Wire harness welding method and wire harness welding assembly

Abstract

The invention belongs to the technical field of welding, and discloses a wire harness welding method and a wire harness welding assembly. The method specifically comprises the following steps: providing a first wire harness, a second wire harness, a terminal and a set of ultrasonic welding system; placing the first welding section of the first wire harness on a bottom die; the terminal is arranged on the first welding section, and the first welding surface abuts against the first welding section; a second welding section of a second wire harness is arranged on the terminal, and the second welding surface abuts against the second welding section; and a welding head is placed on the second welding section, the ultrasonic welding system is started, and the first welding section and the second welding section are welded to the first welding face and the second welding face through the welding head correspondingly. According to the wiring harness welding method, double-face welding of the terminal can be achieved, raw materials can be saved, and cost can be saved. And through double-sided welding of the terminals, the contact area between the core wires of the first wire harness and the second wire harness and the terminals is increased, so that the conductivity and the heat-conducting property are improved. The wiring harness welding assembly saves raw materials, and is low in cost and good in electrical conductivity and thermal conductivity.

Description

Technical Field

[0001] The invention relates to the technical field of wire harness welding, and in particular to a wire harness welding method and a wire harness welding assembly. Background Art

[0002] With the widespread application of high-power wiring harness terminal connectors, ultrasonic welding is also widely used, especially for welding large square wiring harness terminals. Large square wiring harnesses generally refer to wiring harnesses with a total cross-sectional area of ​​more than 70 square millimeters. The existing ultrasonic welding technology usually directly welds large square wiring harnesses and metal terminals (hereinafter referred to as terminals), but this direct welding method uses a relatively large amount of raw materials, which is costly and the subsequent matching terminal connector is large in size. Take the welding wire diameter as 70mm 2 For example, the wiring harness and copper plate terminal of the terminal are 18mm wide, 50mm long and 3mm thick, so the volume is 18mm*3mm*50mm=2700mm 3 , and the welding area of ​​the wire harness after welding is smaller than the terminal area, so the connector connected to the terminal needs to be designed to be large in order to connect with the terminal.

[0003] Therefore, there is an urgent need to provide a wire harness welding method and a wire harness welding assembly to solve the above problems. Summary of the invention

[0004] The first object of the present invention is to provide a wire harness welding method that can save raw materials and costs, improve electrical conductivity and thermal conductivity, and has strong welding position stability.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] A wire harness welding method comprises the following steps:

[0007] S1: providing a first wire harness, a second wire harness, a terminal and an ultrasonic welding system, wherein the first wire harness has a first welding section, the second wire harness has a second welding section, the terminal has a first welding surface and a second welding surface, and the ultrasonic welding system includes a bottom mold and a welding head;

[0008] S2: placing the first welding section on the bottom mold;

[0009] S3: placing the terminal on the side of the first welding section away from the bottom mold, with the first welding surface abutting against the first welding section;

[0010] S4: placing the second welding section on the side of the terminal away from the bottom mold, and the second welding surface abuts against the second welding section;

[0011] S5: placing the welding head on the side of the second welding section away from the bottom mold, starting the ultrasonic welding system, and the welding head welds the first welding section and the second welding section to the first welding surface and the second welding surface respectively.

[0012] As an optional technical solution for the wire harness welding method, the step S2 also includes placing the welding head on the side of the first welding section away from the bottom mold, starting the ultrasonic welding system, and pre-welding the first welding section with the welding head.

[0013] As an optional technical solution for the wire harness welding method, the wire harness welding method also includes providing a positioning component, the positioning component includes two groups of adjusting push blocks, the two groups of adjusting push blocks can respectively abut against the first welding section, the terminal and the two end sides of the second welding section along the first direction, the spacing between the two groups of adjusting push blocks along the first direction is a, the width of the welding head along the first direction is b, a>b.

