JPH1050446A - Manufacturing method of wire harness - Google Patents

Abstract

(57) Abstract: The present invention relates to a method of manufacturing a wire harness mainly used for electric wiring of an automobile. By conducting a continuity test in a wiring step, productivity of the manufacturing process of the wire harness is remarkably increased. An object of the present invention is to provide a method of manufacturing a wire harness which is improved. SOLUTION: A plurality of receiving members 3 each having a built-in conductive pin are provided in a wiring board 1, and connectors K constituting a wire harness are respectively arranged in the receiving members 3, and a terminal accommodation room Y of the connector K is provided.
The terminal T of the electric wire W with a terminal is inserted into
A conduction test is performed based on the presence or absence of conduction between the conduction pin provided therein and the terminal T to form a wire harness.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a wire harness mainly used for electric wiring of an automobile.

[0002]

2. Description of the Related Art In general, a wire harness used for electric wiring of an automobile generally has a plurality of electric wires with terminals that are bundled and a connector is provided at an end thereof for coupling with a connector of a mating electric device. It is used. In the process of manufacturing such a wire harness, for example, a worker arranges a wire with terminals using a routing table a as shown in FIG. 12 to form a wire harness H.

[0003] A holding tool b is provided upright on the routing table a, and holds the electric wire with terminal in the form of a wire harness. After inserting the terminal at the end of the terminal-equipped wire into the connector c for connection to the other party's electrical device, bundling the terminal-equipped wire, applying a corrugated tube or tape winding d to adjust the form of the wire harness H, and then arranging it The continuity test of each connector c is performed by detaching from the cable stand a and mounting the continuity test table separately provided.

[0004] Therefore, a continuity inspection step involving an operation of moving the wire harness H to the continuity inspection table and an operation of assembling the wire harness H to the continuity inspection device is required. It is necessary to solve the problem and re-route the electric wire with terminal at the defective part. Such a repair work is troublesome and takes a lot of time, and has problems such as loss of members such as a corrugated tube and a tape.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems. The present invention is directed to a wire harness for conducting a continuity test by performing a continuity test in a wiring step of a terminal-attached electric wire. An object of the present invention is to provide a method of manufacturing a wire harness in which a moving operation and an assembling operation are omitted, and a correcting operation of a wiring process is simplified, and productivity of the manufacturing process of the wire harness is significantly improved.

[0006]

In order to achieve the above-mentioned object, a method of manufacturing a wire harness according to the present invention comprises providing, at a predetermined position on a routing table, a plurality of receiving members having built-in conductive pins,
The connectors constituting the wire harness were respectively arranged in the receiving members, the terminals of the electric wires with terminals were inserted into the respective terminal receiving chambers of the connectors, and the terminals inserted into the terminal receiving chambers and the terminals were provided in the receiving members. A continuity test is performed on the terminal inserted into the terminal accommodating chamber based on the presence or absence of continuity with the continuity pin, thereby forming a wire harness having a connector at an end of the terminal-attached electric wire. It is preferable that the connector constituting the wire harness is a connector of an intermediate electric wire bundle in which terminals of electric wires with terminals are previously inserted into a predetermined terminal accommodating chamber (claim 2).

[0007] Each terminal accommodating chamber of the connector constituting the wire harness is set according to the terminal insertion state as shown in FIG.
(A), (B) of a terminal accommodation chamber in which a terminal-inserted wire with no terminals inserted therein, (B) a terminal accommodation chamber in which a terminal-equipped electric wire with one end not inserted is inserted, and (C) a terminal accommodation chamber in which a terminal-equipped electric wire with both ends inserted. ),
(C) After setting the three types in the terminal registration unit of the continuity tester described in (C), the terminal of the electric wire with the terminal is sequentially inserted into the terminal accommodating chamber (A) where no terminal is inserted for each connector. It is preferable to conduct a continuity test between predetermined terminal accommodating chambers of the connectors by comparing the terminal insertion states (A) and (B) of the terminal registration section (claim 3).

According to the terminal insertion state, (A) a terminal accommodation room where no terminal is inserted, and (B) one end not inserted depending on the terminal insertion state, among the connectors constituting the wiring harness. (A), (B), and (C) of the terminal accommodating chamber into which the terminal-attached electric wire is inserted and (C) the terminal accommodating chamber into which the terminal-attached electric wire having both ends inserted is inserted.
The terminals are set in the terminal registration section of the continuity tester in accordance with the type, and the respective terminal accommodating chambers of the unwired connectors are set as (D) in the terminal registration section of the continuity tester, and are selectively arranged. By inserting the terminal of the electric wire with a terminal into the connector to be cabled and comparing the terminal insertion states (A) and (B) of the terminal registration section with each other, a predetermined terminal accommodating chamber between the connectors is provided. After conducting a continuity test between
For an unrouted connector registered as the terminal insertion state (D), the registration of the terminal insertion state (D) is changed to the terminal insertion states (A), (B), and (C), and the connectors are sequentially wired. It is effective to perform a continuity test.

