Flexible electronic wire harness preparation process

Abstract

The invention discloses a flexible electronic wire harness preparation process, relates to the technical field of flexible electronic wire harness structures, and aims to solve the problem that an existing flexible electronic wire harness cannot be designed and prepared according to own needs due to the fact that the flexible electronic wire harness is prepared by splicing different finished product materials. According to the technical scheme, the method is characterized by comprising the steps of designing, raw material purchasing, wire harness preparation, blanking, crimping and testing, the flexible wire harness can be well prepared, the wire harness can be well prepared and formed through the steps of wire harness preparation and the like, and the quality of the flexible wire harness is better; through the extruding device, the stranding machine and other devices, the preparation effect of the wire harness can be improved, the wire harness has better performance, and meanwhile the performance of the prepared flexible wire harness is detected. And the effect of preparing the electronic wire harnesses with different requirements according to different requirements is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of flexible electronic wire harness structures, and in particular to a process for preparing a flexible electronic wire harness. Background Art

[0002] Flexible electronic wiring harness refers to a combination of wires and connectors used to connect and transmit electrical signals, power signals and control signals. It is usually composed of multiple wires, insulating sleeves, connectors and other accessories. It is used to connect various electronic components such as automobiles, electronic equipment, and electrical equipment. Flexible electronic wiring harness is widely used in automobiles, aerospace, electronic equipment, industrial automation and other fields.

[0003] After searching, the authorization announcement number CN209516278U discloses a flexible intelligent wire harness production device, which involves the field of automobile parts processing, including a base, the top of the base is symmetrically provided with a first limit column and a second limit column, the first limit column and the second limit column are jointly sleeved with an upper pressure plate, and both sides of the bottom end of the upper pressure plate are embedded with positioning plates, and a clamping plate is provided between the positioning plates. Compared with the traditional direct-entry crimping, the crimping mechanism provided in the utility model adopts a multi-directional crimping method for fixed connection, so that the crimping effect is better and the crimping deviation phenomenon is not easy to occur. First, the clamping plate is driven to move downward by the upper pressure plate, and the clamping plate is pressed down to press the extrusion plate to achieve the tightening of the upper and lower parts, and then the push plate is pushed to move by two cylinders at the same time, and then the push plate pushes the side pressure plate to perform two side crimpings. In this way, the entire crimping process is achieved without dead angles, and the crimping quality is guaranteed.

[0004] However, the existing flexible electronic wire harnesses are prepared by splicing different finished materials, which cannot be designed and prepared according to one's own needs. Therefore, the market is in urgent need of a flexible electronic wire harness preparation process to solve these problems. Summary of the invention

[0005] The purpose of the present invention is to provide a flexible electronic wire harness preparation process to solve the problem that the existing flexible electronic wire harness proposed in the above background technology is prepared by splicing different finished materials, so it cannot be designed and prepared according to one's own needs.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A flexible electronic wire harness preparation process comprises the following steps:

[0008] Step 1: Design, design the structure and layout of the wiring harness according to production requirements and product specifications, determine the type, specification and quantity of wires and cables used in the wiring harness, design the connectors and plugs of the wiring harness, and ensure its compatibility with the equipment;

[0009] Step 2: Raw material procurement: According to the design requirements, purchase the required connectors, plugs and other raw materials, as well as the raw materials for preparing the wiring harness;

[0010] Step 3: preparing a wire harness, preparing a conductor from a plurality of copper wires, extruding an insulating sheath on the outside of the conductor to form a wire core, then gathering multiple wire cores, filling the outside of the multiple wire cores with a filling layer, and then wrapping with a tape through a tape wrapping machine to form a tape layer, and then extruding a sheath layer on the outside of the tape layer through an extrusion device, and then extruding an insulation layer on the outside of the sheath layer through an extrusion device, and then weaving a shielding layer on the insulation layer, and finally extruding an outer sheath on the outside of the shielding layer through an extrusion device to form a cable, and then extruding a layer of sheath on multiple cables through an extrusion device to form a wire harness 1 and a wire harness 2;

