Cable welding control device and method

Abstract

A cable assembly and welding control device and method were developed, primarily for fixing the plugs of J27A type electrical connectors. The device, which includes connector fixing slots, wire harness fixing slots, and scales, solved problems encountered during production such as repeated cable length measurements, insecure connector fixing, and difficulty in welding. After workshop review, it was applied to cable assembly production with good results, effectively improving cable assembly and welding efficiency.

Description

Technical Field

[0001] This application belongs to the field of cable production technology, and specifically relates to a cable welding control device and method. Background Technology

[0002] The electronic compartment self-guiding cable consists of three branches, involving the soldering of three J27A type connectors. The connector body is secured with tape and measured with a measuring tape. This method carries the risk of insecure fixing, easy loosening, and significant deviations in cable length measurement. Inaccurate measurements increase rework frequency. Furthermore, if the cut length is shorter than the drawing requirements, the product risks being scrapped (otherwise, the solder joints will be under stress). Summary of the Invention

[0003] The technical problem solved by this application is to overcome the shortcomings of the prior art and provide a cable welding control device and method to improve welding efficiency.

[0004] The technical solution provided in this application is as follows:

[0005] A cable assembly and welding control device is disclosed for assembling and welding cables. The cable includes a main connector and at least two branch connectors of different models. The main connector is connected to a main wire harness, which branches into multiple branch wire harnesses. The end of each branch wire harness is connected to a corresponding branch connector. The device includes a base plate, on the surface of which are formed a main control slot, branch control slots, a main wire harness control slot, and a branch wire harness control slot. The main control slot is used to position the main connector so that after the main connector is inserted into the main control slot in a direction perpendicular to the base plate surface, it will not move in a direction parallel to the base plate surface. The branch connectors are used for... The branch connector is positioned such that a branch harness control slot is connected between the main harness control slot and a branch control slot. The number of branch harness control slots is consistent with the number of different types of branch connectors connected to the main connector. One branch harness control slot is collinear with the main harness control slot and connects the main control slot to the corresponding branch control slot. This branch harness control slot is the central branch harness control slot, and the other branch harness control slots are side branch harness control slots. One end of the side branch harness control slot is connected to the side of the central branch harness control slot near the end of the main control slot, and the other end is connected to the corresponding branch control slot.

[0006] The side branch harness control slot includes a connecting section and a parallel section. One end of the connecting section is connected to the side of the middle branch harness control slot near the end of the main control slot, and the other end extends away from the middle branch harness control slot. One end of the parallel section is connected to the middle branch harness control slot, and the other end is connected to the corresponding sub-control slot. The parallel section is parallel to the middle branch harness control slot.

[0007] Along the direction away from the central branch harness control slot, the side of the connecting section away from the main control slot is inclined in the direction away from the main control slot, so that an acute angle of 30° is formed between the side of the connecting section away from the main control slot and the side wall of the central branch harness control slot.

[0008] The acute angle tip between the connecting section and the side wall of the central branch harness control slot is rounded.

[0009] The sub-control slot includes a sub-positioning area and a sub-umbrella-shaped binding area. The sub-umbrella-shaped binding area is connected to the sub-positioning area and the corresponding branch harness control slot. The sub-positioning area is used to position and fix the sub-connector. The width direction of the sub-control slot is along the direction parallel to the substrate surface and perpendicular to the length of the main harness control slot. The width of the sub-umbrella-shaped binding area increases along the direction from the branch harness control slot to the sub-positioning area.

[0010] When there are at least two branch connectors that cooperate with the sub-control slot corresponding to the central branch harness control slot, the branch harness in the central branch harness control slot is split at a position at a distance of (20%-40%) × the length of the central branch harness control slot.

[0011] The substrate surface is provided with etched grooves, which include end position grooves of the main wire harness control groove, branch position grooves, and end grooves of each branch wire harness control groove. The branch position grooves are the branch positions of the branch wire harness within the corresponding branch wire harness control groove.

[0012] The substrate is made of nylon.

[0013] A welding method for a cable welding control device includes:

[0014] The main connector is inserted into the main control slot, and the branch connector is inserted into the branch control slot. The main harness is then pressed into the main harness control slot. The main harness is then split into branch harnesses, and the branch harnesses are pressed into their corresponding branch harness control slots. The branch harnesses are then branched at their ends according to the branch positions, and the ends of the branch harnesses are cut according to the end grooves of the branch harness control slots. Finally, the ends of the branch harnesses are soldered to the branch connectors. After all soldering is completed, the cable is removed.

