JP6749010B2 - Manufacturing method of terminalized electric wire - Google Patents

Description

The present invention relates to a method for manufacturing a terminalized electric wire in which a plurality of exposed wires obtained by peeling off an insulating coating on an end portion of an electric wire are molded into a terminal shape by welding.

Conventionally, when an electric wire is electrically connected to a connection destination, a terminal fitting is attached to a terminal portion of the electric wire, and the electric wire is connected to the connection destination through the terminal fitting.

However, when the electric wire is connected to the connection destination by using the terminal fitting in this manner, the terminal fitting causes the cost of parts to increase.

Therefore, in order to reduce the cost of parts, peel off the insulation coating on the end of the wire and form a plurality of exposed wires into a terminal shape so that they can be electrically connected to the connection destination without using terminal fittings. Has been proposed (for example, see Patent Document 1).

JP-A-4-249875

However, the terminalized electric wire described in Patent Document 1 is formed by annularly stacking a plurality of elemental wires into a bundle of elemental wires, the tip of which is overlapped at the base end so as to form a hole corresponding to the mounting hole. Therefore, a step is formed in the portion where the wire bundles are overlapped, and the step causes a variation in the thickness of the terminal molding shape. Further, a weakly welded part and a strongly welded part are formed, the weakly welded part causes the strands of the wire to be frayed and peeled off poorly, and the strongly welded part causes a decrease in the adhesive strength.

The present invention has been made in view of the above, and provides a method of manufacturing a terminalized electric wire capable of suppressing variation in thickness of a terminal molding portion formed by welding a plurality of element wires into a terminal shape. With the goal.

In order to solve the above-mentioned problems and to achieve the object, a method of manufacturing a terminalized electric wire according to claim 1 of the present invention is a method of peeling an insulating coating on an end portion of an electric wire and attaching a plurality of exposed wires. In a method of manufacturing a terminalized electric wire having a terminal molding portion fusion-molded into a terminal shape having a hole ,
A step of dividing the exposed plurality of strands into two bundles of bundles of strands ;
A branching portion twisting step of twisting around a branching portion at which the two bundles of wire bundles separated in the plurality of strands of wire bundle splitting step branch from each other;
A two-bundle overlapping annular forming step of forming the two bundles of the bundle of wires divided in the plurality of bundles of bundles of wires into an annular shape in which their tips overlap each other so as to form holes corresponding to the attachment holes ;
A welding forming step of forming the terminal forming portion by welding the wire bundles formed in an annular shape in the two-bundle overlapping annular forming step ;
It is characterized by including.

A method of manufacturing a terminalized electric wire according to claim 1 of the present invention comprises: a plurality of strands 2 bundle splitting step of splitting the exposed plurality of strands into 2 bundles of strands; and a plurality of strands 2 bundle splitting step. A two-bundle overlapping annular forming step of forming the divided two bundles of wire bundles in an annular shape in which at least some of them overlap each other so as to form holes corresponding to the mounting holes, In the portion where the wire bundles are overlapped, the respective bundles of the plurality of wires forming the electric wire are overlapped with each other, so that the wire bundles obtained by collecting the plurality of wires into one bundle are overlapped on themselves. Compared with the case, it is possible to suppress the step difference in the overlapping portion to be small, and it is possible to prevent a difference in the welding state of the forming portion when forming this step difference by welding, and as a result, it is possible to reduce the number of elements. It is possible to suppress variations in the thickness of the terminal molding portion in which the wire is welded to form the terminal shape.

FIG. 1 is a perspective view of a terminalized electric wire manufactured by the method for manufacturing a terminalized electric wire according to an embodiment of the present invention. FIG. 2 is a diagram for explaining a method of manufacturing a terminalized electric wire according to an embodiment of the present invention. FIG. 3 is a diagram for specifically explaining the welding forming process. FIG. 4 is a diagram for explaining a step of splitting a plurality of strands into two bundles and a step of forming a two-bundle overlapping ring in the method for manufacturing a terminalized electric wire according to a modified example. FIG. 5 is a perspective view of the electric wire in a state in which the bundle stacking annular forming step is completed. FIG. 6 is a perspective view of a terminalized electric wire in which a terminal molding portion is bent.

Hereinafter, with reference to the drawings, a preferred embodiment of a method for manufacturing a terminalized electric wire according to the present invention will be described in detail.

