New energy automobile wire harness and processing equipment thereof

Abstract

The application relates to a new energy automobile wire harness and a processing equipment thereof, and relates to the automobile wire harness processing field.The new energy automobile wire harness comprises a wire harness cable, the wire harness cable has, from inside to outside, a composite conductor, a dynamic insulation layer and a sheath in sequence, the composite conductor is composed of silver-plated copper wire and nanometer carbon tube spiral weaving, the outer layer is coated with a vapor deposition aluminum oxide film, and the inside is pre-buried with a cooling material, the sheath is composed of aramid fiber woven net and polyurethane foam, and the inside is provided with a titanium-nickel alloy spring; the processing equipment of the wire harness comprises a winding assembly and a flattening piece, the winding assembly can realize adhesive tape winding, the flattening piece can flatten the wire harness, and the equipment further comprises a conveying device. The application has the effect of improving safety.

Description

Technical Field

[0001] This application relates to the field of automotive wiring harness processing, and in particular to a new energy vehicle wiring harness and its processing equipment. Background Technology

[0002] With the booming development of the new energy vehicle industry, the level of intelligence and electrification of automobiles is constantly improving. As a key component for power transmission and signal transmission in new energy vehicles, the performance and quality of automotive wiring harnesses directly affect the safety, reliability, and overall performance of the vehicle. High-quality automotive wiring harnesses can ensure stable power transmission, reduce signal interference, and guarantee the normal operation of various vehicle systems, which is of great significance for enhancing the market competitiveness of new energy vehicles. At the same time, with the continuous increase in the driving range requirements of new energy vehicles and the widespread application of various advanced electronic devices, the performance requirements for automotive wiring harnesses are also becoming increasingly stringent.

[0003] In existing technologies, ordinary copper wire is typically used as the conductor in automotive wiring harnesses. However, this conductor is prone to oxidation and aging during long-term use, affecting its conductivity. For the insulation layer, common plastic or rubber materials are generally chosen, but these materials exhibit poor insulation stability in complex working environments. Regarding the sheath, the traditional approach is to use ordinary rubber or plastic sheaths, which offer limited protection and are ill-suited to withstand scratches from sharp objects and external impacts. When securing the cables, simple binding methods are usually employed, which are ineffective and prone to causing the cables to loosen.

[0004] However, ordinary copper wires are prone to oxidation and aging, which reduces the conductivity of the wire harness, increases energy consumption, and may even cause safety hazards. Common insulation materials have unstable insulation performance in complex environments, which may lead to problems such as leakage. Ordinary sheaths have weak protective capabilities and cannot effectively protect cables from external damage. Simple binding methods for fixing cables are not secure and can easily cause the cables to shift during vehicle movement. All of these defects can cause safety problems. Summary of the Invention

[0005] To improve safety, this application provides a wiring harness for a new energy vehicle and its processing equipment.

[0006] Firstly, this application provides a wiring harness for a new energy vehicle, employing the following technical solution: A wiring harness for new energy vehicles includes several cables with connectors fixed at both ends. The cables are secured by wrapping with tape. From the inside out, each cable includes a composite conductor, a dynamic insulation layer, and a sheath. The connectors are fixedly connected to the composite conductor. The composite conductor is made of silver-plated copper wire and carbon nanotubes spirally braided together. The outer layer of the composite conductor is covered with a vapor-deposited alumina film. Cooling material is pre-embedded along the axial direction inside the composite conductor. The sheath is made of aramid fiber braided mesh and polyurethane foam composite. A titanium-nickel alloy spring is installed on the inner side of the sheath.

[0007] By adopting the above technical solutions, the composite conductor improves the conductivity and mechanical strength of the cable, reducing signal transmission losses. The vapor-deposited alumina film isolates the composite conductor from external oxidizing and corrosive substances, preventing oxidation and corrosion and thus extending the cable's lifespan. When the cable temperature rises, the cooling material absorbs heat and undergoes a phase change, lowering the cable temperature and preventing damage due to overheating, ensuring stable operation under different working conditions. The aramid fiber braided mesh, with its high strength and high modulus, enhances the sheath's wear resistance and tensile strength, while the polyurethane foam provides excellent cushioning and insulation, further protecting the cable's internal structure. A titanium-nickel alloy spring inside the sheath not only enhances the cable's bending and tensile strength, making it less prone to deformation or damage under external forces, but also provides some shielding against external electromagnetic interference. Multiple cables are secured with tape, facilitating organization and installation while reducing mutual interference, thereby improving safety during use.

[0008] Optionally, the dynamic insulating layer comprises an inner layer, a middle layer, and an outer layer from the inside out. The inner layer is made of a polyolefin-based phase change elastomer, the middle layer is made of radiation-crosslinked silicone rubber, and the outer layer is made of a fluorinated ethylene propylene copolymer film. The outer surface of the dynamic insulating layer is etched with micron-level trenches and filled with silicone oil gel.

[0009] By adopting the above technical solutions, polyolefin-based phase change elastomers possess flexibility and phase change characteristics, enabling them to undergo phase changes upon temperature variations, absorbing or releasing heat. This effectively suppresses heat accumulation during cable operation, acting as a thermal buffer and improving the cable's thermal stability. Radiation-crosslinked silicone rubber offers electrical insulation, heat resistance, and aging resistance, providing insulation protection for cables and preventing current leakage and short circuits. Fluorinated ethylene-propylene copolymer films exhibit chemical stability, corrosion resistance, and a low coefficient of friction, protecting the inner and middle layers from external environmental factors and extending the cable's service life. Silicone oil gel possesses high lubricity and insulation properties, further enhancing the insulation effect of the dynamic insulation layer, reducing friction between the cable and the external environment, and minimizing cable wear during use. Furthermore, micron-level grooves increase the adhesion area of ​​the silicone oil gel, allowing it to function more effectively.