[0011] Wherein, connector 1 is installed on one side of the wiring harness 1, connector 2 is installed on one side of the wiring harness 2, cables are arranged inside the wiring harness 1 and the wiring harness 2, the cable comprises a cable core, the cable core comprises a wire core and a filling layer, the filling layer is filled in the gap between the wire core and the cable core, a tape layer is arranged outside the cable core, a sheath layer is arranged outside the tape layer, an insulating layer is arranged outside the sheath layer, a shielding layer is arranged outside the insulating layer, and an outer sheath is arranged outside the shielding layer;

[0012] Step 4: Cutting: According to the design requirements, use the wire shearing machine to cut the wire harness 1 and wire harness 2 into the required length, and then use the wire stripping machine to strip the wires at both ends of the wire harness 1 and wire harness 2, so as to ensure the accuracy and quality of cutting;

[0013] Step 5: Crimping: Crimping the ends of the wire harness 1 and the wire harness 2 with the connector 1 and the connector 2 through the crimping equipment, and then installing the crimped connector 1 and the connector 2;

[0014] Step six: Testing: Use an oscilloscope to test the electrical performance of wiring harness one and wiring harness two, use a multimeter to test the resistance, continuity, short circuit and open circuit of wiring harness one and wiring harness two, and use a withstand voltage testing device to test the withstand voltage performance of wiring harness one and wiring harness two, thereby completing the preparation of the wiring harness.

[0015] By adopting the above technical solution, flexible electronic wire harnesses can be conveniently produced and prepared, and the produced electronic wire harnesses can be tested at the same time, so that the produced electronic wire harnesses can work better and avoid problems after the production of the electronic wire harnesses, which will affect the use effect.

[0016] Furthermore, a mounting slot is provided inside the connector 1, mounting sockets are provided at both ends of the connector 1, and a limit socket is provided at the upper end of the connector 1.

[0017] By adopting the above technical solution, the connector 1 and the wiring harness 1 can be connected and fixed, and the connector 1 can be conveniently connected and installed by providing the installation socket and the limit socket.

[0018] Furthermore, two mounting sockets are provided, the two mounting sockets are symmetrical with respect to the vertical center line of the connector one, and the mounting socket and the connector one are an integral structure.

[0019] By adopting the above technical solution, the structure between the mounting socket and the connector 1 can be made more solid, and the connector 1 can be conveniently mounted by snapping on the mounting socket.

[0020] Furthermore, a limited docking seat is provided at one end of the connector 2, the limited docking seat is provided corresponding to the connector 1, and a card connection seat is provided at the upper end of the connector 2.

[0021] By adopting the above technical solution, the connector 2 can be installed with the connector 1, so that the electronic wiring harnesses can be conveniently connected and fixed.

[0022] Furthermore, the card connector and the second connector are an integral structure, a card block corresponding to the mounting card connector is provided at the lower end of the card connector, and the card block and the card connector are an integral structure.

[0023] By adopting the above technical solution, the structure between the card seat and connector two can be made more solid, and the structure between the card block and the card seat can be made more solid. By pressing one end of the card seat, the card block can be rotated, so that connector one and connector two can be easily detached and separated.

[0024] Furthermore, the wiring harness 1 is electrically connected to the connector 1, and the wiring harness 2 is electrically connected to the connector 2.

[0025] By adopting the above technical solution, the wiring harness 1 and the connector 1 can be connected and fixed, and the wiring harness 2 and the connector 2 can be connected and fixed.

[0026] Furthermore, the wire core includes a conductor and an insulating sheath, the conductor is prepared by a plurality of copper wires through a twisting device, the insulating sheath is extruded on the outside of the conductor through an extrusion device, and the insulating sheath material is polyethylene.

[0027] By adopting the above technical solution, the structural strength of the conductor can be made higher, the polyethylene insulating sheath provided by extrusion can make the conductors well insulated, and the polyethylene can improve the insulation effect.

[0028] Furthermore, the tape layer is made of mica tape, the sheath layer is made of polyvinyl chloride, the insulation layer and the outer sheath are made of polyethylene, the filling layer is made of glass fiber, and the shielding layer is made of cross-woven copper wires.

