U.S. patent application number 09/761689 was filed with the patent office on 2001-05-24 for wire harness and method and apparatus for manufacturing the same.
Invention is credited to Aikawa, Jiro, Kudo, Shigeji, Miyamoto, Yutaka, Nakayama, Tsutomu, Suzuki, Hiroo.
Application Number | 20010001345 09/761689 |
Document ID | / |
Family ID | 16912117 |
Filed Date | 2001-05-24 |
United States Patent
Application |
20010001345 |
Kind Code |
A1 |
Miyamoto, Yutaka ; et
al. |
May 24, 2001 |
Wire harness and method and apparatus for manufacturing the
same
Abstract
A wire harness is made up of a plurality of partial harnesses.
Each of the partial harnesses is arranged such that opposite end
portions of a plurality of electric wires having terminals at ends
thereof are retained in advance in U-shapes with predetermined
intervals provided so as to correspond to a plurality of connectors
into which the terminals are inserted, by a plurality of wire
clamps juxtaposed at equal pitches on a wire clamping bar. The
terminals at the ends of the plurality of electric wires in each of
the partial harnesses are inserted into terminal accommodating
chambers of predetermined connectors selected from the plurality of
connectors, thereby aggregating the partial harnesses into a
combined unit.
Inventors: |
Miyamoto, Yutaka; (Shizuoka,
JP) ; Kudo, Shigeji; (Shizuoka, JP) ; Suzuki,
Hiroo; (Shizuoka, JP) ; Nakayama, Tsutomu;
(Shizuoka, JP) ; Aikawa, Jiro; (Shizuoka,
JP) |
Correspondence
Address: |
SUGHRUE, MION, ZINN, MACPEAK & SEAS, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
WASHINGTON
DC
20037-3213
US
|
Family ID: |
16912117 |
Appl. No.: |
09/761689 |
Filed: |
January 18, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09761689 |
Jan 18, 2001 |
|
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|
09140669 |
Aug 26, 1998 |
|
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Current U.S.
Class: |
29/749 ;
29/755 |
Current CPC
Class: |
Y10T 29/49147 20150115;
H01R 43/20 20130101; Y10T 29/49117 20150115; Y10T 29/53265
20150115; Y10T 29/49174 20150115; Y10T 29/5313 20150115; Y10T
29/53217 20150115; Y10T 29/53213 20150115; Y10T 29/53261 20150115;
Y10T 29/53209 20150115; Y10T 29/49151 20150115; Y10T 29/5187
20150115; Y10T 29/5193 20150115; Y10T 29/53243 20150115; B60R
16/0207 20130101; Y10T 29/49208 20150115 |
Class at
Publication: |
29/749 ;
29/755 |
International
Class: |
B23P 019/00; H01R
043/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 27, 1997 |
JP |
P. HEI. 9-230711 |
Claims
What is claimed is:
1. A wire harness comprising a plurality of partial harnesses,
wherein each of the partial harnesses is arranged such that
opposite end portions of a plurality of electric wires having
terminals at ends thereof are retained in advance in U-shapes with
predetermined intervals provided so as to correspond to a plurality
of connectors into which the terminals are inserted, by a plurality
of wire clamps juxtaposed at equal pitches on a wire clamping bar,
and wherein the terminals at the ends of the plurality of electric
wires in each of the partial harnesses are inserted into terminal
accommodating chambers of predetermined connectors selected from
the plurality of connectors, thereby aggregating the plurality of
partial harnesses into a combined unit.
2. A wire harness according to claim 1, wherein the plurality of
connectors into which the terminals are inserted comprise at least
one of connectors proper to a relevant partial harness into which
only the terminals of the plurality of electric wires making up
each of the partial harnesses are inserted and hybrid connectors
into which the terminals of the electric wires of two or more of
the partial harnesses are inserted in mixed form.
3. A wire harness according to claim 1, wherein the proper
connector is fitted in advance to the ends of predetermined ones of
the electric wires of each of the partial harnesses.
4. A wire harness according to claim 1, wherein the hybrid
connector is fitted in advance to the ends of the electric wires of
one or two of the partial harnesses selected from the plurality of
partial harnesses.
5. A wire harness according to claim 1, wherein each of the partial
harnesses includes electric wires to stripped ends of which
terminals are unconnected, and the stripped ends thereof are
jointed in the aggregated state.
6. A method of manufacturing a wire harness from the plurality of
partial harnesses, comprising: a step of transferring a wire
clamping bar which holds an initial one of the partial harnesses to
a wire-harness fabricating station; a step of inserting the
terminals at ends of a plurality of electric wires consecutively
into predetermined terminal accommodating chambers of predetermined
ones of the connectors selected from the plurality of connectors
set on a connector receiving jig in the wire-harness fabricating
station; a step of removing the wire clamping bar which has been
emptied; and repeating the steps of transferring, inserting and
removing consecutively for ensuing ones of the partial
harnesses.
7. A method of manufacturing a wire harness according to claim 6,
further comprising a step of transferring a proper connector fitted
in advance to ends of predetermined ones of the electric wires of
each of the partial harnesses to the connector receiving jig in the
wire-harness fabricating station.
8. A method of manufacturing a wire harness according to claim 6,
further comprising a step of collectively jointing, in the
wire-harness fabricating station, two or more stripped portions of
the electric wires included in each of the partial harnesses.
9. A method of manufacturing a wire harness according to claim 7,
further comprising a step of collectively jointing, in the
wire-harness fabricating station, two or more stripped portions of
the electric wires included in each of the partial harnesses.
10. A method of manufacturing a wire harness according to claim 6,
further comprising a step of jointing, in the wire-harness
fabricating station, stripped portions of the ends of the electric
wires included in each of the partial harnesses, such that the
stripped portions are consecutively superposed one on top of
another each time each of the partial harnesses is transferred to
the wire-harness fabricating station.
11. A method of manufacturing a wire harness according to claim 7,
further comprising a step of jointing, in the wire-harness
fabricating station, stripped portions of the ends of the electric
wires included in each of the partial harnesses, such that the
stripped portions are consecutively superposed one on top of
another each time each of the partial harnesses is transferred to
the wire-harness fabricating station.
