U.S. patent application number 10/772169 was filed with the patent office on 2004-08-12 for wire harness mounting method, wire harness mounting portion structure, wire harness mounting type vehicle component, wire harness mounting type vehicle component module, and method of assembling and inspecting wire harness.
Invention is credited to Asano, Minoru, Matsuda, Yutaka.
Application Number | 20040158413 10/772169 |
Document ID | / |
Family ID | 27567002 |
Filed Date | 2004-08-12 |
United States Patent
Application |
20040158413 |
Kind Code |
A1 |
Matsuda, Yutaka ; et
al. |
August 12, 2004 |
Wire harness mounting method, wire harness mounting portion
structure, wire harness mounting type vehicle component, wire
harness mounting type vehicle component module, and method of
assembling and inspecting wire harness
Abstract
Disclosed is a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component, such as an air conditioning duct,
wherein the wire harness consists of two or more sub wire harnesses
produced separately, the sub wire harnesses being arranged on the
wire harness holding portion and collectively held by the wire
harness holding portion to thereby complete the mounting of the
wire harness.
Inventors: |
Matsuda, Yutaka; (Tokyo,
JP) ; Asano, Minoru; (Tokyo, JP) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
27567002 |
Appl. No.: |
10/772169 |
Filed: |
February 4, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10772169 |
Feb 4, 2004 |
|
|
|
10005384 |
Nov 2, 2001 |
|
|
|
Current U.S.
Class: |
702/33 ; 174/72A;
702/35 |
Current CPC
Class: |
Y10T 29/49117 20150115;
B60R 16/0207 20130101; Y10T 29/49194 20150115; H02G 3/0462
20130101; Y10T 29/49169 20150115; Y10T 29/49174 20150115 |
Class at
Publication: |
702/033 ;
174/072.00A; 702/035 |
International
Class: |
G01B 003/00; G01B
005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 2, 2000 |
JP |
2000-336486 |
Apr 9, 2001 |
JP |
2001-110345 |
Jun 13, 2001 |
JP |
2001-178215 |
May 2, 2001 |
JP |
2001-134885 |
Jun 6, 2001 |
JP |
2001-171729 |
Aug 6, 2001 |
JP |
2001-237899 |
Aug 22, 2001 |
JP |
2001-250926 |
Claims
What is claimed is:
1. A wire harness inspecting method, wherein after a wire harness
has been assembled by a wire harness assembly method for assembling
a wire harness by selectively combining a plurality of sub
harnesses in accordance with vehicle specifications, wherein every
sub harness is provided with a specific connector to be fitted into
an electrical connection box prepared for the purpose, and wherein,
when assembling a wire harness by combining the plurality of sub
harnesses, the specific connector of each sub harness is fitted
into a predetermined portion of the electrical connection box, it
is checked whether the combination of sub harnesses is in
conformity with the vehicle specifications or not according to the
presence/absence of a specific connector fitted into the electrical
connection box.
2. The wire harness inspecting method according to claim 1, wherein
identifying means, such as marks or bar-codes, for identifying the
sub harnesses are provided on the surfaces of the specific
connectors of the sub harnesses, inspecting being conducted by
reading the identifying means of the specific connector fitted into
the electrical connection box.
3. The wire harness inspecting method according to claim 1, wherein
the presence/absence of a specific connector fitted into the
electrical connection box is checked by an optical means for
transmission, interception, reflection, etc. of light.
4. The wire harness inspecting method according to claim 1, wherein
the presence/absence of a specific connector fitted into the
electrical connection box is checked electrically.
5. The wire harness inspecting method according to claim 1, wherein
different colors are given to the specific connectors of the sub
harnesses, and inspection is executed by identifying the color of
the specific connector fitted into the electrical connection box.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 10/005,384 filed Nov. 2, 2001 and is incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a wire harness mounting
method, a wire harness mounting portion structure, a wire harness
mounting type vehicle component, a wire harness mounting type
vehicle component module, and a method of assembling and inspecting
a wire harness.
[0003] Nowadays, to achieve an improvement in production
efficiency, in quality, etc. for wire harnesses, a sub division
production system is adopted, in which a wire harness to be
produced is divided into a number of sub wire harnesses. In this
system, production is performed for each of the sub wire harnesses,
obtained through division, in a sub wire harness production
process. The sub wire harnesses produced are assembled in a harness
assembly process to finally complete a wire harness.
[0004] Recently, an automatic sub wire harness producing machine is
often used in the sub wire harness production process. In this
automatic sub wire harness producing machine, the manufacturing
steps for each circuit of each sub wire harness, including wire
cutting, insulation coating removal at wire terminals, terminal
crimping, and connector insertion, are automatically performed to
automatically manufacture each sub wire harness.
[0005] In this automatic sub wire harness producing machine, there
are usually limitations regarding the kind of connector, terminal,
and wire to be used therewith, depending upon the scale of the
equipment. Thus, the number of circuits of a single sub wire
harness that can be produced by the automatic producing machine is
restricted.
[0006] Further, when the sub wire harness is large, the operational
efficiency of the harness assembly process, in which sub wire
harnesses are assembled to complete one wire harness, deteriorates.
In view of this, it is regarded, at present, as desirable for the
number of circuits in each sub wire harness to be approximately
twenty to thirty at the maximum.
[0007] Usually, in the harness assembly process for assembling each
sub wire harness, a harness assembly wiring table is used. On this
harness assembly wiring table, wiring jigs for performing wiring on
a sub wire harness, such as a connector temporary fixing jig and a
branching portion temporary fixing jig, and exterior component
mounting jigs for mounting, after wiring and assembly of each sub
wire harness, exterior components, such as a wire tying tape, a
wire harness fastening clip, and a wire protecting tube, are
arranged in accordance with the size and configuration of the wire
harness to be completed. After performing wiring on each sub wire
harness in conformity with the above-mentioned wiring jigs and
assembling the sub wire harness, the exterior components are
mounted in conformity with the exterior component mounting jigs,
whereby a single wire harness is finally completed.
[0008] When circuits of different sub wire harnesses are to be
connected by using a press contact connector, the press contact
connector is retained on the harness assembly wiring table, and
when or after the sub wire harnesses are combined together, the
wires of the circuits in the sub wire harnesses to be connected are
respectively set on the press contact connector, and press contact
connection is effected by a press contact fitting machine provided
on the harness assembly wiring table side.
[0009] When circuits of different sub wire harnesses are to be
connected by welding, the sub wire harnesses are combined together,
and then the crimp terminals of the circuits of the sub wire
harnesses to be connected and wire conductor terminal portions not
inserted into a connector are put together, and the conductor
terminals are collectively connected by welding by means of a
welder provided on the harness assembly wiring table side.
[0010] The wire harness thus completed is usually mounted to a
vehicle or to a vehicle-mounted component in an automotive assembly
line.
[0011] Recently, however, a so-called module production system is
under consideration, according to which instrument panel components
are previously assembled in an instrument panel assembly line,
which is separate from the vehicle assembly line, and instrument
panel modules completed are collectively mounted to a vehicle in
the vehicle assembly line. The instrument panel components include
control units such as an air conditioning unit and an audio unit,
an indicating device such as a meter, an operating panel such as a
center cluster panel, various switches and sensors, structures such
as are in forcing bar and an instrument panel main body, and a wire
harness.
[0012] As is also being considered, when the above-mentioned module
production system is adopted, the wire harness production process
is executed, for example, beside the instrument panel assembly sub
line, and the wire harness produced is supplied directly to the
instrument panel assembly sub line and mounted to an instrument
panel module, thereby reducing wire harness distribution,
inventories, etc. and achieving an improvement in the efficiency in
vehicle production.
[0013] As a result of the diversification in customer needs, as
many as several hundreds kinds of wire harnesses are required
depending on the presence/absence of various types of equipment and
combinations of variations.
[0014] To reduce the number of kinds of wire harnesses, a single
wire harness product number is assigned to a plurality of
relatively similar vehicle specifications. Despite this measure,
however, the wire harness product number can be as large as
approximately one hundred.
SUMMARY OF THE INVENTION
[0015] The present invention provides a wire harness mounting
method for mounting a wire harness to a wire harness holding
portion provided on a vehicle-mounted component or a vehicle main
body, wherein the wire harness consists of two or more sub wire
harnesses produced separately, the sub wire harnesses being
arranged on the wire harness holding portion and collectively held
by the wire harness holding portion to thereby complete the
mounting of the wire harness.
[0016] The present invention provides a wire harness mounting
method according to claim 1, wherein the two or more sub harnesses
include a common base sub harness consisting of a collection of
circuits common to a plurality of vehicle types or a plurality of
specifications of a single vehicle type and option sub harnesses
each consisting of a collection of at least one circuit for a
specific vehicle type or certain specifications, the sub harnesses
being appropriately combined in accordance with the vehicle type or
specifications and arranged on the wire harness holding
portion.
[0017] The present invention provides a wire harness mounting
method according to claim 1, wherein the arrangement of the two or
more sub wire harnesses on the wire harness holding portion is
conducted in parallel with the assembly of the vehicle in
accordance with information on vehicle specifications of the
vehicle assembly line.
[0018] The present invention provides a wire harness mounting
method for mounting a wire harness to a wire harness holding
portion provided on a vehicle-mounted component, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, and wherein the vehicle-mounted component is arranged
on a wiring table,for assembling the sub wire harnesses into a wire
harness, the two or more sub harnesses being arranged on the wire
harness holding portion of the vehicle-mounted component and on the
wiring table, the two or more sub harnesses arranged being
collectively held by the wire harness holding portion to thereby
complete the mounting of the wire harness to the vehicle-mounted
component.
[0019] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0020] wherein the wire harness holding portion has a cutout for
effecting the positioning of a branch line portion of a sub wire
harness, and wherein a guide portion extending in the branch line
portion lead-out direction is provided at the edge of the
cutout.
[0021] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0022] wherein the wire harness holding portion has two or more
cutouts for effecting the positioning of branch line portions of
the sub wire harnesses, wherein different colors are given to the
edges of the cutouts, and wherein tapes of different colors
respectively corresponding to those of the cutout edges are
attached to the branch line portions of the sub wire harnesses.
[0023] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0024] wherein the wire harness holding portion has two or more
cutouts for effecting the positioning of branch line portions of
the sub wire harnesses, wherein different colors are given to the
edges of the cutouts, and wherein different colors respectively
corresponding to those of the cutout edges are given to connectors
mounted to the forward ends of the branch line portions of the sub
wire harnesses.
[0025] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0026] wherein connector temporary fixing jigs for temporarily
fixing connectors mounted to the forward ends of branch line
portions of the sub wire harnesses and/or branching-off portion
temporary fixing jigs for temporarily fixing branching-off portions
of the branch line portions of the sub wire harnesses are provided
on the vehicle-mounted component or an assembly table thereof or on
the vehicle main body or an assembly table thereof.
[0027] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0028] wherein exterior component temporary fixing jigs for
temporarily fixing exterior components of the wire harness are
provided on the vehicle-mounted component or an assembly table
thereof or on the vehicle main body or an assembly table
thereof.