[0029] By adopting the above technical scheme, the cable core can be conveniently wrapped with the mica tape, so that the cable core can be installed more firmly, the protective effect of the cable can be improved by setting the polyvinyl chloride sheath layer, the insulation layer can make the insulation effect of the cable better, the outer sheath can make the protective effect of the cable better, and the glass fiber filling layer can support the inside of the cable to protect the inside of the cable from being squeezed and worn, thereby improving the service life of the cable, and at the same time can absorb external vibration and impact force, and improve the durability and impact resistance of the cable.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] (1) The present invention can well prepare the flexible wire harness through design, raw material procurement, wire harness preparation, material cutting, crimping and testing. The wire harness can be well prepared and formed through the steps of wire harness preparation, so that the quality of the flexible wire harness is better. The preparation effect of the wire harness can be improved through devices such as a package extrusion device and a stranding machine, so that the wire harness has better performance. At the same time, the performance of the prepared flexible wire harness is tested to avoid unqualified products affecting the use of the wire harness;

[0032] (2) The conductor made of twisted copper wires in the present invention has a more solid structure, which can avoid the situation where the conductor is easily broken when it is a whole. By filling it with a glass fiber filling layer, it can support the inside of the cable and protect the inside of the cable from being squeezed and worn, thereby increasing the service life of the cable. At the same time, it can absorb external vibration and impact force, improve the durability and impact resistance of the cable, so that the use effect of the wiring harness is better. The shielding layer formed by cross-weaving of copper wires can make the cable have a good electromagnetic shielding effect, so that the wiring harness will not be disturbed by the external environment during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is the overall front view of the present invention;

[0034] Figure 2 is a cross-sectional view of a cable of the present invention;

[0035] Figure 3 It is a schematic diagram of the local structure of the shielding layer of the present invention;

[0036] Figure 4 For the present invention Figure 1 A partial enlarged view of area A.

[0037] In the figure: 1. Wire harness 1; 2. Connector 1; 201. Mounting slot; 202. Mounting socket; 203. Limiting socket; 3. Wire harness 2; 4. Connector 2; 401. Limiting docking socket; 402. Connecting socket; 403. Block; 5. Cable; 6. Cable core; 7. Wire core; 8. Conductor; 9. Insulating sheath; 10. Tape layer; 11. Sheath layer; 12. Insulating layer; 13. Shielding layer; 14. Filling layer; 15. Outer sheath. DETAILED DESCRIPTION

[0038] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0039] See also Figure 1-4 , an embodiment provided by the present invention: a flexible electronic wire harness preparation process, comprising the following steps:

[0040] Step 1: Design, design the structure and layout of the wiring harness according to production requirements and product specifications, determine the type, specification and quantity of wires and cables used in the wiring harness, design the connectors and plugs of the wiring harness, and ensure its compatibility with the equipment;

[0041] Step 2: Raw material procurement: According to the design requirements, purchase the required connectors, plugs and other raw materials, as well as the raw materials for preparing the wiring harness;

[0042] Step 3: preparing a wiring harness, preparing a conductor 8 from a plurality of copper wires, forming a wire core 7 by extruding a layer of insulating sheath 9 on the outside of the conductor 8, and then gathering a plurality of wire cores together, filling a filling layer 14 on the outside of the plurality of wire cores 7, and then wrapping with a tape by a tape wrapping machine to form a tape layer 10, and then extruding a sheath layer 11 on the outside of the tape layer 10 by an extrusion device, and then extruding an insulating layer 12 on the outside of the sheath layer 11 by an extrusion device, and then weaving a shielding layer 13 on the insulating layer 12, and finally extruding an outer sheath 15 on the outside of the shielding layer 13 by an extrusion device to form a cable 5, and then extruding a layer of sheath on the plurality of cables 5 by an extrusion device to form a wiring harness 1 and a wiring harness 2 3;