[0014] As an optional technical solution for the wire harness welding method, the first wire harness and the second wire harness are both wire harnesses composed of multiple thin single filaments, and the distance between the bottom surface of the adjusting push block and the top surface of the bottom mold is less than or equal to the diameter of a single thin single filament.

[0015] As an optional technical solution for the wire harness welding method, a slot is provided inside the adjusting push block, and the terminals are respectively inserted into the two slots at both ends along the first direction, and the side surfaces of the terminals abut against the bottom walls of the slots.

[0016] As an optional technical solution for the wire harness welding method, an escape space is provided on the inner side of the adjusting push block, and the terminals are respectively clamped in the two escape spaces at both ends along the first direction, so that only the second welding surface and the side surface of the terminal abut against the inner wall of the escape space.

[0017] As an optional technical solution for the wire harness welding method, the welding head welds the first welding section and the second welding section, and the terminal moves along a second direction toward the bottom mold, and the second direction is perpendicular to the first direction.

[0018] As an optional technical solution for the wire harness welding method, the positioning assembly further includes a downward pressing structure, which can enable the two groups of the adjusting push blocks to move along the second direction toward or away from the bottom mold.

[0019] As an optional technical solution of the wire harness welding method, the wire harness welding method also includes providing a top wire tooling and a wire clamping tooling, the top wire tooling locates the axial position of the first wire harness and the second wire harness, and the wire clamping tooling locates the radial position of the first wire harness and the second wire harness.

[0020] A second object of the present invention is to provide a wire harness welding assembly that saves raw materials, has low cost, and has good electrical and thermal conductivity.

[0021] To achieve this object, the present invention adopts the following technical solutions:

[0022] A wire harness welding assembly is manufactured using the wire harness welding method.

[0023] Beneficial effects of the present invention:

[0024] The wire harness welding method provided by the present invention provides a first wire harness, a second wire harness, a terminal and an ultrasonic welding system. The first welding section of the first wire harness is placed on the bottom mold; the terminal is placed on the first welding section, and the first welding surface is abutted against the first welding section; the second welding section of the second wire harness is placed on the terminal, and the second welding surface is abutted against the second welding section; the welding head is placed on the second welding section, and the ultrasonic welding system is started, and the welding head welds the first welding section and the second welding section to the first welding surface and the second welding surface respectively. By providing two welding wire harnesses, the first wire harness and the second wire harness, double-sided welding of the terminal can be achieved, which can save raw materials and costs. In addition, by double-sided welding of the terminal, the contact area between the core wires of the first wire harness and the second wire harness and the terminal is increased, thereby improving the electrical conductivity and thermal conductivity.

[0025] Providing an ultrasonic welding system can realize simultaneous welding of the first welding surface and the second welding surface of the terminal, thereby improving welding quality and saving costs. The first welding section, the terminal and the second welding section are sequentially stacked on the bottom mold, which plays a fixed supporting role during welding, and only the welding head vibrates for welding, thereby improving the welding position stability of the first welding section, the terminal and the second welding section during welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a flow chart of a wire harness welding method provided by an embodiment of the present invention;

[0027] Figure 2 The structure diagram of the positioning assembly in the wire harness welding method provided by the embodiment of the present invention is Figure 1 ;

[0028] Figure 3 yes Figure 2 A magnified view at point A;

[0029] Figure 4 The structure diagram of the positioning assembly in the wire harness welding method provided by the embodiment of the present invention is Figure 2 ;

[0030] Figure 5The structure diagram of the positioning assembly in the wire harness welding method provided by the embodiment of the present invention is Figure 3 ;

[0031] Figure 6 The materials used in the single-sided incomplete welding in the background technology are compared with the double-sided incomplete welding and double-sided full welding provided in this embodiment;

[0032] Figure 7 It is an assembly schematic diagram of a wire top tool and a wire clamping tool in a wire harness welding method provided in an embodiment of the present invention.