12. An apparatus for manufacturing a wire harness, comprising: a
wire-harness fabricating station for forming a single wire harness
from partial harnesses, the wire-harness fabricating station having
a connector receiving jig which detachably holds a plurality of
proper connectors and a plurality of hybrid connectors.
13. An apparatus for manufacturing a wire harness according to
claim 12, wherein the wire-harness fabricating station comprises a
connector transferring device for transferring, to the connector
receiving jig, ones of the proper connectors and hybrid connectors
which are fitted in advance to the partial harness.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a wire harness and a method and an
apparatus for manufacturing the same, and more particularly to the
manufacture of one wire harness (or one sub-harness) by combining a
plurality of partial harnesses.
[0003] The present application is based on Japanese Patent
Application No. Hei. 9-230711, which is incorporated herein by
reference.
[0004] 2. Description of the Related Art
[0005] As is known, there are a plurality of wire harnesses used in
the electrical wiring of an automobile, including such as an engine
harness, an instrument panel harness, a cowl side harness, a door
harness, and a roof harness.
[0006] As a method and an apparatus for manufacturing such wire
harnesses, as shown in FIG. 13, a method and an apparatus are known
which use a wire clamping bar 101 in which a multiplicity of wire
clamps 100 are juxtaposed at equal pitches. Incidentally, each wire
clamp 100 comprises a pair of mutually opposing clamp members 100a,
and electric wires are clamped therebetween.
[0007] After a plurality of electric wires 102 for forming one wire
harness are cut to a predetermined length, opposite end portions
thereof are retained by mutual adjacent wire clamps 100 and are
held in U-shapes on the wire clamping bar 101. In this state, end
processing such as stripping (removal of an insulating sheath) of a
wire end and crimping of a terminal is performed.
[0008] This wire clamping bar 101 is set in or transferred to a
case fitting station 103, and terminals 104 at wire ends are
respectively inserted and fitted into terminal accommodating
chambers (not shown) of a connector housing (hereafter, simply
referred to as the connector) 105 by using an automatic terminal
inserting device 107.
[0009] A plurality of connectors 105 are arranged in advance on a
setting table 106 as shown at reference numerals 105.sub.1 to
105.sub.4. The terminals 104 are inserted into and retained in
predetermined terminal accommodating chambers of connectors
selected from the plurality of connectors 105.sub.1 to 105.sub.4 in
a predetermined order.
[0010] As shown in FIG. 14, the automatic terminal inserting device
107 has a mounting head 108, a pair of terminal gripping claws 109
for a wire connecting portion 104a of the terminal 104 and a pair
of wire gripping claws 110 are provided at a lower end of the
mounting head 108 in such a manner as to be capable of being raised
or lowered and of being opened or closed. Further, a pair of wire
clamp plates 111 which can be opened or closed is provided at the
lower end of the mounting head 108, and a terminal holding plate
112 is provided between the pair of terminal gripping claws 109 in
such a manner as to be capable of being raised or lowered.
[0011] Further, the mounting head 108 is provided in such a manner
as to be capable of moving close to or away from the wire clamp 100
(or the wire clamping bar 101) and of being raised or lowered with
respect to the same. Further, a moving plate 113 for supporting the
mounting head 108 is mounted on a supporting frame 114 of the case
fitting station 103, and is provided in such a manner as to be
horizontally movable with respect to the setting table 106 on which
the plurality of connectors 105 are arranged.
[0012] Accordingly, according to the automatic terminal inserting
device 107, the terminal 104 can be automatically inserted into the
connector 105 by repeating the following steps a to d.
[0013] a. The mounting head is moved to immediately above desired
wire clamp 100 of the wire clap bar 101 by means of the moving
plate 113.
[0014] b. At the same time as the lowering and raising operation of
the mounting head 108, an end portion of the wire 102 including the
terminal 104 is gripped by the opening/closing operation of the
terminal gripping claws 109, the wire gripping claws 110, and the
wire clamp plates 111, and is lifted up from the wire clamp 100
which retained the wire.
[0015] c. Then, the mounting head 108 is moved in parallel to the
wire clamping bar 101, and is stopped at a position opposing a
desired terminal accommodating chamber of the desired connector
105.
[0016] d. The mounting head 108 is advanced forward toward the
connector 105, and while the terminal 104 is being inserted into
the terminal accommodating chamber, the terminal gripping claws
109, the wire gripping claws 110, and the wire clamp plates 111 are
opened consecutively beginning at the front side, thereby releasing
the wire end portion. Namely, the terminal 104 is automatically
inserted and fitted into the predetermined terminal accommodating
chamber of the predetermined connector.
[0017] Thus, there is an advantage, among others, in that, by using
the wire clamping bar 101 in which the multiplicity of wire clamps
100 are juxtaposed, all the end processing of wires, including the
cutting, retention, stripping, terminal crimping, and case fitting
(insertion and fitting of a terminal into a connector) of a
multiplicity of wires which make up one wire harness, can be
handled on one side of the wire clamping bar. A method and an
apparatus similar to the above-described method and apparatus have
been disclosed in Japanese Patent Publication No. Hei. 5-55994.
[0018] However, since the engine harness, for example, is made up
by numerous wires which generally comprise as many as 200 circuits
(the number of wires: 200, the number of both end portions that are
retained in U-shapes: 400), the number of connectors that are
fitted to the wire ends is also numerous. As such, if end
processing is performed with respect to these wires by using a
single wire clamping bar, troubles are liable to occur, such as
erroneous wiring of wires, erroneous crimping of a terminal,
erroneous insertion into a connector, and entanglement of wires or
terminals.
[0019] On the other hand, to handle numerous wires by a single wire
clamping bar, an extremely long bar is required, and not only is a
wide working space required, but also a pitch time from the cutting
of the wire until completion of final case fitting becomes very
long. Hence, the apparatus becomes large and automatic control
becomes complex and expensive. Furthermore, if there occurs
erroneous wiring or erroneous insertion or the like, since it takes
time and trouble in correcting them in an ensuing process, wastage
can occur such as discarding the entire wires on the wire clamping
bar as defective products.