[0043] Among them, a connector 1 2 is installed on one side of the wiring harness 1, a connector 2 4 is installed on one side of the wiring harness 2 3, a cable 5 is arranged inside the wiring harness 1 and the wiring harness 2 3, the cable 5 includes a cable core 6, the cable core 6 includes a wire core 7 and a filling layer 14, the filling layer 14 is filled in the gap between the wire core 7 and the cable core 6, a tape layer 10 is arranged outside the cable core 6, a sheath layer 11 is arranged outside the tape layer 10, an insulating layer 12 is arranged outside the sheath layer 11, a shielding layer 13 is arranged outside the insulating layer 12, and an outer sheath 15 is arranged outside the shielding layer 13;

[0044] Step 4: Cutting: According to the design requirements, use a wire shear to cut the wire harness 1 and the wire harness 2 3 into the required length, and then use a wire stripping machine to strip the wire harness 1 and the wire harness 2 3 at both ends, so as to ensure the accuracy and quality of cutting;

[0045] Step 5: crimping, crimping the ends of the wire harness 1 and the wire harness 2 3 after cutting with the connector 1 2 and the connector 2 4 through a crimping device, and then installing the crimped connector 1 2 and the connector 2 4;

[0046] Step six: Testing: Conduct electrical performance tests on wiring harness 1 and wiring harness 2 3 through an oscilloscope, test the resistance, continuity, short circuit and open circuit of wiring harness 1 and wiring harness 2 3 through a multimeter, and test the withstand voltage performance of wiring harness 1 and wiring harness 2 3 through a withstand voltage testing device, thereby completing the preparation of the wiring harness.

[0047] Among them, the flexible wire harness can be well prepared through design, raw material procurement, wire harness preparation, cutting, crimping and testing. The wire harness can be well prepared and formed through the steps of wire harness preparation, so that the quality of the flexible wire harness is better. The preparation effect of the wire harness can be improved through devices such as extrusion devices and twisting machines, so that the wire harness has better performance. At the same time, the performance of the prepared flexible wire harness is tested to avoid unqualified products affecting the use of the wire harness. It should be noted that in order to save space and highlight the innovative elements of this patent, such as how to extrude and twist the wire, the working principle and working process will not be repeated in this patent.

[0048] See also Figure 1 and Figure 4, a mounting slot 201 is provided inside the connector 1 2, mounting seats 202 are provided at both ends of the connector 1 2, a limited position seat 203 is provided at the upper end of the connector 1 2, two mounting seats 202 are provided, the two mounting seats 202 are symmetrical about the vertical center line of the connector 1 2, the mounting seat 202 and the connector 1 2 are an integral structure, a limited position docking seat 401 is provided at one end of the connector 2 4, the limited position docking seat 401 is provided corresponding to the connector 1 2, a card seat 402 is provided at the upper end of the connector 2 4, the card seat 402 and the connector 2 4 are an integral structure, and a card seat 403 is provided at the lower end of the card seat 402 The card block 403 corresponding to the seat 202, the card block 403 and the card seat 402 are an integrated structure, the wiring harness 1 and the connector 1 are electrically connected, and the wiring harness 2 3 and the connector 2 4 are electrically connected, wherein the wiring harness 1 and the wiring harness 2 3 can be conveniently connected and installed through the connector 1 2 and the connector 2 4, and the card block 403 corresponding to the installation seat 202 is provided at the lower end of the card seat 402, and the card block 403 can be moved up by pressing one end of the card seat 402, so that the connector 2 4 and the connector 1 2 can be conveniently separated, which makes the flexible electronic wiring harness very convenient to use.

[0049] See also Figure 2 and Figure 3 The wire core 7 includes a conductor 8 and an insulating sheath 9. The conductor 8 is prepared by a plurality of copper wires through a twisting device. The insulating sheath 9 is extruded on the outside of the conductor 8 by an extrusion device. The insulating sheath 9 is made of polyethylene, the tape layer 10 is a mica tape, the sheath layer 11 is made of polyvinyl chloride, the insulating layer 12 and the outer sheath 15 are made of polyethylene, the filling layer 14 is made of glass fiber, and the shielding layer 13 is made of copper wires cross-woven. The conductor 8 made by twisting the copper wires has a stronger structure, which can avoid the conductor 8 from being easily broken when it is a whole, thereby affecting the use of the conductor 8. The polyethylene insulating sheath The sleeve 9 can prevent the conductors 8 from conducting each other, thereby affecting the use of the wiring harness. The mica tape wrapping layer 10 can wrap and fix the wire core 7. The glass fiber filling layer 14 can support the inside of the cable 5 and protect the inside of the cable 5 from being squeezed and worn, thereby increasing the service life of the cable 5. At the same time, it can absorb external vibration and impact force, improve the durability and impact resistance of the cable, so that the use effect of the wiring harness is better. The shielding layer 13 formed by cross-weaving of copper wires can make the cable have a good electromagnetic shielding effect, so that the wiring harness will not be disturbed by the external environment during use.