[0009]

Embodiments of the present invention will be described below. FIG. 1 is an explanatory diagram showing a simplified structure of an electric wire W with a terminal according to an embodiment of the present invention. FIG. 1 (a)
The terminal-attached electric wire W shown in FIG. 1 has terminals T attached to both ends, and the terminal-attached electric wire W shown in FIG.
And a terminal T is attached to each end.

In the manufacturing process of the wire harness according to the present embodiment, first, a plurality of intermediate electric wire bundles S as shown in FIG. Intermediate wire bundle S
Is an intermediate product of a wire harness in which one or both terminals T of the terminal-equipped electric wire W are inserted into a predetermined terminal accommodating chamber Y of a connector K for connecting to a counterpart electric device.

Next, as shown in FIG. 3, a plurality of intermediate electric wire bundles S are placed on the routing table 1 and placed in the terminal receiving chamber Y where the terminals of the connector K are not inserted. T is inserted. A holding section 2 for holding the intermediate electric wire bundle S is provided on the routing table 1.
And a receiving member 3 for mounting the connector K attached to the end of the intermediate electric wire bundle S. Although not shown, a plurality of conduction pins are provided in the receiving tool 3, and each conduction pin is provided on the back side of the routing table 1 and connected to the continuity inspection device 5 through the wiring 4.

The continuity inspection device 5 is provided with a terminal registration unit, which will be described in detail later.
The information corresponding to the terminal insertion state of each terminal accommodating room Y can be registered. After checking the continuity between the connector K and the receiver 3 and the registration of the terminal registration unit, the continuity test of the connector K is performed.
A plurality of intermediate electric wire bundles S are bundled, and attached parts such as corrugated tubes and tape winding are attached to form a wire harness as a final product.

[0013] In a wire harness for an automobile, generally, a large number of terminals W with electric wires and a large number of mounted connectors K are used, and dozens of terminals are used. 4 (a), (b) and (c),
The three intermediate wire bundles S ₁ , S ₂ and S ₃ will be described as an example.

[0014] Intermediate wire bundle S _1, as shown in FIG. 4 (a), has a connector K _1, K _2, intermediate wire bundle S ₂ is 4
A connector K ₃ shown in (b), the intermediate wire bundle S ₃ has a connector K ₄ shown in FIG. 4 (c), and a terminal T not inserted at the end of the wire with terminals W. In the terminal accommodating chamber Y of each of the connectors K _{1 to} K ₄ , the terminal insertion state of the terminal accommodating chamber Y is divided into the following three types (A), (B), and (C), and A, B , C. (A) Terminal accommodation room in which the terminal of electric wire W with terminal is not inserted. (B) Terminal accommodation room in which terminal of one end of electric wire W with terminal is inserted. Terminal housing)

Further, as shown in FIG. 5, numbers 1 to 12 are assigned to the terminal accommodating chambers Y of the connectors K _{1 to} K ₄ , and the numbers A to B correspond to the numbers A to B. Te, the terminal registration section of the continuity test unit 4, as the position designation code of the terminal accommodating chamber Y connector _{K 1 ~K 4, C1, A2} , B3, a
4, A5, C6, A7, B8, A9, A10, A11,
B12, A13, and B14 are registered.

[0016] Then, the intermediate wire bundle S ₁ and S _2, as shown in FIG. 3, arranged Haisakudai 1, intermediate wire bundle S ₁ and S by the holding section 2 provided on Haisakudai 1 holds the _2, intermediate wire into receptacle 2 bundle S ₁ and the connector K ₁ of S _2,
The K _2, K ₃ is mounted, as shown in FIG. 6, the connector K ₁
Of the terminal T at the other end of the wire with terminals W which one end of the terminal in the terminal receiving chamber B3 is inserted, it is inserted into the terminal accommodating chambers A9 connector K _2, the one end of the terminal accommodating chambers B8 connector K ₃ pins There performs routing to insert the terminal T of the other end of the wire with terminals W which has been inserted into the terminal accommodating chambers A7 connector K _2.

When the above-mentioned wiring is completed, a continuity test is performed. In this conduction inspection, as shown in the conduction display diagram of FIG.
0, A11, and A13) and the terminal insertion state B
This is performed by collating all the data (4 points of B3, B8, B12, and B14). As a means for matching, a method of sequentially scanning the terminal insertion states A and B recorded in the memory of the terminal registration unit can be used. If the terminal T is correctly inserted, the continuity is displayed by the symbol 〇 shown in the continuity display diagram of FIG. on the other hand,
In the state of the terminal insertion state A (terminal not inserted), the conduction display is not performed as shown by the-mark.