[0033] In the figure:

[0034] 100, first wiring harness; 110, first welding section; 200, second wiring harness; 210, second welding section; 300, terminal; 410, welding head; 420, bottom mold; 500, adjustment push block; 501, slot; 502, avoidance space; 600, top wire tooling; 700, wire clamping tooling. DETAILED DESCRIPTION

[0035] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0036] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0037] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0038] In the description of this embodiment, the terms "upper", "lower", "right", etc., directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0039] The wire harness welding method provided in this embodiment can save raw materials and costs, improve electrical conductivity and thermal conductivity, and has strong welding position stability.

[0040] Specific as Figure 1 As shown, the wire harness welding method comprises the following steps:

[0041] S1: Provide a first wire harness 100, a second wire harness 200, a terminal 300 and an ultrasonic welding system, wherein the first wire harness 100 has a first welding section 110, the second wire harness 200 has a second welding section 210, the terminal 300 has a first welding surface and a second welding surface, and the ultrasonic welding system includes a bottom mold 420 and a welding head 410;

[0042] S2: placing the first welding section 110 on the bottom mold 420;

[0043] S3: placing the terminal 300 on the side of the first welding section 110 away from the bottom mold 420 , with the first welding surface abutting against the first welding section 110 ;

[0044] S4: placing the second welding section 210 on the side of the terminal 300 away from the bottom mold 420, and the second welding surface abuts against the second welding section 210;

[0045] S5: The welding head 410 is placed on the side of the second welding section 210 facing away from the bottom mold 420, and the ultrasonic welding system is started. The welding head 410 welds the first welding section 110 and the second welding section 210 to the first welding surface and the second welding surface respectively.

[0046] In this embodiment, by providing two welding harnesses, the first harness 100 and the second harness 200, respectively welding the first welding surface and the second welding surface of the terminal 300, it is possible to achieve double-sided welding of the terminal 300, which can save raw materials and save costs. In addition, by double-sided welding of the terminal 300, the contact area between the core wires of the first harness 100 and the second harness 200 and the terminal 300 is increased, thereby improving the electrical conductivity and thermal conductivity.

[0047] The specific value is based on the required welding wire diameter of 70mm in the background technology. 2Taking the wiring harness and copper plate terminal as an example, in the background technology, the terminal width is 18mm, the length is 50mm, and the thickness is 3mm, so the volume is 18mm*3mm*50mm=2700mm 3 In this embodiment, the wire diameters of the first wire harness 100 and the second wire harness 200 are both 35 mm. 2 , the required width of the terminal 300 is about 13mm, the length of the terminal 300 is 50mm (the same as in the background technology), the thickness of the terminal 300 is 3mm (the same as in the background technology), then the volume of the terminal 300 is 13mm*3mm*50mm=1950mm 3 <2700mm 3 .

[0048] It should be noted that the double-sided welding in this embodiment reduces the width of the terminal 300. The length (50 mm) and thickness (3 mm) of the terminal 300 in the above example are only values ​​in one embodiment. Of course, in other embodiments, the length and thickness of the terminal 300 can be other values.

[0049] Secondly, by providing an ultrasonic welding system, it is possible to simultaneously weld the first welding surface and the second welding surface of the terminal 300, thereby saving costs.

[0050] Again, the provided ultrasonic welding system includes a base mold 420 and a welding head 410. The first welding section 110, the terminal 300 and the second welding section 210 are stacked in sequence on the base mold 420. The base mold 420 plays a fixed supporting role during welding, and only the welding head 410 vibrates for welding, thereby improving the welding position stability of the first welding section 110, the terminal 300 and the second welding section 210 during the welding process.

[0051] It should be noted that the first wire harness 100 and the second wire harness 200 can be made of copper wire harness, aluminum wire harness or other metal wire harnesses with good conductivity; the terminal 300 can be made of copper nickel-plated terminal 300, copper silver-plated terminal 300, aluminum terminal 300 or other metal terminal 300 with good conductivity. The first welding section 110 and the second welding section 210 are stripping sections at the ends of the first wire harness 100 and the second wire harness 200, respectively, and are used for welding.