SUMMARY OF THE INVENTION
[0020] An object of the present invention is to eliminate the
above-mentioned drawbacks. More specifically, an object of the
present invention is to provide a wire harness which can be
fabricated in a relatively narrow space in a short time, and in
which erroneous wiring of wires, erroneous crimping or insertion of
terminals, and entanglement of wires are unlikely to occur, as well
as a method and an apparatus for manufacturing the same. In
addition, another object of the present invention is to provide a
wire harness and a method for manufacturing the same which are
suitable for production of a large variety of products in small
lots.
[0021] In order to achieve the above objects, the present inventors
first analyzed various forms of wire harness which are used in a
single automobile.
[0022] Namely, as shown in FIG. 1, one wire harness WH is provided
with a plurality of connectors C.sub.1 to C.sub.5 and connectors
C.sub.1' to C.sub.4' in correspondence with its installation
routes. The connectors C.sub.1 to C.sub.5 are connectors which are
proper to a relevant partial harness and in which only terminals of
wires making up the partial harness are inserted and fitted, as
will be described later. The connectors C.sub.1' to C.sub.4' are
hybrid connectors into which terminals of different partial
harnesses are respectively inserted and fitted in mixed form.
[0023] For example, among a plurality of wires 1 making up a
partial harness H.sub.A to one end of which the proper connector
C.sub.1 is fitted, three wires 1.sub.5 to 1.sub.7 are fitted to the
proper connector C.sub.5. However, other wires 1.sub.1 and 1.sub.2
are connected to the hybrid connector C.sub.1', a wire 1.sub.3 is
connected to the hybrid connector C.sub.2', a wire 1.sub.4 is
connected to the hybrid connector C.sub.3', and a wire 1.sub.8 is
connected to the hybrid connector C.sub.4'.
[0024] Thus, although one connector (the proper connector C.sub.1)
is fitted to one ends of a plurality of wires, terminals at other
ends of these wires are not necessarily inserted and fitted into
only one connector (the proper connector C.sub.5), but are inserted
and fitted into other connectors (hybrid connectors C.sub.1' to
C.sub.4') in a distributed manner, so that troubles such as
erroneous wiring of wires and erroneous insertion of terminals are
liable to occur.
[0025] Accordingly, by taking note of the fact that one wire
harness (or one sub-harness) is divided into a number of partial
harnesses in which terminals of one ends of a group of wires are
inserted and fitted into a specific connector (e.g., one of the
proper connectors C.sub.1 to C.sub.5 ), while terminals at the
other ends thereof are inserted and fitted into two or more
connectors (e.g., the hybrid connectors C.sub.1 to C.sub.4') in a
distributed manner, the present inventors found out that numerous
troubles associated with the conventional technique can be overcome
by combining these partial harnesses into one unit.
[0026] Namely, according to the first aspect of the present
invention, there is provided a wire harness comprising a plurality
of partial harnesses, wherein each of the partial harnesses is
arranged such that opposite end portions of a plurality of electric
wires having terminals at ends thereof are retained in advance in
U-shapes with predetermined intervals provided so as to correspond
to a plurality of connectors into which the terminals are inserted,
by a plurality of wire clamps juxtaposed at equal pitches on a wire
clamping bar, and wherein the terminals at the ends of the
plurality of electric wires in each of the partial harnesses are
inserted into terminal accommodating chambers of predetermined
connectors selected from the plurality of connectors, thereby
aggregating the plurality of partial harnesses into a combined
unit. In accordance with the above-described first aspect of the
present invention, if a wire harness formed by, for example, about
200 wires is divided into four parts, the wire harness can be
formed as partial harnesses each comprising about 50 wires, the
partial harnesses can be fabricated in a relatively narrow space by
using a short wire clamping bar, and end processing can be
performed in a short time. In a case where, for example, two
partial harnesses each comprising 50 wires are aggregated as one
sub-harness comprising 100 wires, and two sub-harnesses are
combined into one wire harness comprising 200 wires, the
sub-harness, which is a semifinished product, is also included in
the wire harness referred to in the present invention. In addition,
each individual partial harness has a small number of wires,
erroneous wiring and erroneous insertion of the terminal are
unlikely to occur, such troubles can be easily detected, correction
thereof is easy, and it is possible to speedily cope with circuit
changes such as optional circuits. Furthermore, since the number of
wires is small, entanglement of wires and terminals during case
fitting is reduced, and smooth end processing can be effected.
[0027] According to the second aspect of the present invention, in
the wire harness according to the first aspect of the present
invention, the plurality of connectors into which the terminals are
inserted comprise at least one of connectors proper to a relevant
partial harness into which only the terminals of the plurality of
electric wires making up each of the partial harnesses are inserted
and hybrid connectors into which the terminals of the electric
wires of two or more of the partial harnesses are inserted in mixed
form. Since the plurality of connectors which are fitted to one
wire harness are clearly classified into connectors proper to the
partial harness alone and hybrid connectors into which the electric
wires of a plurality of partial harnesses are fitted in mixed form,
end processing of wires is further systematized and simplified, and
programming for automation is facilitated.
[0028] According to the third aspect of the present invention, in
the wire harness according to the first aspect of the present
invention, the proper connector is fitted in advance to the ends of
predetermined ones of the electric wires of each of the partial
harnesses. As a result, in a final process in which the partial
harnesses are aggregated into one wire harness, it suffices if the
terminals are consecutively inserted into only the hybrid
connectors, thereby simplifying the process of end processing.
[0029] According to the fourth aspect of the present invention, in
the wire harness according to the first aspect of the present
invention, the hybrid connector is fitted in advance to the ends of
the electric wires of one or two of the partial harnesses selected
from the plurality of partial harnesses. In accordance with the
fourth aspect of the present invention, if, for example, all the
estimated hybrid connectors are fitted in advance to one partial
harness, the wires of the other partial harnesses are not mixed in
that partial harness, so that there is no possibility of the
occurrence of erroneous wiring. Accordingly, whether the hybrid
connectors are to be fitted in advance to the partial harness can
be selected as required.