FIG. 1 is a perspective view of a terminalized electric wire 1 manufactured by a method of manufacturing a terminalized electric wire according to an embodiment of the present invention. FIG. 2 is a diagram for explaining a method of manufacturing a terminalized electric wire according to an embodiment of the present invention. FIG. 3 is a diagram for specifically explaining the welding forming process.
The terminalized electric wire 1 manufactured by the method for manufacturing a terminalized electric wire according to the embodiment of the present invention is provided with a plurality of element wires 12 exposed by peeling off the insulating coating 11 at the terminal portion of the electric wire 10 and mounting holes 20a. The terminal molding portion 20 is formed by welding in a terminal shape.

The strand 12 is made of a conductive metal material such as copper or aluminum. Therefore, the wire 12 can be formed into a predetermined shape by resistance welding or ultrasonic welding.

The terminal molding portion 20 is a portion that is electrically connected to a connection destination instead of the terminal fitting, and the mounting hole 20a is a hole through which a fixing member for fixing the connection destination such as a bolt is inserted.

Next, a method of manufacturing the terminalized electric wire will be described with reference to FIGS.
First, the worker carries out a wire exposing step of peeling the insulating coating 11 on the end portion of the electric wire 10 to expose the plurality of wires 12 (see FIG. 2A).

After that, the worker carries out a two-bundle splitting process for splitting the exposed plurality of strands 12 into two bundles of strands 12A and 12B (see FIG. 2B).
Here, the worker divides the plurality of strands 12 into two bundles of strands 12A and 12B so as to divide them into substantially equal parts.
The strands 12A and 12B may be made difficult to unwind by twisting the plurality of strands 12 of the strands 12A and 12B.

After that, the worker carries out a branching portion twisting step of twisting the periphery of a branching portion at which the wire bundles 12A and 12B divided into two bundles in the multiple-wire-two-bundle dividing step are branched (FIG. 2(c). )reference). Here, the worker twists the two bundles of strands 12A, 12B so that they overlap each other at the branching portion, and twists the attachment hole 20a in a direction that facilitates molding.
By twisting the branched portions of the two bundles of filaments 12A and 12B in this manner, the molding in the subsequent welding molding step is facilitated and the strength of the branched portions of the two bundles of filaments 12A and 12B is improved. Can be increased.
The twisting process at the branching portion may be twisted by twisting the two bundles 12A and 12B at the branching portion.

After that, the operator forms the two bundles of strands 12A and 12B divided in the plural bundles splitting process into a ring in which at least some of them overlap each other so as to form holes corresponding to the mounting holes 20a. A two-bundle overlapping annular forming process is performed (see FIG. 2D).
Since the mounting hole 20a is a hole through which a fixing member such as a bolt for fixing the terminal molding portion 20 to the connection destination is inserted, the size of the hole formed here corresponds to that of the fixing member such as the bolt. Become.
Here, the two bundles of the wire bundles 12A and 12B overlap each other at their tip portions.
In the portion where the two bundles of strands 12A and 12B are overlapped with each other, the bundles obtained by dividing the plurality of strands 12 forming the electric wire 10 are overlapped with each other. It is possible to suppress the step difference in the overlapped portion as compared with the case where the above-mentioned wire bundle is overlapped on itself.

After that, the worker performs a lap portion twisting process in which the tip portions of the two bundles of wire bundles 12A and 12B that are overlapped with each other are twisted so that they can be easily held in an overlapping state (see FIG. 2(e)). ..
By thus twisting the two bundles of wire bundles 12A and 12B, it becomes easier to hold them in an annular shape, which facilitates the molding in the subsequent welding molding step, and also the overlapping portion of the two bundles of wire bundles. The strength can be increased.
In the twisting process of the overlapped portions, the tip portions of the two bundles 12A and 12B may be twisted together.

After that, the worker carries out a welding forming step of forming the terminal forming portion 20 by welding the wire bundles 12A and 12B formed in an annular shape in the two-bundle overlapping annular forming step (see FIG. 2(f)).
Here, the terminal forming portion 20 is formed by so-called resistance welding.
More specifically, as shown in FIG. 3, resistance welding is performed using a welding device 100 having an upper press electrode 110 and a lower press electrode 120.
That is, the wire bundles 12A and 12B formed in a ring shape are arranged between the upper and lower press electrodes 110 and 120, and the wire bundles 12A and 12A are formed by the two press electrodes 110 and 120 while energizing between the upper and lower press electrodes 110 and 120. Pressurize 12B.

In this embodiment, resistance welding is used to form the terminal forming portion 20, but the present invention is not limited to this, and other welding methods may be used as long as the terminal forming portion 20 can be formed by welding. .. For example, the terminal forming portion 20 may be formed by using ultrasonic welding.