[0052] Furthermore, step S2 also includes placing the welding head 410 on the side of the first welding section 110 away from the bottom mold 420, starting the ultrasonic welding system, and pre-welding the first welding section 110 with the welding head 410. Pre-welding the first welding section 110 can, on the one hand, make the first welding section 110 pre-welded into a whole, and in step S5, avoid the first welding section 110 from running wire during welding; on the other hand, the first welding section 110 can be welded flat, so that in step S3, the terminal 300 can be placed more stably on the first welding section 110; on the other hand, the welding strength of the first wiring harness 100 can be increased, so that the tension of the first wiring harness 100 and the second wiring harness 200 after welding with the terminal 300 is similar, which makes up for the defect of low welding strength of the first welding section 110 caused by the welding head 410 transmitting the input welding from the second welding section 210 to the first welding section 110.

[0053] like Figures 2 to 5 As shown, in order to increase the position stability of the first welding section 110, the terminal 300 and the second welding section 210 during the welding process, the wire harness welding method also includes providing a positioning component, the positioning component includes two groups of adjustment push blocks 500, and the two groups of adjustment push blocks 500 can respectively abut against the two end sides of the first welding section 110, the terminal 300 and the second welding section 210 along the first direction.

[0054] The first direction is Figure 2 The A direction in .

[0055] Continue as Figure 2 and Figure 3 As shown, in this embodiment, the spacing between the two groups of adjusting push blocks 500 along the first direction is a, and the width of the welding head 410 along the first direction is b, a>b, leaving vibration space for the welding head 410 to avoid friction between the welding head 410 and the adjusting push block 500.

[0056] The first wire harness 100 and the second wire harness 200 are both wire harnesses composed of a plurality of thin monofilaments, and the cross-sectional area of ​​the wire harnesses is circular. In this embodiment, the diameter of a single thin monofilament is greater than 0.05 mm.

[0057] Therefore, the vibration space cannot be too large, otherwise it will cause flying wires in the wire harness. Therefore, the vibration space on one side is usually less than or equal to 0.05mm, that is, ab≤0.1mm.

[0058] Similarly, the distance between the bottom surface of the push block 500 and the top surface of the bottom mold 420 is adjusted to be less than or equal to the diameter of the thin monofilament to prevent the wire harness from flying. In this embodiment, the distance between the bottom surface of the push block 500 and the top surface of the bottom mold 420 can be 0.01mm, 0.02mm, 0.03mm, 0.04mm, 0.05mm, etc.

[0059] In this embodiment, the width of the bottom mold 420 along the first direction is equal to the width of the welding head 410 along the first direction.

[0060] In other embodiments, the width of the bottom mold 420 along the first direction is not equal to the width of the welding head 410 along the first direction.

[0061] In a specific embodiment, the wire harness welding method can achieve full welding of the first welding surface and the second welding surface of the terminal 300. Figure 2 As shown, in order to achieve full double-sided welding of the first welding surface and the second welding surface of the terminal 300, the end sides of the first welding section 110, the terminal 300 and the second welding section 210 along the first direction are aligned along the second direction.

[0062] In another specific embodiment, the wire harness welding method can achieve partial full welding of the first welding surface and the second welding surface of the terminal 300. Figure 4 As shown, in order to achieve non-full welding on both sides of the first welding surface and the second welding surface of the terminal 300, a slot 501 is provided on the inner side of the adjusting push block 500, and the terminals 300 are respectively inserted into the two slots 501 at both ends along the first direction, and the side surfaces of the terminal 300 abut against the bottom wall of the slot 501.

[0063] It should be noted that the second welding surface is in contact with the side wall of the slot 501, and a gap is left between the first welding surface and the side wall of the slot 501, and the gap is smaller than the diameter of a single thin monofilament. It can be seen that the slot depth of the slot 501 is half of the difference between the width of the terminal 300 along the first direction and the distance a between the two sets of adjustment push blocks 500 extending out.