[0030] According to the fifth aspect of the present invention, in
the wire harness according to the first aspect of the present
invention, each of the partial harnesses includes electric wires to
stripped ends of which terminals are unconnected, and the stripped
ends thereof are jointed in the aggregated state. In a wire
harness, so-called joint portions are often present which are
formed such that an intermediate portion of a wire is stripped due
to the circuit configuration, and an end of another wire is
connected thereto, or stripped end portions of two or more wires
are connected together by using or without using a joint terminal.
In such a case, by jointing the wire ends or the intermediate
portion in the final process of aggregating into one wire harness,
end processing is facilitated, and the occurrence of erroneous
wiring can be prevented. It should be noted that so-called double
crimping and triple crimping in which stripped ends of two or more
wires are connected to one terminal by crimping or another method
can be included in joint processing.
[0031] Furthermore, according to the sixth aspect of the present
invention, there is provided a method of manufacturing a wire
harness from the plurality of partial harnesses according to any
one of the first to fifth aspects of the present invention,
comprising steps of: a) transferring the wire clamping bar which
holds an initial one of the partial harnesses to a wire-harness
fabricating station; b) inserting the terminals at the ends of the
plurality of electric wires consecutively into predetermined
terminal accommodating chambers of predetermined ones of the
connectors selected from the plurality of connectors set on a
connector receiving jig in the wire-harness fabricating station; c)
removing the wire clamping bar which has been emptied; and d)
repeating the above steps a) to c) consecutively for ensuing ones
of the partial harnesses. Each of the partial harnesses can be
fabricated in accordance with a known manufacturing method and by
using a known method (e.g., Japanese Patent Publication No. Hei.
5-55994). Accordingly, in accordance with the sixth aspect of the
present invention, it suffices if the wire clamping bar for an
initial partial harness is transferred to a wire-harness
fabricating station (step a)), and if the uninserted terminals of
the relevant partial harness are inserted into predetermined
terminal accommodating chambers of predetermined connectors in the
wire-harness fabricating station (step b)). This step b) can be
executed by using the automatic terminal inserting device 107 shown
in FIG. 13. Then, if the wire clamping bar which has been emptied
of the wires for which insertion of the terminals has been
completed is removed, and is transferred to, for instance, an
empty-bar placing rack, the processing of one partial harness ends.
Thus, by the mere addition of steps a), c), an 4), it is possible
to easily manufacture the wire harness by using the known method
and apparatus.
[0032] According to the seventh aspect of the present invention,
the method of manufacturing a wire harness according to the sixth
aspect of the present invention further comprises a step of
transferring the proper connector fitted in advance to the ends of
predetermined ones of the electric wires of each of the partial
harnesses to the connector receiving jig in the wire-harness
fabricating station. Namely, in a case where a proper connector has
been fitted to the partial harness, it suffices if the step of
transferring the proper connector to the connector receiving jig in
the wire-harness fabricating station is merely added. Consequently,
steps a) and b) can be effected smoothly with respect to ensuing
partial harnesses as well.
[0033] According to the eighth aspect of the present invention, the
method of manufacturing a wire harness according to the sixth or
seventh aspect of the present invention further comprises a step of
collectively jointing, in the wire-harness fabricating station, two
or more stripped portions of the electric wires included in each of
the partial harnesses. Since the joint processing of the wires is
collectively effected in the wire-harness fabricating station, the
process is simplified, and erroneous wiring and erroneous
connection can be eliminated.
[0034] According to the ninth aspect of the present invention, the
method of manufacturing a wire harness according to the sixth or
seventh aspect of the present invention further comprises a step of
jointing, in the wire-harness fabricating station, stripped
portions of the ends of the electric wires included in each of the
partial harnesses, such that the stripped portions are
consecutively superposed one on top of another each time each of
the partial harnesses is transferred to the wire-harness
fabricating station. Since stripped ends of the wires are jointed
and integrated in the end processing of each of the partial
harnesses, extra operation for correcting the deformation of the
exposed stripped portions due to contact with other wires can be
eliminated.
[0035] According to the tenth aspect of the present invention,
there is provided an apparatus for implementing the method of
manufacturing a wire harness according to any one of the sixth to
ninth aspects of the present invention, comprising: a wire-harness
fabricating station for forming a single wire harness from the
partial harnesses, the wire-harness fabricating station having a
connector receiving jig for detachably holding the plurality of
proper connectors and the plurality of hybrid connectors.
Consequently, the method according to the sixth aspect of the
present invention, particularly steps a) and b) can be executed
reliably.
[0036] According to the eleventh aspect of the present invention,
in the apparatus for manufacturing a wire harness according to the
tenth aspect of the present invention, the wire-harness fabricating
station is preferably provided with a connector transferring device
for transferring, to the connector receiving jig, the proper
connectors and/or hybrid connectors which are fitted in advance to
the partial harness. In this case, full automation of the
manufacturing method according to the sixth aspect of the present
invention including step b) becomes possible.
[0037] As described above, in the present invention, one wire
harness (or one sub-harness) is formed by a number of partial
harnesses in which terminals of one ends of a group of wires are
inserted into one connector, and terminals at the other ends
thereof are inserted into other connectors in a distributed manner.
