね合わせてコネクタブロック４１を構成させ、各コネクタブロック４１を幹線５で連結して成るハーネス回路体１’を得るものである。
【００４９】
以下各図の構成を詳細に説明する。
図７の如く、上下の成形型（成形板）５２，５３は電線一本につき一以上の櫛歯部４２を有し、櫛歯部４２の左右端は湾曲状に面取り（４３）されて電線５をスムーズに傷付きなく屈曲可能である。各櫛歯部４２は複数の真直な杆（歯）４４を等ピッチで並列に配し、各杆４４の間にスリット４５を構成したものである。各櫛歯部４２に対向して各凹部（切欠部）４６が位置し、上下の櫛歯部４２の左右端の間に電線５を挟み込むように各櫛歯部４２の寸法が規定されている。櫛歯部４２の左右端の歯４４₁の厚さを他の歯４４の半分とし、且つ左右端の歯４４₁の外側に電線保持溝（図示せず）を設け、上下の櫛歯部４２の左右端の歯４４₁に隣接するスリットのピッチを他のスリット４５のピッチと同一とすることが好ましい。各歯４４の先端にも電線保持溝を設けることが好ましい。
【００５０】
図８の如く複数の電線５を検尺切断して並列に並べ、図７の上下の成形型５２，５３を電線５の本数・ピッチと同じ枚数・ピッチで板厚方向に重ね合わせてセットする。重ね合わせた複数の成形型５２，５３は各電線５の屈曲位置や屈曲長さに応じて異なる位置・寸法の櫛歯部４２を有する。
【００５１】
図９の如く上下の成形型５２，５３を上下に合わせることで電線５が上下の各櫛歯部４２の間でコの字状に屈曲変形（成形）され、長手方向に矩形波状に屈曲する。成形型５２，５３の駆動はプレス機等で行われる。
【００５２】
図１０の如く、上下の成形型５２，５３を合わせた状態で横櫛３９を上下の成形型５２，５３の各櫛歯部４２のスリット４５内に矢印の如く水平に挿入し、それによって各電線５の屈曲形状が維持される。横櫛３９は図１１の如く横長の基台４７と、基台４７から等ピッチで突出された真直で断面長方形の複数のブレード（歯）４８とで構成される。ブレード４８の先端は櫛歯部４２（図１０）への挿入性を高めるべく滑らかに面取りされている。ブレード４８の幅（厚さ直交方向の寸法）は図９の如く上下に重なった各櫛歯部４２のラップ長さＬよりも短く設定される。たとえ櫛歯部４２と各ブレード４８とのピッチが多少ずれていても、櫛歯部４２やブレード４８の可撓性によって若干の位置ずれは吸収され、ブレード４８が櫛歯部間にスムーズに挿入される。
【００５３】
上下の成形型５２，５３を開くことで図１１の如く横櫛３９に電線５が屈曲した状態で保持される。各ブレード４８は各電線５の屈曲部５ｋの左右端（コネクタ２の圧接部１１に圧接される部分５ｂ，５ｅ）の位置を正確に規定する。
【００５４】
図１２（ａ）の如く、電線５の各屈曲部５ｋに対応して横櫛３９のブレード４８の先端に各カバー３をセットし、図１２（ｂ）の如くカバー３をブレード４８に沿ってブレード長手方向に移動させ、電線５をカバー３の溝１５内に係合させる。カバー３には図２で示した如く各溝１５の間に貫通孔１７が設けられており、その貫通孔１７にブレード４８が貫通挿入される。溝１５内に各電線５の屈曲端５ｂ，５ｅが圧入気味に保持されることが好ましい。溝１５で電線５が位置決めされることで、後工程の圧接部１１への電線５の圧接が位置ずれなく正確に行われる。
【００５５】
図１２（ｂ）の状態で横櫛３９を挿入反対方向に引き抜くことで、図１３の如く各カバー３の溝１５に電線５が保持された状態の仮組付体４０が構成される。各カバー３は長手方向に並列に位置し、各カバー３が電線５で相互に連結されている。各カバー３の間隔は必ずしも一定ではなく、コネクタ３の配置形態（回路仕様）によって異なる。電線５の屈曲部は上記成形型５２，５３による成形でコの字状に変形し、且つカバー３で保持されているから、元の状態に戻ることはない。
【００５６】
図１３の仮組付体４０の各カバー３を図１の如く並列に配置された各コネクタ２の上面側で端子４の圧接部１１に被せつつカバー内の電線５を圧接部１１に圧接する。例えばカバー３を圧接部１１に向けてプレス機等で強く押圧することで、電線５の圧接が規定のストロークで確実に行われる。一例としてコネクタ２の数は２０個前後となる。
【００５７】
図１４の如く電線５をコネクタの圧接部１１に圧接した後、例えば電線５の端部５ｈで示すように、カバー３の外側近傍で不要な電線部分５ｊ（二点鎖線で示す）をカッタ等（図示せず）で切断し、エアブロー等で除去する。これにより所要の形態の回路が構成される。
【００５８】
図１に示す三つのコネクタ２は図１５の拡大図の如く、重ね合わされてコネクタブロック４１を構成する。三つのコネクタ２のうちの二つの隣接するコネクタ２はハウジング同士が腹合わせに密着し、もう一つのコネクタ２はカバー３を重ね合わせた状態に接合される。各コネクタ２の間で電線５は略Ｕ字状に湾曲して続いている。
【００５９】
図１５の如く三つの短いコネクタ２の左側に電線（幹線）５を介して中程度の長さの二つのコネクタ２１が重ね合わされた状態のコネクタブロック４９として続き、右側に電線（幹線）５を介して三つの長いコネクタ２０が重ね合わされたコネクタブロック５０として続いている。少なくともこれら各コネクタブロック４１，４９，５０と電線５とでハーネス回路体１’が構成される。ハーネス回路体１’の長さは例えば１ｍ程度である。コネクタブロック４１，４９，５０の数や形態及び各コネクタ２，２０，２１の数や形態等は回路仕様に応じて適宜設定される。
【００６０】
図１６に示す如く、電線（幹線）５を合成樹脂製の断面矩形筒状等のプロテクタ５１内に収容し、プロテクタ５１の所要部にコネクタ２，２０，２１（コネクタブロック４１，４９，５０）を固定させてハーネス回路体１”を構成してもよい。プロテクタ５１と幹線５と各コネクタ２，２０，２１とで分岐ボックスが構成される。プロテクタ５１は上下分割式で係止手段で係止され、コネクタ２，２０，２１を例えばコネクタ露出開口に続く溝部に係合固定させる。プロテクタ５１は分岐ボックス本体として作用する。
【００６１】
プロテクタ５１内にカバー３と電線屈曲部５ｋが収容され、コネクタハウジング９の前端部がプロテクタ５１の開口から外部に突出し、ないしは開口内に位置する。コネクタを外部に突出することなくプロテクタ内に完全に収容すれば、一本の長尺なハーネス回路体が構成され、車両のインストルメントパネル等の狭いスペースに引っ掛かりなくスムーズに組み付けることができる。各コネクタ２，２０，２１には分岐線７がコネクタ６で接続される。回路形態に応じてコネクタの数や形態は適宜設定される。分岐回路数の少ない場合はコネクタブロックとしてではなくコネクタ２，２０，２１を一つのみでプロテクタ５１に固定させてもよい。
【００６２】
図１６で例えば右側の分岐線７は車両の右カウルに配索され、中央の分岐線７はセンタクラスタに配索され、左側の分岐線７は左カウルに配索される。右側の分岐線７の隣にはメータやステアリングに配索される図示しない分岐線を設ける。
【００６３】
なお、上記ハーネス回路体の製造方法において、図７の成形型５２，５３に代えて図５の実施形態の成形型２５，２６を用いることも可能である。この場合、図１０の横櫛３９のブレード４８は上下の加圧リブ２７（図５）の付け根側の相互にラップしない部分に沿って進入する。また、横櫛３９の形状を図５の成形型２５，２６に適合するように適宜変更することも可能である。例えば、図７の成形型５２，５３の櫛歯部４２を図５の加圧リブ２７のように左右端のみの歯４４とし、あるいは図５の加圧リブ２７を図７の櫛歯部４２のように全長に渡って配列してもよい。図７の櫛歯部４２のように複数の歯４４を並設することで、電線５の屈曲力や保持性が高まる。また、図７の上下の成形型５２，５３を左右の成形型とし、複数の水平な電線５を上下並列に配置し、横櫛３９を上又は下から垂直方向に成形型内に進入させてもよい。
【００６４】
図１７〜図１８はコネクタを複数段に積層する構造及び方法の一実施形態を示すものである。
この構造及び方法は、例えば前記図３の電線布線作業のように二つのコネクタ７１を水平面上で背中合わせに近接して配置した状態で、図１７の如く両コネクタ７１の端子７２の圧接部１１を電線５で相互に連結させる如く電線５を布線及び圧接し、図１８の如く一方のコネクタ７１を背中合わせ側の端部７１ａの電線５ｍ（図１７）を支点として折り畳むように１８０゜回動させて他方のコネクタ７１の裏面に接合させるものである。なお、図１８では電線５の図示を省略している。
【００６５】
図１７の如く両コネクタ７１は電線５で相互に接続されている。電線５はハウジング７６の後半の基板７６ａ上でコの字状やＵ字状に折り返され、あるいは短くコの字状に折り返された後、相手コネクタ７１の圧接部１１に向けて傾斜状（５ｎ）に最短距離で配索され、再度くの字状に屈曲されてその部分が圧接部１１に圧接される。例えば不要な電線部分は切断して所望の回路形態を得ることができる。圧接部１１には前例同様のカバー３（図１）が被着される。両コネクタ７１は少しの隙間７７を存して背中合わせにされ、この隙間７７のゆえに図１７で電線５を弛みなく布線しても図１８のコネクタ７１の積層時に電線５をコネクタ端部７１ａ側でＵ字ないしコの字状に屈曲させることができる。両コネクタ７１は係止手段（図示せず）で相互に係止される。
【００６６】
本形態の圧接部１１はハウジング７６上に千鳥状にファインピッチで配置され、圧接部１１から直角に屈曲延長されたピン状の接触部７３はハウジング７６の溝部７８内に収容されつつハウジング前端壁７６ｃの孔から外部に突出されている。ハウジング７６の前半７６ｂは複数の端子収容溝７８を並列に有して厚肉に形成され、ハウジング７６の後半７６ａは薄肉に形成されている。ハウジング７６の後半部７６ａには電線５が水平に配索されるが、後半部７６ａが薄肉であるから、上記コネクタ積層時の電線５の屈曲がゆとりをもって一層スムーズに行われる。端子７２はハウジング７６にモールド成形で固定してもよいし、収容溝７８に一本づつ挿入して前端壁７６ｃの孔部に圧入固定してもよい。
【００６７】
また、前記図９で各成形型５２，５３の櫛歯部４２の突出長さを長く設定し、長いコの字に電線５を成形し、図１０の横櫛３９を二つ用いて各横櫛３９に図１２のカバー３を装着し、図１３の電線５のコの字状屈曲部に前後二列にカバー３を装着した状態で図１７の前後のコネクタ７１の圧接部１１にそれぞれカバー３を同時に押し付けて電線５を圧接させることも可能である。ハウジング７６上で電線５を傾斜方向（５ｎ）に配線するには、図９の成形型５２，５３の櫛歯部４２の形状を傾斜状にすることで対応できる。
【００６８】
また、コネクタ７１を背中合わせではなく図４の如く長手方向に配置した状態で電線５を布線して前例（図１４〜図１５）と同様にハウジング７６の側部を支点として回動させて積層することも可能であることは言うまでもない。また、カバー３を用いて三層ないしそれ以上に積層させることも可能であり、その場合、二つのコネクタ７１を背中合わせに回動させて積層し、もう一つのコネクタ７１をハウジング側部を支点に回動させて三層に積層することも可能である。
【００６９】
図１８の如く上下に積層されたコネクタ積層体７９は一回り大きな絶縁樹脂製のケース８０に収容されてコネクタブロック８１を構成する。本形態のコネクタハウジング７６はコネクタ嵌合室を有していないから、コネクタ嵌合室８２を有するケース８０を用い、コネクタ嵌合室８２の底壁の孔８３にコネクタ７１の各端子７２のピン状接触部７３を挿通させてフード部８４内に突出させることで、上下二段の多数のピン状接触部７３を有するコネクタブロック８１が構成される。図１５の実施形態のようにコネクタ嵌合室を有するコネクタ２を用いる場合はケースは不要である。
【００７０】
図１７において二つのコネクタ７１の長手方向（端子並び方向）両側にさらに各二つ（計四つ）のコネクタ７１を背中合わせに並べて配置し、各コネクタ間を図１や図３〜図４の如く端子並び方向の電線で連結し、各二つのコネクタ７１をそれぞれ積層した後、図１８のコネクタブロック８１を並列に複数構成させ、各コネクタブロック８１を端子並び方向の電線５で相互に連結（接続）させてハーネス回路体を構成させることも可能である。その場合、電線５はケース８０の後部開口８５から横方向に導出される。図１８のコネクタブロック８１を図１５〜図１６のハーネス回路体１’，１”の一部として用いることも可能である（この構成が最も効果的である）。一つのコネクタブロック８１のみで回路（電線５）のジョイントを行わせることも可能である。
【００７１】
【発明の効果】
以上の如く、請求項１記載の発明によれば、複数のコネクタや端子といった少ない種類の構成部品で低コストで簡単に分岐用の多種の回路仕様や回路変更に迅速に対応することができる。
【００７２】
また、端子の圧接部で電線の接続を迅速に効率良く行うことができ、生産性が向上する。また、電線屈曲部がコネクタの外面に沿って位置して、配索構造及び全体構造が簡素化・スリム化される。
また、カバーで電線接続部分が保護されて接続の信頼性が高まる。
【００７３】
また、電線の屈曲形状を横櫛で維持し、カバーに電線屈曲部をそのまま移行させ、カバーをコネクタに組み付けると同時に電線を圧接することができるから、真直な幹線を屈曲させてコネクタに接続する作業を効率良くしかも正確に行うことができる。これにより、ハーネス回路体の生産性が向上する。また、電線とカバーとコネクタ（圧接部を含む）という簡単で且つ少ない構成部品で容易に低コストでハーネス回路体を形成することができる。
【００７４】
請求項２記載の発明によれば、複数本の電線を同時に所要位置で所要形状に屈曲させることができ、また、複数の電線屈曲部を一つの前記横櫛で確実に形状保持させることができ、ハーネス回路体の生産性が一層向上する。
【００７５】
請求項３記載の発明によれば、各一対のリブで成形型の構造が簡素化・低コスト化される。
請求項４記載の発明によれば、治具部品の組み付けを各電線の屈曲形態に応じて容易に変更することができ、種々の回路仕様に低コストで迅速に対応することができる。
【００７６】
請求項５記載の発明によれば、インストルメントパネル等における複数の例えば縦並びの電装品や分岐側コネクタに対応して各コネクタを作業性良く接続することができる。
【図面の簡単な説明】
【図１】本発明に係るハーネス回路体の一実施形態を示す分解斜視図である。
【図２】同じくハーネス回路体の電線接続部を分解斜視図である。
【図３】ハーネス回路体の製造方法（電線配索方法）の一実施形態を示す斜視図である。
【図４】ハーネス回路体の製造方法（電線配索方法）の他の実施形態を示す斜視図である。
【図５】（ａ）はハーネス回路体の製造方法（電線屈曲方法）の一実施形態を示す斜視図、（ｂ）は屈曲成形された電線を示す正面図である。
【図６】図５における電線屈曲用の成形型を示す分解斜視図である。
【図７】ハーネス回路体の製造方法（電線屈曲方法）の他の実施形態を示す正面図である。
【図８】屈曲させる電線の初期形態を示す斜視図である。
【図９】図７の成形型で電線を屈曲させた状態を示す正面図である。
【図１０】成形型に電線屈曲形状維持用の横櫛を挿通させた状態を示す斜視図である。
【図１１】横櫛で電線屈曲部を保持した状態を示す斜視図である。
【図１２】（ａ）は横櫛にカバーをセットした状態、（ｂ）は横櫛をカバーに貫通させた状態を示す斜視図である。
【図１３】カバーと電線との仮組付体の一形態を示す斜視図である。
【図１４】電線圧接後に不要な電線部分を切断した状態を示す平面図である。
【図１５】ハーネス回路体の一実施形態を示す斜視図（円内は要部拡大図）である。
【図１６】幹線をプロテクタで覆ったハーネス回路体の完成状態を示す平面図である。
【図１７】コネクタブロックの製造方法の一形態の第一工程を示す斜視図である。
【図１８】同じくコネクタブロックの製造方法の第二工程を示す分解斜視図である。
【図１９】従来のハーネス回路体の一形態を示す斜視図である。
【図２０】図１９のＡ−Ａ断面図である。
【符号の説明】
１ハーネス回路体
２，２０〜２２，７１コネクタ
３カバー
４，７２端子
５ｋ電線屈曲部
５電線（幹線）
７分岐線（電線）
１１圧接部
１５溝
２３自動配索機
２５，２６，５２，５３成形型
２７加圧リブ
２９支持杆
３２スペーサ
３９横櫛
４１，８１コネクタブロック
４２櫛歯部
５１プロテクタ（分岐ボックス本体）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a harness circuit body that is arranged on an instrument panel or the like of an automobile, connects a plurality of connectors to each other with a plurality of electric wires, and branches and connects to each auxiliary machine such as an electrical component, and a manufacturing method thereof.
[0002]
[Prior art]
FIG. 19 shows an embodiment of a conventional harness circuit body for a vehicle, and FIG. 20 shows a cross-sectional view taken along line AA of FIG. 19 (see Patent Document 1).
[0003]
In FIG. 19, reference numeral 61 is a reinforcement (reinforcing material) disposed horizontally in the instrument panel of the automobile, 62 is a wire harness (main line) routed on the rear surface side (close to the passenger compartment) of the reinforcement 61, FIG. Similarly, reference numeral 63 denotes a wire harness (main line) routed on the front side (near the engine room) of the reinforcement 61.
