Integrated wire harness connection method

Abstract

The invention relates to an integrated wire harness connection method, which comprises the following steps of: stripping a cable sheath at a position where a main wire and a branch wire need to be connected; gathering the exposed shielding wires of the main wire and the branch wires to one end of the cable; a main line to-be-connected line I is inserted into the position A of the line-breaking-free wiring terminal I, and a branch line to-be-connected line I is inserted into the position B of the line-breaking-free wiring terminal I; a main line to-be-connected line II is inserted into the position a of the line-breaking-free wiring terminal II, and a branch line to-be-connected line II is inserted into the position b of the line-breaking-free wiring terminal II; winding the position D for 3-5 circles by using a fire-resistant adhesive tape; winding the position C for 3-5 circles by using a fire-resistant adhesive tape; performing recovery connection on the main line shielding wire and the branch line shielding wire at the position E; and the whole peeling position is fully wound in a 1 / 2 winding mode. The time consumption is reduced, the processing technology is simplified, and the material loss is reduced, so that the final purposes of low cost, high efficiency and rapid meeting of customer requirements are achieved.

Description

Technical Field

[0001] This invention relates to the field of integrated wire harness connection technology, and more particularly to an integrated wire harness connection method. Background Technology

[0002] To facilitate installation and maintenance, and to ensure that electrical equipment can operate under the harshest conditions, wires of different specifications and colors used in various electrical devices are rationally arranged and bundled together with insulating material. This is called a wire harness. Typically, copper-formed contact terminals (connectors) are crimped to the wires and cables, and then an insulation material or an outer metal shell is molded onto the outside, forming a component that connects circuits. The wire harness industry chain includes wires and cables, connectors, processing equipment, wire harness manufacturing, and downstream application industries. Wire harnesses have a wide range of applications, including automobiles, home appliances, computer and communication equipment, and various electronic instruments.

[0003] Typically, when connecting a main wire and multiple wires separated at designated locations in an integrated wire harness, the outer insulation layer at the connection point needs to be partially stripped. Then, the shielding wire is cut, and the inner wires at the designated locations are partially stripped to expose the internal fire-resistant mica tape. Without damaging the internal core wires, the mica tape is cut off with pointed-nose scissors. The small branch wires at the designated locations are left with their bare ends exposed. Using pipe pliers and connectors, the exposed copper wire of the main wire and the bare wire of the small branch are connected. The connection point is then wrapped with fire-resistant tape for protection. The shielding wire is then wrapped back with conductive cloth, and the entire stripped portion is wrapped with fire-resistant tape for protection. This wire harness operation is quite cumbersome and time-consuming, requires highly skilled operators, is prone to short circuits, easily damages copper wires, consumes a lot of raw materials, and is costly. Summary of the Invention

[0004] To overcome the shortcomings of existing technologies, an integrated wire harness connection method is proposed to solve the problems mentioned in the background.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] An integrated wire harness connection method includes the following steps:

[0007] Step 1: Strip the outer sheath of the cables at the points where the main line and branch lines need to be connected, exposing the shielding wires after stripping the outer sheath;

[0008] Step 2: At the location where crimping is required, gather the exposed shielding wires of the main wire and the branch wires to one end of the cable without cutting them;

[0009] Step 3: Install no-crushing terminal 1 and no-crushing terminal 2 at the locations where crimping is required;

[0010] Step 4: Insert the main line to be connected into position A of the no-breaking terminal block 1, and insert the branch line to be connected into position B of the no-breaking terminal block 1; insert the main line to be connected into position a of the no-breaking terminal block 2, and insert the branch line to be connected into position b of the no-breaking terminal block 2.

[0011] Step 5: Use pipe wrenches to limit and crimp the No-Breaking Terminal 1 and No-Breaking Terminal 2, and at the same time check whether the locking tongues on both sides of No-Breaking Terminal 1 and No-Breaking Terminal 2 are installed in place.

[0012] Step 6: Select position D near the branch line of the no-breaking terminal block one, and wrap the main line and the branch line to be connected at position D with fire-resistant tape 3-5 times; select position C near the branch line of the no-breaking terminal block two, and wrap the main line and the branch line to be connected at position C with fire-resistant tape 3-5 times.