Therefore, it is possible to provide a wire harness which can be
fabricated in a relatively narrow space in a short time, in which
erroneous wiring of wires, erroneous crimping or insertion of
terminals, and entanglement of wires are unlikely to occur, and
which is suitable for production of a large variety of products in
small lots, as well as a method and an apparatus for manufacturing
the same.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a diagram illustrating a general form of a wire
harness, which is used for explaining the present invention;
[0039] FIGS. 2A to 2C are diagrams respectively illustrating
partial harnesses H.sub.A, H.sub.B, and H.sub.C making up the wire
harness in accordance with an embodiment of the present
invention;
[0040] FIGS. 3A to 3C are diagrams illustrating states in which the
partial harnesses H.sub.A, H.sub.B, and H.sub.C corresponding to
FIGS. 2A, 2B, and 2C are respectively retained by wire clamping
bars;
[0041] FIG. 4 is a schematic diagram illustrating an embodiment of
a device for forming the partial harnesses H.sub.A, H.sub.B, and
H.sub.C shown in FIGS. 2A to 2C and 3A to 3C into one wire
harness;
[0042] FIG. 5 is a flowchart on manufacturing steps illustrating an
embodiment of a method of manufacturing a wire harness in
accordance with the present invention;
[0043] FIG. 6 is a flowchart on manufacturing steps illustrating
another embodiment of the method of manufacturing a wire harness in
accordance with the present invention;
[0044] FIG. 7A is a perspective view of a connector receiving jig
for hybrid connectors C' in accordance with the present
invention;
[0045] FIG. 7B is a cross-sectional view of an air cylinder unit 23
of the connector receiving jig;
[0046] FIG. 8 is an exploded perspective view of the air cylinder
unit 23;
[0047] FIG. 9 is a perspective view of a connector transferring
device 40 for transferring the connector, into which terminals have
been inserted and fitted, from the wire clamping bar to a
wire-harness fabricating station;
[0048] FIGS. 10A to 10D are diagrams respectively illustrating the
operation of the connector transferring device 40 shown in FIG.
9;
[0049] FIG. 11 is a perspective view of a second connector
transferring device for retaining at the wire clamping bar the
connector into which terminals have been inserted and fitted;
[0050] FIGS. 12A to 12D are diagrams respectively illustrating the
operation of the second connector transferring device shown in FIG.
11;
[0051] FIG. 13 is a diagram illustrating a conventional
wire-harness manufacturing apparatus; and
[0052] FIG. 14 is a diagram illustrating a conventional terminal
inserting device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] Referring now to the accompanying drawings, a detailed
description will be given of an embodiment of the present
invention.
[0054] FIGS. 2A to 2C respectively show states in which three
partial harnesses H.sub.A, H.sub.B, and H.sub.C which make up a
wire harness WH shown in FIG. 1 are developed two-dimensionally in
correspondence with actual forms of routing. In the drawings, a
thick line indicates a plurality of electric wires, and a thin line
indicates a single electric wire.
[0055] All terminals (not shown) at one end of a group of electric
wires 1 which make up the partial harness H.sub.A are inserted and
fitted in a proper connector C.sub.1. The other end of the group of
electric wires 1 extends along the arrangement of predetermined
hybrid connectors C.sub.1'-C.sub.4' and a proper connector C.sub.5
of the wire harness WH. The proper connector C.sub.5 is fitted to
the ends of three wires 15-17 among the wires. Since terminals 4
connected to the ends of the other wires 1.sub.1, 1.sub.2, 1.sub.3,
1.sub.4, and 1.sub.8 are inserted and fitted in hybrid connectors
C.sub.1', C.sub.2', C.sub.3', and C.sub.4' by being respectively
mixed with the wires of the other partial harnesses H.sub.B and
H.sub.C , these terminals 4 are in an exposed state.
[0056] Similarly, a proper connector C.sub.2 is fitted to one end
of a group of electric wires 2 of the partial harness H.sub.B,
while electric wires 2.sub.1, 2.sub.2, 2.sub.3, 2.sub.4, 2.sub.5,
2.sub.6, and 2.sub.7 on the other end side extend to corresponding
hybrid connectors C.sub.1', C.sub.2', and C.sub.3', respectively.
The terminals 4 connected to the respective ends are exposed.
[0057] In addition, a proper connector C.sub.3 is fitted to one end
of a group of electric wires 3 of the partial harness H.sub.C ,
while a proper connector C.sub.4 is fitted to wires 3.sub.1,
3.sub.2, and 3.sub.3 on the other end side, and the remaining wires
3.sub.4, 3.sub.5, 3.sub.6, 3.sub.7, and 3.sub.8 extend to
corresponding hybrid connectors C.sub.3' and C.sub.4',
respectively. The terminals 4 connected to the respective ends are
exposed.
[0058] Thus, the connectors C.sub.1, C.sub.2, and C.sub.3 proper to
the relevant partial harnesses are respectively fitted to one ends
of the groups of wires 1, 2, and 3 which respectively make up the
partial harnesses H.sub.A, H.sub.B, and H.sub.C, and the other end
sides of the groups of wires are provided with the terminals 4 in
the hybrid connectors C.sub.1' to C.sub.4'. At the same time,
proper connectors such as the connectors C.sub.4 and C.sub.5 are
fitted, as required, to the wires in which other partial harnesses
are not present in mixed form.
[0059] FIGS. 3A to 3C show states in which the groups of wires 1,
2, and 3 of the partial harnesses H.sub.A, H.sub.B, and H.sub.C
corresponding to FIGS. 2A to 2C are respectively retained by wire
clamps 100 of a wire clamping bar 101 shown in FIG. 13.
[0060] In FIG. 3A, all one ends of the group of wires 1 which make
up the partial harness H.sub.A are collectively retained on the
right end side in the drawing of the wire clamping bar 101, and the
proper connector C.sub.1 is thus fitted. The other end sides of the
group of wires 1 are respectively retained in U-shapes with
appropriate intervals so as to correspond to the hybrid connectors
C.sub.1' to C.sub.4' and the proper connector C.sub.5,
respectively.
[0061] Namely, the two wires 1.sub.1 and 1.sub.2 are retained close
to the proper connector C.sub.1, one wire 1.sub.8 is retained on
the left end side, and the wires 1.sub.3, 1.sub.4, and 1.sub.5,
1.sub.6, and 1.sub.7 are retained between them consecutively from
the right-hand side. Of these wires, as explained with reference to
FIG. 2A, the terminals (not shown) at opposite ends of the three
wires 1.sub.5 to 1.sub.7 are already inserted and fitted in the
proper connectors C.sub.1 and C.sub.5, and the terminals 4 at the
ends of the remaining wires 1.sub.1 to 1.sub.4 and 1.sub.8 are in
an uninserted state. It should be noted that the group of wires 1
on the proper connector C.sub.1 side and the wires 1.sub.5 to
1.sub.7 of the proper connector C.sub.5 should preferably be
retained in a vertical row by one wire clamp 100 after the
insertion and fitting of the terminals to the connectors, as will
be explained later.