[0010] Secondly, this application provides a processing equipment for wiring harnesses of new energy vehicles, which adopts the following technical solution: A processing device for wiring harnesses of new energy vehicles includes a winding assembly and two flattening members that move synchronously in opposite directions in the horizontal direction. The flattening members are used to flatten the wiring harness along the axial direction. The winding assembly is located between the two flattening members. The winding assembly includes a tape fixing member, a drive seat, an external gear ring, a winding motor, and two winding gears of the same size. The tape fixing member is rotatably connected to the inside of the external gear ring. The drive seat moves parallel to the moving direction of the flattening members and perpendicular to the moving direction of the flattening members. The external gear ring is rotatably connected to the drive seat and has a wire inlet channel. The winding motor is fixedly connected to the drive seat. The output end of the winding motor is coaxially fixedly connected to one of the gears. Both winding gears mesh with the external gear ring. Both winding gears are coaxially fixed with synchronous pulleys. Synchronous belts are connected to the outside of the two synchronous pulleys.

[0011] By adopting the above technical solutions, the flattening component can flatten the wire harness along the axial direction, ensuring the flatness of the wire harness during processing, avoiding bending or twisting, and improving processing quality. The winding assembly is used to wind the flattened wire harness. The tape fixing component can flexibly wind the wire harness with tape, and the winding position and angle can be adjusted according to actual needs. The wire inlet channel opened on the external gear ring facilitates the entry of the wire harness into the winding area. Driven by the winding motor, the two winding gears can rotate synchronously, thereby driving the external gear ring and the tape fixing component to rotate, realizing efficient and stable winding processing of new energy vehicle wire harnesses.

[0012] Optionally, a pressure roller is provided on the side of the tape fixing member near the axis of the outer toothed ring. The pressure roller is located in front of the moving path of the tape fixing member. The pressure roller is rotatably connected to the outer toothed ring. An elastic element is provided between the pressure roller and the tape fixing member. In the initial state, the elastic element drives the pressure roller away from the tape fixing member.

[0013] By adopting the above technical solution, when the tape fixing component conveys the tape to wind the wiring harness of new energy vehicles, the pressure roller can pre-treat the winding position, making the winding surface smoother and facilitating the tape's adhesion and winding. The pressure roller is rotatably connected to the external toothed ring, ensuring that the pressure roller can rotate flexibly during operation, reducing frictional resistance with the wiring harness and preventing damage to the wiring harness. Simultaneously, an elastic element is installed between the pressure roller and the tape fixing component. In its initial state, the elastic element drives the pressure roller away from the tape fixing component. Thus, when encountering new energy vehicle wiring harnesses of different thicknesses, the elastic element can elastically deform according to the actual condition of the wiring harness, allowing the pressure roller to adaptively adjust its fit with the wiring harness, ensuring appropriate clamping force. This effectively clamps the tape, ensuring the winding effect, without damaging the wiring harness or tape due to excessive pressure.

[0014] Optionally, the flattening component includes a sliding frame, a stop bar, a clamping cylinder, an upper clamping roller, and a lower clamping roller. The sliding frame moves horizontally, and the clamping cylinder is fixedly connected to the upper end of the sliding frame. The clamping cylinder is used to push the upper clamping roller to move vertically. The lower clamping roller is rotatably connected to the sliding frame. The upper end of the stop bar is fixedly connected to the sliding frame, and the lower end of the stop bar is located below the upper clamping roller. The stop bar is located on the side of the upper clamping roller near the winding assembly.

[0015] By adopting the above technical solution, the sliding frame can drive all its components to move together in the horizontal direction, which facilitates the straightening operation of the wire harness; the clamping cylinder pushes the upper clamping roller to move vertically, which can realize the clamping or loosening action of the upper and lower clamping rollers on the wire harness, thereby flexibly fixing and releasing the wire harness; the lower clamping roller is rotatably connected to the sliding frame, which can reduce the friction on the wire harness during the flattening process, which is conducive to smoother flattening of the wire harness; the stop bar can prevent the wire harness from deviating from the predetermined flattening path during the flattening process, and the stop bar plays a limiting and guiding role, ensuring a more stable and reliable flattening effect.

[0016] Optionally, the upper clamping roller is provided with an upper clamping plate on the side away from the winding assembly, and the lower clamping roller is provided with a lower clamping arc plate on the side away from the winding assembly. The lower clamping arc plate is coaxially arranged with the stop rod, and the upper clamping plate is rotatably connected to the stop rod along the axis of the stop rod. When the upper and lower clamping rollers clamp the wire harness, the lower end of the upper clamping is higher than the lower side of the upper clamping roller, and the upper end of the lower clamping is lower than the upper side of the lower clamping roller.