[0064] In another specific embodiment, the wire harness welding method can achieve full welding of the first welding surface and incomplete welding of the second welding surface of the terminal 300. Figure 5 As shown, in order to achieve full welding of the first welding surface of the terminal 300 and incomplete welding of the second welding surface, that is, full welding on one side and incomplete welding on the other side, an avoidance space 502 is provided on the inner side of the adjusting push block 500, and the two ends of the terminal 300 along the first direction are respectively clamped in the two avoidance spaces 502, so that only the second welding surface and the side of the terminal 300 are in contact with the inner wall of the avoidance space 502.

[0065] Similarly, it can be known that the depth of the avoidance space 502 along the first direction is half of the difference between the width of the terminal 300 along the first direction and the distance a between the two sets of adjustment push blocks 500 extending out.

[0066] Since the welding head 410 welds the first welding section 110 and the second welding section 210 , as the first welding section 110 and the second welding section 210 are compressed, in this embodiment, the terminal 300 moves along the second direction toward the bottom mold 420 , and the second direction is perpendicular to the first direction.

[0067] The second direction is Figure 2 In the B direction, in this embodiment, the second direction (B direction) is the vertical direction.

[0068] Furthermore, the adjusting push block 500 also needs to move along the second direction toward the bottom mold 420 in order to cooperate with the terminal 300 to move along the second direction toward the bottom mold 420. In this embodiment, the positioning assembly further includes a pressing structure (not shown in the figure), which can enable the two groups of adjusting push blocks 500 to move along the second direction toward or away from the bottom mold 420.

[0069] The following is a comparison of the raw material volumes used in single-sided partial full welding (welding method in the background art), double-sided partial full welding and double-sided full welding. Figure 6 As shown:

[0070] Welding method: Method 1, partial welding on one side; Method 2, partial welding on both sides; Method 3, full welding on both sides.

[0071] Symbol definition: Terminal 300 length L, Terminal 300 welding end thickness T, Terminal 300 outer diameter D (corresponding to three welding methods D1, D2, D3), Terminal 300 welding end width W b (The corresponding three welding methods are W b1 ,W b2 ,W b3 ), welding width W a (The corresponding three welding methods are W a1 ,W a2 ,W a3 ), unwelded width W c (The corresponding three welding methods are W c1 ,W c2 ,W c3 ), not shown in the figure.

[0072] The terminal 300 is usually processed from a round bar with an outer diameter slightly larger than D. Without considering the processing loss, the minimum terminal raw material size is a round bar with a diameter of D and a length of L.

[0073] Among them, the minimum value of the terminal outer diameter D is D min The corresponding cross-sectional circle is W b and the minimum envelope of T, i.e. D min 2 =W b 2 +T 2 ,

[0074] Then the minimum value of the raw material cross-sectional area S is min =Pi x D min 2 / 4=Pi x(W b 2 +T 2 ) / 4.

[0075] The minimum value of the blank raw material volume V is V min =Pi x(W b 2 +T 2 )x L / 4. (The corresponding three welding methods are V1, V2, and V3).

[0076] For method 1, due to non-full welding, W can be obtained b1 =W a1 +W c1 , that is, W b1 >W a1 .

[0077] For method 2, due to non-full welding, W can be obtained b2 =W a2 +W c2 , that is, W b2 >W a2 .

[0078] For method 3, due to full welding, W can be obtained b3 =W a3 .

[0079] Among them, since the welding width of double-sided welding is smaller than that of single-sided welding, that is, W a1 >W a2 =W a3 .

[0080] Among them. Because we want to make W c1 =W c2 , we can get W b1 >W b2 .

[0081] Then we can get W b1 >W b2 >W b3 =W a2 =W a3 .

[0082] Then we can get V1>V2>V3.