[0062] Since the retention of the other partial harnesses H.sub.B
and H.sub.C in the wire clamping bar 101 in FIGS. 3B and 3C is
carried out in the same way as the partial harness H.sub.A, a
description thereof will be omitted.
[0063] In the partial harness H.sub.A in FIG. 3A, the proper
connectors C.sub.1 and C.sub.5 are already fitted to required
portions of the group of wires 1, but the connectors C.sub.1 and
C.sub.5 may be fitted in a wire-harness fabricating station which
will be described later. If, to the contrary, not only the
aforementioned proper connectors C.sub.1 and C.sub.5 but the hybrid
connectors C.sub.1 to C.sub.4' are fitted advance in the stage of
the partial harness H.sub.A, the number of uninserted terminals in
the partial harness H.sub.A can be reduced to an extremely small
level.
[0064] In addition, if the hybrid connector C.sub.1', for example,
is a waterproof connector, waterproof rubber caps (not shown)
should preferably be applied in advance to its connection wires
1.sub.1 and 1.sub.2 in the stage of the partial harness H.sub.A
before connection to the terminals 4.
[0065] It should be noted that wires which are stripped at one ends
or both ends and whose terminals are unconnected may also be
retained at the wire clamping bar 101 of the partial harness
H.sub.A in preparation for the crimping or jointing of terminals of
special sizes.
[0066] The other partial harnesses H.sub.B and H.sub.C are arranged
in the same way as the partial harness H.sub.A.
[0067] Since the partial harnesses H.sub.A, H.sub.B, and H.sub.C
shown in FIGS. 2A to 2C and FIGS. 3A to 3C can be fabricated by
using a conventional apparatus such as a case fitting station 103
shown in FIG. 13 and in accordance with a conventional method as
described above, a detailed description of the manufacture of the
partial harness itself will be omitted.
[0068] FIG. 4 is an explanatory diagram of a wire-harness
fabricating station 10 illustrating an embodiment of a wire-harness
manufacturing apparatus in accordance with the present invention,
as well as a partial-harness placing rack 8 and an empty-bar
placing rack 9.
[0069] The station 10 is provided with a stand 11 for supporting
and fixing the wire clamping bar 101 on this side, a connector
setting table 12 in the middle, and a supporting frame 13 on the
rear side. Arranged on the connector setting table 12 are a
connector receiving jig 20 for the hybrid connectors C.sub.1' to
C.sub.4' and connector receiving jigs 30 for the proper connectors
C.sub.1 to C.sub.5.
[0070] In addition, a connector transferring device 40 and a
mounting head 108 of the aforementioned automatic terminal
inserting device 107 (see FIGS. 13 and 14) are mounted on the
supporting frame 13 in such a manner as to be movable in parallel
to the frame 13. It should be noted that the pair of terminal
gripping claws 109, the pair of wire gripping claws 110, and the
pair of wire clamp plates 111 are openably provided on this
mounting head 108 in such a manner as to be capable of being raised
or lowered between the stand 11 and the connector setting table 12
and capable of moving close to or away from the same.
[0071] Next, referring to FIGS. 4 and 5, a description will be
given of a method of manufacturing one wire harness WH from a
plurality of partial harnesses H.
[0072] First, as shown in the flowchart in FIG. 5, in Step S1, the
partial harnesses H.sub.A, H.sub.B, and H.sub.C fabricated in a
known method as described above are consecutively transported, and
are placed and stocked on the partial-harness placing rack 8
located in front of the wire-harness fabricating station 10 in
accordance with the processing order (Step S2).
[0073] Next, in Step S3, the initial partial harness H.sub.A among
the stocked partial harnesses H is transferred to the stand 11 of
the station 10 by an unillustrated transfer hand.
[0074] At the same time as this transfer or prior to the transfer,
the hybrid connectors C.sub.1' to C.sub.4' to be fitted to the wire
harness WH are set in a horizontal row in the connector receiving
jig 20 of the station 10.
[0075] In Step S4, the uninserted terminals 4 of the transferred
partial harness H.sub.A are respectively inserted and fitted into
terminal accommodating chambers 5 of predetermined hybrid
connectors C' (case fitting). The insertion and fitting is
automatically effected by the aforementioned automatic terminal
inserting device 107, and control is provided such that
entanglement with the inserted wires is reduced and the traveling
and operating time of the device 107 is minimized. Namely, the case
fitting is effected by repeating the step of inserting the
terminals 4 of the predetermined wires 1 consecutively into the
predetermined terminal accommodating chambers 5 of the
predetermined hybrid connectors C'. For instance, as shown in FIGS.
2A and 2B, in a case where the hybrid connector C.sub.1' has five
terminal accommodating chambers 5 (a to e) in two upper and lower
stages, the terminals 4c and 4d of the wires 1.sub.1 and 1.sub.2
are inserted into the c-th and d-th terminal accommodating chambers
5. Then, the a-th, b-th, and e-th terminal accommodating chambers 5
in the middle are left vacant in preparation for the terminals 4a,
4b, and 4eof the wires 2.sub.1 to 2.sub.3 of the ensuing partial
harness H.sub.B.
[0076] In Step S5, with respect to the partial harness H.sub.A for
which case fitting has been completed, since the proper connectors
C.sub.1 and C.sub.5 are held on the wire clamping bar 101 through
the group of wires 1, these proper connectors C.sub.1 and C.sub.5
are transferred to the connector receiving jigs 30 by the connector
transferring device 40. As a result, the wire clamping bar 101
becomes empty.
[0077] It should be noted that a detailed description will be given
later of the holding of the proper connectors C.sub.1 and C.sub.5
by the wire clamping bar 101, as well as the connector receiving
jigs 30 and the connector transferring device 40. In addition, as
will be easily understood, the order of the steps of case fitting
in Step S4 and the transfer of the proper connectors in Step S5 may
be reversed.