[0013] Step 7: The position between position C and position D is position E. At position E, restore and reconnect the main line shielding wire and the branch line shielding wire to ensure the shielding effect.

[0014] Step 8: Wrap the entire stripped section of the main line and branch line in a 1 / 2 wrapping motion.

[0015] As a further technical solution of the present invention: in step one, a multi-functional stripping pliers is used to strip the outer sheath of the cable.

[0016] As a further technical solution of the present invention: in step four, when connecting the wire-free terminal one and the wire-free terminal two, the shielding wire must not be mixed in.

[0017] As a further technical solution of the present invention: in step seven, nickel-plated conductive cloth is used to restore and connect the main wire shielding wire and the branch wire shielding wire.

[0018] As a further technical solution of the present invention: in step eight, fire-resistant tape is used to wrap the entire stripping position of the main line and the branch line.

[0019] The beneficial effects of this invention are:

[0020] This invention allows for connection without stripping the insulation of the main wire and branch wires, thus avoiding damage to the internal core wires. It also avoids the problem of inadequate protection and short circuits caused by traditional stripping and crimping of exposed copper wires. Furthermore, it solves the problem of low efficiency and high cost associated with traditional stripping and crimping where the shielding wire is connected to the internal copper wires of the cable, requiring two layers of protection—including wrapping the exposed copper wires with tape and silicone sleeves.

[0021] The present invention allows for connection of the main wire shielding wire without cutting or removing the mica tape inside the wire. A small amount of conductive cloth can be used to connect the shielding wire, reducing material usage and solving the problems of high cost and large amount of conductive cloth used in the original wiring process.

[0022] This invention selects appropriate tools and matches optimized connection terminals according to different processes to quickly and effectively complete multi-wire connections; it eliminates the need for inner and outer stripping and restores the shielding wire, reducing time consumption, simplifying the processing technology, and reducing material waste, thereby achieving the ultimate goal of low cost, high efficiency, and rapid satisfaction of customer needs. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the main structure of the connection position of the wire-breaking-free terminal block in step four of the present invention;

[0024] Figure 2 This is a schematic diagram of the main structure of the refractory tape winding position in step six of the present invention;

[0025] Figure 3 This is a schematic diagram of the main structure of the shielding wire restoration position in step seven of the present invention.

[0026] In the diagram: 1-Main line, 11-Main line to be connected 1, 12-Main line to be connected 2, 2-Branch line, 21-Branch line to be connected 1, 22-Branch line to be connected 2, 3-No-breaking terminal block 1, 4-No-breaking terminal block 2, 5-Position A, 6-Position B, 7-Position a, 8-Position b, 9-Position D, 10-Position C, 31-Position E, 31-Fire-resistant tape. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Reference Figure 1-3 An integrated wire harness connection method includes a main wire 1 and a branch wire 2 to be connected, comprising the following steps:

[0029] Step 1: Strip the outer sheath of the cables at the connection points of main line 1 and branch line 2. Use multi-functional stripper pliers to strip the cable sheath. Select the appropriate multi-functional stripper pliers according to the wire diameter. After stripping the cable sheath, the shielding wire will be exposed.

[0030] Step 2: At the location where crimping is required, gather the exposed shielding wires of both the main cable 1 and the branch cable 2 to one end of the cable without cutting them. The shielding wires block external signal interference, ensuring effective signal transmission.

[0031] Step 3: At the location where crimping is required, install the wire-break-free terminal block 1 (3) and the wire-break-free terminal block 2 (4).

[0032] Step 4: Main line 1 includes main line wire 11 and main line wire 2 12, and branch line 2 includes branch line wire 21 and branch line wire 22. Insert main line wire 11 into position A 5 of the wire-free terminal block 3, and insert branch line wire 21 into position B 6 of the wire-free terminal block 3; insert main line wire 2 12 into position a 7 of the wire-free terminal block 4, and insert branch line wire 22 into position b 8 of the wire-free terminal block 4; when connecting the wire-free terminal block 3 and the wire-free terminal block 4, do not mix in the shielding wire.

[0033] Step 5: Use pipe wrenches to limit and crimp the non-breaking wire terminal 1 (3) and non-breaking wire terminal 2 (4), and at the same time check whether the locking tongues on both sides of non-breaking wire terminal 1 (3) and non-breaking wire terminal 2 (4) are installed in place.