[0017] By adopting the above technical solution, the upper clamping plate and the lower clamping arc plate move with the sliding frame to achieve the contact and clamping of the joint; by rotating the upper clamping plate, the wire harness abuts against the stop bar, and the joint rotates along the axis of the stop bar and in contact with the lower clamping arc plate. When the joint disengages from the lower clamping arc plate, the joint disengages from the upper clamping plate under the action of gravity, allowing the wire harness at the joint to fall from the gap between the stop bar and the upper clamping roller. Then the upper clamping plate returns in the opposite direction to continue clamping and winding the remaining wire harness, thereby improving the automation level of wire harness winding.

[0018] Optionally, the upper clamping plate is fixedly connected to a first bevel gear, which is located on the side of the two clamping rollers that are far apart from each other. The first bevel gear is rotatably connected to the stop rod on the same axis. The first bevel gear is meshed with a second bevel gear, which is rotatably connected to the sliding frame. The second bevel gear is coaxially fixedly connected to a rotating gear. A frame is rotatably connected above the upper clamping rollers, and the frame is fixedly provided with a rack that meshes with the rotating gear in the vertical direction.

[0019] By adopting the above technical solution, when the upper clamping roller moves up and down, it drives the frame body rotatably connected to it to move. The rack on the frame body moves vertically accordingly. Since the rack meshes with the rotating gear, the rotating gear rotates. The rotating gear drives the second bevel gear, which is fixedly connected to it on the same axis, to rotate. The second bevel gear meshes with the first bevel gear, which in turn rotates. Because the first bevel gear is fixedly connected to the upper clamping plate and rotatably connected to the stop rod on the same axis, the rotation of the upper clamping plate around the axis of the stop rod can be controlled. This facilitates the adjustment of the angle of the upper clamping plate when the clamping roller clamps the wire harness, better matching the clamping and flattening operation of the wire harness, and improving the stability and efficiency of the processing equipment for processing new energy vehicle wire harnesses.

[0020] Optionally, a conveying device is also included, which includes a conveyor belt, a feeding frame, and a feeding drive. The conveyor belt is located at the middle position of the two flattening members along the moving direction, and the conveying direction of the conveyor belt is perpendicular to the moving direction of the flattening members. The feeding frame is located below the material discharge end of the conveyor belt, and the upper end face of the feeding frame is located between the upper clamping roller and the lower clamping roller. Mounting frames are provided on both sides of the conveyor belt, and support frames are fixedly mounted on the mounting frames. The feeding drive is fixedly connected to the support frames, and the feeding drive is located on the side of the feeding frame away from the fixed device. The width of the feeding frame is smaller than the width of the conveyor belt.

[0021] By adopting the above technical solution, the conveyor belt can transport the wire harness to be processed to the designated position, improving processing efficiency. The feeding rack can accurately receive the wire harness falling from the conveyor belt and send it to the clamping rollers of the flattening component for flattening, ensuring the accuracy and continuity of wire harness transportation. The feeding drive component can stably drive the feeding rack to move, ensuring the smoothness of the feeding process. The width of the feeding rack is smaller than the width of the conveyor belt, allowing the wire harness to fall smoothly from the conveyor belt onto the feeding rack, and the joint is located below the feeding rack, allowing the wire harness on the feeding rack to be transported between the upper and lower clamping rollers, improving the reliability of transportation.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. Composite conductors improve the conductivity and mechanical strength of cables, reducing signal transmission losses. Vapor-deposited alumina film isolates the composite conductor from external oxidizing and corrosive substances, preventing oxidation and corrosion and extending cable lifespan. When cable temperature rises, cooling materials absorb heat and undergo phase change, lowering the cable temperature and preventing damage from overheating, ensuring stable operation under various conditions. Aramid fiber braided mesh, with its high strength and high modulus, enhances the sheath's wear resistance and tensile strength, while polyurethane foam provides excellent cushioning and insulation, further protecting the cable's internal structure. Titanium-nickel alloy springs inside the sheath not only enhance the cable's bending and tensile strength, making it less prone to deformation or damage under external forces, but also shield against external electromagnetic interference to some extent. Multiple cables are secured with tape, facilitating organization and installation while reducing interference between cables, thus improving safety during use. 2. The flattening component can flatten the wire harness along its axial direction, ensuring its flatness during processing, preventing bending or twisting, and improving processing quality. The winding assembly facilitates the winding operation of the flattened wire harness. The tape fixing component allows for flexible tape winding of the wire harness, and the winding position and angle can be adjusted according to actual needs. The wire inlet channel opened on the external gear ring facilitates the entry of the wire harness into the winding area. Driven by the winding motor, the two winding gears rotate synchronously, thereby driving the external gear ring and the tape fixing component to rotate, achieving efficient and stable winding processing of new energy vehicle wire harnesses; 3. The upper clamping plate and the lower clamping arc plate move with the sliding frame to achieve abutment and clamping of the joint; by rotating the upper clamping plate, the wire harness abuts against the stop bar, and the joint rotates along the axis of the stop bar and in contact with the lower clamping arc plate. When the joint disengages from the lower clamping arc plate, the joint disengages from the upper clamping plate under the action of gravity, allowing the wire harness at the joint to fall from the gap between the stop bar and the upper clamping roller. Then the upper clamping plate returns in the opposite direction to continue clamping and winding the remaining wire harness, which improves the automation level of wire harness winding. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of a wiring harness for a new energy vehicle.

[0024] Figure 2 yes Figure 1 A cross-sectional view along the AA direction.

[0025] Figure 3 This is a schematic diagram of the structure of a car wiring harness after the outer sheath has been removed.