[0078] In Step S6, the wire clamping bar 101 which has been emptied
of the partial harness H.sub.A is transferred, and is stocked on
the empty-bar placing rack 9, for example.
[0079] In step S7, a determination is made as to whether or not
there is any untransferred partial harness H in the wire-harness
fabricating station 10. If YES is the answer, Steps S3 to S6 are
repeated, whereas if NO is the answer, all the process ends, and
the completed wire harness WH is obtained. In this embodiment,
following the partial harness H.sub.A, Steps S3 to S6 are
consecutively repeated with respect to the partial harnesses
H.sub.B and H.sub.C.
[0080] The flowchart shown in FIG. 6 is for the case of jointing
the wires when the partial harnesses H are processed by the
wire-harness fabricating station 10.
[0081] In this case, the step of preparing wires for jointing (Step
S5') is added between the aforementioned Steps S5 and S6, and the
step of collectively jointing the joint wires (Step S8) is added
after Step S7.
[0082] As for the preparation of the wires for jointing in Step
S5', in a case where wires which are stripped at one ends or both
ends and do not have terminals are retained in U-shapes at the wire
clamping bar 101 in the stage of each partial harness H, the
stripped portions are removed from the wire clamp 100, are placed
on a single clamp or an anvil of a welding machine (neither are
shown) set on the connector setting table 12, and are consecutively
secured temporarily thereby. In a final Step S8, these stripped
portions are collectively jointed by one of various methods. The
jointing can be effected by a known method such as crimping,
soldering, or ultrasonic welding.
[0083] Incidentally, instead of being retained at the wire clamping
bar in the stage of the partial harness H, the wires for jointing
may be carried in from another stock site and may be retained for
the first time after the processing in Step S5 for the partial
harnesses H.sub.A, H.sub.B, and H.sub.C is completed. In addition,
it is possible to effect attachment or terminal processing of
special wires, such as shielded wires, instead of the wires for
jointing or in conjunction with such wires.
[0084] In the flowcharts shown in FIGS. 5 and 6, although a
description has been given of the example in which the partial
harnesses H are temporarily stocked on the partial-harness placing
rack 8 in Step S2, the partial harnesses H may be consecutively
transported from the place of fabrication of the partial harnesses
by omitting Step S2, and may be directly transferred to the
wire-harness fabricating station 10.
[0085] FIGS. 7A and 7B show the connector receiving jig 20 for the
hybrid connectors C', in which FIG. 7A is a perspective view
thereof and FIG. 7B is a cross-sectional view of an air cylinder
23. FIG. 8 shows an exploded perspective view of the air cylinder
23.
[0086] The connector receiving jig 20 is a substantially U-shaped
frame member which is made up of a base 21, a pair of upright side
plates 22 and 22' on both sides, and coming-off prevention pieces
22a formed by being bent into L-shapes at upper ends and rear ends
of the side plates. The base 21 is formed in such a manner as to be
elongated in the horizontal direction so as to be able to
collectively support and fix the hybrid connectors C', i.e., four
hybrid connectors C.sub.1' to C.sub.4' in the illustrated example,
in a horizontal row, but may be formed in a compact size to fix
each of the individual hybrid connectors C.sub.1', C.sub.2'. . . .
Further, an attaching window (not shown) is provided on one side
plate 22 (the right-hand side plate in the drawing) of the
connector receiving jig 20, and an air cylinder unit 23 for
tightening and fixing the hybrid connectors C' is attached
thereto.
[0087] As shown in FIGS. 7B and 8, the air cylinder unit 23 is
constructed such that a piston 27 is slidably fitted in a cylinder
25, which is formed by a front cover 24 and a rear cover 24', via a
spring 26, and a piston bar 27a is caused to project and retract
through a hole 24a in the front cover 24, so as to fix the hybrid
connectors C' by causing a tip of the piston bar 27a to press the
hybrid connectors C' against the other side plate 22'. In the
drawings, reference numeral 28 denotes an air tube; 28a, a joint;
and 29, a screw 29.
[0088] Incidentally, the stroke of the piston bar 27a is sufficient
if it is 1 to 2 mm or thereabouts, and it suffices if the stroke
makes it possible to effect smooth insertion and withdrawal of the
hybrid connectors C' with respect to the connector receiving jig 20
and effect sufficient tightening, fixing, and positioning.
[0089] Thus, since the connector receiving jig 20 having a fixing
means such as the air cylinder unit 23 is provided on the connector
setting table 12, the attachment and removal of the plurality of
hybrid connectors C.sub.1' to C.sub.4' can be easily performed
automatically or manually, and the hybrid connectors C.sub.1' to
C.sub.4' can be secured positively.
[0090] FIG. 9 shows the connector transferring device 40 and the
connector receiving jig 30 for the proper connector C.
[0091] The connector receiving jig 30 has a pair of mutually
opposing U-shaped side plates 31 and 31' for inserting or removing
the proper connector C in the vertical direction. An air cylinder
unit 32 is attached to one side plate 31. Since this air cylinder
unit 32 is similar to the above-described air cylinder unit 23, a
description thereof will be omitted.
[0092] The connector transferring device 40 has a mounting base 41
which is mounted perpendicular to the supporting frame 13 in the
wire-harness fabricating station 10 and in such a manner as to be
horizontally movable with respect to the frame 13.
[0093] A horizontally moving plate 43, which advances or retracts
in parallel to the base 41 by means of a cylinder 42, is slidably
mounted on the mounting base 41, and a raising/lowering plate 45,
which reciprocates vertically by means of a cylinder 44, is mounted
on the horizontally moving plate 43. Attached to the
raising/lowering plate 45 are a clamp head 47 having a pair of
openable wire clamp plates 46 as well as a hand head 49 having a
pair of openable connector hands 48. In the drawing, reference
numerals 41a and 43a denote guide rails, respectively.