The total number of points in the continuity test is 8 (points) × 4 (points) = 32 (points). Since all the points of the terminal accommodating room registered in the terminal registration unit are [14 (points) × 14 (points) −14 (points)] × 1/2 = 91 (points), the registered terminals Compared with the case where all the points in the accommodation room are inspected, the time required for the inspection of this embodiment is reduced to 32 (points) / 91 (points) ≒ 0.35, and the continuity inspection can be performed efficiently. There are advantages that can be implemented.

After the continuity test relating to the routing of the intermediate wire bundles S ₁ and S ₂ is completed, as shown in FIG.
To ₁ and S _2, performs routing by adding intermediate wire bundle S _3. That is, the similar to the routing step, the connector K ₁ of A4 and connectors K ₄ B12, connectors K ₁ of A5 and connectors K ₄ B12, A10 and connectors K ₄ of B14 connectors K _3, the connector K ₄ routing the like are performed (conducted by the terminal T bifurcation ') A13 and connectors A9 of K ₁ of B3 and connectors K _3. After the completion of the wiring, the continuity test device 5 is operated to perform the same continuity test as described above. As shown in the continuity display diagram of FIG. Such a display is obtained.

After the continuity inspection accompanying the wiring process is completed as described above, the intermediate wire bundles S ₁ , S ₂ , and S ₃ are bundled and attached with a corrugated tube and an accessory such as a tape winding. A harness is formed. Because the formed wire harness has been tested for continuity,
A finished product can be obtained immediately without the need for a separate continuity inspection step.

Next, another embodiment of the present invention will be described.
You. Intermediate wire bundle S₁, S_Two, S_ThreeEach connector K₁~ K
_FourAs shown in FIG.
First, an intermediate wire bundle S for selective routing first₁, S _Twoof
Connector K₁~ K_ThreeAbout (A) of the said Example,
(B) and (C), the unrouted intermediate wire bundle S_ThreeNo
Necta K_FourThe terminal insertion state of the terminal accommodating chamber Y is shown below.
(D) in the terminal registration unit. (A) Terminal accommodation room in which the terminal of the electric wire W with a terminal is not inserted. (B) End where the terminal of one end of the electric wire W with a terminal is inserted.
(C) All terminals (including the branch part) of electric wire W with terminal
Terminal accommodation room in which the terminal is inserted (D) Terminal accommodation room of unarranged connector Unarranged connector (state not arranged on routing table 1)
Registration of terminal accommodation room as (D) and verification at continuity inspection
Is omitted, as shown in FIG.
Intermediate wire bundle S₁And S_TwoWhen conducting continuity inspection after wiring with
Is the intermediate wire bundle S _ThreeTerminal accommodation chambers (D12, D13, D
14) does not need to be the object of continuity inspection
The terminal insertion state (A) from C1 to A11 and the terminal
The collation with the insertion state (B) may be performed.

[0022] Thus, the terminal insertion state A all but the connector _{K 4 (A2, A4, A5} , A7, A9, A10,
A11, 7 points) and all the terminal insertion states B (B3,
The conduction state may be inspected by comparing two points (B8). The total number of points in the continuity test is 7 (points) × 2 (points) = 14 (points). Since all the points of the terminal accommodating room registered in the terminal registration unit are 91 (points) as in the above-described embodiment, the number of points in the terminal accommodating room is smaller than that in the case of inspecting all the registered points of the terminal accommodating room. The time required for the inspection in the embodiment is reduced to 14 (points) / 91 (points) ≒ 0.15, which is advantageous in that the continuity inspection can be performed more efficiently.

Next, when placing the intermediate wire bundle S ₃ to Haisakudai 1 performs routing and is already (D) Connector K ₄ of the terminal receiving chamber which has been registered as (D12, D13, D14 )
Is changed to the terminal accommodating chamber (B12, A13, B14), and a continuity test is performed, whereby a wire harness can be formed in the same manner as in the above embodiment.

[0024]

According to the present invention, the terminal insertion state of the connector constituting the wire harness can be changed as described in the above (A), (B),
(C) or (D), which is registered in the terminal position register, and each time wiring is completed for the connector, a continuity test is performed based on the insertion of the terminal into the terminal receiving chamber in the terminal non-inserted state (A). Therefore, the continuity test can be performed efficiently, and the productivity of the manufacturing process of the wire harness for a high-density circuit having a large number of connectors and terminals can be remarkably improved. In addition, since it is not necessary to conduct a continuity test after attaching various components to the wire harness, unnecessary loss of the attaching member due to correction of the continuity defect after attaching various components can be prevented, and members can be saved. There are many advantages, such as:

[Brief description of the drawings]

FIG. 1 is a perspective view showing a terminal-attached electric wire according to an embodiment of the present invention, wherein (a) shows an example having terminals at both ends,
(B) has shown the example which has a branch part.