The method for manufacturing a terminalized electric wire according to the embodiment of the present invention includes a plurality of strands 2 bundle splitting step of splitting the exposed plurality of strands 12 into two bundles of strands 12A and 12B, and a plurality of strands 2 bundle splitting step. 2 bundle overlapping annular forming step of forming two bundles of the separated wire bundles 12A and 12B in an annular shape in which at least some of them overlap each other so as to form a hole corresponding to the attachment hole 20a. In the portion where the bundles of strands 12A and 12B are superposed, the bundles obtained by dividing the plurality of strands 12 constituting the electric wire 10 are superposed, and thus the bundle of strands 12 is bundled into one bundle. It is possible to suppress the step difference in the overlapped portion as compared with the case where it is overlapped with itself, and it is possible to prevent a difference in the welding state of the forming portion when forming this step difference by welding. In addition, it is possible to suppress variations in the thickness of the terminal molding portion 20 in which the plurality of element wires 12 are molded into a terminal shape by welding.

In addition, the manufacturing method of the terminalized electric wire according to the embodiment of the present invention has exemplified the one including the branching portion twisting step and the overlapping portion twisting step. These two steps may not be included as long as they can be molded.

(Modification)
Next, a modified example of the method of manufacturing a terminalized electric wire according to the embodiment of the present invention will be described with reference to FIGS. 4 and 5.
FIG. 4 is a diagram for explaining a step of splitting a plurality of strands into two bundles and a step of forming a two-bundle overlapping ring in the method of manufacturing a terminalized electric wire according to a modification. FIG. 5 is a perspective view of the electric wire 10 in a state where the bundle-stacking annular forming step is completed.
The method of manufacturing the terminalized electric wire of this modified example is different from the method of manufacturing the terminalized electric wire of the embodiment in that the two bundles of wire bundles 12A and 12B are overlapped with each other from the base end portion to the tip end portion of the exposed portion.
The rest of the configuration is the same as that of the embodiment, and the same components as those of the embodiment are designated by the same reference numerals.

In the method of manufacturing a terminalized electric wire of this modification, an operator superposes two bundles of wire bundles 12A and 12B on each other from the base end portion to the tip end portion of the exposed portion in the two-bundle overlapping annular forming step (Fig. 4(b)).
As a result, it is possible to secure a larger area where the two bundles of filaments 12A and 12B overlap each other.

The manufacturing method of the terminalized electric wire of this modification can suppress the variation in the thickness of the terminal molding portion 20 as well as the two terminal wire bundles 12A and 12B, as in the method of manufacturing the terminalized electric wire of the embodiment. It is possible to secure a wide overlapping portion, and since the terminal molding portion 20 can be thickened, the strength of the terminal molding portion 20 can be increased.

In the terminalized electric wire 1 manufactured by the method for manufacturing a terminalized electric wire according to the embodiment and the modified example, since the terminal forming portion 20 has flexibility as compared with the terminal fitting, as shown in FIG. The base end of the portion 20 can be bent. In addition, it is preferable to leave the portions of the filament bundles 12A and 12B in a state where they are not welded to the portions that require higher flexibility. For example, when it is desired to increase the flexibility of the base end portion of the terminal forming portion 20, the base end portion is not welded but left in the state of the wire bundles 12A and 12B. In this case, when dividing the plurality of strands 12 into two bundles of strands 12A and 12B as in the present invention, the thickness of the bundle of strands at the base end portion can be halved to reduce the thickness. The flexibility of the part can be further enhanced.

The invention made by the present inventor has been specifically described above based on the embodiments of the invention described above, but the invention is not limited to the embodiments of the invention described above, and does not depart from the scope of the invention. Can be variously changed.

DESCRIPTION OF SYMBOLS 1 Terminalized electric wire 10 Electric wire 11 Insulation coating 12 Elementary wires 12A, 12B Elementary wire bundle 20 Terminal forming part 20a Mounting hole 100 Welding device 110 Upper press electrode 120 Lower press electrode

Claims (1)

In a method of manufacturing a terminalized electric wire, which has a terminal molding portion in which a plurality of wires exposed by peeling off the insulating coating of the terminal portion of the electric wire is welded and molded into a terminal shape provided with a mounting hole,
A step of dividing the exposed plurality of strands into two bundles of bundles of strands ;
A branching portion twisting step of twisting around a branching portion at which the two bundles of wire bundles separated in the plurality of strands of wire bundle splitting step branch from each other;
A two-bundle overlapping annular forming step of forming the two bundles of the bundle of wires divided in the plurality of bundles of bundles of wires into an annular shape in which their tips overlap each other so as to form holes corresponding to the attachment holes;
A welding forming step of forming the terminal forming portion by welding the wire bundles formed in an annular shape in the two-bundle overlapping annular forming step;
The including
A method of manufacturing a terminalized electric wire, comprising:

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