[0004]
Each of the wire harnesses 62 and 63 supplies power to electrical equipment such as instrument panels, switches, and audio, and auxiliary equipment, exchanges signals, and supplies power to auxiliary equipment such as an air conditioner on the engine room side.
[0005]
These two wire harnesses 62 and 63 are connected to each other by both branch boxes 64 and 65 in FIG. 20, and are connected to each electrical component and auxiliary machine from one (rear side) branch box 64 via a connector 66 and a branch line 67. Connected.
[0006]
The other (front side) branch box 65 includes a plurality of insulating plates arranged vertically in the housing, and each electric wire 63 of the wire harness is arranged in parallel on each insulating plate, and each electric wire 63 is connected to a crimp terminal, The tab portion of the long terminal of one branch box 64 is appropriately connected to the fitting connection portion of the crimp terminal. The long terminal is connected to the electric wire in one branch box 64, is located in the connector at the rear end of the branch box, and is connected to the terminal in the connector 66 on the branch line side. A harness circuit body 68 is configured by the wire harnesses (main lines) 62 and 63, the branch line 67, and the branch boxes 64 and 65.
[0007]
[Patent Document 1]
JP 2001-191870 (pages 3 to 4, FIGS. 1 to 3)
[0008]
[Problems to be solved by the invention]
However, in the above conventional harness circuit body, it is difficult to redesign the arrangement of electric wires and terminals when changing the circuit specifications, and connection between trunk lines and connection between trunk lines and branch lines There has been a problem that the structure is complicated and the cost of parts is high, or that many labors and devices are required for manufacturing, and the manufacturing cost is high.
[0009]
  In view of the above-described points, the present invention can facilitate circuit design when changing specifications, can simplify components, and can easily and efficiently perform a harness. Circuit bodyofAn object is to provide a manufacturing method.
[0010]
[Means for Solving the Problems]
  In order to achieve the above object, a harness circuit body according to claim 1 of the present invention.Manufacturing methodIncludes a plurality of connectors arranged in parallel and connectable to branch lines, and a trunk line that is in pressure contact with an exposed pressure contact portion of a required terminal of the required connector of the plurality of connectors and extends in the connector arrangement direction. The trunk has a wire bent portion arranged in a substantially U shape along the upper surface of the connector, and the wire bent portion includes a straight portion in the connector arranging direction and both ends of the straight portion. A straight portion in the connector fitting direction that is bent on the side, the straight portion in the connector arrangement direction interconnects the connectors, and the straight portion in the connector fitting direction is pressed against the pressure contact portion.Further, a method of manufacturing a harness circuit body configured to include a cover that covers the pressure contact portion, wherein the trunk line is bent into a substantially U-shape with a pair of opposed comb teeth portions, Insert a horizontal comb into the comb teeth of a pair of molds to hold the wire bending portion in the horizontal comb, open the pair of molds, pass the horizontal comb through the cover, and into the groove of the cover Engage the wire bending portion, pull out the horizontal comb, and press the cover against the pressure contact portion of the connector to connect the wire bending portion to the pressure contact portion.It is characterized by that.