[0029] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0030] wherein an exterior component mounting instruction table
providing instructions on the mounting of exterior components on
the wire harness is provided on the vehicle-mounted component or an
assembly table thereof or on the vehicle main body or an assembly
table thereof.
[0031] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0032] wherein a press contact connector for connecting wires of
the wire harness is held on the wire harness holding portion, on
the vehicle-mounted component or an assembly table thereof, or on
the vehicle main body or an assembly table thereof.
[0033] The present invention provides a harness mounting portion
structure for a wire harness mounting method for mounting a wire
harness to a wire harness holding portion provided on a
vehicle-mounted component or a vehicle main body, wherein the wire
harness consists of two or more sub wire harnesses produced
separately, the sub wire harnesses being arranged on the wire
harness holding portion and collectively held by the wire harness
holding portion to thereby complete the mounting of the wire
harness,
[0034] wherein a welding machine for connecting wires of the wire
harness by welding is provided on a vehicle-mounted component
assembly table or in the vicinity thereof, or on a vehicle main
body assembly table or in the vicinity thereof.
[0035] The present invention provides a wire harness mounting
vehicle component module, wherein a wire harness holding portion to
which a wire harness trunk portion is to be mounted is provided on
at least one of the vehicle components constituting the module, and
wherein temporary locking means which temporarily lock, of
connectors mounted to the forward ends of branch lines of the wire
harness, those connectors having no associated connection elements
at the stage where the module is assembled, are provided on the
outer surface of other vehicle components constituting the module
or the vehicle component to which the wire harness holding portion
is mounted, the positions of the temporary locking means being
determined such that, when such connectors are temporarily
connected, a prescribed branch line length is ensured.
[0036] The present invention provides a wire harness mounting
method for mounting a wire harness to a wire harness holding
portion provided on a vehicle-mounted component, wherein the wire
harness is produced by separately preparing a common base sub
harness consisting of a collection of circuits for use common to a
plurality of vehicle types or a plurality of specifications of a
single vehicle type and at least two option sub harnesses each
consisting of a collection of circuits for a specific vehicle type
or certain specifications, and wherein, when appropriately
combining these sub harnesses in accordance with the vehicle type
or specifications and mounting them to the wire harness holding
portion, the option sub harnesses are first mounted and the common
base sub harness is finally mounted.
[0037] The present invention provides a wire harness mounting type
vehicle component, wherein a trunk line holding portion for holding
a trunk line of a wire harness is formed integrally with a vehicle
component, wherein a branching-off guide is integrally formed at a
position where a branch line branches off from the wire harness
trunk line held by the trunk line holding portion, and wherein a
branch line protecting member on which the wire harness branch line
extends is integrally formed at the forward end of the
branching-off guide.
[0038] The present invention provides a wire harness assembly
method for assembling a wire harness by selectively combining a
plurality of sub harnesses in accordance with vehicle
specifications, wherein every sub harness is provided with a
specific connector to be fitted into an electrical connection box
prepared for the purpose, and wherein, when assembling a wire
harness by combining the plurality of sub harnesses, the specific
connector of each sub harness is fitted into a predetermined
portion of the electrical connection box.
[0039] The present invention provides a wire harness inspecting
method, wherein after a wire harness has been assembled by a wire
harness assembly method for assembling a wire harness by
selectively combining a plurality of sub harnesses in accordance
with vehicle specifications, wherein every sub harness is provided
with a specific connector to be fitted into an electrical
connection box prepared for the purpose, and wherein, when
assembling a wire harness by combining the plurality of sub
harnesses, the specific connector of each sub harness is fitted
into a predetermined portion of the electrical connection box, it
is checked whether the combination of sub harnesses is in
conformity with the vehicle specifications or not according to the
presence/absence of a specific connector fitted into the electrical
connection box.
[0040] The present invention provides a wire harness mounting type
vehicle component, wherein a wire harness holding portion for
holding a trunk line portion of a wire harness is formed on a
vehicle component, wherein a branching-off guide is integrally
formed at a position where a branch line branches off from the wire
harness trunk line held by the wire harness holding portion, and
wherein a branch line protecting member on which the wire harness
branch line extends is integrally formed at the forward end of the
branching-off guide.
[0041] The present invention provides a wire harness mounting type
vehicle component, wherein a wire harness holding portion for
protecting a trunk line portion of a wire harness is formed on a
vehicle component, and wherein a movement restraining means for
restraining the wire harness in its movement is provided on the
wire harness holding portion.
[0042] The present invention provides a wire harness mounting type
vehicle component, wherein a wire harness holding portion for
holding a trunk line of a wire harness is formed on a vehicle
component, wherein a branching-off guide is integrally formed at a
position where a branch line branches off from the wire harness
trunk line held by the trunk line holding portion, wherein a branch
line protecting member on which the wire harness branch line
extends is integrally formed at the forward end of the
branching-off guide, and wherein a movement restraining means for
restraining the wire harness in its movement is provided on the
wire harness holding portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] In the accompanying drawings:
[0044] FIG. 1 a perspective view of an air conditioning duct
provided with a wire harness holding portion used in an embodiment
of the present invention;
[0045] FIG. 2 is a perspective view of a plurality of sub wire
harnesses used in an embodiment of the present invention;
[0046] FIG. 3 is a perspective view of a wire harness assembled
using the sub wire harnesses shown in FIG. 2;
[0047] FIG. 4 is a perspective view showing how the sub wire
harness shown in FIG. 2 is attached to the wire harness holding
portion shown in FIG. 1;
[0048] FIG. 5 is a perspective view showing how the air
conditioning duct provided with the wire harness holding portion of
FIG. 1 is placed on an instrument panel module assembly stand, and
the sub wire harness of FIG. 2 is attached;
[0049] FIG. 6 is a perspective view showing a connector temporary
fixing jig installed on the instrument panel module assembly stand
of FIG. 5;
[0050] FIG. 7 is a perspective view showing another example of the
connector temporary fixing jig;
[0051] FIG. 8 is a perspective view showing an exterior component
contemporary fixing jig installed on the instrument panel module
assembly stand of FIG. 5;
[0052] FIG. 9 is a perspective view showing an exterior component
mounting indication table installed on the instrument panel module
assembly stand of FIG. 5;
[0053] FIG. 10 is a perspective view showing how the wire of a sub
wire harness is connected by a press contact connector on the
instrument panel module assembly stand of FIG. 5;
[0054] FIG. 11 is an enlarged perspective view of the press contact
connector portion of FIG. 10;
[0055] FIG. 12 is a perspective view showing an example in which
the wire harness holding portion to which the press contact
connector is mounted is reinforced by a reinforcing plate;
[0056] FIG. 13 is a perspective view showing an example in which
the wire harness holding portion to which the press contact
connector is mounted is mounted to a reinforcing bar;
[0057] FIG. 14 is a perspective view showing a state in which a
welder for connecting the wire of a sub wire harness by welding is
installed beside the instrument panel module assembly stand;
[0058] FIG. 15 is a perspective view showing a state in which
insulation processing is performed on a wire connected by welding
by means of the welder of FIG. 14;
[0059] FIG. 16 is a perspective view showing an example of how a
wire terminal portion is protected until welding;
[0060] FIG. 17 is a block diagram showing the relationship between
a vehicle assembly line and a line for mounting a sub wire harness
to a vehicle-mounted component;
[0061] FIG. 18 is a perspective view showing another example of a
wire harness holding portion provided in an air conditioning
duct;
[0062] FIG. 19 is a perspective view showing still another example
of a wire harness holding portion;
[0063] FIG. 20 is a perspective view showing still another example
of a wire harness holding portion;
[0064] FIG. 21 is a perspective view showing still another example
of a wire harness holding portion;
[0065] FIG. 22 is a perspective view showing still another example
of a wire harness holding portion;
[0066] FIG. 23 is a perspective view showing another embodiment of
a wire harness mounting method according to the present
invention;
[0067] FIG. 24 is a perspective view showing how a wire harness is
mounted to an air conditioning duct by the method shown in FIG.
23;
[0068] FIG. 25 is a perspective view showing still another
embodiment of the wire harness mounting method of the present
invention;
[0069] FIG. 26 is a perspective view showing a state in which a
wire harness mounting vehicle component module according to an
embodiment of the present invention is being assembled;
[0070] FIG. 27 is an enlarged front view of a portion surrounded by
the dashed line in FIG. 26;
[0071] FIG. 28 is a perspective view showing a wire harness
mounting method according to an embodiment of the present
invention;
[0072] FIG. 29 is a perspective view showing a state in which a
wire harness is mounted to an air conditioning duct by the method
shown in FIG. 28;
[0073] FIG. 30 is a perspective view showing another embodiment of
the wire harness mounting method of the present invention;
[0074] FIG. 31 is a sectional view showing a preferred embodiment
of a wire harness holding portion used in a wire harness mounting
method according to the present invention;
[0075] FIG. 32 is a perspective view showing a wire harness
mounting type vehicle component according to an embodiment of the
present invention;
[0076] FIG. 33 is a perspective view showing a state in which a guy
of a wire harness is protected by a guy protecting member of the
vehicle component of FIG. 32;
[0077] FIGS. 34(A) through 34(D) are perspective views showing
other examples of a guy protecting member that can be used in a
wire harness mounting type vehicle component according to the
present invention;
[0078] FIG. 35 is a perspective view showing a wire harness
mounting type vehicle component according to another embodiment of
the present invention;
[0079] FIG. 36 is a perspective view showing still another example
of a guy support member that can be used in a wire harness mounting
type vehicle component according to the present invention;
[0080] FIG. 37 is a perspective view showing a wire harness
assembly method according to an embodiment of the present
invention;
[0081] FIG. 38 is a perspective view showing the relationship
between each sub harness and an electrical connection box in the
assembly method of the present invention;
[0082] FIG. 39 is a perspective view showing a wire harness
inspecting method according to an embodiment of the present
invention;
[0083] FIG. 40 is a perspective view showing another
embodiment;
[0084] FIG. 41 is a main-portion sectional view of still another
embodiment;
[0085] FIG. 42(A) is a main-portion sectional view of still another
embodiment, and FIG. 42(B) is a circuit diagram thereof;
[0086] FIG. 43 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention;
[0087] FIG. 44(A) is an explanatory diagram showing a state in
which a sub wire harness is mounted to the wire harness holding
portion of the vehicle component of FIG. 6, and FIG. 44(B) is an
explanatory diagram showing a case in which a different form is
adopted for the bar-like protrusion;
[0088] FIG. 45 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention;
[0089] FIG. 46 is a plan view of a wire harness holding portion of
the vehicle component of FIG. 45;
[0090] FIG. 47 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention;
[0091] FIG. 48 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention;
[0092] FIGS. 49(A) and 49(B) are diagrams showing a state in which
a wire harness is accommodated in the wire harness holding portion
of the vehicle component of FIG. 48, of which FIG. 49(A) is a
sectional view showing a case in which the number of option sub
wire harnesses is small, and FIG. 49(B) is a sectional view showing
a case in which the number of option sub wire harnesses is
large;
[0093] FIG. 50 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention;
[0094] FIGS. 51(A) and 51(B) are diagrams showing a state in which
a wire harness is accommodated in the wire harness holding portion
of the vehicle component of FIG. 50, of which FIG. 51(A) is a
sectional view showing a case in which the number of option sub
wire harnesses is small, and FIG. 51(B) is a sectional view showing
a case in which the number of option sub wire harnesses is
large;
[0095] FIG. 52 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention; and
[0096] FIG. 53 is a perspective view showing a wire harness
mounting type vehicle component according to still another
embodiment of the present invention.
DETAILED DESCRIPTION
[0097] Embodiments of the present invention will now be described
with reference to the drawings while comparing them with the prior
art.
FIRST EMBODIMENT
[0098] As stated above, apart from the sub wire harness production
process in which a plurality of automatic sub wire harness
producing machines are installed according to the number of sub
wire harnesses, the conventional wire harness production process
requires a harness assembly process in which a harness assembly
wiring table, a press contact connector fitting machine, a wire
terminal conductor welding machine, etc. are installed, so that a
large space is required. Further, when line production is conducted
by installing a plurality of harness assembly wiring tables in
order to shorten the tact time in the harness assembly process, a
still larger space is required, and it is very difficult to ensure
such a large space beside, for example, the instrument panel
assembly line.
[0099] Further, the wire harness requires assembly and mounting
processes in which after wiring on the harness assembly wiring
table for assembly, the sub wire harness produced by an automatic
sub wire harness producing machine is detached from the harness
assembly wiring table and mounted again to the instrument panel or
the like. At present, these assembly and mounting operations are
manually conducted in most cases, so that the processing cost ratio
is very high, which leads to an increase in cost.
[0100] Further, the wire harness production process requires a
harness assembly wiring table, a stand for securing it in position,
etc. When line production is conducted by installing a plurality of
harness assembly wiring tables, it is necessary to provide
equipment, such as a conveyor for moving the harness assembly
wiring tables, which also leads to an increase in cost.
[0101] Apart from this, the wire harness product number is
enormous, resulting in high management cost. Further, the
specifications of the wire harness to be mounted are only known
immediately before the mounting, so that it is necessary to provide
a considerable amount of inventories for each of wire harnesses of
different specifications, making it necessary to provide a
warehouse. Further, it takes time and effort to control loading and
unloading, which also leads to an increase in cost.
[0102] In the conventional technique for reducing the wire harness
product number, one product number is assigned to the
specifications of a plurality of relatively similar vehicles, that
is, the wire harness of maximum specifications is assigned, so that
unnecessary circuits are imparted to vehicles which are of not
maximum specifications, resulting in an increase in cost and
weight.
[0103] In accordance with a first embodiment of the present
invention, there are provided a wire harness mounting method that
solves the problems mentioned above, and a wire harness mounting
portion structure suitable for executing the method.
[0104] In the first embodiment, a wire harness is mounted to an air
conditioning duct inside an instrument panel.
[0105] FIG. 1 shows an air conditioning duct 10 incorporated into
an instrument panel, and a reinforcing bar 12 combined therewith.
The air conditioning duct 10 is provided with a wire harness
holding portion 14 extending along the longitudinal direction
thereof. While in this example the wire harness holding portion 14
has a trough-like configuration, it is also possible to adopt some
other configuration as long as it allows a wire harness to be
easily mounted. The wire harness holding portion 14 may be prepared
as a separate component to be attached to the air conditioning duct
10, or it may be formed integrally with the air conditioning duct
10.
[0106] The wire harness holding portion 14 is provided with a
plurality of cutouts 16 for performing positioning of the branch
portions of the wire harness and a plurality of fastening members
18 for fastening the wire harness. Each of the fastening members 18
is of a band type. One end of each fastening member 18 is hinged on
one side edge of the wire harness holding portion 14, and the other
end thereof has a hole 22 to be engaged with an engagement
protrusion 20 formed on the other side edge of the wire harness
holding portion 14. The fastening members 18 may be formed
integrally with the wire harness holding portion 14, or prepared as
separated parts.
[0107] As shown in FIG. 2, the wire harness to be mounted to the
wire harness holding portion 14 is composed of a plurality of sub
wire harnesses 24A, 24B, and 24C prepared as separate components.
In each of the sub wire harnesses 24A, 24B, and 24C, numeral 26
indicates a trunk portion, numeral 28 indicates branch portions,
numeral 30 indicates connectors mounted to the forward ends of the
branch portions 28, and numeral 32 indicates uniting members for
uniting the branching-off portions of the branch portions 28 with
the trunk portions. These sub wire harnesses 24A through 24C can be
automatically produced by an automatic sub wire harness producing
machine. At the stage where the sub wire harnesses are produced, up
to the following operations are conducted: wire cutting, removal of
insulating coating at wire terminals, terminal crimping, and
connector insertion.
[0108] Conventionally, these sub wire harnesses 24A through 24C are
combined and tied together by a tape to complete a wire harness 34
as shown in FIG. 3, and this wire harness 34 is mounted to a
vehicle-mounted component or a vehicle, whereas, in the present
invention, the sub harnesses are mounted individually.
[0109] FIG. 4 shows how the sub wire harnesses 24A through 24C
separately produced as shown in FIG. 2 are attached to the wire
harness holding portion 14 provided in the air conditioning duct 10
of FIG. 1 (The air conditioning duct 10 and the reinforcing bar 12
are not shown). Cabling is effected such that the trunk portions 26
of the sub wire harnesses 24A through 24C extend along the wire
harness holding portion 14, and that the branch portions 28 are
passed through the cutouts 16. The cabling of the sub wire
harnesses 24A through 24C may be effected one by one or
collectively. When there are a large number of sub wire harnesses,
the cabling may be performed in groups of two to three.
[0110] When, as in the case of the example shown, there are a
plurality of cutouts 16 for positioning, it is convenient to give
different colors to the edges of the cutouts 16 and to attach tapes
of corresponding colors to the branch portions 28 of the sub wire
harnesses. This makes it possible to effect cabling such that the
branch portions 28 and the cutouts 16 are respectively in color
correspondence with each other, enabling the cabling of the branch
potions to be effected correctly. If a branch portion is arranged
in a wrong cutout, that can be easily noticed.
[0111] When giving different colors to the edges of the plurality
of cutouts 16, the same effect can be obtained by coloring the
connectors 30 at the forward ends of the branch portions in colors
in correspondence with the colors of the cutouts 16, instead
attaching colored tapes to the branch portions.
[0112] When performing the cabling of the sub wire harnesses 24A
through 24C on the wire harness holding portion 14, it is desirable
to perform the cabling in a state in which, as shown in FIG. 5, the
air conditioning duct 10 and the reinforcing bar 12 are placed on
an instrument panel module assembly stand 36. Also set in the
assembly stand 36 are other instrument panel module components,
such as an air conditioning unit 38 and a blower unit 40. Further,
in the assembly stand 36, connector temporary fixing jigs 42, jigs
44 for temporarily fixing the branching-off portions of the branch
portions, exterior component temporary fixing jigs 46, exterior
component mounting indication plates 48, etc. are arranged at
predetermined positions, each supported by a column 50.
[0113] It is also possible for the connector temporary fixing jigs
42 to be mounted to the air conditioning unit 38, etc., which are
instrument panel module components.
[0114] The cabling of the sub wire harnesses 24A through 24C is
effected, with the connectors 30 being set in the connector
temporary fixing jigs 42 in order to adapt the dimensions of the
branch portions (the length between the trunk portion 26 and the
connector 30 at the forward end of the branch portion 28) to the
requisite predetermined length when the wire harness is finally
completed, whereby the predetermined dimension of the branch
portions is ensured.
[0115] The connector temporary fixing jigs 42 should allow the
connectors 30 to be easily detached or temporarily fixed.
Preferably, they are formed, for example, by bending round metal
bars into a U-shape, as shown in FIG. 6. The connector temporary
fixing jigs 42 should be large enough not to allow the connector 30
engaged therewith to be detached if pulled from the branch portion
28 side. The jigs 44 for temporarily fixing the branching-off
portions of the branch portions may also have the same
structure.
[0116] When installing two or more connector temporary fixing jigs
close to each other, it is necessary for the connectors to be
temporarily connected at the right positions. In this regard, it is
convenient for each connector temporary fixing jig 42 to be formed
as a resin case having a recess large enough to accommodate the
associated connector 30. In that case, however, it is necessary for
the adjacent connectors to be of different configurations.
[0117] FIG. 8 shows an example of the configuration of the exterior
component temporary fixing jig 46. In this case, the exterior
component is a clip 52 for fixing a part of the wire harness to a
stationary body (e.g., an instrument panel main body). Such clip 52
has an anchor portion (indicated by the dashed line), which is
inserted into a hole of the exterior component temporary fixing jig
46 to thereby temporarily fix the clip 52; after the completion of
the cabling of the sub wire harnesses, the wire receiving portion
of the clip 52 and the branch portion 28 of the wire harness are
collectively tied by a tape, whereby it is possible to mount the
clip 52 at a predetermined position of the branch portion 28.
[0118] As shown in FIG. 9, the exterior component mounting
indication plate 48 indicates the configuration, mounting
direction, position, etc. of an exterior component 54 mounted to
the wire harness.
[0119] The exterior component 54 mounted to the wire harness
consists of a wire tying tape, wire protecting tube, protector or
the like. At the stage where the cabling of all the sub wire
harnesses 24A through 24C has been completed, with the connectors
30 being set in the connector temporary fixing jigs 42, the
operator mounts the exterior components 54 to the branch portions
28 in accordance with the indication plates 48.
[0120] The columns 50 supporting the connector temporary fixing
jigs 42, the exterior component mounting indication plates 48, etc.
can be tilted in one direction around their lower ends, and formed
in the assembly stand 36 are grooves 56 for accommodating the
columns 50 and the temporary fixing jigs 42, 44, and 46 and the
indication plates 48 supported thereby (See FIG. 5). Thus,
temporary fixing jigs, etc. not to be used can be accommodated in
the grooves 56 by tilting the columns 50.
[0121] In assembling a wire harness, it is sometimes necessary to
connect wires of different sub wire harnesses to each other. When
using a press contact connector for this connection, a press
contact connector 58 is integrally mounted to the wire harness
holding portion 14 as shown in FIGS. 10 and 11; the wires 60 to be
connected are set in the press contact connector 58, and press
contact connection is effected on the wire harness holding portion
14.
[0122] In this case, as shown in FIG. 11, the press contact
connector 58 is installed such that the openings of the press
contact teeth are directed upwards, enabling the wires 60 to be
easily arranged on the press contact teeth. As shown in FIG. 10,
above the instrument panel module assembly stand 36, there is
installed a press contact connector fitting machine 62. The press
contact fitting machine 62 is a well-known one. In the example
shown, it is composed of a press contact head 64 for forcing the
associated force-in member (not shown) into the press contact
connector 58, a cylinder 68 for lowering the same, etc.
[0123] The connection of the wires 60 by the press contact
connector 58 is effected by forcing the wires 60 into the press
contact teeth by the press contact fitting machine 62 after the
cabling of all the sub wire harnesses 24A through 24C has been
completed and after the wires 60 of the circuits to be connected of
the sub wire harnesses 24A through 24C have been arranged on the
press contact teeth of the press contact connector 58.
[0124] As shown in FIG. 12, a metal reinforcing plate 73 is
advantageously provided on the back side of the portion of the wire
harness holding portion 14 where the press contact connector 58 is
fixed so that it can withstand the external force applied when
effecting press contact fitting. The reinforcing plate 73 is
fastened, for example, to the reinforcing bar 12. As shown in FIG.
13, it is also possible for the portion of the wire harness holding
portion 14 where the press contact connector 58 is fixed to be
positioned on the reinforcing bar 12.
[0125] When welding connection is adopted in connecting wires to
each other between different sub wire harnesses, a welding machine
74 is installed, for example, beside the instrument panel module
assembly stand 36, as shown in FIG. 14, and the wire terminals to
be connected are collectively welded by this welding machine 74. It
is also possible for the welding machine 74 to be installed on the
assembly stand 36.
[0126] After the cabling of all the sub wire harnesses 24A through
24C has been completed as shown in FIG. 14, the terminal portions
of the wires to be connected of the sub wire harnesses 24A through
24C are put together and placed in the welding machine 74 to
collectively effect welding connection. The insulating coating is
removed from the terminal portions of the wires to be connected by
welding to expose the conductors. The wires to be connected by
welding are preferably arranged in the sub wire harnesses such that
their terminal portions are concentrated in predetermined terminal
portions of predetermined branch portions of the sub wire
harnesses.
[0127] As shown in FIG. 15, after the welding, an insulating cap 76
is fitted onto the welding connection portions of the wires 60, and
fixing is effected by an insulating tape 78 to thereby effect
insulating processing.
[0128] At the stage where the sub wire harnesses are produced, the
insulating coating is removed from the terminal portions of the
wires to be connected by welding, the conductors at the terminal
ends being exposed until welding connection is effected. As shown
in FIG. 16, to protect the exposed conductors, a protecting member
80 is mounted to the end portion of each wire 60 at the stage where
the insulating coating is removed in producing the sub wire
harnesses. When performing welding connection, this protecting
member 80 is removed.
[0129] As is apparent from the above description, in this
embodiment, the cabling of all the sub wire harnesses 24A through
24C is effected on the wire harness holding portion 14 while
temporarily fixing the connectors 30 of the sub wire harnesses 24A
through 24C to the connector temporary fixing jigs 42, and fixing
is effected by the fastening members 18. Then, the exterior
components 54 are mounted to the branch portions 28 of the wire
harnesses in accordance with the exterior component mounting
indication plates 48. At the same time, the exterior components 52
are mounted to the branch portions 28 on the exterior component
temporary fixing jigs 46. Further, as needed, press contact
connection of the wires 60 by the press contact connector 58 and
collective welding connection of the wires 60 by the welding
machine 74 are effected. Finally, the connectors 30 are detached
from the connector temporary fixing jigs 42, and the exterior
components 52 are detached from the exterior component temporary
fixing jigs 46, whereby the mounting of the wire harness is
completed on the wire harness holding portion 14 provided on the
air conditioning duct 10. Thus, it is possible to omit the
conventional wire harness assembly process.
[0130] As shown in FIG. 17, it is desirable for the cabling of the
sub wire harnesses on the wire harness holding portion, which is a
vehicle-mounted component, to be performed in parallel with the
assembly of the vehicle in accordance with information on the
vehicle specifications of the vehicle to be produced in the vehicle
assembly line. This is due to the following circumstances.
Generally speaking, the production of automobiles is conducted
according to various grades and variations. Such variations include
those in coating colors and interior colors. Regarding
specifications in electrical wiring, it is necessary to take into
account engine type, transmission (manual or automatic), and the
presence/absence of various kinds of electrical equipment, such as
a power window. Such specifications are supplied to the vehicle
assembly line when producing a vehicle in accordance with vehicle
order information. Even in the case of an ordinary vehicle, there
are several thousands of variations in specifications, and there
are several tens of kinds of wire harnesses for a portion. To
produce vehicles of such varying specifications in a single line,
an instruction sheet indicating the specifications is attached, for
example, to the body of each vehicle in the assembly line at the
start of production, and the operator mounts the requisite
equipment in accordance with this instruction sheet. Thus, to
assemble a wire harness in conformity with the specifications for a
vehicle, information on the specifications of the next vehicle to
be produced is obtained before the requisite time for the mounting
of sub wire harnesses has elapsed, and sub wire harnesses are
mounted to the vehicle-mounted components in accordance with the
specifications.
[0131] While in the above-described embodiment the wire harness
holding portion 14 provided on the air conditioning duct 10 assumes
the form as shown in FIG. 1, it is possible for the wire harness
holding portion 14 to assume some other form. For example, as shown
in FIG. 18, a number of wire harness holding portions 14 may be
arranged in the longitudinal direction of the air conditioning duct
10. These wire harness holding portions 14 are provided at least at
the branching-off portions where the branch portions branch off
from the trunk portion of the wire harness, and between
branching-off portions as needed. In FIG. 18, the components which
are the same as those of FIG. 1 are indicated by the same reference
numerals (This also applies to the following drawings).
[0132] Further, as shown in FIG. 19, the wire harness holding
portion 14 preferably has a guide portion 82 extending in the
branch portion lead-out direction at the edge of the cutout 16 for
the positioning of a wire harness branch portion. The provision of
this guide portion 82 helps to stabilize the branching portion
lead-out direction. By fastening the branching portion to the guide
portion 82 by means of tape winding or the like, the branching
portion lead-out direction is further stabilized.
[0133] Further, as shown in FIG. 20, the engagement portions of the
fastening members 18 to be engaged with engagement protrusions 20
provided on one side of the wire harness holding portion 14 may be
holes 22 or hook-like protrusions 84. In particular, when a
plurality of holes 22 or hook-like protrusions 84 are formed in the
end portion of a fastening member 18, it is possible to vary the
position where it is engaged with the associated engagement
protrusion 20 according to the thickness of the wire harness
mounted to the wire harness holding portion 14, making it possible
to appropriately adjust the fastening condition.
[0134] Further, as shown in FIG. 21, the fastening members 18 may
be formed so as to partly cover the branching-off portions of the
wire harness arranged on the wire harness holding portion 14.
Further, as shown in FIG. 22, the fastening member 18 may be formed
so as to entirely cover the wire harness arranged on the wire
harness holding portion 14.
[0135] While in the above-described embodiment the wire harness
holding portion is provided on an air conditioning duct, it is also
possible to provide the wire harness holding portion on the
reinforcing bar or the instrument panel main body, arranging the
sub wire harnesses on the reinforcing bar side or the instrument
panel main body side.
[0136] FIG. 23 shows another embodiment of the present invention.
In this embodiment also, the wire harness is mounted to the air
conditioning duct 10, which is a vehicle-mounted component (The
reinforcing bar is not shown). As in the above-described
embodiment, the air conditioning duct 10 is provided with the wire
harness holding portion 14, which is provided with the cutouts 16
for the positioning of the wire harness branching portions, and the
fastening members 18 for fixing the wire harness.
[0137] The wire harness mounted to the wire harness holding portion
14 is produced in separate parts: one single common base sub
harness 24P and four option sub harnesses 24Q through 24T. In the
sub harnesses 24P through 24T, numeral 26 indicates trunk portions,
numeral 28 indicates branch portions, and numeral 30 indicates
connectors (Tying members are not shown).
[0138] The common base sub harness 24P consists of a collection of
circuits to be commonly used for a plurality of specifications for
a plurality of vehicle types or a single vehicle type. For example,
it includes an engine control circuit, an illuminating system
circuit, a meter indication common portion circuit, and a circuit
for safety equipment, such as an air bag. Further, while it depends
on the degree of commonness, in the case where an air conditioner,
etc. are standard equipment, the air conditioner circuit is also
included in the common base sub harness.
[0139] The option sub harnesses 24Q through 24T are collections of
circuits for specific vehicle types or certain specifications. The
option sub harnesses 24Q through 24T include the following
circuits.
[0140] The first option sub harness 24Q is a circuit for, for
example, an automatic transmission vehicle. This sub harness 24Q
has a connector for connection to an engine computer and a
connector for connection to a meter. The common base sub harness
24P also has a connector for connection to the engine computer and
a connector for connection to the meter. Thus, it is necessary to
respectively connect the connectors for connection to the engine
computer of the common base sub harness 24P and the first option
sub harness 24Q to the engine computer, and to respectively connect
the connectors for connection to the meter of the two sub harness
to the meter, resulting in an increase in the number of connectors.
If, in this case, connectors of the two sub harnesses connected to
the same element are inserted into one connector holder, or
connectors of the two sub harnesses connected to the same element
are integrated with each other, it is possible to perform the
connection to the engine computer or the meter through one
connector as in the prior art.
[0141] The second option sub harness 24R is used for a remote
control mirror circuit.
[0142] The third option sub harness 24S is used for a power window
circuit.
[0143] The fourth option sub harness 24T is used for a front fog
lamp circuit.
[0144] Although not shown, apart from the above, there exist an
option sub harness for a rear fog lamp circuit, an option sub
harness for a head lamp leveling circuit, etc. In the case of this
embodiment, the specifications required of the wire harness are as
follows: an automatic transmission vehicle equipped with a remote
control mirror, a power window, and a front fog lamp. Thus, apart
from the common base sub harness 24P, four option sub harnesses 24Q
through 24T are selected and mounted.
[0145] These option sub harnesses 24Q through 24T are connected to
the requisite circuit of the common base sub harness 24P by putting
at least one connector in a joint box or a joint connector or by
means of a welding joint or the like, and are connected to the
requisite power source, ground, and signal.
[0146] When the cabling of the common base sub harness 24P and the
option sub harnesses 24Q through 24T on the wire harness holding
portion 14 of the air conditioning duct 10 has been completed,
one-unit wire harness 86 is completed, as shown in FIG. 24.
Thereafter, by fastening the wire harness 86 to the wire harness
holding portion 14 by means of the fastening members 18, a
composite component 88 in which the air conditioning duct 10 and
the wire harness 86 are integrated with each other is
completed.
[0147] When the assembly of this composite component 88 is
conducted, with the air conditioning duct 10 (vehicle-mounted
component) being arranged on a wire harness assembly wiring table
90, as shown in FIG. 25, the assembly can be executed efficiently.
FIG. 25 shows a state in which, after arranging the air
conditioning duct 10 at a predetermined position on the wiring
table 90, the common base sub harness 24P is first arranged in the
wiring path of the wiring table 90 including the wire harness
holding portion 14 of the air conditioning duct 10. The connectors
30 at the ends of the common base sub harness 24P are held by
connector receiving jigs 92 mounted at predetermined positions of
the wiring table 90. The connector receiving jigs 92 also serve as
continuity inspection jigs.
[0148] After arranging the common base sub harness 24P as shown in
FIG. 25, the option sub harnesses 24Q through 24T shown in FIG. 23
are successively arranged in a similar manner. When the wiring of
all the sub harnesses 24P through 24T has been completed, the wire
harness trunk portion on the wire harness holding portion 14 is
wrapped in a soft sheet, and is fixed as it is by the fastening
members 18. Those branch portions of the common base sub harness
24P and the option sub harnesses 24Q through 24T which extend
through the same path are put together and undergo sheathing
processing such as tape winding or corrugate tube attachment.