[0026] Figure 4 This is a schematic diagram of the overall structure of a processing equipment for wiring harnesses in new energy vehicles.

[0027] Figure 5 This is a structural schematic diagram of the conveying device viewed from below.

[0028] Figure 6 This is a structural schematic diagram of the flattening component.

[0029] Figure 7 yes Figure 6 An enlarged schematic diagram of part A in the middle.

[0030] Figure 8 This is a schematic diagram of the winding assembly after the drive seat has been removed.

[0031] Explanation of reference numerals in the attached diagram: 1. Cable; 11. Composite conductor; 111. Silver-plated copper wire; 112. Carbon nanotube; 12. Dynamic insulation layer; 121. Inner layer; 122. Middle layer; 123. Outer layer; 13. Sheath; 14. Cooling material; 15. Spring; 2. Connector; 3. Winding assembly; 31. Tape fixing component; 32. Drive base; 33. External gear ring; 331. Cable inlet channel; 34. Winding motor; 35. Winding gear; 351. Synchronous pulley; 352. Same... 36. Stepping belt; 37. Pressure roller; 4. Elastic component; 5. Flattening component; 6. Sliding frame; 7. Second bevel gear; 8. Rotating gear; 9. Stop bar; 10. Clamping cylinder; 11. Upper clamping roller; 12. Frame body; 13. Rack; 14. Lower clamping roller; 15. Upper clamping plate; 16. First bevel gear; 17. Lower clamping arc plate; 18. Conveying device; 19. Conveyor belt; 20. Feeding frame; 31. Feeding drive component; 22. Mounting frame; 33. Support frame. Detailed Implementation

[0032] The present application will be further described in detail below with reference to all the accompanying drawings.

[0033] In one aspect, embodiments of this application disclose a wiring harness for new energy vehicles.

[0034] Reference Figure 1 and Figure 2 A wiring harness for new energy vehicles includes several cables 1 and connectors 2. The two ends of each cable 1 are connected to the same connector 2. The cables 1 are wrapped together with tape to form wiring harnesses that perform different functions. Several wiring harnesses of different lengths and functions are further wrapped together with tape to form a wiring harness group. This facilitates organization and installation, while also reducing mutual interference between the cables 1 and improving safety performance during use.

[0035] Reference Figure 2 and Figure 3The cable 1 comprises, from the inside out, a composite conductor 11, a dynamic insulation layer 12, and a sheath 13. Connectors 2 are fixed to both ends of the cable 1 and connected to the composite conductor 11. The composite conductor 11 is constructed by spirally braiding silver-plated copper wire 111 and carbon nanotubes 112. The silver-plated copper wire 111 has good conductivity, while the carbon nanotubes 112 have high strength and good conductivity. The spiral braiding improves the conductivity and mechanical strength of the cable 1, reducing signal transmission losses. The outer layer 123 of the composite conductor 11 is coated with a vapor-deposited alumina film. This film isolates the composite conductor from external oxidizing and corrosive substances, preventing oxidation and corrosion and thus extending the cable 1's lifespan. Alternatively, nickel-plated copper wire and graphene fiber spirally braided can be used to construct the composite conductor 11, similarly improving conductivity and mechanical strength. A cooling material 14 is pre-embedded inside the composite conductor 11 along the axial direction. The cooling material 14 can be a phase change material. When the temperature of the cable 1 rises, the cooling material 14 absorbs heat and undergoes a phase change, reducing the temperature of the cable 1 and preventing the cable 1 from being damaged due to excessive temperature, thus ensuring the stable operation of the cable 1 under different working conditions. Alternatively, the cooling material 14 can also be a paraffin-based phase change material.

[0036] Reference Figure 2 The dynamic insulation layer 12 comprises, from the inside out, an inner layer 121, a middle layer 122, and an outer layer 123. The inner layer 121 is made of a polyolefin-based phase change elastomer, which possesses flexibility and phase change characteristics. It can undergo a phase change upon temperature change, absorbing or releasing heat, thereby effectively suppressing heat accumulation during cable 1 operation, acting as a thermal buffer, and improving the thermal stability of cable 1. Alternatively, the inner layer 121 can be made of other elastomer materials with similar phase change characteristics. The middle layer 122 is made of radiation-crosslinked silicone rubber, which possesses electrical insulation properties, heat resistance, and aging resistance, providing insulation protection for cable 1 and preventing current leakage and short circuits. Alternatively, fluorosilicone rubber can be used as the material for the middle layer 122. The outer layer 123 is made of a fluorinated ethylene propylene copolymer film, which possesses chemical stability, corrosion resistance, and a low coefficient of friction, protecting the inner layer 121 and the middle layer 122 from external environmental factors and extending the service life of cable 1. Alternatively, the outer layer 123 can be made of polytetrafluoroethylene film. Micron-level trenches are etched on the outer surface of the dynamic insulation layer 12 and filled with silicone oil gel. The silicone oil gel has high lubricity and insulation properties, which can further improve the insulation effect of the dynamic insulation layer 12, reduce the friction between the cable 1 and the outside world, reduce the wear of the cable 1 during use, and the micron-level trenches can increase the adhesion area of ​​the silicone oil gel, so that the silicone oil gel can play a better role.