[0050] Working principle: When in use, according to production requirements and product specifications, design the structure and layout of the wiring harness, determine the type, specification and quantity of wires and cables used in the wiring harness, design the connectors and plugs of the wiring harness, and ensure its compatibility with the equipment, so that the flexible electronic wiring harness to be prepared can be designed in advance, so that it can be prepared more conveniently. According to the design requirements, purchase the required connectors, plugs and other raw materials, as well as the raw materials for preparing the wiring harness, and then prepare the raw materials for preparing the wiring harness. Prepare the conductor 8 by preparing a plurality of copper wires, extrude a layer of insulating sheath 9 on the outside of the conductor 8 through an extrusion device to form a wire core 7, and then gather multiple wire cores together, fill the outside of the multiple wire cores 7 with a filling layer 14, and then wrap them through a taping machine to form a taping layer 10, and then extrude a sheath layer 11 on the outside of the tape layer 10 through an extrusion device, and then extrude a layer of insulating layer 12 on the outside of the sheath layer 11 through an extrusion device, and then weave a layer of shielding layer 13 in the insulating layer 12, and finally extrude a shielding layer 13 on the outside of the shielding layer 13 through an extrusion device A layer of outer sheath 15 is formed to form a cable 5, and then a plurality of cables 5 are extruded with a layer of sheath through an extrusion device to form a wire harness 1 and a wire harness 2 3. In this way, the wire harness can be easily prepared to meet the design requirements. According to the design requirements, the wire harness 1 and the wire harness 2 3 are cut into the required length by a wire cutting machine, and then the wires are stripped at both ends of the wire harness 1 and the wire harness 2 3 by a wire stripping machine. In this way, the accuracy and quality of the cutting can be ensured, and the ends of the wire harness 1 and the wire harness 2 3 after cutting are crimped with the connector 1 2 and the connector 2 4 by a crimping device. Connect, so that the ends of the wiring harness 1 and the wiring harness 2 3 can be installed between the connector 1 2 and the connector 2 4, and then the crimped connector 2 and the connector 2 4 are installed, and the electrical performance of the wiring harness 1 and the wiring harness 2 3 is tested by an oscilloscope, and the resistance, continuity, short circuit and open circuit of the wiring harness 1 and the wiring harness 2 3 are tested by a multimeter, and the voltage resistance performance of the wiring harness 1 and the wiring harness 2 3 is tested by a voltage resistance testing device to avoid unqualified wiring harnesses affecting the use effect, thereby completing the preparation of the wiring harness.