[0149] In this embodiment, all the connectors 30 are held by the
connector receiving jigs 92 also serving as continuity inspection
jigs,so that the length of the branch portions 28 can be set
correctly. Further, by performing continuity inspection after the
wiring of all the sub harnesses 24P through 24T, it is possible to
complete the inspection of the wire harness. When the wire harness
thus mounted to the air conditioning duct 10 is detached from the
wiring table 90 along with the air conditioning duct 10, a
composite component in which the wire harness and the air
conditioning duct are integrated with each other is completed.
[0150] It is desirable for the wiring of the sub wire harnesses on
the wire harness holding portion, which is a vehicle-mounted
component, and on the wiring table to be conducted in parallel with
the assembly of the vehicle in accordance with obtained information
on the specifications of the vehicle in the vehicle assembly line.
The reason for this is the same as that in the above-described
embodiment.
[0151] As described above, in accordance with the first embodiment
of the present invention, instead of assembling the sub wire
harnesses produced in the sub wire harness production process into
a wire harness on the harness assembly wiring table, the sub wire
harnesses are directly arranged on the vehicle-mounted component or
the wire harness holding portion provided on the vehicle body to be
assembled into a wire harness, so that it is possible to
substantially reduce the requisite space for wire harness
assembly.
[0152] In the prior art technique, the sub wire harnesses produced
by the automatic sub wire harness producing machine are
respectively arranged on the harness assembly wiring table and
assembled. Then, the wire harness is detached from the harness
assembly wiring table and mounted again to a vehicle-mounted
component or the like. In the present invention, a substantial
reduction is achieved in terms of assembly and mounting processes,
so that it is possible to reduce the cost for processing the wire
harness, thereby achieving a reduction in cost.
[0153] Further, there is no need for the harness assembly wiring
table, the stand for securing it in position, the conveyor for
moving the harness assembly wiring table, etc., which have been
necessary in the conventional harness assembly process, so that it
is possible to substantially reduce the equipment cost.
[0154] Further, two or more sub harnesses are classified into a
common base sub harness common to a plurality of vehicle types or a
plurality of specifications of a single vehicle type and option sub
harnesses to be used for specific vehicle types or certain
specifications, and the common base sub harness and the option sub
harnesses are appropriately combined for mounting in accordance
with the vehicle type or specifications, whereby it is possible to
substantially reduce the product number of the wire harness, and
the minimum requisite circuits for the vehicle specifications are
combined, so that it is possible to incorporate an optimum circuit
into a vehicle without paying any particular attention to the
product number, thereby effectively achieving a reduction in cost
and weight.
[0155] Further, the vehicle-mounted component is arranged on the
wire harness assembly wiring table, and the wiring on the wiring
table is effected while mounting the sub harnesses to the
vehicle-mounted component, whereby it is possible to complete the
mounting to the vehicle-mounted component simultaneously with the
wiring of the sub harnesses, and the wiring of the sub harnesses
can be effected substantially in a plane, thereby enabling the
operation to be conducted efficiently. Further, since the branch
portions can be secured in a state in which they are stretched in a
plane, the requisite dimensional accuracy for the branch portions
can be easily ensured, and continuity inspection can be
advantageously conducted using the existing equipment.
SECOND EMBODIMENT
[0156] When mounting the wire harness directly to the wire harness
holding portion of the vehicle component, of the connectors mounted
to the forward ends of the branch lines of the wire harness, those
connectors to be connected to a vehicle component constituting a
module may be directly connected to the vehicle component, whereby
it is also possible to ensure the prescribed branch line length.
However, among the connectors mounted to the forward ends of the
branch lines of the wire harness, there exist connectors to be
connected to the associated elements after the module assembled has
been mounted on the vehicle. At the module assembly stage, there
are no associated elements to which these connectors are to be
connected, so that these connectors are left dangling, making it
difficult to ensure the prescribed branch line length (When the
connectors are not secured in position, the branch lines can be
drawn by the trunk line to be reduced in length).
[0157] To eliminate this problem, it might be possible to provide
connector temporary fixing jigs on the module assembly stand, and
to temporarily fix thereto the connectors with no associated
elements to thereby ensure the prescribed branch line length. This
method, however, makes it necessary to three-dimensionally arrange
the connector temporary fixing jigs on the module assembly stand,
resulting in a very complicated jig design. Moreover, the connector
temporary fixing jigs jumbled up on the module assembly stand would
hinder the module assembly operation. Further, when, after the
module assembly, the connectors are detached from the temporary
fixing jigs, the connectors will again be left dangling, so that
some measure must be taken for this, with the result that a lot of
time and labor is required.
[0158] In accordance with the second embodiment of the present
invention, there is provided a vehicle component module with a wire
harness mounted thereto in which the above-mentioned problems have
been eliminated.
[0159] FIG. 26 shows an embodiment of the present invention. FIG.
26 shows a state in which the air conditioning duct 10 and the
reinforcing bar 12 as shown in FIG. 1 are placed on a module
assembly stand 36, and vehicle components, such as an air
conditioning unit 38, a blower unit 40, and an electrical
connection box 39, are mounted thereto, and further, a plurality of
sub wire harnesses 24A through 24C are mounted to assemble a
vehicle component module with a wire harness mounted thereto.
[0160] The sub wire harnesses 24A through 24C consist of a common
base sub harness having a collection of circuits to be commonly
used in a plurality of vehicle types or a plurality of
specifications of a single vehicle type and option sub harnesses
having a collection of at least one circuit to be used in a
specific vehicle type or certain specifications, these sub
harnesses being appropriately combined with each other to
constitute one wire harness set according to the vehicle type or
specifications. When the sub wire harnesses are thus directly
mounted, it is possible to omit the harness assembly process.
Further, it is possible to incorporate a wire harness in conformity
with the vehicle product number into the module, whereby the wire
harness product number is eliminated. Further, it is possible to
eliminate the so-called "mounted-for-nothing" circuits which have
been added in order to reduce the wire harness product number.
[0161] The trunk portions of the sub wire harnesses 24A through 24C
are mounted to the wire harness holding portion 14 of the air
conditioning duct 10. Of the connectors mounted to the forward ends
of the sub wire harnesses 24A through 24C, the connectors which are
connected to vehicle components at the module assembly stage, that
is, the connectors 30K (which are shown only partially) to be
connected to the air conditioning unit 38, the blower unit 40, and
the electrical connection box 39, are connected at this stage to
the associated connectors. By connecting the connectors 30K to the
associated connectors, the prescribed lengths of the branch lines
28K having the connectors 30K are ensured.
[0162] Among the connectors of the sub wire harnesses 24A through
24C, there exist connectors 30N which have no associated elements
to which they are to be connected at the module assembly stage
(connectors to be connected to the associated elements after the
module has been mounted to the vehicle). Temporary locking means
140 for temporarily locking such connectors 30N are formed on the
outer surfaces of the air conditioning unit 38 and the blower unit
40. In this embodiment, each of these temporary locking means 140
is in the form of a pair of protrusions, between which the
connector 30N is fitted in to thereby temporarily lock the
connector 30N.
[0163] Further, on the outer surface of the air conditioning unit
38, there are formed branch line holding means 142 for
detour-wiring the branch line 28N when the branch line 28N of the
connector 30N is long. FIG. 27 is an enlarged front view of the
portion of FIG. 26 surrounded by the dashed line. These branch line
temporary holding means 142 are so positioned that when the
connector 30N is temporarily locked to the temporary locking means
140, the branch line 28N exhibits the prescribed length. In this
embodiment, the branch line temporary holding means 142 are in the
form of protrusions where the branch line 28 is bent.
[0164] On the outer surface of the blower unit 40, there are formed
branch line temporary holding means 144 for restricting the wiring
path of the branch line 28N. These branch line holding means 144
are in the form of guide walls for guiding the branch line 28N in
the wiring direction.
[0165] The temporary locking means 140 and the branch line
temporary holding means 144 can be formed integrally with the cases
of the air conditioning unit 38 and the blow unit 40, which are
formed by injection molding.
[0166] In order that the temporary locking operation may be
executed efficiently and correctly, it is desirable to provide on
the outer surfaces of the air conditioning unit 38 and the blower
unit 40 marks 146 (16P, 6P, etc.) indicating the temporary locking
positions for the connectors 30N. Further, in order that the
cabling operation may be executed efficiently and correctly, it is
also desirable to provide on the outer surfaces of the air
conditioning unit 38 and the blower unit 40 marks (not shown)
indicating the cabling path for the branch line 28N.
[0167] As described above, in accordance with the second embodiment
of the present invention, when assembling a vehicle component
module with a wire harness mounted thereto, it is possible to
temporarily lock the connectors with no associated elements at the
module assembly stage to the vehicle component without using any
special jig. Further, it is possible to maintain the prescribed
length for the branch line corresponding to the connector. This
makes it possible to assemble a vehicle component module with a
wire harness mounted thereto easily and efficiently.
[0168] When the branch line corresponding to the connector with no
associated element is long, a branch line temporary holding means
for detour-wiring the branch line is provided on the outer surface
of the vehicle component, whereby cabling is possible with the
prescribed length of the branch line secured on the outer surface
of the vehicle component. Further, by providing marks indicating
the temporary locking positions for the connectors with no
associated elements and marks indicating the cabling path for the
branch lines corresponding to such connectors, it is possible to
perform the temporary locking operation and cabling operation more
efficiently and correctly.
THIRD EMBODIMENT
[0169] As shown in FIG. 28, the wire harness mounted to the wire
harness holding portion 14 is produced in separate parts: one
common base sub harness 24P and a plurality of (four in the example
shown) option sub harnesses 24Q through 24T. In the sub harnesses
24P through 24T, numeral 26 indicates trunk portions, numeral 28
indicates branch portions, and numeral 30 indicates connectors
(Tying members are not shown).
[0170] The common base sub harness 24P consists of a collection of
circuits to be commonly used for a plurality of specifications for
a plurality of vehicle types or a single vehicle type. For example,
it includes an engine control circuit, an illuminating system
circuit, a meter indication common portion circuit, and a circuit
for safety equipment, such as an air bag. Further, while it depends
on the degree of commonness, in the case where an air conditioner,
etc. are standard equipment, the air conditioner circuit is also
included in the common base sub harness.
[0171] The option sub harnesses 24Q through 24T are collections of
circuits for specific vehicle types or certain specifications. The
option sub harnesses 24Q through 24T include the following
circuits.
[0172] The first option sub harness 24Q is a circuit for, for
example, an automatic transmission vehicle. This sub harness 24Q
has a connector for connection to an engine computer and a
connector for connection to a meter. The common base sub harness
24P also has a connector for connection to the engine computer and
a connector for connection to the meter. Thus, it is necessary to
respectively connect the connectors for connection to the engine
computer of the common base sub harness 24P and the first option
sub harness 24Q to the engine computer, and to respectively connect
the connectors for connection to the meter of the two sub harness
to the meter, resulting in an increase in the number of connectors.
If, in this case, connectors of the two sub harnesses connected to
the same element are inserted into one connector holder, or
connectors of the two sub harnesses connected to the same element
are integrated with each other, it is possible to perform the
connection to the engine computer or the meter through one
connector as in the prior art.