[0037] Reference Figure 2The sheath 13 is composed of an aramid fiber braided mesh and polyurethane foam. The aramid fiber braided mesh features high strength and high modulus, enhancing the sheath 13's abrasion resistance and tensile strength. The polyurethane foam provides excellent cushioning and insulation, further effectively protecting the internal structure of the cable 1. Alternatively, a fiberglass braided mesh combined with rubber foam can be used to form the sheath 13. A titanium-nickel alloy spring 15 is installed inside the sheath 13, which not only enhances the cable 1's bending and tensile strength, making it less prone to deformation or damage under external forces, but also provides a certain degree of shielding against external electromagnetic interference. Alternatively, a shape memory alloy spring 15 can be used to replace the titanium-nickel alloy spring 15.

[0038] The implementation principle of a new energy vehicle wiring harness according to this application embodiment is as follows: By adopting a composite conductor 11, a dynamic insulation layer 12, and a specially structured sheath 13, the conductivity, insulation performance, mechanical strength, and protection capability of the new energy vehicle wiring harness are improved. Simultaneously, the thermal buffering effect of the cooling material 14 and the dynamic insulation layer 12 ensures the stable operation of the cable 1 under different operating conditions. The tape wrapping and fixing method improves the convenience of wiring harness organization and installation, reduces mutual interference between cables 1, and comprehensively enhances the safety and reliability of the new energy vehicle wiring harness. Compared with existing technologies, it effectively solves problems such as easy oxidation and aging, unstable insulation performance, weak protection capability, and insecure fixing of ordinary wiring harnesses.

[0039] On the other hand, this application discloses a processing equipment for wiring harnesses of new energy vehicles.

[0040] Reference Figure 4 A processing device for wiring harnesses of new energy vehicles includes a winding assembly 3, two flattening members 4 that move synchronously in opposite directions along the horizontal direction, and a conveying device 5. The conveying device 5 is used to convey the wiring harness or cable 1 to the flattening member 4, the flattening member 4 is used to flatten the wiring harness or cable 1 along the axial direction, and the winding assembly 3 is located between the two flattening members 4, and the winding assembly 3 is used to wind the flattened wiring harness or cable 1.

[0041] Reference Figure 4 and Figure 5The conveying device 5 includes a conveyor belt 51, a feeding rack 52, and a feeding drive unit 53. The conveyor belt 51 is located in the middle of the two flattening members 4 along the moving direction. The conveying direction of the conveyor belt 51 is perpendicular to the moving direction of the flattening members 4. The conveyor belt 51 is driven by a motor, and the wire harness falls from the conveyor belt 51 onto the feeding rack 52. The feeding rack 52 is located below the unloading end of the conveyor belt 51. The feeding rack 52 can accurately receive the wire harness falling from the conveyor belt 51 and send it to the flattening member 4 for flattening, ensuring the accuracy and continuity of the wire harness or cable 1 conveying. The conveyor belt 51 is provided with mounting frames 54 on both sides, and the mounting frames 54 are fixedly provided with support frames 55. The feeding drive component 53 is fixedly connected to the support frame 55. The feeding drive component 53 is located on the side of the feeding frame 52 away from the fixed device. The feeding drive component 53 can be a cylinder. The feeding drive component 53 drives the feeding frame 52 to slide on the support frame 55 along the conveying direction parallel to the conveyor belt 51, and conveys the wire harness on the feeding frame 52 to the flattening component 4.

[0042] Reference Figure 5 The feeding frame 52 is a "mountain" shaped frame, consisting of a push rod and three support rods. The push rod is fixedly connected to the telescopic end of the feeding drive 53, and the three support rods are fixed at the end of the push rod near the fixed device. The middle support rod supports the cable 1, and the two side support rods slide on the support frame 55 and support the wire harness. The width of the feeding frame 52 is smaller than the width of the conveyor belt 51. When the wire harness or cable 1 is placed on the conveyor belt 51 for conveying, the connector 2 is in front and close to the side of the conveyor belt 51, and the wire harness or cable 1 is bent at the back. As the conveyor belt 51 conveys, the connector 2 first detaches from the conveyor belt 51 and falls downward. The connector 2 falls to the position between the feeding frame 52 and the mounting frame 54. As the conveyor belt 51 continues to rotate, the connector 2 continues to descend to below the feeding frame 52, and the wire harness or cable 1 falls to the upper end of the feeding frame 52, so that the wire harness or cable 1 on the feeding frame 52 can be clamped by the flattening component 4, improving the reliability of the conveying. Alternatively, the conveyor belt 51 can be a chain conveyor belt 51.

[0043] Reference Figure 6 The flattening component 4 includes a sliding frame 41, a stop bar 42, a clamping cylinder 43, an upper clamping roller 44, and a lower clamping roller 45. The sliding frame 41 moves horizontally, driving all its components to move horizontally as well, facilitating the straightening of the cable 1 or wire harness. The movement of the sliding frame 41 can be driven by an electric screw. The clamping cylinder 43 is fixedly connected to the upper end of the sliding frame 41 and is used to push the upper clamping roller 44 to move vertically, enabling the upper clamping roller 44 and the lower clamping roller 45 to clamp or release the wire harness, thus allowing for flexible fixing and release of the wire harness. The upper end face of the feeding frame 52 is located between the upper clamping roller 44 and the lower clamping roller 45, allowing the cable 1 or wire harness to be fed between the upper clamping roller 44 and the lower clamping roller 45. The upper clamping roller 44 and the lower clamping roller 45 of each flattening component 4 clamp the cable 1 or wire harness between two adjacent support rods.