[0015] The final step of soldering the end of the branch harness to the sub-connector includes: when there are at least two sub-connectors of the same model, placing one sub-connector in the sub-control slot, first soldering one sub-connector to one end branch of the branch harness, after soldering, placing the sub-connector on one side of the branch harness control slot, and then placing the other sub-connector in the sub-control slot to solder one end branch of the branch harness to the sub-connector.

[0016] To adapt to product updates and changes in manufacturing processes for different product models, the design of welding control fixtures has become a crucial component in optimizing production processes. It plays a vital role in improving product assembly and welding accuracy, shortening processing time, increasing production efficiency, reducing costs, and alleviating operator workload. This invention proposes a dynamic solution integrating cable clamping, ranging, and welding, addressing the following three main operational challenges:

[0017] ① The product uses fixed-length cables and requires multiple length measurements, which poses a risk of measurement errors and makes the operation complex and redundant.

[0018] ② During the connector assembly and soldering process, it is necessary to fix the plug and bind the wire harness, which requires the cooperation of multiple people, resulting in high labor costs.

[0019] ③ The process of bundling wire harnesses requires measuring the distance between the wires, which is cumbersome.

[0020] In summary, this application includes at least the following beneficial technical effects:

[0021] 1. The cable welding device is used in the production of this cable, which basically solves the problems of repeated measurement of cable size and unreliable connector fixing.

[0022] 2. The improved process of a certain type of cable welding device can be extended to the production of other types of cables.

[0023] 3. The design concept of this device can be extended to other processes that require repetitive operations, reducing the number of repetitions while improving welding efficiency. It effectively solves the problem of high labor intensity for workers. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the cable welding control device of this application;

[0025] Figure 2 This is a schematic diagram of the cable and cable welding control device assembly.

[0026] Explanation of reference numerals in the attached diagram: 3, substrate; 31, main control slot; 311, main positioning area; 312, main umbrella-shaped binding area; 32, sub-control slot; 321, sub-positioning area; 322, sub-umbrella-shaped binding area; 33, main wire harness control slot; 34, branch wire harness control slot. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments disclosed in the present invention will be described in further detail below with reference to the accompanying drawings.

[0028] This application discloses a cable welding control device for welding cables. The cable includes a main connector and at least two branch connectors. The main connector and each branch connector are connected by a cable. This embodiment uses a specific cable as an example. The cable includes a J30J type self-contained connector (main connector), a J27A-17TJL2ⅡH type connector (branch connector), and two J27A-53TJL2ⅡH type connectors (branch connectors). The J30J type self-contained connector is connected to a main wire harness. The main wire harness branches into branch wire harnesses. In this embodiment, the branch wire harnesses include a branch first wire harness, a branch second wire harness, and a branch third wire harness. The other end of the branch first wire harness is connected to the J27A-17TJL2ⅡH type connector. The branch second wire harness and the branch third wire harness are respectively connected to the two J27A-53TJL2ⅡH type connectors.

[0029] A cable welding control device, such as Figure 1 As shown, the system includes a substrate 3, on which a main control slot 31 and sub-control slots 32 are formed. The main connector is placed in the main control slot 31. The number of sub-control slots 32 is consistent with the number of sub-connector models connected to the main connector. Sub-connectors are placed in their corresponding sub-control slots 32. In this embodiment, there are two sub-control slots 32, namely the first sub-control slot 32 and the second sub-control slot 32. The J27A-17TJL2ⅡH type connector is placed in the first sub-control slot 32, and the J27A-53TJL2ⅡH type connector is placed in the second sub-control slot 32.

[0030] The substrate 3 has a main harness control slot 33 and a branch harness control slot 34. The branch harness control slot 34 is connected between the main harness control slot 33 and a sub-control slot 32. The number of branch harness control slots 34 is consistent with the number of sub-connector models connected to the main connector. In this embodiment, the branch harness control slot 34 includes a second branch harness control slot and a first branch harness control slot. The main harness control slot 33 and the branch harness control slot 2 are collinear and connected between the main control slot 31 and the second sub-control slot 32. The branch harness control slot 1 connects to the first sub-control slot 32 from the side of the first end of the branch harness control slot 2 (the first end is the end near the main control slot 31). The branch harness control slot 1 includes a connecting section and a parallel section. One end of the connecting section is connected to the side of the branch harness control slot 2 near the end of the main control slot 31, and the other end extends away from the branch harness control slot 2. One end of the parallel section is connected to the branch harness control slot 2, and the other end is connected to the first sub-control slot 32. The parallel section is parallel to the branch harness control slot 2. Along the direction away from the branch two wire harness control slot, the side of the connecting section away from the main control slot 31 is inclined in the direction away from the main control slot 31, so that the side of the connecting section away from the main control slot 31 forms an acute angle with the side wall of the branch two wire harness control slot. In this embodiment, the acute angle is 30°, and the tip of the acute angle is rounded, so that the branch one wire harness can be inserted into the parallel section more smoothly through the connecting section, and the rounded corner setting avoids scratching the cable at this position.