[0094] Next, referring to FIGS. 10A to 10D, a description will be
given of the transfer of the proper connector C to the connector
receiving jig 30 in the aforementioned Step S5.
[0095] First, by moving the mounting base 41 in parallel to the
supporting frame 13, as shown in FIG. 10A, the connector
transferring device 40 is stopped immediately above the wire clamp
100 where the proper connector C.sub.1 and its group of wires 1 are
retained vertically at the wire clamping bar 101 for the partial
harness H.sub.A, and the wire clamp plates 46 and the connector
hands 48 are lowered in open states by means of the cylinder
44.
[0096] Next, as shown in FIG. 10C, through the aforementioned
parallel movement of the mounting base 41 and the driving of the
cylinder 42, the proper connector C.sub.1 gripped by the connector
hands 48 is moved to immediately above the connector receiving jig
30.
[0097] Finally, as shown in FIG. 10D, the connector hands 48 are
lowered by the driving of the cylinder 44, the proper connector
C.sub.1 is inserted between the pair of side plates 31 and 31' of
the connector receiving jig 30, and the proper connector C.sub.1 is
fixed by the air cylinder unit 32. As a result, the transfer of the
proper connector C.sub.1 from the wire clamping bar 101 to the
wire-harness fabricating station 10 is completed.
[0098] It should be noted that if it is unnecessary to insert a
terminal into the proper connector, there is no need for fixing and
positioning the connector inside the connector receiving jig 30 by
means of the air cylinder unit 32, and it suffices if the connector
does not fall off the connector receiving jig 30.
[0099] As described above, in the wire-harness fabricating station
10, if a plurality of connector receiving jigs 30 are set so that
the proper connectors C.sub.1 to C.sub.5 fitted to the partial
harnesses H can be fixed or placed in vertically oriented states,
it is possible to reduce the space for the connector setting table
12, hence, the station 10 itself, and to reduce the traveling
distance necessary for processing by the aforementioned automatic
terminal inserting device 107 and the connector transferring device
40.
[0100] FIG. 11 shows a second connector transferring device 50 used
in the stage of fabrication of each partial harness H.
[0101] In the conventional case fitting station 103 shown in FIG.
13, a plurality of connectors 105.sub.1 to 105.sub.5 are arranged
in horizontally oriented states on a setting table 106.
[0102] Accordingly, the proper connectors C (C.sub.1 to C.sub.5) of
the partial harnesses (H.sub.A, H.sub.B, and H.sub.C) in the
present invention are also held in horizontally oriented states on
the wire clamping bar 101, as shown in FIGS. 2A to 2C. However,
these proper connectors C together with the wires should be
preferably retained and held in vertically oriented states, as
described above with reference to FIGS. 10A to 10D.
[0103] Therefore, the station for manufacturing the partial
harnesses H in the present invention is equipped with the connector
transferring device 50, and it is recommended that the wires for
which casing fitting has been completed and the proper connectors C
be held in vertically oriented states in the stage of the partial
harness H.
[0104] The second connector transferring device 50 has, for
example, a mounting base 51 which is mounted perpendicular to a
supporting frame 114 in the case fitting station 103 in FIG. 13 and
in such a manner as to be horizontally movable with respect to the
frame 114.
[0105] A raising/lowering plate 53, which moves vertically by means
of a cylinder 52, is slidably mounted on the mounting base 51, and
a horizontally moving plate 54, which advances or retracts in
parallel to the raising/lowering plate 53 by means of a cylinder
52', is mounted on the raising/lowering plate 53. Further, a rotary
head 57, which rotates 90.degree.by means of a pulley 56 by the
rotation of a motor 55, is pivotally attached to a front plate
portion 54a of the horizontally moving plate 54. A clamp head 59
having a pair of openable wire clamp plates 58 is fixed to the
rotary head 57.
[0106] It should be noted that the setting table 106 should be
preferably provided with a connector receiving jig 115 for the
proper connector C and a cylinder 52", for advancing and retracting
the same.
[0107] Next, referring to FIG. 11 and FIGS. 12A to 12D, a
description will be given of the transfer of the proper connector C
in the partial harness H.
[0108] In FIGS. 11 and 12A, the proper connector C in a
horizontally oriented state is fitted to the ends of the group of
wires 1, and the connector C is held in the connector receiving jig
115. The pair of wire clamp plates 58 has an opening extending in
the horizontal direction, and is located in such a manner as to
clamp the group of wires 1 from upper and lower directions.
Further, the retention of the group of wires 1 by the wire clamp
100 has been canceled.
[0109] Next, as shown in FIG. 12B, in a state in which the upper
and lower wire clamp plates 58 are closed to grip the group of
wires 1, the connector receiving jig 115 is retracted by the
actuation of the cylinder 52" and moves away from the proper
connector C.
[0110] Next, as shown in FIG. 12C, at a position where the wire
clamp plates 58 have been sufficiently raised by the actuation of
the cylinder 52, the rotary head 57, i.e., the wire clamp plates
58, is rotated 90.degree.by the driving of the motor 55. This sets
the group of wires 1 and the proper connector C in a vertically
oriented state.
[0111] Finally, as shown in FIG. 12D, the wire clamp plates 58 are
lowered, and inserts and retains the group of wires 1 in a vertical
row into a desired wire clamp 100 (between a pair of clamp members
100a). As a result, in the stage of the partial harness H, it is
possible to obtain the partial harness H in which the proper
connector C is held in a vertical state.
[0112] As described above, by virtue of the second connector
transferring device 50, it is possible to obtain the partial
harness H in which the proper connector C is held in a vertical
state with respect to the wire clamping bar 101.
[0113] Although, with reference to FIG. 11 and FIGS. 12A to 12D, a
description has been given of the example in which the connector
receiving jig 115 is provided in such manner as to be capable of
advancing and retracting by means of the cylinder 52", an
arrangement may be provided such that, instead of the connector
receiving jig 115, the connector transferring device 50 is advanced
or retracted by the cylinder 52', and the proper connector C
together with the group of wires 1 is pulled out from the receiving
jig 115.
* * * * *