[0044] Reference Figure 6 The lower clamping roller 45 is rotatably connected to the sliding frame 41, and the frame body 441 is rotatably connected above the upper clamping roller 44. This reduces the friction on the wire harness during the flattening process, which facilitates smoother flattening of the wire harness. The upper end of the frame body 441 is fixedly connected to the telescopic end of the clamping cylinder 43. The clamping cylinder 43 pushes the frame body 441 to achieve the vertical movement of the upper clamping roller 44.

[0045] Reference Figure 6 The upper end of the stop rod 42 is fixedly connected to the sliding frame 41, and the lower end of the stop rod 42 is located below the upper clamping roller 44. The stop rod 42 is located on the side of the upper clamping roller 44 closer to the winding assembly 3. When the feeding frame 52 conveys the wire harness or cable 1 between the upper clamping roller 44 and the lower clamping roller 45, the stop rod 42 can limit the position of the wire harness or cable 1 between the upper clamping roller 44 and the lower clamping roller 45. At the same time, it can play a limiting and guiding role during the flattening process, ensuring a more stable and reliable flattening effect.

[0046] Reference Figure 6 The upper clamping roller 44 has an upper clamping plate 46 on the side away from the winding assembly 3, and the lower clamping roller 45 has a lower clamping arc plate 47 on the side away from the winding assembly 3. The lower clamping arc plate 47 is coaxially arranged with the stop rod 42. The upper clamping plate 46 is rotatably connected to the stop rod 42 along the axis of the stop rod 42. When the upper clamping roller 44 and the lower clamping roller 45 clamp the wire harness or cable 1, the lower end of the upper clamping is higher than the lower side of the upper clamping roller 44, and the upper end of the lower clamping is lower than the upper side of the lower clamping roller 45. The upper clamping plate 46 and the lower clamping arc plate 47 move with the sliding frame 41 to achieve abutment and clamping of the connector 2. By rotating the upper clamping plate 46, the wire harness or cable 1 abuts against the stop bar 42, and the connector 2 rotates along the axis of the stop bar 42 and in contact with the lower clamping arc plate 47. When the connector 2 disengages from the lower clamping arc plate 47, the connector 2 disengages from the upper clamping plate 46 under the action of gravity, so that the wire harness or cable 1 at the connector 2 falls from the gap between the stop bar 42 and the upper clamping roller 44. Then the upper clamping plate 46 returns in the opposite direction and continues to clamp and wind the remaining wire harness or cable 1, which improves the automation level of the winding of the wire harness or cable 1.

[0047] Reference Figure 6 and Figure 7The upper clamping plate 46 is fixedly connected to a first bevel gear 461, which is located on the side of the two clamping rollers that are far apart from each other. The first bevel gear 461 is rotatably connected to the stop rod 42 on the same axis. The first bevel gear 461 is meshed with a second bevel gear 411, which is rotatably connected to the sliding frame 41. The second bevel gear 411 is fixedly connected to a rotating gear 412 on the same axis. The frame body 441 is fixedly provided with a rack 442 that meshes with the rotating gear 412 in the vertical direction. When the upper clamping roller 44 moves up and down, it drives the frame 441, which is rotatably connected to it above, to move. The rack 442 on the frame 441 moves vertically accordingly. Since the rack 442 meshes with the rotating gear 412, the rotating gear 412 rotates. The rotating gear 412 drives the second bevel gear 411, which is coaxially fixedly connected to it, to rotate. The second bevel gear 411 meshes with the first bevel gear 461, which in turn rotates. Since the first bevel gear 461 is fixedly connected to the upper clamping plate 46 and rotatably connected to the stop rod 42, the upper clamping plate 46 can be controlled to rotate around the axis of the stop rod 42. This facilitates the angle adjustment of the upper clamping plate 46 when the clamping roller clamps the wire harness or cable 1, better cooperating with the clamping and flattening operation of the wire harness or cable 1, and improving the stability and efficiency of the processing equipment for processing new energy vehicle wire harnesses.

[0048] Specifically, after the upper clamping plate 46 and the lower clamping arc plate 47 have finished clamping the connector 2, the upper clamping roller 44 moves away from the wire harness, and the upper clamping plate 46 can rotate around the stop bar 42, so that the connector 2 of the short wire harness moves away from other long wire harnesses, and the long wire harnesses fall onto the lower clamping roller 45, making it easier for the winding assembly 3 to continue winding and fixing other long wire harnesses. After the connector 2 of the short wire harness is wound between the stop bar and the upper clamping roller 44, the connector 2 of the short wire harness falls downward, and the upper clamping roller 44 of the same sliding frame 41 moves again to approach the lower clamping roller 45 to clamp the remaining wire harness. Then the upper clamping plate 46 rotates in the opposite direction, and the sliding frame 41 continues to move, so that the upper clamping plate 46 and the lower clamping arc plate 47 clamp the connector 2 of the long wire harness again.

[0049] Reference Figure 4 and Figure 8 The winding assembly 3 includes a tape holder 31, a drive base 32, an external gear ring 33, a winding motor 34, and two winding gears 35 of the same size. The tape holder 31 is rotatably connected inside the external gear ring 33, enabling flexible tape winding of the wire harness. The winding position and angle can be adjusted according to actual needs. The drive base 32 moves parallel to and perpendicular to the moving direction of the flattening member 4. Movement in both directions can be achieved through a screw drive, hydraulic cylinder, pneumatic cylinder, or electric push rod structure.

[0050] Reference Figure 8The external gear ring 33 is rotatably connected to the drive base 32. The external gear ring 33 has an inlet channel 331 to facilitate the entry of the wire harness into the winding area. The winding motor 34 is fixedly connected to the drive base 32. The output end of the winding motor 34 is coaxially fixedly connected to one of the gears. Both winding gears 35 mesh with the external gear ring 33. Each of the two winding gears 35 is coaxially fixed with a synchronous pulley 351, and a synchronous belt 352 is connected to the outer side of each synchronous pulley 351. Driven by the winding motor 34, the two winding gears 35 rotate synchronously, thereby driving the external gear ring 33 and the tape fixing component 31 to rotate, achieving efficient and stable winding processing of the new energy vehicle wire harness. Alternatively, the winding motor 34 can also be a servo motor for more precise control.

[0051] Reference Figure 8 A pressure roller 36 is provided on the side of the tape fixing component 31 near the axis of the outer toothed ring 33. The pressure roller 36 is located in front of the moving path of the tape fixing component 31 and is rotatably connected to the outer toothed ring 33. An elastic element 37 is provided between the pressure roller 36 and the tape fixing component 31. In the initial state, the elastic element 37 drives the pressure roller 36 away from the tape fixing component 31. When the tape fixing component 31 conveys the tape to wind the new energy vehicle wiring harness, the pressure roller 36 can pre-process the winding position to make the winding surface smoother and facilitate the tape's adhesion and winding. At the same time, when encountering new energy vehicle wiring harnesses of different thicknesses, the elastic element 37 can generate elastic deformation according to the actual situation of the wiring harness, so that the pressure roller 36 can adaptively adjust the degree of adhesion with the wiring harness to ensure appropriate clamping force. This effectively clamps the tape, ensuring the winding effect, without damaging the wiring harness or tape due to excessive pressure. Alternatively, the elastic element 37 can be a spring 15 or a rubber pad.

[0052] This application embodiment discloses a processing equipment for new energy vehicle wiring harnesses, which can both wind and fix cable 1 to form a wiring harness, and wind and fix several automotive wiring harnesses of different lengths or functions. When wind and fix several automotive wiring harnesses of different lengths or functions, before placing them on the conveyor belt 51, several wiring harnesses can be initially arranged according to size requirements, and the middle part can be wrapped with tape for preliminary fixation.

[0053] This application embodiment describes a processing method for winding and fixing multiple wire harnesses using a new energy vehicle wiring harness processing device. The wire harnesses are fed between the upper clamping roller 44 and the lower clamping roller 45. The lower clamping roller 45 moves downwards to clamp the wire harness. Subsequently, two sliding frames 41 move in opposite directions until one set of upper clamping plates 46 and lower clamping arc plates 47 abuts against the connector 2 of the shortest wire harness. As the two sliding frames 41 continue to move in opposite directions, they push the connector 2 to move until the other set of upper clamping plates 46 and lower clamping arc plates 47 abuts against the connector 2 at the other end of the wire harness. At this time, the winding assembly 3 begins to move towards one of the sliding frames 41 and winds multiple wire harnesses until the drive seat 32 reaches the stop bar 42 and stops moving. The upper clamping roller 44 near the winding assembly 3 rises, causing the upper clamping plate 46 to rotate, causing the connector 2 of the short wire harness at this point to disengage downwards from the lower clamping roller 45. The upper clamping plate 46 at the other end still clamps the connector 2 of the short wire harness. The sliding frame 41 and the winding assembly 3 continue to move in the previous direction, winding the remaining wire harness until all the wire harness in this direction is wound. At this point, the upper clamping plate 46 abuts against the longest connector 2, and then the tape is cut. The winding assembly 3 retracts to the initial winding position and reverses the operation to wind the wire harness on the other side. After all winding is completed, the winding assembly 3 moves along the conveyor belt 51 in the conveying direction, and the wire harness disengages from inside the winding assembly 3. The wire harness is then removed, completing the processing.

[0054] The implementation principle of a new energy vehicle wiring harness processing device according to an embodiment of this application is as follows: the processing device flattens the wiring harness using a flattening component 4, wraps the wiring harness with tape using a winding component 3, and automatically transports the wiring harness using a conveying device 5. The coordinated operation of these components improves the processing quality and efficiency of the new energy vehicle wiring harness. The pressure roller 36 and elastic component 37 are designed to adapt to wiring harnesses of different thicknesses, ensuring effective winding. The upper clamping plate 46 and transmission structure enhance the automation of the wiring harness winding process. The conveying device 5 ensures the accuracy and continuity of the wiring harness transport. Overall, compared to existing technologies, this device effectively solves problems such as uneven flattening, unstable winding, and inaccurate transport during wiring harness processing.

[0055] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A wiring harness for a new energy vehicle, comprising a plurality of cables (1), each cable (1) having a connector (2) fixed at both ends, the plurality of cables (1) being secured by wrapping with tape, characterized in that: The cable (1) includes a composite conductor (11), a dynamic insulation layer (12), and a sheath (13) from the inside out. The connector (2) is fixedly connected to the composite conductor (11). The composite conductor (11) is made of silver-plated copper wire (111) and carbon nanotubes (112) spirally braided. The outer layer (123) of the composite conductor (11) is covered with a vapor-deposited alumina film. Cooling material (14) is embedded in the composite conductor (11) along the axial direction. The sheath (13) is made of aramid fiber braided mesh and polyurethane foam. A titanium-nickel alloy spring (15) is set on the inner side of the sheath (13).

2. The wiring harness for a new energy vehicle according to claim 1, characterized in that: The dynamic insulating layer (12) includes an inner layer (121), a middle layer (122) and an outer layer (123) from the inside out. The inner layer (121) is made of polyolefin-based phase change elastomer, the middle layer (122) is made of radiation crosslinked silicone rubber, and the outer layer (123) is made of fluorinated ethylene propylene copolymer film. The outer surface of the dynamic insulating layer (12) is etched with micron-level trenches and filled with silicone oil gel.

3. A processing equipment for a new energy vehicle wiring harness as described in any one of claims 1-2, characterized in that: The device includes a winding assembly (3) and two flattening members (4) that move synchronously in opposite directions in the horizontal direction. The flattening members (4) are used to flatten the wire harness along the axial direction. The winding assembly (3) is located between the two flattening members (4). The winding assembly (3) includes a tape fixing member (31), a drive seat (32), an external gear ring (33), a winding motor (34), and two winding gears (35) of the same size. The tape fixing member (31) is rotatably connected to the inside of the external gear ring (33). The drive seat (32) moves in a direction parallel to the flattening members (4). The external gear ring (33) moves perpendicular to the direction of the flattening member (4). The external gear ring (33) is rotatably connected to the drive seat (32). The external gear ring (33) has an inlet channel (331). The winding motor (34) is fixedly connected to the drive seat (32). The output end of the winding motor (34) is coaxially fixedly connected to one of the gears. Both winding gears (35) mesh with the external gear ring (33). Both winding gears (35) are coaxially fixed with synchronous pulleys (351). The outer sides of the two synchronous pulleys (351) are connected with synchronous belts (352).

4. The processing equipment for new energy vehicle wiring harnesses according to claim 3, characterized in that: The tape fixing member (31) is provided with a pressure roller (36) on the side near the axis of the outer toothed ring (33). The pressure roller (36) is located in front of the moving path of the tape fixing member (31). The pressure roller (36) is rotatably connected to the outer toothed ring (33). An elastic element (37) is provided between the pressure roller (36) and the tape fixing member (31). In the initial state, the elastic element (37) drives the pressure roller (36) away from the tape fixing member (31).

5. The processing equipment for new energy vehicle wiring harnesses according to claim 3, characterized in that: The flattening component (4) includes a sliding frame (41), a stop bar (42), a clamping cylinder (43), an upper clamping roller (44), and a lower clamping roller (45). The sliding frame (41) moves horizontally. The clamping cylinder (43) is fixedly connected to the upper end of the sliding frame (41). The clamping cylinder (43) is used to push the upper clamping roller (44) to move vertically. The lower clamping roller (45) is rotatably connected to the sliding frame (41). The upper end of the stop bar (42) is fixedly connected to the sliding frame (41). The lower end of the stop bar (42) is located below the upper clamping roller (44). The stop bar (42) is located on the side of the upper clamping roller (44) close to the winding assembly (3).

6. The processing equipment for new energy vehicle wiring harnesses according to claim 5, characterized in that: The upper clamping roller (44) is provided with an upper clamping plate (46) on the side away from the winding assembly (3), and the lower clamping roller (45) is provided with a lower clamping arc plate (47) on the side away from the winding assembly (3). The lower clamping arc plate (47) is coaxially arranged with the stop rod (42). The upper clamping plate (46) is rotatably connected to the stop rod (42) along the axis of the stop rod (42). When the upper clamping roller (44) and the lower clamping roller (45) clamp the wire harness, the lower end of the upper clamping is higher than the lower side of the upper clamping roller (44), and the upper end of the lower clamping is lower than the upper side of the lower clamping roller (45).

7. The processing equipment for new energy vehicle wiring harnesses according to claim 6, characterized in that: The upper clamping plate (46) is fixedly connected to a first bevel gear (461). The first bevel gear (461) is located on the side where the two clamping rollers are far apart from each other. The first bevel gear (461) is rotatably connected to the stop rod (42) on the same axis. The first bevel gear (461) is meshed with a second bevel gear (411). The second bevel gear (411) is rotatably connected to the sliding frame (41). The second bevel gear (411) is fixedly connected to a rotating gear (412) on the same axis. A frame (441) is rotatably connected above the upper clamping roller (44). The frame (441) is fixedly provided with a rack (442) that meshes with the rotating gear (412) in the vertical direction.

8. The processing equipment for new energy vehicle wiring harnesses according to claim 3, characterized in that: It also includes a conveying device (5), which includes a conveyor belt (51), a feeding rack (52) and a feeding drive (53). The conveyor belt (51) is located in the middle of the two flattening parts (4) along the moving direction. The conveying direction of the conveyor belt (51) is perpendicular to the moving direction of the flattening parts (4). The feeding rack (52) is located below the material discharge end of the conveyor belt (51). The upper end face of the feeding rack (52) is located between the upper clamping roller (44) and the lower clamping roller (45). Mounting frames (54) are provided on both sides of the conveyor belt (51). The mounting frames (54) are fixedly provided with support frames (55). The feeding drive (53) is fixedly connected to the support frame (55). The feeding drive (53) is located on the side of the feeding rack (52) away from the fixed device. The width of the feeding rack (52) is smaller than the width of the conveyor belt (51).

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