  With the configuration described above, a branch circuit corresponding to various circuit specifications can be easily configured by connecting each electric wire constituting the trunk line to a required terminal of a required connector. Components such as connectors and terminals are commonly used. In addition, since the electric wire is connected to the connector terminal at the bent portion, the trunk line is located straight in the longitudinal direction at the portion excluding the connector, the extension direction of the trunk line and the arrangement direction of the connector match, and the harness circuit body The structure is simplified and slimmed, and the connector is arranged at a required position on the main line, and the connection position with the branch line is optimized.
[0011]
  Also,By connecting the electric wire to the press contact portion of the terminal, the electric wire can be connected easily and efficiently. The electric wire bent portion is connected in a direction orthogonal to the arrangement direction of the plurality of press contact portions.
  Further, since the electric wire bent portion is positioned along the outer surface of the connector, the electric wire bent portion does not protrude in the connector fitting direction, and the electric wire routing structure and the entire structure are simplified and slimmed. Each connector is mutually connected by the electric wire bending part. Each connector can be overlapped and formed into a block while the electric wire bent portion is folded back into a U shape.
[0012]
  Also,The connection between the terminal and wire is insulated and protected by the cover.
  Further, by closing the pair of molds, the electric wire (trunk line) is bent and deformed (molded) into a substantially U-shape by the substantially U-shaped comb tooth portion of the mold. The electric wire is bent and formed into a rectangular wave shape by the comb tooth portion of each mold. The bending shape of the electric wire is maintained by the horizontal comb by inserting the horizontal comb between the comb teeth, that is, between the blades constituting the comb teeth with the comb teeth closed. Therefore, even if the mold is opened, the horizontal comb holds the electric wire bent portion, and the bent shape of the electric wire is accurately maintained. Next, by passing the horizontal comb through the cover, the bent portion of the electric wire between the horizontal combs is transferred to the groove of the cover and held in engagement. By pulling out the horizontal comb from the cover, a temporary assembly of a plurality of covers and a plurality of electric wires is formed. By pressing the cover strongly while covering the pressure contact portion of the connector, the electric wire in the cover is pressure contact connected to the pressure contact portion, and a harness circuit body is formed. The cover insulates and protects the wire pressure contact part from the outside.
[0013]
  A method for manufacturing a harness circuit body according to claim 2 is the method for manufacturing a harness circuit body according to claim 1, wherein a plurality of the molds having the comb teeth portions are overlapped at a required length and position, A plurality of the trunk lines arranged in parallel are bent at the same time.
  With the above configuration, a plurality of electric wires are bent and formed into a required bent shape of each electric wire by a plurality of pairs of forming dies. The horizontal comb according to the first aspect penetrates through the comb teeth of the plurality of molding dies and holds the bent portion of each electric wire.
[0014]
  A method for manufacturing a harness circuit body according to a third aspect is the method for manufacturing a harness circuit body according to the first or second aspect, wherein at least each pair of pressure ribs is used as the comb tooth portion.
  With the above configuration, the electric wire (trunk line) is bent in the shearing direction at the tip of each pair of pressure ribs of each molding die so as to be sandwiched between the pressure ribs in the opposing direction in the rib longitudinal direction.
[0015]
  A method for manufacturing a harness circuit body according to claim 4 is the method for manufacturing a harness circuit body according to claim 3, wherein the pressure rib is inserted and assembled together with a spacer into a plurality of support rods. The molding die is configured to be disassembled by the spacer and the support rod.
  With the above configuration, spacers and pressure ribs that are jig parts can be used in common, the assembly of jig parts can be changed according to the bending form of each electric wire, and the mold can be assembled in various forms. The circuit specification (form) can be easily and quickly handled.
[0016]
  The method for manufacturing a harness circuit body according to claim 5 is the method for manufacturing a harness circuit body according to any one of claims 1 to 4, wherein the plurality of connectors are overlapped with each other after the press contact of the wires. It is characterized by doing.
  With the above configuration, a harness circuit body is configured by a plurality of connector blocks and a plurality of electric wires (main lines) that connect and connect the connector blocks. It is preferable to superimpose connectors having the same shape to form one connector block. The connector on the branch line side is arranged and connected in parallel in the height direction by the connector block.
[0025]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
1 to 2 show an embodiment of a harness circuit body according to the present invention.
[0026]
This harness circuit body 1 includes a plurality of connectors 2 arranged in parallel, a cover 3 disposed on the base end side of the upper wall surface of each connector 2, and terminals 4 of each connector 2 below each cover 3. It is provided with a plurality of electric wires (main lines) 5 connected to (FIG. 2) to connect the respective connectors. A branch line side connector 6 is fitted and connected to each connector 2, and the branch line 7 is connected by a connector 8 to various electrical components and auxiliary equipment such as an ECU.
[0027]
As shown in FIG. 2, the connector 2 of the harness circuit body 1 includes a female housing 9 that is thinly formed of synthetic (insulating) resin, and a pressure contact portion that projects perpendicularly to the outer surface of the upper wall (wall portion) 10 of the housing 9. The terminal 4 includes a horizontal tab portion 12 protruding into the fitting chamber 13 of the housing 9 following the press contact portion 11. The male connector 6 (FIG. 1) on the branch line side is inserted into the fitting chamber 13, and the tab portion 12 and the female terminal (not shown) on the branch line side are connected to each other. The branch line 7 and its connector 6 may be referred to as a harness circuit body.
[0028]
In each connector 2, a plurality of pressure contact portions 11 are arranged in parallel at an equal pitch, and a locking piece 14 for the cover 3 is integrally projected from the housing 9 outside the pressure contact portions 11 at the left and right ends. Each locking piece 14 has an outward locking projection. The press contact portion 11 is for connecting the wire core wire portion while pressing the insulation covered electric wire 5 into the slot between the pair of left and right press contact teeth to tear the insulation cover. Since the press contact portion 11 protrudes vertically from the upper surface 10 of the housing 9, a wire accommodating space is secured on the housing. The arrangement direction of the press contact portions 11 is equal to the longitudinal direction of the electric wire (main line) 5.
[0029]
As shown in FIG. 1, the electric wire 5 is connected between the connectors in a state of being bent in a substantially U shape. That is, the electric wires 5 extended in the direction in which the connectors 2 are arranged are bent at a substantially right angle outside the base end of the housing 9 (part 5a) and extend straight at a short distance along the upper surface of the housing 9 (this part 5b is 1), bent again on the housing (portion 5c), extends toward the adjacent connector 2, and bent on the upper surface of the adjacent housing 9 (portion 5d in FIG. 1) toward the proximal side of the housing It extends short and straight (this portion 5e is pressed into contact), is bent again outside the proximal end of the housing, and extends toward the next or required housing or parallel to the main line. The plurality of electric wires 5 constituting the trunk line of the wire harness are arranged in parallel in the horizontal direction, and extend parallel to the vertical surface of the press contact portion 11 outside the proximal end of the connector 2. Which wire 5 is pressed against which terminal 4 of which connector 2 is appropriately set according to circuit specifications.
[0030]
As shown in FIG. 2, the cover 3 is made of synthetic (insulating) resin and has a length approximately the same as the width of the housing 9, and has a plurality of grooves 15 for inserting electric wires in parallel at equal pitches on the lower side (the grooves 15 are Formed between adjacent protrusions 16), having an insertion space for the pressure contact portion 11 in communication with the groove 15, and elongated through holes 17 arranged in parallel at an equal pitch above the protrusion 16 between the grooves. And a flexible engaging frame piece 18 for the locking piece 14 on the connector side is provided at the left and right ends. Although the through-hole 17 will be described later, the through-hole 17 is not particularly necessary unless a later-described electric wire positioning member (lateral comb) is used.
[0031]
In FIG. 2, each electric wire 5 is brought into pressure contact with the pressure contact portion 11 with a jig (not shown) such as an elevating pressure contact blade, and then the cover 3 is attached to insulate the pressure contact portion 11 from the outside. Alternatively, after setting each electric wire 5 in the groove 15 of the cover 3 in advance, the electric wire 5 can be pressed against the press contact portion 11 by attaching the cover 3 toward the press contact portion 11 (about this) Will be described later).
[0032]
Moreover, it is also possible to connect the electric wire 5 to the connection part where the terminal 4 is exposed by means such as crimping, soldering or welding as well as the pressure contact part 11 as the connection part. However, in the case of crimping, the intermediate part of the electric wire 5 is peeled off, and in the case of soldering or welding, a large number of man-hours and a large apparatus are required, so the pressure welding is the best. Further, as the connector 2, a male connector (not shown) containing a female terminal (not shown) following the press contact portion 11 is used, and the branch line side connector 6 (FIG. 1) is connected to the female side. It is also possible to use a connector.
[0033]
The harness circuit body 1 is routed, for example, on the inner side or back side (portion near the engine room) of an automobile instrument panel. In addition to the instrument panel, it is also possible to route on the vehicle floor, various panels, and the like.
[0034]
FIG. 3 shows an embodiment of a method for routing an electric wire to each connector of the harness circuit body. The same components as those in FIG. 1 are denoted by the same reference numerals, and detailed description thereof is omitted.
[0035]
This harness circuit body 19 includes a connector 21 having three fitting chambers 13 in parallel, a connector 20 having four fitting chambers 13 in parallel, and a large number (for example, 12) of fitting chambers (in the rear side in FIG. 3). And a long connector 22 that cannot be seen).
[0036]
A long connector 22 and other short connectors 20, 21 are arranged (fixed) back-to-back on the work table, and each connector 20, 21, 22 is drawn from the nozzle 24 of the automatic routing machine 23 with a single stroke. Discharge wiring in order on the upper surface of the. The automatic routing machine 23 moves the nozzles 24 alternately in the XY direction, that is, the connector longitudinal direction and the longitudinal orthogonal direction (connector fitting direction) as shown by the arrow, while the electric wire 5 is substantially U-shaped (rectangular wave shape) on the connector. Between the connectors, the electric wire 5 is routed in a small pitch waveform (portion 5f) to form a trunk portion. When the number and length of the connectors are small, the connectors 5 may be arranged in parallel in the longitudinal direction of the main line, and the electric wires 5 may be routed by moving the automatic routing machine 23 in the two-dimensional direction.
[0037]
FIG. 4 shows another embodiment of a method of routing electric wires to each connector. Upper connectors 20 to 22 are set in parallel in the longitudinal direction on a moving table, and a moving table (not shown) is arranged. The nozzles 24 of one or a plurality of the above-described automatic routing machines 23 are disposed so as to be movable in the direction orthogonal to the connector longitudinal direction, and the movable table, that is, the connectors 20 to 22 are moved in the connector longitudinal direction (X direction) as indicated by arrows After wiring the electric wire 5 from the nozzle 24 in the connector longitudinal direction with a required length, the nozzle 24 is moved in the connector longitudinal orthogonal direction (Y direction), the electric wire 5 is wired on the press contact portion 11, and the moving table ( The connector) is moved in the X direction, and the electric wire 5 is wired in a rectangular wave shape.
[0038]
By using a plurality of automatic routing machines 23, a plurality of electric wires 5 can be routed in a required shape at the same time, and productivity is improved as compared with the case of using one automatic routing machine 23. Since each automatic routing machine 23 moves only in the Y direction, there is no worry of interference between the automatic routing machines. It is also possible to move (drive) only the connectors 20 to 22 in the longitudinal direction on the moving table. If the working space in the longitudinal direction is small, the connectors 20 to 22 are arranged back to back on the moving table as shown in FIG. 3, and after the wires 5 are routed to the connectors 20 and 21 in the first row, the moving table is returned. It is also possible to route the electric wires to the connectors 22 in the second row by largely moving the automatic routing machine 23 in the connector crossing direction.
[0039]
In each form of FIG. 3, FIG. 4, you may protrude the pin for electric wire positioning etc. (not shown) on the table. After wiring the electric wire 5 on the one press contact portion 11, the press contact portion 11 may be immediately press-contacted by a press contact blade or the like. It is also possible to provide the automatic routing machine 23 integrally with the pressure contact blade and its driving means. Alternatively, the wire 5 may be temporarily press-fitted into the press-contact portion 11 from the nozzle 24 to perform positioning. In this case, the nozzle 24 may be movable in the vertical direction.
[0040]
3 and 4, only the nozzle side portion of the automatic routing machine 23 is illustrated, but an actual automatic routing machine has at least a rotating roller that feeds the electric wire 5 and a head portion including the nozzle 24 in the XY direction. The rail part etc. to move are included. In addition, as for the form of the connector, the connector 1 of one fitting chamber 13 shown in FIG.
[0041]
5 to 6 show an embodiment of a jig and method for bending an electric wire in advance into a U-shape (rectangle) without using the automatic routing machine 23. FIG.
[0042]
As shown in FIGS. 5A and 5B, the horizontal electric wire 5 is bent and formed into a U-shape by vertical pressure ribs (pressure teeth) 27 of a pair of upper and lower forming dies 25 and 26. That is, the upper pressure rib 27 is positioned inside the lower pressure rib 27, and the electric wires 5 are pushed in the shearing direction at the tips of the upper and lower pressure ribs 27 and bent substantially at right angles. The electric wire 5 is sandwiched between the pressurizing ribs 27 and is positioned vertically. Thereby, the electric wire 5 is bent and deformed into a U-shape. The bending points of the bent portions are indicated by reference numerals 5a, 5c, 5d, and 5g. Reference numerals 5b and 5e are parts to be pressed. It is also possible to use a horizontal comb or a pin that maintains a bent shape, which will be described later.
[0043]
As shown in FIG. 6, the upper mold 25 and the lower mold 26 are each a base 30 in which a plurality of comb-like horizontal support rods 29 are arranged in parallel at an equal pitch on a horizontally long base 28, and each support. A plurality of spacers 32 having slits 31 inserted into the flange 29 from above, and a hole portion 33 inserted into the predetermined support rod 29 from the tip side are formed in the plate portion 34, and the rectangular section is formed from the plate portion 34. It is comprised with the pressurization member 35 which makes the pressurization rib 27 protrude.
[0044]
A pair of upper and lower pressure ribs 27 are used for one electric wire, and in order to arrange two electric wires 5 in parallel and bend at the same time, two pairs of upper and lower pressure ribs 27 are arranged, and a plurality of (n) In order to bend the electric wires 5 simultaneously, n pairs of upper and lower pressure ribs 27 are arranged. In that case, since the position of each pressure rib 27 differs depending on the bending position and the bending length of each electric wire 5, the pressure member 35 is set on the required support rod 29.
[0045]
The spacer 32 acts as a member for determining (fixing) the position of the pressure rib 27. Since the pressure rib 27 can be easily and quickly arranged at a desired position, the bent form of each electric wire 5 can be accurately obtained in response to a change in circuit specifications. The same upper and lower molds 25 and 26 can be used in common by simply inverting the pressure member 25 up and down.
[0046]
It is also effective to provide a wire holding groove on the tip or side surface of the pressure rib 27. It is also possible to replace the slit 31 of the spacer 32 with a hole similar to the pressure member 35. It is also possible to arrange the electric wires 5 vertically or horizontally and use the upper and lower molding dies 25 and 26 as left and right molding dies.
[0047]
7-15 shows one Embodiment of the manufacturing method of the harness circuit body based on this invention.
[0048]
This harness circuit body is manufactured by bending the plurality of parallel electric wires 5 of FIG. 8 using the forming dies 52 and 53 of FIG. 7, as shown in FIG. The shape maintaining member 39 is inserted into the molds 52 and 53 to maintain the bent shape of each electric wire 5 as shown in FIG. 11, and the cover 3 is inserted into the horizontal comb 39 as shown in FIG. 13, the horizontal comb 39 is removed as shown in FIG. 13 to form a temporary assembly 40 of the cover 3 and the electric wire 5, and the electric wire 5 is connected to the connector 2 while the cover 3 is assembled to the connector 2 as shown in FIG. 11, the unnecessary electric wire portion 5j is cut and removed as shown in FIG. 14 to form a required circuit, and then the adjacent connectors 2 having the same shape as shown in FIG. Connect each connector block 41 to the main line 5 It is intended to obtain a harness circuit body 1 'formed by sintering.
[0049]
  The configuration of each figure will be described in detail below.
  As shown in FIG. 7, upper and lower molds (molded plates)52,53Has one or more comb teeth 42 per electric wire, and the left and right ends of the comb teeth 42 are chamfered (43) in a curved shape so that the electric wire 5 can be bent smoothly without being damaged. Each comb tooth portion 42 includes a plurality of straight ridges (teeth) 44 arranged in parallel at an equal pitch, and a slit 45 is formed between the ridges 44. Each concave portion (notch portion) 46 is positioned so as to face each comb tooth portion 42, and the size of each comb tooth portion 42 is defined so that the electric wire 5 is sandwiched between the left and right ends of the upper and lower comb tooth portions 42. . Teeth 44 at the left and right ends of the comb teeth portion 42₁The thickness of the other teeth 44 and the left and right teeth 44₁An electric wire holding groove (not shown) is provided on the outside of the upper and lower teeth 44 of the upper and lower comb teeth 42.₁It is preferable to make the pitch of the slits adjacent to the same as the pitch of the other slits 45. It is preferable to provide a wire holding groove at the tip of each tooth 44.
[0050]
As shown in FIG. 8, the plurality of electric wires 5 are cut and arranged in parallel, and the upper and lower forming dies 52 and 53 of FIG. 7 are set so as to overlap in the thickness direction with the same number and pitch as the number and pitch of the electric wires 5. . The plurality of superimposed forming dies 52 and 53 have comb teeth portions 42 having different positions and dimensions according to the bending position and bending length of each electric wire 5.
[0051]
As shown in FIG. 9, the upper and lower forming dies 52 and 53 are vertically aligned, whereby the electric wire 5 is bent and deformed (shaped) between the upper and lower comb teeth 42 and bent in a rectangular wave shape in the longitudinal direction. . The molds 52 and 53 are driven by a press machine or the like.
[0052]
As shown in FIG. 10, with the upper and lower molds 52 and 53 being combined, the horizontal comb 39 is inserted horizontally into the slits 45 of the comb teeth portions 42 of the upper and lower molds 52 and 53 as indicated by the arrows. The bent shape of the electric wire 5 is maintained. As shown in FIG. 11, the horizontal comb 39 includes a horizontally long base 47 and a plurality of straight blades (teeth) 48 having a rectangular cross section protruding from the base 47 at an equal pitch. The tip of the blade 48 is smoothly chamfered so as to enhance the insertability into the comb tooth portion 42 (FIG. 10). The width (dimension in the direction perpendicular to the thickness) of the blade 48 is set to be shorter than the wrap length L of each comb tooth portion 42 that overlaps vertically as shown in FIG. Even if the pitch between the comb tooth portion 42 and each blade 48 is slightly deviated, the slight misalignment is absorbed by the flexibility of the comb tooth portion 42 and the blade 48, and the blade 48 is smoothly inserted between the comb tooth portions. Is done.
[0053]
By opening the upper and lower molds 52 and 53, the electric wire 5 is held in a bent state by the horizontal comb 39 as shown in FIG. Each blade 48 accurately defines the positions of the left and right ends of the bent portion 5k of each electric wire 5 (the portions 5b and 5e that are in pressure contact with the pressure contact portion 11 of the connector 2).
[0054]
12A, each cover 3 is set at the tip of the blade 48 of the horizontal comb 39 corresponding to each bent portion 5k of the electric wire 5, and the cover 3 is moved along the blade 48 as shown in FIG. The wire 5 is moved in the longitudinal direction of the blade to engage the wire 5 in the groove 15 of the cover 3. As shown in FIG. 2, the cover 3 is provided with through holes 17 between the grooves 15, and the blades 48 are inserted through the through holes 17. It is preferable that the bent ends 5b and 5e of each electric wire 5 are held in the groove 15 in a press-fit manner. By positioning the electric wire 5 in the groove 15, the press-contact of the electric wire 5 to the press-contact portion 11 in the subsequent process is accurately performed without positional deviation.
[0055]
By pulling out the horizontal comb 39 in the direction opposite to the insertion direction in the state of FIG. 12B, the temporary assembly 40 in a state where the electric wire 5 is held in the groove 15 of each cover 3 as shown in FIG. The covers 3 are arranged in parallel in the longitudinal direction, and the covers 3 are connected to each other by electric wires 5. The interval between the covers 3 is not necessarily constant, and varies depending on the arrangement form (circuit specifications) of the connectors 3. Since the bent portion of the electric wire 5 is deformed into a U shape by molding with the molding dies 52 and 53 and is held by the cover 3, it does not return to its original state.
[0056]
The cover 3 of the temporary assembly 40 in FIG. 13 is pressed against the press contact portion 11 while the cover 3 is covered with the press contact portion 11 of the terminal 4 on the upper surface side of each connector 2 arranged in parallel as shown in FIG. . For example, when the cover 3 is strongly pressed with a press or the like toward the press contact portion 11, the press contact of the electric wire 5 is reliably performed with a specified stroke. As an example, the number of connectors 2 is about 20.
[0057]
After the electric wire 5 is pressed into contact with the connector pressure contact portion 11 as shown in FIG. 14, for example, as shown by an end portion 5h of the electric wire 5, an unnecessary electric wire portion 5j (indicated by a two-dot chain line) near the outside of the cover 3 is cut. Cut with (not shown) and remove by air blow or the like. Thus, a required form of circuit is configured.
[0058]
The three connectors 2 shown in FIG. 1 are overlapped to form a connector block 41 as shown in the enlarged view of FIG. Two adjacent connectors 2 out of the three connectors 2 are in close contact with each other, and the other connector 2 is joined with the cover 3 overlapped. Between each connector 2, the electric wire 5 is curving in a substantially U shape and continues.
[0059]
As shown in FIG. 15, the two short connectors 2 are connected to the left side of the three short connectors 2 via the electric wires (main lines) 5 as a connector block 49, and the electric wires (main lines) 5 are connected to the right side. The three long connectors 20 continue as a connector block 50 overlaid. At least each of these connector blocks 41, 49, 50 and the electric wire 5 constitute a harness circuit body 1 '. The length of the harness circuit body 1 'is, for example, about 1 m. The number and form of the connector blocks 41, 49, and 50 and the number and form of each of the connectors 2, 20, and 21 are appropriately set according to circuit specifications.
[0060]
As shown in FIG. 16, the electric wire (main line) 5 is accommodated in a protector 51 having a rectangular cross section made of synthetic resin, etc., and connectors 2, 20, and 21 (connector blocks 41, 49, and 50) are provided at required portions of the protector 51. The harness circuit body 1 ″ may be configured by fixing the protector 51. The protector 51, the main line 5, and the connectors 2, 20, and 21 form a branch box. The connectors 2, 20, and 21 are engaged and fixed in, for example, a groove portion following the connector exposure opening, and the protector 51 functions as a branch box body.
[0061]
The cover 3 and the electric wire bent portion 5k are accommodated in the protector 51, and the front end portion of the connector housing 9 protrudes outside from the opening of the protector 51, or is located in the opening. If the connector is completely accommodated in the protector without projecting to the outside, one long harness circuit body is formed, and can be smoothly assembled without being caught in a narrow space such as an instrument panel of the vehicle. A branch line 7 is connected to each connector 2, 20, 21 by a connector 6. The number and form of connectors are appropriately set according to the circuit form. When the number of branch circuits is small, the connectors 2, 20, and 21 may be fixed to the protector 51 with only one connector instead of as a connector block.
[0062]
In FIG. 16, for example, the right branch line 7 is routed to the right cowl of the vehicle, the center branch line 7 is routed to the center cluster, and the left branch line 7 is routed to the left cowl. Next to the branch line 7 on the right side, a branch line (not shown) routed to the meter or the steering is provided.
[0063]
In the harness circuit body manufacturing method, the molds 25 and 26 of the embodiment of FIG. 5 can be used instead of the molds 52 and 53 of FIG. In this case, the blades 48 of the horizontal comb 39 in FIG. 10 enter along the portions of the bases of the upper and lower pressure ribs 27 (FIG. 5) that do not overlap each other. Further, the shape of the horizontal comb 39 can be appropriately changed so as to fit the molds 25 and 26 of FIG. For example, the comb teeth 42 of the molds 52 and 53 in FIG. 7 are teeth 44 only at the left and right ends like the pressure ribs 27 in FIG. 5, or the pressure ribs 27 in FIG. As shown in FIG. By arranging the plurality of teeth 44 side by side like the comb teeth portion 42 in FIG. 7, the bending force and retention of the electric wires 5 are increased. Further, the upper and lower molding dies 52 and 53 in FIG. 7 are the left and right molding dies, a plurality of horizontal electric wires 5 are arranged in parallel in the vertical direction, and the horizontal comb 39 is allowed to enter the molding die vertically from above or below. Also good.
[0064]
17 to 18 show an embodiment of a structure and method for stacking connectors in a plurality of stages.
In this structure and method, for example, in the state where the two connectors 71 are arranged close to each other on the horizontal plane as in the wiring operation of FIG. 3, the pressure contact portions 11 of the terminals 72 of both connectors 71 as shown in FIG. As shown in FIG. 18, the connector 5 is rotated by 180 ° so that one connector 71 is folded around the wire 5m (FIG. 17) at the back end 71a as a fulcrum. Thus, it is joined to the back surface of the other connector 71. In addition, illustration of the electric wire 5 is abbreviate | omitted in FIG.
[0065]
As shown in FIG. 17, both connectors 71 are connected to each other by electric wires 5. The electric wire 5 is folded back into a U-shape or U-shape on the substrate 76a in the latter half of the housing 76, or is folded back into a short U-shape, and then inclined toward the press-contact portion 11 of the mating connector 71 (5n ) Is routed at the shortest distance, bent again in the shape of a dogleg, and that portion is pressed against the press contact portion 11. For example, unnecessary wire portions can be cut to obtain a desired circuit form. A cover 3 (FIG. 1) similar to the previous example is attached to the pressure contact portion 11. Both connectors 71 are back-to-back with a slight gap 77, so that even if the wires 5 are wired without slack in FIG. 17, the wires 5 are connected to the connector end 71a side when the connectors 71 in FIG. Can be bent into a U or U shape. Both connectors 71 are locked to each other by locking means (not shown).
[0066]
The pressure contact portions 11 of this embodiment are arranged in a staggered manner on the housing 76 at a fine pitch, and the pin-shaped contact portions 73 that are bent and extended at right angles from the pressure contact portions 11 are accommodated in the groove portions 78 of the housing 76 while housing front end walls It protrudes from the hole 76c to the outside. The front half 76b of the housing 76 has a plurality of terminal receiving grooves 78 in parallel and is formed thick, and the rear half 76a of the housing 76 is formed thin. The electric wires 5 are routed horizontally in the rear half 76a of the housing 76. However, since the rear half 76a is thin, the bending of the electric wires 5 when the connectors are stacked is performed more smoothly. The terminals 72 may be fixed to the housing 76 by molding, or may be inserted one by one into the receiving groove 78 and press-fitted and fixed into the holes of the front end wall 76c.
[0067]
Further, in FIG. 9, the protruding length of the comb tooth portion 42 of each molding die 52, 53 is set long, the electric wire 5 is molded into a long U-shape, and each horizontal comb 39 of FIG. 12 is attached to the comb 39, and the cover 3 is attached to the U-shaped bent portion of the electric wire 5 in FIG. It is also possible to press the wire 5 and press the wire 5 at the same time. Wiring the electric wires 5 on the housing 76 in the inclined direction (5n) can be handled by making the shape of the comb teeth 42 of the molds 52 and 53 of FIG. 9 inclined.
[0068]
Further, in a state where the connector 71 is not back-to-back but arranged in the longitudinal direction as shown in FIG. 4, the electric wires 5 are laid out and rotated by using the side portion of the housing 76 as a fulcrum as in the previous example (FIGS. It goes without saying that it is also possible to do. It is also possible to stack three or more layers using the cover 3, in which case, the two connectors 71 are rotated back to back, and the other connector 71 is used as a fulcrum on the side of the housing. It is also possible to rotate and stack three layers.
[0069]
As shown in FIG. 18, the connector laminated body 79 laminated vertically is accommodated in a slightly larger insulating resin case 80 to constitute a connector block 81. Since the connector housing 76 of this embodiment does not have a connector fitting chamber, the case 80 having the connector fitting chamber 82 is used, and the pin of each terminal 72 of the connector 71 is inserted into the hole 83 in the bottom wall of the connector fitting chamber 82. The connector block 81 having a plurality of upper and lower two pin-like contact portions 73 is formed by inserting the like contact portion 73 and projecting it into the hood portion 84. When the connector 2 having the connector fitting chamber is used as in the embodiment of FIG. 15, no case is necessary.