[0051] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A process for preparing a flexible electronic wire harness, characterized in that: The steps include: Step 1: Design, design the structure and layout of the wiring harness according to production requirements and product specifications, determine the type, specification and quantity of wires and cables used in the wiring harness, design the connectors and plugs of the wiring harness, and ensure its compatibility with the equipment; Step 2: Raw material procurement: According to the design requirements, purchase the required connectors, plugs and other raw materials, as well as the raw materials for preparing the wiring harness; Step 3: preparing a wiring harness, by preparing a conductor (8) from a plurality of copper wires, by extruding a layer of insulating sheath (9) on the outside of the conductor (8) to form a wire core (7), then gathering a plurality of wire cores, filling a filling layer (14) on the outside of the plurality of wire cores (7), then wrapping with a tape using a wrapping machine to form a wrapping layer (10), then extruding a sheath layer (11) on the outside of the wrapping layer (10) using an extrusion device, then extruding an insulating layer (12) on the outside of the sheath layer (11) using an extrusion device, then weaving a shielding layer (13) on the insulating layer (12), and finally extruding an outer sheath (15) on the outside of the shielding layer (13) using an extrusion device to form a cable (5), and then extruding a layer of sheath on a plurality of cables (5) using an extrusion device to form a wiring harness 1 (1) and a wiring harness 2 (3); Wherein, a connector one (2) is installed on one side of the wiring harness one (1), a connector two (4) is installed on one side of the wiring harness two (3), a cable (5) is arranged inside the wiring harness one (1) and the wiring harness two (3), the cable (5) comprises a cable core (6), the cable core (6) comprises a wire core (7) and a filling layer (14), the filling layer (14) is filled in the gap between the wire core (7) and the cable core (6), a tape layer (10) is arranged outside the cable core (6), a sheath layer (11) is arranged outside the tape layer (10), an insulating layer (12) is arranged outside the sheath layer (11), a shielding layer (13) is arranged outside the insulating layer (12), and an outer sheath (15) is arranged outside the shielding layer (13); Step 4: Cutting the wires. According to the design requirements, use a wire cutter to cut the wire harness 1 (1) and the wire harness 2 (3) into the required lengths. Then use a wire stripper to strip the wires at both ends of the wire harness 1 (1) and the wire harness 2 (3). This ensures the accuracy and quality of the cutting. Step 5: crimping, using a crimping device to crimp the ends of the wire harness 1 (1) and the wire harness 2 (3) with the connector 1 (2) and the connector 2 (4), and then installing the crimped connector 1 (2) and the connector 2 (4); Step 6: Testing: Conducting an electrical performance test on the wiring harness 1 (1) and the wiring harness 2 (3) using an oscilloscope, testing the resistance, continuity, short circuit and open circuit of the wiring harness 1 (1) and the wiring harness 2 (3) using a multimeter, and testing the withstand voltage performance of the wiring harness 1 (1) and the wiring harness 2 (3) using a withstand voltage testing device, thereby completing the preparation of the wiring harness.

2. A process for preparing a flexible electronic wire harness according to claim 1, characterized in that: The connector one (2) is provided with a mounting slot (201) inside, both ends of the connector one (2) are provided with mounting sockets (202), and the upper end of the connector one (2) is provided with a limit socket (203).

3. A process for preparing a flexible electronic wire harness according to claim 2, characterized in that: Two mounting sockets (202) are provided, and the two mounting sockets (202) are symmetrical with respect to the vertical center line of connector one (2), and the mounting socket (202) and connector one (2) are an integral structure.

4. A process for preparing a flexible electronic wire harness according to claim 3, characterized in that: A limited docking seat (401) is provided at one end of the second connector (4), and the limited docking seat (401) is provided corresponding to the first connector (2). A clamping seat (402) is provided at the upper end of the second connector (4).

5. A process for preparing a flexible electronic wire harness according to claim 4, characterized in that: The card connector (402) and the second connector (4) are an integral structure, and a card block (403) corresponding to the mounting card connector (202) is provided at the lower end of the card connector (402), and the card block (403) and the card connector (402) are an integral structure.

6. A process for preparing a flexible electronic wire harness according to claim 5, characterized in that: The wiring harness 1 (1) is electrically connected to the connector 1 (2), and the wiring harness 2 (3) is electrically connected to the connector 2 (4).

7. A process for preparing a flexible electronic wire harness according to claim 6, characterized in that: The wire core (7) comprises a conductor (8) and an insulating sheath (9); the conductor (8) is prepared by a plurality of copper wires through a twisting device; the insulating sheath (9) is extruded on the outside of the conductor (8) through an extrusion device; and the insulating sheath (9) is made of polyethylene.

8. A process for preparing a flexible electronic wire harness according to claim 7, characterized in that: The tape layer (10) is a mica tape, the sheath layer (11) is made of polyvinyl chloride, the insulation layer (12) and the outer sheath (15) are made of polyethylene, the filling layer (14) is made of glass fiber, and the shielding layer (13) is made of cross-woven copper wires.

Images