[0173] The second option sub harness 24R is used for a remote
control mirror circuit.
[0174] The third option sub harness 24S is used for a power window
circuit.
[0175] The fourth option sub harness 24T is used for a front fog
lamp circuit.
[0176] Although not shown, apart from the above, there exist an
option sub harness for a rear fog lamp circuit, an option sub
harness for a head lamp leveling circuit, etc. In the case of this
embodiment, the specifications required of the wire harness are as
follows: an automatic transmission vehicle equipped with a remote
control mirror, a power window, and a front fog lamp. Thus, apart
from the common base sub harness 24P, four option sub harnesses 24Q
through 24T are selected and mounted.
[0177] These option sub harnesses 24Q through 24T are connected to
the requisite circuit of the common base sub harness 24P by putting
at least one connector in a joint box or a joint connector or by
means of a welding joint or the like, and are connected to the
requisite power source, ground, and signal.
[0178] When mounting the common base sub harness 24P and the option
sub harnesses 24Q through 24T to the wire harness holding portion
14 of the air conditioning duct 10, the option sub harnesses 24Q
through 24T are first successively mounted (There is no restriction
regarding the order in which the option sub harnesses are mounted),
and the common base sub harness is finally mounted. Due to this
arrangement, the relatively thin option sub harnesses 24Q through
24T are arranged at the bottom of the wire harness holding portion
14, and the relatively thick common base sub harness 24P is placed
thereon to press down the option sub harnesses 24Q through 24T, so
that there is no danger of the thin option sub harnesses 24Q
through 24T being allowed to stick out of the wire harness holding
portion 14, making it possible to mount all the sub harnesses 24P
through 24T in position.
[0179] When the mounting of all the sub harnesses 24P through 24T
is thus completed, one wire harness unit 86 is completed on the
wire harness holding portion 14, as shown in FIG. 29. Thereafter,
the wire harness 86 is fixed to the wire harness holding portion 14
by the fastening members 18, where by a composite component
(module) 88 is completed, in which the air conditioning duct 10 and
the wire harness 86 are integrated with each other.
[0180] As shown in FIG. 30, the assembly of this composite
component 88 can be efficiently conducted, with the air
conditioning duct 10 (vehicle-mounted component) being arranged on
a wire harness assembly wiring table 90. FIG. 30 shows a state in
which, after arranging the air conditioning duct at a predetermined
position on the wiring table 90, the common base sub harness 24P is
arranged in the wiring path of the wiring table 90 including the
wire harness holding portion 14 of the air conditioning duct 10.
Actually, as stated above, the common base sub harness 24P is
finally arranged after the completion of the wiring of the option
sub harnesses 24Q through 24T. Numeral 92 indicates connector
temporary fixing jigs for holding the connectors 30 at the ends of
the sub harnesses at predetermined positions on the wiring table
90. The connector temporary fixing jigs 92 also serve as continuity
inspection jigs.
[0181] As shown in FIG. 30, the option sub harnesses 24Q through
24T shown in FIG. 29 are successively arranged on the wiring table
90 where the air conditioning duct 10 is arranged, and then the
common base sub harness 24P is finally arranged. When the wiring of
all the sub harnesses 24P through 24T has been completed, the trunk
portion of the wire harness on the wire harness holding portion 14
is wrapped in a soft sheet, and fixed as it is by the fastening
members 18. Those branch portions of the common base sub harness
24P and the option sub harnesses 24Q through 24T which extend
through the same path are put together and undergo sheathing
processing such as tape winding or corrugate tube attachment.
[0182] When the wiring of the sub harnesses 24P through 24T is thus
conducted on the wiring table 90, all the connectors 30 are held by
the connector temporary fixing jigs 92 also serving as continuity
inspection jigs, so that it is possible to set the lengths of the
branch portions 28 accurately. Further, by performing continuity
inspection after the wiring of all the sub harnesses 24P through
24T, it is also possible to complete inspection on the wire
harness. The wire harness thus mounted to the air conditioning duct
10 is detached from the wiring table 90 along with the air
conditioning duct 10, whereby a composite component (module) can be
obtained, in which the wire harness and the air conditioning duct
are integrated with each other.
[0183] FIG. 31 shows a preferred embodiment of the wire harness
holding portion provided on a vehicle-mounted component. This wire
harness holding portion 14 has a substantially V-shaped sectional
configuration whose bottom portion is rounded, and a soft sheet 94,
such as a foam plastic sheet, is attached to the inner surface
thereof.
[0184] Using this wire harness holding portion 14 having a
substantially V-shaped sectional configuration, the option sub
harnesses 24Q through 24T are first mounted, and the common base
sub harness 24P is finally mounted. In this case, the thin option
sub harnesses 24Q through 24T are easily gathered at the bottom of
the wire harness holding portion 14, and the thick common base sub
harness 24P is placed thereon to press them down, so that it is
possible to prevent dislocation of the option sub harnesses 24Q
through 24T and to prevent wire sticking out and noise generation.
Further, by attaching the soft sheet 94 to the inner surface, it is
possible to prevent damage to the wire and effectively prevent
noise generation.
[0185] As described above, in accordance with the third embodiment,
the sub wire harnesses produced in the sub wire harness production
process are directly mounted to the wire harness holding portion
provided on the vehicle-mounted component to assemble the wire
harness. Thus, as compared with the prior art technique, in which
the sub wire harnesses produced by the automatic sub wire harness
producing machine are arranged on the harness assembly wiring table
and assembled, and then the wire harness is detached from the
harness assembly wiring table and mounted again to a
vehicle-mounted component or the like, a substantial reduction is
achieved in terms of assembly and mounting processes, so that it is
possible to reduce the cost for processing the wire harness,
thereby achieving a reduction in cost.
[0186] Further, the sub harnesses are classified into a common base
sub harness common to a plurality of vehicle types or a plurality
of specifications of a single vehicle type and option sub harnesses
to be used for specific vehicle types or certain specifications,
and the common base sub harness and the option sub harnesses are
appropriately combined for mounting in accordance with the vehicle
type or specifications, whereby it is possible to substantially
reduce the product number of the wire harness, and the minimum
requisite circuits for the vehicle specifications are combined, so
that it is possible to incorporate an optimum circuit into a
vehicle without paying any particular attention to the product
number, thereby effectively achieving a reduction in cost and
weight.
[0187] Further, when mounting the sub harnesses to the wire harness
holding portion, the option sub harnesses are first mounted, and
the common base sub harness is finally mounted, so that the thin
option sub harnesses are pressed down by the thick common base sub
harness, which enables the entire sub harnesses to be secured in
position, and helps to prevent the option sub harnesses from being
dislocated to stick out of the wire harness holding portion or
cause noise generation.
[0188] Further, by adopting a wire harness holding portion having a
substantially V-shaped sectional configuration, the option sub
harnesses are easily gathered at the bottom of the wire harness
holding portion, thereby further enabling the sub harnesses to be
set in position.
[0189] When, instead of using the wiring table, the wire harness is
directly mounted to the vehicle-mounted component, it is possible
to omit the conventional wire harness assembly process, making it
possible to substantially reduce the requisite space for wire
harness assembly.
FOURTH EMBODIMENT
[0190] In the wire harness mounting type vehicle component of the
above-described embodiments, the trunk portion of the wire harness
is held, whereas no consideration is given to the protection of the
branch lines. Thus, after the mounting of the wire harness, it is
necessary to perform sheathing processing for protecting the branch
lines, which takes time and labor. In particular, in the production
system in which the mounting of the wire harness is executed
simultaneously with the assembly of the vehicle component, if the
processing of the wire harness takes time, the requisite balance in
cycle time for the entire system cannot be ensured, resulting in a
deterioration in productivity.
[0191] In accordance with the fourth embodiment of the present
invention, there is provided a wire harness mounting type vehicle
component in which the above problem has been eliminated.
[0192] FIG. 32 shows an embodiment of the present invention. In
this wire harness mounting type vehicle component, the air
conditioning duct 10 is formed integrally with a trunk line holding
portion 14 for holding the trunk line of a wire harness. At the
positions of the trunk line holding portion 14 where the branch
lines branch off from the trunk line, branching-off guides 232 are
integrally formed, and at the forward end of each branching-off
guide 232, there is integrally formed, through the intermediation
of a connecting member 234, a branch line protecting member 236
along which a branch line of the wire harness extends.
[0193] The trunk line holding portion 14 is a trough-like member
extending parallel to the air conditioning duct 10. The
branching-off guides 232 are in the form of short trough-like
members protruding from the trunk line holding portion 14. Each
branch line protecting member 236 is in the form of a thin and
narrow plate having on its back side a longitudinal groove 238
(dashed line) formed at the center with respect to the width
direction, the branch line protecting member being bendable along
this groove 238. When protecting a branch line of the wire harness
by this branch line protecting member 236, the branch line
protecting member 236 is bent into a V-shape along the groove 238,
as shown in FIG. 33. The branch line 228 of the wire harness is
held in this V-shaped groove and secured in position by winding an
adhesive tape 240 around the outer periphery of the whole. Numeral
230 indicates a connector mounted to the forward end of the branch
line 228. The direction of the branch line protecting member 236
can be adapted to the lead-out direction of the branch line 228 by
bending at the connecting member 234.
[0194] The wire harness mounting type vehicle component as shown in
FIG. 32 can be produced by blow molding. In blow molding,
semi-molten resin, such as polyethylene or polypropylene, in the
form of a cylinder is put in a mold, and high-pressure air is
introduced into the cylinder to thereby effect molding. The portion
other than the hollow air conditioning duct 10 is formed by
crushing a resin cylinder into a twofold structure.
[0195] The branch line protecting member 236 is not restricted to
the form as shown in FIG. 32. FIGS. 34A through 34D show examples
of other possible forms. The branch line protecting member 236
shown in FIG. 34A has on its back side an integrally formed clip
242. By locking this clip 242 to some other member, it is possible
to control the lead-out direction of the branch line of the wire
harness. The branch line protecting member 236 shown in FIG. 34B is
composed of two semi-cylindrical members 244 hinged to each other.
By mating the two semi-cylindrical members 244 with each other into
a cylinder, the entire periphery of the wire harness branch line is
covered. The branch line protecting member 236 shown in FIG. 34C
has a substantially U-shaped sectional configuration, which
facilitates the accommodation of the wire harness branch line and
helps to achieve an improvement in terms of the efficiency in the
tape winding operation. The branch line protecting member 236 shown
in FIG. 34D has in the middle portion thereof a curved portion in
conformity with the cabling path of the wire harness branch line.
On either side of the curved portion, there is provided a side wall
246 to thereby achieving an improvement in terms of the efficiency
in the operation of shaping the wire harness branch line.
[0196] FIG. 35 shows another embodiment of the present invention.
In this embodiment, the wire harness mounting type vehicle
component is produced by injection molding. Unlike blow molding,
injection molding does not allow molding into a closed form. Thus,
the air conditioning duct 10 is divided into two longitudinal
members 10a and 10b. One member 10a is formed integrally with the
trunk line holding portion 14, branching-off guides 232, connecting
members 234, and branch line protecting members 236, whereas the
other member 10b is formed as a unitary member. The two members 10a
and 10b are then joined to each other by oscillation welding or the
like to form the air conditioning duct 10.