[0034] Step Six: Refer to Figure 2 Select position D9 of the no-breaking-wire terminal 3 near branch line 2, and wrap the main wire 1 and branch line 21 at position D9 with fire-resistant tape 31 for 3-5 turns. Select position C10 of the no-breaking-wire terminal 4 near branch line 2, and wrap the main wire 1 and branch line 22 at position C10 with fire-resistant tape 31 for 3-5 turns. Wrapping the no-breaking-wire terminal 31 with fire-resistant tape 31 at positions D9 and C10 for 3-5 turns enhances the tensile strength of the no-breaking-wire terminal 3 and no-breaking-wire terminal 4, meeting better tensile strength requirements. The fire-resistant tape 31 protects the internal wires, enhances strength, and provides fire resistance and flame retardancy.

[0035] Step 7: The position between positions C10 and D9 is position E31. At position E31, reconnect the main line shielding wire and the branch line shielding wire. Use nickel-plated conductive cloth to reconnect the main line shielding wire and the branch line shielding wire to ensure shielding effectiveness. Nickel-plated conductive cloth uses fiber cloth (commonly polyester fiber cloth) as the base material. After pretreatment, it is electroplated with a metallic layer to give it metallic properties, thus becoming conductive fiber cloth. The material is polyester fiber, first electroplated with metallic nickel, then with a highly conductive copper layer, and finally with anti-oxidation and anti-corrosion nickel metal. The combination of copper and nickel provides excellent conductivity and good electromagnetic shielding effect, with a shielding range of 100K GHz.

[0036] Step 8: Fully wrap the stripped sections of main wire 1 and branch wire 2 with fire-resistant tape 31. The fire-resistant tape 31 protects the internal wires, enhances strength, and provides fire resistance and flame retardancy.

[0037] It will be apparent to those skilled in the art that the present 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 its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0038] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A method for connecting integrated wire harnesses, characterized in that: Includes the following steps, Step 1: Strip the outer sheath of the cables at the connection points of the main line (1) and the branch line (2), exposing the shielding wire after stripping the outer sheath; Step 2: At the location where crimping is required, gather the exposed shielding wires of the main wire (1) and the branch wire (2) to one end of the cable without cutting them; Step 3: At the location where crimping is required, install the first (3) and the second (4) of the wire-breaking-free terminal block. Step 4: Insert the main line to be connected (11) into position A (5) of the no-breaking terminal block (3), insert the branch line to be connected (21) into position B (6) of the no-breaking terminal block (3); insert the main line to be connected (12) into position a (7) of the no-breaking terminal block (4), insert the branch line to be connected (22) into position b (8) of the no-breaking terminal block (4); Step 5: Use pipe wrenches to limit and crimp the non-breaking wire terminal 1 (3) and non-breaking wire terminal 2 (4), and at the same time check whether the locking tongues on both sides of non-breaking wire terminal 1 (3) and non-breaking wire terminal 2 (4) are installed in place; Step 6: Select position D (9) of the no-break terminal block 1 (3) near the branch line (2), and wrap the main line (1) and the branch line to be connected (21) at position D (9) with fire-resistant tape (31) 3-5 times; Select position C (10) of the no-break terminal block 2 (4) near the branch line, and wrap the main line (1) and the branch line to be connected (22) at position C (10) with fire-resistant tape (31) 3-5 times; Step 7: The position between position C (10) and position D (9) is position E (31). At position E (31), the main line shielding wire and the branch line shielding wire are restored and connected to ensure the shielding effect. Step 8: Wrap the entire peeled area of ​​the main line (1) and the branch line (2) in a 1 / 2 wrapping manner.

2. The integrated wire harness connection method according to claim 1, characterized in that: In step one, multi-functional stripping pliers are used to remove the cable sheath.

3. The integrated wire harness connection method according to claim 1, characterized in that: In step four, when connecting the wire-free terminal one (3) and the wire-free terminal two (4), the shielding wire must not be mixed in.

4. The integrated wire harness connection method according to claim 1, characterized in that: In step seven, nickel-plated conductive cloth is used to restore and connect the main wire shielding wire and the branch wire shielding wire.

5. The integrated wire harness connection method according to claim 1, characterized in that: In step eight, fire-resistant tape (31) is used to wrap the entire peeling position of the main line (1) and the branch line (2).

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