[0070]
In FIG. 17, two (a total of four) connectors 71 are arranged side by side on both sides in the longitudinal direction (terminal arrangement direction) of the two connectors 71, and the connectors are arranged as shown in FIG. 1 and FIGS. After connecting two electric wires in the terminal arrangement direction and laminating each of the two connectors 71, a plurality of connector blocks 81 in FIG. 18 are formed in parallel, and the connector blocks 81 are connected (connected) by the electric wires 5 in the terminal arrangement direction. It is also possible to configure a harness circuit body. In that case, the electric wire 5 is led out from the rear opening 85 of the case 80 in the lateral direction. The connector block 81 shown in FIG. 18 can be used as a part of the harness circuit bodies 1 ′ and 1 ″ shown in FIGS. 15 to 16 (this configuration is most effective). It is also possible to perform the joint of (electric wire 5).
[0071]
【The invention's effect】
As described above, according to the first aspect of the present invention, it is possible to quickly cope with various circuit specifications and circuit changes for branching at low cost with a small number of components such as a plurality of connectors and terminals.
[0072]
  Further, the wire can be quickly and efficiently connected at the terminal pressure contact portion, and the productivity is improved. In addition, the electric wire bent portion is positioned along the outer surface of the connector, so that the wiring structure and the entire structure are simplified and slimmed.
  Also,The wire connection part is protected by the cover, and the connection reliability is increased.
[0073]
  In addition, the bent shape of the electric wire can be maintained with a horizontal comb, the bent portion of the electric wire can be transferred to the cover as it is, and the electric wire can be pressed at the same time that the cover is assembled to the connector. Work can be done efficiently and accurately. Thereby, the productivity of the harness circuit body is improved. Moreover, a harness circuit body can be easily formed at low cost with simple and few components such as an electric wire, a cover, and a connector (including a pressure contact portion).
[0074]
  According to the second aspect of the present invention, a plurality of electric wires can be bent into a required shape at a required position at the same time, and a plurality of electric wire bent portions can be reliably held in shape by the one horizontal comb. The productivity of the harness circuit body is further improved.
[0075]
  According to the invention of claim 3, the structure of the mold is simplified and the cost is reduced by each pair of ribs.
  According to the fourth aspect of the present invention, the assembly of the jig parts can be easily changed according to the bending form of each electric wire, and various circuit specifications can be quickly coped with at low cost.
[0076]
  According to the fifth aspect of the present invention, each connector can be connected with good workability corresponding to a plurality of, for example, vertically arranged electrical components and branch side connectors in an instrument panel or the like.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view showing an embodiment of a harness circuit body according to the present invention.
FIG. 2 is an exploded perspective view of a wire connection portion of the harness circuit body.
FIG. 3 is a perspective view showing an embodiment of a method for manufacturing a harness circuit body (wire wiring method).
FIG. 4 is a perspective view showing another embodiment of a method for manufacturing a harness circuit body (wire wiring method).
5A is a perspective view showing an embodiment of a method for manufacturing a harness circuit body (electric wire bending method), and FIG. 5B is a front view showing a bent electric wire.
6 is an exploded perspective view showing a wire bending mold in FIG. 5. FIG.
FIG. 7 is a front view showing another embodiment of a method for manufacturing a harness circuit body (electric wire bending method).
FIG. 8 is a perspective view showing an initial form of an electric wire to be bent.
9 is a front view showing a state where an electric wire is bent with the forming die of FIG. 7; FIG.
FIG. 10 is a perspective view showing a state in which a transverse comb for maintaining a bent shape of an electric wire is inserted through a forming die.
FIG. 11 is a perspective view showing a state in which the electric wire bent portion is held by a horizontal comb.
12A is a perspective view showing a state in which a cover is set on a horizontal comb, and FIG. 12B is a perspective view showing a state in which the horizontal comb is passed through the cover.
FIG. 13 is a perspective view showing an embodiment of a temporary assembly of a cover and an electric wire.
FIG. 14 is a plan view showing a state in which an unnecessary wire portion is cut after the wire pressure welding.
FIG. 15 is a perspective view showing an embodiment of a harness circuit body (inside circles are enlarged views of main parts).
FIG. 16 is a plan view showing a completed state of the harness circuit body in which the trunk line is covered with a protector.
FIG. 17 is a perspective view showing a first step in one embodiment of a method for manufacturing a connector block.
FIG. 18 is an exploded perspective view showing a second step of the connector block manufacturing method.
FIG. 19 is a perspective view showing one embodiment of a conventional harness circuit body.
20 is a cross-sectional view taken along the line AA in FIG.
[Explanation of symbols]
1 Harness circuit body
2,20-22,71 connector
3 Cover
4,72 terminals
5k wire bending part
5 Electric wires (trunk line)
7 Branch line (electric wire)
11 Press contact
15 groove
23 Automatic routing machine
25, 26, 52, 53 Mold
27 Pressure rib
29 Supporting cage
32 Spacers
39 Horizontal Comb
41, 81 Connector block
42 comb teeth
51 Protector (Branch box body)

Claims

A plurality of connectors arranged in parallel and connectable to a branch line; and a trunk line that is in pressure contact with an exposed pressure contact portion of a required terminal of the required connector of the plurality of connectors and extends in the connector arrangement direction, The main line has an electric wire bent portion arranged to be bent in a substantially U shape along the upper surface of the connector, and the electric wire bent portion has a straight portion in the connector arrangement direction and both ends of the straight portion. A straight portion in the connector fitting direction that is bent, the straight portion in the connector arrangement direction interconnects the connectors, the straight portion in the connector fitting direction is in pressure contact with the pressure contact portion, and the pressure contact A method of manufacturing a harness circuit body configured to include a cover that covers a portion,
The main wire is bent in a substantially U shape by a pair of opposing comb teeth of the molding die, and a horizontal comb is inserted into the comb teeth of the pair of molding dies to hold the wire bending portion in the horizontal comb. The pair of molds are opened, the horizontal comb is passed through the cover, the wire bending portion is engaged with the groove of the cover, the horizontal comb is pulled out, and the cover is pressed against the pressure contact portion of the connector. A method of manufacturing a harness circuit body, comprising connecting the wire bent portion to the pressure contact portion.

Superposing a plurality of said mold having said comb teeth to the required length and position, the harness circuit according to claim 1, wherein simultaneously bending a plurality said mains arranged in parallel Body manufacturing method.

The method according to claim 1 or 2 harness circuit body, wherein the use of at least each pair of pressure ribs as the comb teeth.

The pressure rib is assembled by inserting with spacers in a plurality of supporting rods, according to claim 3, characterized in that the degradable configure the mold with at least pressurizing rib and said spacer and said supporting rod Method of manufacturing a harness circuit body.

The method of manufacturing a harness circuit body according to any one of claims 1 to 4 , wherein the plurality of connectors are overlapped to form a connector block after the main line is pressed.