[0083] And the raw material volume saved by method 2 is ΔV compared with method 1 12 =V1-V2=Pi x(W b1 2 -W b2 2 )x L / 4,

[0084] The raw material volume saved by method 3 compared with method 2 is ΔV23 =V2-V3=Pi x(W b2 2 -W b3 2 )x L / 4.

[0085] It can be seen that the double-sided full welding in the wire harness welding method saves the most raw materials, followed by the double-sided partial full welding. Both of them save raw materials more than the single-sided partial full welding in the background technology.

[0086] like Figure 7 As shown, in order to better fix and position the first wire harness 100 and the second wire harness 200, the wire harness welding method also includes providing a top wire tooling 600 and a wire clamping tooling 700, wherein the top wire tooling 600 positions the axial position of the first wire harness 100 and the second wire harness 200, and the wire clamping tooling 700 positions the radial position of the first wire harness 100 and the second wire harness 200.

[0087] In this embodiment, the specific process of the wire harness welding method is as follows:

[0088] Provide a first wire harness 100, a second wire harness 200, a terminal 300, an ultrasonic welding system, a positioning assembly, a wire top tool 600 and a wire clamping tool 700. Strip the ends of the first wire harness 100 and the second wire harness 200 to form a first welding section 110 and a second welding section 210; determine the first welding surface and the second welding surface of the terminal 300.

[0089] Adjust the spacing a between the two groups of adjusting push blocks 500 after extending in the first direction, so that the spacing a after extending is larger than the width b of the welding head 410, but the value of 1 / 2 (ab) needs to be not less than the diameter of the thin single wire, and the spacing between each group of adjusting push blocks 500 and the welding head 410 is not greater than the diameter of a single thin single wire; adjust the position of the bottom mold 420 and the adjusting push block 500, so that the distance between the bottom mold 420 and the adjusting push block 500 along the second direction is less than or equal to the diameter of a single thin single wire.

[0090] It should be noted that the two groups of adjusting push blocks 500 can move closer to and farther from each other along the first direction so as to adjust the distance a between the two groups of adjusting push blocks 500 when they are working.

[0091] First, the first wire harness 100 is pushed onto the top wire fixture 600 to place the first welding section 110 of the first wire harness 100 on the bottom mold 420 , and then the first wire harness 100 is fixed by the wire clamping fixture 700 .

[0092] Next, the terminal 300 is placed on the side of the first welding section 110 facing away from the bottom mold 420 , and the first welding surface is in contact with the first welding section 110 .

[0093] At this time, the two sets of adjusting push blocks 500 are extended to be clamped at both ends of the first welding section 110 and the terminal 300 along the first direction.

[0094] Next, after the second wiring harness 200 is pushed onto the top wire fixture 600, the second welding section 210 of the second wiring harness 200 is placed on the side of the terminal 300 away from the bottom mold 420, the second welding surface is in contact with the second welding section 210, and then the second wiring harness 200 is fixed with the wire clamping fixture 700.

[0095] Finally, the welding head 410 is placed on the side of the second welding section 210 away from the bottom mold 420 and between the two sets of adjustment push blocks 500 , and the ultrasonic welding system is started. The welding head 410 is pressed down to weld the second welding section 210 .

[0096] During the welding process, the downward pressing structure pushes the two groups of adjusting push blocks 500 to move along the second direction toward the bottom mold 420 .

[0097] The wire harness welding assembly provided in this embodiment saves raw materials, has low cost, and has good electrical and thermal conductivity.

[0098] The wire harness welding assembly is made by the above-mentioned wire harness welding method, and includes two welding wire harnesses, namely, a first wire harness 100 and a second wire harness 200. The first wire harness 100 and the second wire harness 200 are welded on both sides of the terminal 300. Compared with single-sided welding, the width of the terminal 300 needs to be smaller, thereby saving raw materials for making the terminal and reducing the cost. In addition, double-sided welding enables the first wire harness 100 and the second wire harness 200 to contact the terminal 300 on both sides, increasing the contact area between the core wires of the first wire harness 100 and the second wire harness 200 and the terminal, thereby making the entire wire harness welding assembly have good electrical conductivity and thermal conductivity.