[0031] The main harness connected to the J30J type self-contained connector is located in the main control slot 31. After passing through the main control slot 31, the main harness branches into two bundles: a branch first bundle and a combined branch second and branch third bundle. The branch first bundle mates with the branch first bundle control slot, and the combined branch second and branch third bundle mates with the branch second bundle control slot. The combined branch second and branch third bundle splits into branch second and branch third bundles at a distance of (20%-40%) × the length of the branch second bundle control slot from the second sub-control slot 32. This allows one J27A-53TJL2ⅡH type connector to be placed in the second sub-control slot 32 for cable connection, while the other is placed to the side. The two J27A-53TJL2ⅡH type connectors can be placed in the second sub-control slot 32 alternately for cable connection.

[0032] The main control slot 31 includes a main positioning area 311 and a main umbrella-shaped binding area 312. The main umbrella-shaped binding area 312 connects the main positioning area 311 and the main wire harness control slot 33. The main positioning area 311 is used to position and fix the J30J type self-contained wire connector and protect the mating end of the J30J type self-contained wire connector. The direction perpendicular to the second sub-control slot 32 and the parallel segment is the width direction of the main umbrella-shaped binding area 312. Along the direction from the main positioning area 311 to the main control slot 31, the width of the main umbrella-shaped binding area 312 gradually decreases. Along the direction from the main positioning area 311 to the main control slot 31, the width of the main wire harness connected to the J30J type self-contained wire connector after binding gradually decreases until it matches the width of the main control slot 31.

[0033] The sub-control slot 32 includes a sub-positioning area 321 and a sub-umbrella-shaped binding area 322. The sub-umbrella-shaped binding area 322 connects the sub-positioning area 321 and the corresponding branch harness control slot 34. The sub-positioning area 321 is used to position and fix the sub-connector. Along the direction from the branch harness control slot 34 to the sub-positioning area 321, the width of the sub-umbrella-shaped binding area 322 gradually increases. In this embodiment, the first sub-control slot 32 includes a first sub-umbrella-shaped binding area 322 and a first sub-positioning area 321, and the second sub-control slot 32 includes a second sub-umbrella-shaped binding area 322 and a second sub-positioning area 321. After the J27A-17TJL2ⅡH type connector and the J27A-53TJL2ⅡH type connector are soldered to the cable, the cable harness is bound into an umbrella shape to ensure that the cable ends are all located within the corresponding sub-umbrella-shaped binding area 322, thereby ensuring that the entire cable is located within the slot, ensuring the accuracy of its position, and thus ensuring the accuracy of the cable length positioning.

[0034] The substrate 3 has etched grooves on its surface for indicating critical dimensions. These grooves are located at several key positions on the surface of the substrate 3 to ensure the correct cable length. The etched grooves include end position grooves for the main harness control groove 33, branch position grooves, and end grooves for each branch harness control groove 34. The branch position grooves mark the branching positions of the combined branch two and branch three harnesses within the branch two harness control groove.

[0035] This embodiment of a cable welding control device is made entirely of nylon, with a designed weight between 2 and 3 kg. The tooling is 600 mm long, 26 mm thick, and 124 mm wide. The main harness control groove 33 is 40 mm long, 20 mm wide, and 13 mm deep. The branch harness control groove is 440 mm long, 20 mm wide, and 8 mm deep. The first umbrella-shaped binding area 322 is 20 mm long, 25 mm wide, and 8 mm deep. The second umbrella-shaped binding area 322 is 40 mm long, 70 mm wide, and 8 mm deep. The groove from the first end of the branch harness control groove to the branch position is 350 mm long, 20 mm wide, and 13 mm deep. The groove from the first end of the branch harness control groove to the branch position is 150 mm long, 20 mm wide, and 13 mm deep.

[0036] The method for resist welding using the above-mentioned cable welding control device includes:

[0037] The main connector is inserted into the main control slot 31, the branch connector is inserted into the branch control slot 32, the main harness is pressed into the main harness control slot 33, the main harness is then split into branch harnesses, the branch harnesses are pressed into the corresponding branch harness control slots 34, the branch harnesses are branched at the end according to the branch position, and the ends of the branch harnesses are cut according to the end grooves of the branch harness control slots 34. Finally, the ends of the branch harnesses are soldered to the branch connectors. After all soldering is completed, the cable is removed.