[0197] In this embodiment, the branch line protecting member 236,
which is in the form of a plate, has a V-shaped cutout 248 at one
side edge of the middle portion with respect to the length
direction. This allows the branch line protecting member 236 to be
bent in the width direction or the thickness direction in
conformity with the cabling path of the branch line of the wire
harness.
[0198] As shown in FIG. 36, it is also possible to form a V-shaped
cutout 248 at either side edge of the middle portion of the branch
line protecting member 236 so as to allow it to be bent at the
middle portion with respect to the length direction.
[0199] While in the above-described embodiments the vehicle
component is an air conditioning duct, this should not be construed
restrictively. The present invention is also applicable to vehicle
components other than the air conditioning duct.
[0200] As described above, in the wire harness mounting type
vehicle component of the fourth embodiment of the present
invention, the wire harness branch line protecting members are
formed integrally with the wire harness trunk line holding portion,
which is formed integrally with the vehicle component. Thus, in the
process for mounting the wire harness to the vehicle component, the
sheathing operation for protecting the branch lines of the wire
harness can be conducted easily and in a short time. When adopting
the production system in which the mounting of the wire harness is
conducted simultaneously with the assembly of the vehicle
component, this not only helps to achieve an improvement in
productivity but also makes it easier to keep cycle time in balance
for the entire system, whereby the design of the production line is
facilitated.
FIFTH EMBODIMENT
[0201] When combining a plurality of sub harnesses to produce a
wire harness in accordance with the vehicle specifications, it is
necessary to check whether the wire harness produced consists of a
combination of sub harnesses in conformity with the vehicle
specifications. When the sub harnesses are produced automatically,
the requisite quality can be guaranteed by executing a sampling
inspection on continuity. Also in the case in which the sub
harnesses are produced manually, the requisite quality can be
guaranteed by performing continuity inspection at the stage where
the sub harnesses have been completed. It is disadvantageous from
the viewpoint of efficiency to conduct continuity inspection again
on the wire harness obtained by joining the sub harnesses to each
other.
[0202] Conventionally, however, no effective method has been
available for checking whether a combination type wire harness
obtained consists of a combination of sub harnesses in conformity
with the vehicle specifications.
[0203] In view of this, in accordance with the fifth embodiment of
the present invention, there are provided a wire harness assembly
method and a wire harness inspecting method in which, when
assembling a single wire harness by selectively combining a
plurality of sub harnesses in accordance with the vehicle
specifications, it is possible to easily check whether the wire
harness assembled consists of a combination of sub harnesses in
conformity with the vehicle specifications.
[0204] In FIG. 37, numeral 60 indicates an electrical connection
box, which is fastened to the left-hand side of the reinforcing bar
12 by means of a bracket. As shown in FIG. 38, in the electrical
connection box 360, there are aligned fitting portions 362P through
362T into which the specific connectors 31aand 31 of the sub
harnesses 24P through 24T are aligned to be fitted.
[0205] First, the wiring of the common sub harness 24P is effected,
and the specific connectors 31a through 31c thereof (See FIG. 28)
are fitted into the electrical connection box 360. The common sub
harness 24P mounted is common to all vehicle specifications, so
that it is not always necessary for this sub harness to be
inspected like the option sub harnesses. However, if one of the
specific connectors 31a through 31c, for example, the specific
connector 31a (FIGS. 37 and 38 do not show the connectors 31b and
31c), is aligned with the specific connectors 31 of the option sub
harnesses on the electrical connection box 360 and fitted into it,
it is possible to check whether the common sub harness has been
incorporated simultaneously with the inspection on the combination
of option sub harnesses.
[0206] Next, the wiring of the first option sub harness 24Q is
effected, and the specific connector 31 thereof is fitted into the
predetermined fitting portion 362Q of the electrical connection box
360. In the example shown in FIG. 37, the specifications of the
wire harness to be produced is such that the first option such
harness 24Q (for automatic vehicle) and the third option sub
harness 24S (for power window) are incorporated, the other option
sub harnesses not being incorporated. Thus, when the wiring of the
third option sub harness 24S is finally effected, and the specific
connector 31 thereof is fitted into the predetermined fitting
portion 362S of the electrical connection box 360, the mounting of
the sub harnesses is completed.
[0207] After this, the trunk portion of the wire harness is wrapped
in a soft sheet material, and fixed to the wire harness holding
portion 14 by means of the fastening members 18. Further, the
portions of the branch portions 28 of the common sub harness 24P
and those of the branch portions 28 of the sub harnesses 24Q and
24S which extend through the same paths are respectively put
together, and sheathing processing, such as tape winding and
corrugate tube attachment, is executed thereon. In this way, a wire
harness in conformity with vehicle specifications is assembled.
[0208] Next, a method for inspecting a wire harness assembled will
be described. FIG. 39 shows an embodiment of the inspecting method
of the present invention. In this embodiment, bar-codes 364 for
identifying the sub harnesses 24P through 24T are imparted to the
specific connectors 31a and 31 of the sub harnesses 24P through
24T, and the bar-codes 364 of the specific connectors 31a and 31
fitted into the electrical connection box 360 are read by a
bar-code reader 366, whereby the presence/absence of the specific
connectors is detected, and a judgment is made as to whether the
sub harness combination is in conformity with the vehicle
specifications. It is also possible to link the reading result of
the bar-code reader with information on the vehicle specifications
to make the above judgment.
[0209] FIG. 40 shows another embodiment of the wire harness
inspecting method of the present invention. In this embodiment, the
inspection is performed by an optical means. A light emitter 368
and a light receiver 370 are installed so as to be opposed to each
other, with the specific connectors 31a and 31 fitted into the
electrical connection box 360 being therebetween. The light from
the light emitter 368 is intercepted where the specific connectors
31a and 31 are fitted, and the light can only be received by the
light receiver 370 where no specific connectors are fitted, whereby
the presence/absence of specific connectors is detected, and a
judgment is made as to whether the sub harness combination is in
conformity with the vehicle specifications. It is also possible to
detect the presence/absence of specific connectors from reflection
of light by the specific connectors. This is advantageous in that
the light emitting portion and the light receiving portion can be
installed on one side of the specific connectors.
[0210] FIG. 41 shows still another embodiment of the wire harness
inspecting method of the present invention. In this embodiment, a
protrusion 372 is formed on the specific connector 31 of each sub
harness 24, and a limit switch 374 is installed in the vicinity of
each fitting portion 362 of the electrical connection box 360. When
the specific connector 31 is fitted into the fitting portion 362,
the protrusion 372 operates the limit switch 374, whereby it is
detected whether the specific connector 31 has been fitted into the
fitting portion 362, thereby checking whether the sub harness
combination is in conformity with the vehicle specifications. While
FIG. 41 only shows one sub harness 24 and one fitting portion 362,
the same above construction applies to other sub harnesses and
fitting portions as well.
[0211] In the above-described embodiments the specific connectors
of the sub harnesses are aligned on an electrical connection box,
whereby the inspection device is simplified, and the inspection
time is shortened.
[0212] FIGS. 42A and 42B show still another embodiment of the wire
harness inspecting method of the present invention. In this
embodiment, the inspection is conducted electrically. A short
circuit 376 for a pair of terminals is provided in the specific
connector 31 of each sub harness 24, and, in each fitting portion
362 of the electrical connection box 360, there are provided a pair
of terminals 378, 380 adapted to be short-circuited by fitting in
the specific connector 31. An inspection device 382 detects whether
the terminals 378 and 380 have been short-circuited to detect the
presence/absence of the specific connector 31, thereby checking
whether the sub harness combination is in conformity with the
vehicle specifications or not. While FIG. 42A only shows one sub
harness 24 and one fitting portion 362, the same above construction
applies to other sub harnesses and fitting portions as well. In the
case of this inspecting method, there is no need for the sub
harnesses to be aligned on the electrical connection box.
[0213] In another embodiment, different colors are given to the
specific connectors of the sub harnesses, and inspection is
effected by identifying the color of the connector fitted into the
electrical connection box.
[0214] While in the above-described embodiments there is only one
electrical connection box, a plurality of electrical connection
boxes may be installed. In this case, the requisite power circuits
for the sub harnesses are all provided from one electrical
connection box, and the specific connector of each sub harness is
always fitted into one electrical connection box, which leads to
simplification of the inspection device. However, also in the case
where there are a plurality of electrical connection boxes, an
inspection similar to that of the above-described embodiments may
be conducted in the plurality of electrical connection boxes to
collect information obtained by the plurality of electrical
connection boxes, whereby it is possible to check whether
predetermined sub harnesses have been incorporated or not.
[0215] As described above, in accordance with the fifth embodiment
of the present invention, when assembling a wire harness by
selectively combining a plurality of sub harnesses in accordance
with the vehicle specifications, specific connectors to be fitted
into an electrical connection box are provided respectively for all
the sub harnesses, and, when assembling the wire harness, the
specific connector of each sub harness is fitted into a
predetermined portion of the electrical connection box. Thus, by
detecting the presence/absence of a specific connector at the
electrical connection box, it can be easily checked whether the sub
harness combination is in conformity with the vehicle
specifications or not, whereby the inspection of the wire harness
assembled can be conducted reliably and in a short time.
[0216] Further, by aligning on the electrical connection box
fitting portions into which the specific connectors of the sub
harnesses are to be fitted, the inspection device is simplified,
and the presence/absence of all the specific connectors can be
checked simultaneously, thereby making it possible to shorten the
inspection time.
[0217] Further, there is a secondary effect that the mounting of
the base/option sub harness can be performed easily, as the end of
the sub harness is fitted and fixed to the electrical connection
box.
SIXTH EMBODIMENT
[0218] Sub wire harnesses are classified into a common base sub
harness common to a plurality of vehicle types or a plurality of
specifications of a single vehicle type and consisting of a
collection of a relatively large number of common circuits, and an
option sub wire harness used for a specific vehicle type or certain
specifications and having a relatively small number of (at least
one) circuits. These sub wire harnesses are appropriately combined
in accordance with the vehicle type and specifications and mounted
to a wire harness holding portion of a vehicle component.
[0219] However, the conventional wire harness mounting type vehicle
component under study involves the following problems. When
mounting the sub wire harnesses to the wire harness holding
portion, the option sub wire harnesses, having a relatively small
number of circuits, are not tied in a satisfactory manner, so that
the wires are allowed to move freely with respect to the wire
harness holding portion, which makes it difficult to correctly set
the branch line branching-off positions. Thus, it is difficult to
ensure the requisite dimensional accuracy for the branch lines.
Further, after the mounting, the sub wire harnesses can freely move
in the wire harness holding portion, which leads to generation of
noise due to vibration, etc. when the vehicle is running. Further,
in the case of a minimum equipment specification, it is only a
common base sub wire harness that is incorporated into a vehicle;
in the case of a full equipment specification, there are
incorporated, in addition to the common base sub wire harness, all
the option sub wire harnesses. Thus, the thickness of the wire
harness greatly varies depending on the specifications. On the
other hand, the size of the wire harness holding portion provided
on an air conditioning duct, reinforcing bar or the like remains
mostly the same. Thus, in the case of a vehicle with a relatively
small number of equipment items, the void in the wire harness
holding portion is rather large, with the result that the
above-mentioned problem is conspicuous.