[0099] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A wire harness welding method, characterized in that: The steps include: S1: providing a first wire harness (100), a second wire harness (200), a terminal (300), and an ultrasonic welding system, wherein the first wire harness (100) has a first welding section (110), the second wire harness (200) has a second welding section (210), the terminal (300) has a first welding surface and a second welding surface, and the ultrasonic welding system comprises a bottom mold (420) and a welding head (410); S2: placing the first welding section (110) on the bottom mold (420); S3: placing the terminal (300) on the side of the first welding section (110) facing away from the bottom mold (420), with the first welding surface abutting against the first welding section (110); S4: placing the second welding section (210) on the side of the terminal (300) facing away from the bottom mold (420), so that the second welding surface abuts against the second welding section (210); S5: placing the welding head (410) on the side of the second welding section (210) facing away from the bottom mold (420), starting the ultrasonic welding system, and the welding head (410) welds the first welding section (110) and the second welding section (210) to the first welding surface and the second welding surface respectively.

2. The wire harness welding method according to claim 1, characterized in that: The step S2 further comprises placing the welding head (410) on the side of the first welding section (110) facing away from the bottom mold (420), starting the ultrasonic welding system, and the welding head (410) pre-welding the first welding section (110).

3. The wire harness welding method according to claim 1, characterized in that: The wire harness welding method further comprises providing a positioning component, wherein the positioning component comprises two groups of adjusting push blocks (500), wherein the two groups of adjusting push blocks (500) are respectively capable of abutting against the first welding section (110), the terminal (300) and the side surfaces of both ends of the second welding section (210) along a first direction, wherein the spacing between the two groups of adjusting push blocks (500) along the first direction is a, and the width of the welding head (410) along the first direction is b, and a>b.

4. The wire harness welding method according to claim 3, characterized in that: The first wire harness (100) and the second wire harness (200) are both wire harnesses composed of a plurality of thin monofilaments, and the distance between the bottom surface of the adjusting push block (500) and the top surface of the bottom mold (420) is less than or equal to the diameter of a single thin monofilament.

5. The wire harness welding method according to claim 3, characterized in that: A slot (501) is provided inside the adjusting push block (500), and the terminals (300) are respectively inserted into the two slots (501) at two ends along the first direction, and the side surfaces of the terminals (300) abut against the bottom walls of the slots (501).

6. The wire harness welding method according to claim 3, characterized in that: An escape space (502) is provided inside the adjusting push block (500), and the terminal (300) is respectively clamped in the two escape spaces (502) at both ends along the first direction, so that only the second welding surface and the side surface of the terminal (300) are in contact with the inner wall of the escape space (502).

7. The wire harness welding method according to any one of claims 5 or 6, characterized in that: The welding head (410) welds the first welding section (110) and the second welding section (210), and the terminal (300) moves along a second direction toward the bottom mold (420), wherein the second direction is perpendicular to the first direction.

8. The wire harness welding method according to claim 7, characterized in that: The positioning assembly further comprises a pressing structure, wherein the pressing structure is capable of causing the two groups of adjusting push blocks (500) to move along the second direction towards or away from the bottom mold (420).

9. The wire harness welding method according to claim 1, characterized in that: The wire harness welding method further comprises providing a top wire fixture (600) and a wire clamping fixture (700), wherein the top wire fixture (600) locates the axial position of the first wire harness (100) and the second wire harness (200), and the wire clamping fixture (700) locates the radial position of the first wire harness (100) and the second wire harness (200).

10. A wire harness welding assembly, characterized in that: The wire harness welding assembly is manufactured by the wire harness welding method described in any one of claims 1-9.

Images