[0038] The contents not described in detail in this application specification are common knowledge to those skilled in the art.

[0039] The present application has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present application. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and implementation methods of the present application without departing from the spirit and scope of the present application, and all such modifications and improvements fall within the scope of the present application. The scope of protection of the present application is determined by the appended claims.

Claims

1. A cable assembly and welding control device for assembling and welding cables, the cables comprising a main connector and at least two branch connectors of different types, the main connector being connected to a main wire harness, the main wire harness branching into multiple branch wire harnesses, the end of each branch wire harness being connected to a corresponding branch connector, characterized in that: The system includes a substrate (3), on which a main control slot (31), a sub-control slot (32), a main harness control slot (33), and a branch harness control slot (34) are formed. The main control slot (31) is used to position the main connector so that the main connector is inserted into the main control slot (31) in a direction perpendicular to the surface of the substrate (3) and will not move in a direction parallel to the surface of the substrate (3). The sub-connector is used to position the sub-connector. The branch harness control slot (34) is connected between the main harness control slot (33) and a sub-control slot (32). The branch harness... The number of control slots (34) is consistent with the number of sub-connector models connected to the main connector. One branch harness control slot (34) is collinear with the main harness control slot (33) and connected between the main control slot (31) and the corresponding sub-control slot (32). This branch harness control slot (34) is the middle branch harness control slot, and the other branch harness control slots (34) are the side branch harness control slots. One end of the side branch harness control slot is connected to the side of the middle branch harness control slot near the end of the main control slot (31), and the other end is connected to the corresponding sub-control slot (32). The sub-control slot (32) includes a sub-positioning area (321) and a sub-umbrella-shaped binding area (322). The sub-umbrella-shaped binding area (322) is connected to the sub-positioning area (321) and the corresponding branch harness control slot (34). The sub-positioning area (321) is used to position and fix the sub-connector. The width direction of the sub-control slot (32) is parallel to the surface of the substrate (3) and perpendicular to the length of the main harness control slot (33). The width of the sub-umbrella-shaped binding area (322) increases along the direction from the branch harness control slot (34) to the sub-positioning area (321). The substrate (3) has a scribe groove on its surface. The scribe groove includes an end position scribe groove of the main wire harness control groove (33), a branch position scribe groove and an end scribe groove of each branch wire harness control groove (34). The branch position scribe groove is the branch position of the branch wire harness in the corresponding branch wire harness control groove (34).

2. The cable welding control device according to claim 1, characterized in that: The side branch harness control slot includes a connecting section and a parallel section. One end of the connecting section is connected to the side of the middle branch harness control slot near the end of the main control slot (31), and the other end extends away from the middle branch harness control slot. One end of the parallel section is connected to the middle branch harness control slot, and the other end is connected to the corresponding sub-control slot (32). The parallel section is parallel to the middle branch harness control slot.

3. The cable welding control device according to claim 2, characterized in that: Along the direction away from the central branch harness control slot, the side of the connecting section away from the main control slot (31) is inclined in the direction away from the main control slot (31) so that an acute angle of 30° is formed between the side of the connecting section away from the main control slot (31) and the side wall of the central branch harness control slot.

4. The cable welding control device according to claim 3, characterized in that: The acute angle tip between the connecting section and the side wall of the central branch harness control slot is rounded.

5. The cable welding control device according to claim 1, characterized in that: When there are at least two branch connectors that cooperate with the sub-control slot (32) corresponding to the central branch harness control slot, the branch harness in the central branch harness control slot is split at a position (20%-40%) × the length of the central branch harness control slot from the sub-control slot (32).

6. The cable welding control device according to claim 1, characterized in that: The substrate (3) is made of nylon.

7. The welding method of the cable welding control device according to any one of claims 1-6, characterized in that, include: The main connector is inserted into the main control slot (31), the branch connector is inserted into the branch control slot (32), the main harness is pressed into the main harness control slot (33), the main harness is then split into branch harnesses, the branch harnesses are pressed into the corresponding branch harness control slots (34), the end of the branch harness is branched according to the branch position, and the end of the branch harness is cut according to the end of the branch harness control slot (34). Finally, the end of the branch harness is soldered to the branch connector. After all the soldering is completed, the cable is taken out.

8. The welding method according to claim 7, characterized in that, The final step of welding the end of the branch harness to the sub-connector includes: when there are at least two sub-connectors of the same model, placing one sub-connector in the sub-control slot (32), first welding one sub-connector to one end branch of the branch harness, and after welding, placing the sub-connector on one side of the branch harness control slot (34), and then placing the other sub-connector in the sub-control slot (32) to weld one end branch of the branch harness to the sub-connector.

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