[0220] In accordance with the sixth embodiment of the present
invention, there is provided a wire harness mounting type vehicle
component in which the protection of the branch lines of the wire
harness can be easily effected.
[0221] Further, in accordance with the sixth embodiment of the
present invention, there is provided a wire harness mounting type
vehicle in which the requisite dimensional accuracy for the branch
lines of the wire harness can be easily ensured and in which there
is no fear of noise generation due to vibration or the like.
[0222] FIG. 43 shows the sixth embodiment of the present invention.
In this wire harness mounting type vehicle component, the wire
harness holding portion 14 is formed integrally with the air
conditioning duct 10 (which is of two parts, as shown in FIG. 4,
the cover member not being shown), and a large number of bar-like
protrusions 452 protrude from the bottom of the wire harness
holding portion 14. The bar-like protrusions 452 are integrally
formed of the same resin (polypropylene, polyethylene or the like)
as the wire harness holding portion 14. Numeral 12 indicates a
reinforcing bar extending along the air conditioning duct 10.
[0223] Due to the formation of the bar-like protrusions 452, when
mounting to the wire harness holding portion 14 an option sub wire
harness of a relatively small circuit scale, the bar-like
protrusions 452 get into (i.e. pierce through) the gaps between the
wires in the sub wire harness 24, as shown in FIG. 44A, whereby the
sub wire harness 24 is prevented from moving freely. Thus, there is
no fear that the branch line branching-off positions will be
displaced at the time of mounting or that noise will be generated
due to vehicle vibration after the mounting.
[0224] Further, also when a plurality of option sub wires are
successively mounted, the operational efficiency is quite
satisfactory. Note that, FIG. 44A only shows the bottom plate
portion, with the side walls of the wire harness holding portion 14
being omitted.
[0225] It is desirable that injection molding be adopted when
forming the bar-like protrusions 452 on the bottom plate portion of
the wire harness holding portion 14. However, by providing the mold
with recesses corresponding to the bar-like protrusions, it is also
possible to adopt blow molding.
[0226] FIG. 44B shows an example in which the forward ends of the
bar-like protrusions 452 have a hook-like configuration. This helps
to prevent the wires of the sub wire harness 24 mounted to the wire
harness holding portion 14 from being dislocated to stick out of
the wire harness holding portion 14, thereby achieving an
improvement in terms of operational efficiency in mounting.
[0227] FIGS. 45 and 46 show still another embodiment of the present
invention. In this wire harness mounting type vehicle component,
the wire harness holding portion 14 is formed integrally with the
air conditioning duct 10, and plate-like protrusions 456a and 456b
whose forward ends are to be pressed against the wire harness
protrude alternately from the inner surfaces of the side walls 454a
and 454b of the wire harness holding portion 14, as shown in FIG.
46. The protrusions 456a and 456b are formed such that their lower
sides are spaced apart from the bottom plate portion of the wire
harness holding portion 14. This embodiment is suitable for the
case in which the option sub wire harnesses are first mounted to
the wire harness holding portion 14, and in which the common base
sub wire harness is finally mounted.
[0228] The common base sub wire harness consists of a collection of
circuits provided common to various vehicle equipment
specifications, so that, as compared with the option sub wire
harness, it is of a relatively large circuit scale and has a
considerably large outer diameter. The width W as defined by the
forward ends of the plate-like protrusions 456a and 456b protruding
from the side walls 454a and 454b is set so as to be somewhat
smaller than the outer diameter of the common base sub wire
harness. The upper forward end portions of the protrusions 456a and
456b are formed as inclined surfaces (i.e., beveled), whereby, when
mounting the sub wire harness from above, it is easy to put the sub
wire harness between the protrusions 456a and 456b.
[0229] The width W defined by the forward ends of the protrusions
456a and 456b is sufficiently larger than the outer diameter of the
option sub wire harnesses. Thus, the mounting of the option sub
wire harnesses can be effected easily. After the sub wire harnesses
have been accommodated in the wire harness holding portion 14, the
protrusions 456a and 456b prevent the wires of the option sub wire
harnesses from being dislocated to get out of the wire harness
holding portion 14.
[0230] After all the requisite option sub wire harnesses have been
mounted to the wire harness holding portion 14, the common base sub
wire harness is finally mounted. Since the upper forward end
portions of the protrusions 456a and 456b are formed as inclined
surfaces, the common base sub wire harness can be pushed in with a
small force. However, since the width W defined by the forward ends
of the protrusions is somewhat smaller than the outer diameter of
the common base sub wire harness, the common base sub wire harness
is accommodated in the wire harness holding portion 14, with its
trunk line portion meandering to some degree. As a result, the
common base sub wire harness is fixed to the wire harness holding
portion 14 due to the friction between it and the protrusions 456a
and 456b. As for the option sub wire harnesses previously mounted,
they are pressed down by the common base sub wire harness. Thus,
the sub wire harnesses are restrained in their movement in the wire
harness holding portion 14.
[0231] In FIGS. 45 and 46, numeral 232 indicates a branching-off
guide formed at a position where a branch line branches off from
the trunk line of the wire harness. It is desirable for a branch
line protecting member 236 (See FIG. 32) to be integrally formed at
the forward end of the branching-off guide 232. This also applies
to the following embodiments.
[0232] FIG. 47 shows still another embodiment of the present
invention. In this wire harness mounting type vehicle component,
the wire harness holding portion 14 is formed integrally with the
air conditioning duct 10, and formed on the inner sides of the side
walls 54a and 54b of the wire harness holding portion 14 are
elastic arm members 458 for pressing down the wire harnesses in the
wire harness holding portion 14. When a sub wire harness is mounted
to the wire harness holding portion 14, the elastic arm members 458
undergo elastic deformation to enable the sub wire harness to be
pushed in. After the sub wire harness has been accommodated in the
wire harness holding portion 14, the elastic arm members prevent
the wires from being dislocated to stick out of it. After all the
sub wire harnesses have been mounted, the elastic arm members press
down the wire harnesses from above, preventing the sub wire
harnesses from moving inside the wire harness holding portion 14.
Providing the elastic arm members 458 at the position corresponding
to the branching-off guide 232 and on either side thereof is
particularly effective in preventing the wires from sticking out,
moving, etc.
[0233] FIG. 48 shows still another embodiment of the present
invention. In this wire harness mounting type vehicle component,
the wire harness holding portion 14 is formed integrally with the
air conditioning duct 10, the reinforcing bar 12 extends along the
same, and there is provided a cover 460 to be placed on the air
conditioning duct 10 and the wire harness holding portion 14, the
cover 460 having a large number of elastic protrusions 462 on the
wire harness holding portion 14 side inner surface. While in this
example the cover 460 is hinged to the edge of the wire harness
holding portion 14 so as to allow opening and closing, it may also
be a component separate from the air conditioning duct 10 and the
wire harness holding portion 14.
[0234] The elastic protrusions 462 are freely deformed in
accordance with the void in the wire harness holding portion 14 so
as to press down the common base sub wire harness 24A and the
option sub wire harnesses 24B in the wire harness holding portion
14. When the number of option sub wire harnesses 24B in the wire
harness holding portion 14 is small, the elastic protrusions 462
are substantially straight as shown in FIG. 49A when they press
down the wire harnesses 24A and 24B when the cover 460 is closed,
whereas, when the number of option sub wire harnesses 24B is large,
the elastic protrusions 462 are bent as shown in FIG. 49B when they
press down the wire harnesses 24A and 24B. Thus, it is possible to
restrain the wire harnesses in their movement inside the wire
harness holding portion 14.
[0235] By combining the construction of FIG. 48 with the
construction shown in FIG. 43, in which bar-like protrusions 452
are provided, it is possible to achieve a further improvement in
terms of operational efficiency in mounting and noise prevention
after mounting in the vehicle.
[0236] FIG. 50 shows still another embodiment of the present
invention. In this wire harness mounting type vehicle component,
the wire harness holding portion 14 is formed integrally with the
air conditioning duct 10, the reinforcing bar 12 extends along the
same, and there is provided a cover 460 to be placed on the air
conditioning duct 10 and the wire harness holding portion 14, the
cover 460 having on the wire harness holding portion 14 side an
elastic presser 464 for pressing down the wire harnesses inside the
wire harness holding portion 14. While in this example the cover
460 is formed as a component separate from the air conditioning
duct 10 and the wire harness holding portion 14, it may also be
hinged to the edge of the wire harness holding portion 14 as in the
case of FIG. 48.
[0237] When the number of option sub wire harnesses 24B in the wire
harness holding portion 14 is small, the elastic presser 464 is
slightly raised by the wire harnesses 24A and 24B as shown in FIG.
51A when it presses down the wire harnesses 24A and 24B, whereas,
when the number of the option sub wire harnesses 24B is large, the
presser 464 is raised high by the wire harnesses 24A and 24B as
shown in FIG. 51B and firmly presses down the wire harnesses 24A
and 24B. Thus, it is possible to restrain the wire harnesses in
their movement inside the wire harness holding portion 14.
[0238] FIG. 52 shows still another example of the present
invention. This wire harness mounting type vehicle component is
made of a material obtained by attaching a resin sheet 468 to a
metal plate 466 consisting of aluminum, iron or the like. The
composite sheet material thus obtained is bent so as to integrally
form the air conditioning duct 10 and the wire harness holding
portion 14, with the inner surface of at least the wire harness
holding portion 14 being covered with the resin sheet 468. A strap
470 for fixing the wire harnesses is formed integrally with the
resin sheet 468. Numeral 472 indicates a lock portion, into which
the forward end portion of the strap 470 is inserted so as not to
allow pulling out. It is desirable for the strap 470 to be formed
integrally with the resin sheet 468 before it is attached to the
metal plate 466. In this embodiment, the metal plate 466 formed by
bending serves as the reinforcing member. The wire harnesses
mounted to the wire harness holding portion 14 are secured in
position by the strap 470 and restrained in their movement inside
the wire harness holding portion 14.
[0239] FIG. 53 shows still another embodiment of the present
invention. In this wire harness mounting type vehicle component,
the air conditioning duct 10 and the wire harness holding portion
14 are integrally formed of resin, and the strap 470 for fixing
wire harnesses is formed integrally with the wire harness holding
portion 14. Numeral 472 indicates a lock portion, into which the
forward end portion of the strap 470 is inserted so as not to allow
pulling out. In this construction also, the wire harnesses mounted
to the wire harness holding portion 14 can be secured in position
by the strap 470 and restrained in their movement.
[0240] In the wire harness mounting type vehicle component of the
sixth embodiment, a movement restraining means for restraining the
wire harnesses in their movement is provided in the wire harness
holding portion provided on a vehicle component, so that it is
possible to restrain the movement of the wire harnesses held by the
wire harness holding portion, whereby the requisite dimensional
accuracy for the branch lines can be easily ensured, and noise
generation due to vibration when the vehicle is running can be
prevented.
* * * * *