FIG. 2 is a perspective view showing an intermediate electric wire bundle formed by using terminals of the electric wire with terminals shown in FIG. 1;

FIG. 3 is a perspective view showing a state in which the intermediate electric wire bundle of FIG. 2 is arranged on a routing board.

FIGS. 4A and 4B show three examples of the intermediate electric wire bundle shown in FIGS.
It is a schematic diagram which shows the terminal insertion state of (c).

FIG. 5 is an explanatory diagram showing the numbers assigned to the terminal accommodating chambers of all the connectors of the intermediate electric wire bundle of FIG. 4;

FIG. 6 is an explanatory view showing a wiring process between the intermediate electric wire bundles in FIGS. 4 (a) and 4 (b).

FIG. 7 is a continuity display diagram in a continuity test after wiring between the intermediate electric wire bundles of FIG. 6;

FIG. 8 is an explanatory view showing a wiring step between the intermediate electric wire bundles of FIGS. 4 (a), (b) and (c).

FIG. 9 is a continuity display diagram in a continuity test after wiring between the intermediate electric wire bundles of FIG. 8;

FIG. 10 is a schematic diagram showing a terminal insertion state of an intermediate wire bundle according to another embodiment of the present invention.

11 is a continuity display diagram in a continuity test after routing of the intermediate electric wire bundles in FIG. 10;

FIG. 12 is a perspective view showing a manufacturing process of a conventional wire harness.

[Explanation of symbols]

K (K ₁ , K ₂ , K ₃ , K ₄ ) Connector S (S ₁ , S ₂ , S ₃ ) Intermediate electric wire bundle T, T ′ terminal W Electric wire with terminal Y Terminal accommodation room 1 Routing table 3 Receiver 5 Continuity inspection device

Claims (4)

[Claims] A plurality of receptacles each having a built-in conductive pin are provided at a predetermined position of a routing table, and connectors constituting a wire harness are arranged in the receptacles, respectively. By inserting the terminal of the terminal-attached electric wire and conducting a continuity test on the terminal inserted into the terminal accommodating chamber based on the presence / absence of conduction between the terminal inserted into the terminal accommodating chamber and the conducting pin provided in the receiving member, A method for manufacturing a wire harness, comprising: forming a wire harness having a connector at an end of an attached wire. 2. The wire harness according to claim 1, wherein the connector constituting the wire harness is a connector of an intermediate wire bundle in which terminals of wires with terminals are inserted in a predetermined terminal accommodating chamber in advance. Manufacturing method. 3. A terminal accommodating chamber in which a terminal is not inserted, and (B) a terminal-equipped electric wire in which a terminal is not inserted at one end, according to a terminal insertion state. (C) The terminal storage chamber into which the terminal-equipped electric wire with both ends inserted is inserted, and the terminal storage section is divided into three types described in (A), (B), and (C) and is stored in the terminal registration section of the continuity test apparatus. After the setting, the terminal of the electric wire with the terminal is sequentially inserted into the terminal accommodating chamber (A) where the terminal is not inserted for each connector, and the terminal insertion state (A) and (B) of the terminal registration unit are collated. The method according to claim 1, wherein a continuity test is performed between the predetermined terminal receiving chambers of the connectors by performing the test. 4. A terminal accommodating chamber in which a terminal is not inserted, and a terminal accommodating chamber in which a terminal is not inserted, and (B) one end of each of the terminal accommodating chambers of a connector which selectively wires out of the connectors constituting the wire harness. (A), (B), and (C) of the terminal accommodating room in which the uninserted terminal-equipped electric wire is inserted, and (C) the terminal accommodating room in which the terminal-equipped electric wire with both ends inserted is inserted. The terminal is set in the terminal registration section of the continuity test apparatus, and the respective terminal accommodating chambers of the unrouted connectors are set as (D) in the terminal registration section of the continuity test apparatus, and the wiring is selectively performed. By inserting the terminal of the electric wire with a terminal into the connector and comparing the terminal insertion states (A) and (B) of the terminal registration section with each other, conduction between the predetermined terminal accommodating chambers of the connectors is achieved. After the test, the terminal insertion state (D )), Changing the registration of the terminal insertion state (D) to the terminal insertion states (A), (B), and (C) and sequentially performing the wiring and the continuity test on the unrouted connector registered as The method for manufacturing a wire harness according to claim 1 or 2, wherein: