Insulated ultrathin automobile wire and production winding equipment

Abstract

The utility model relates to the technical field of wire harnesses, and discloses an insulating ultrathin automobile wire and production winding equipment, which comprises a wire harness body, the wire harness body comprises a central lead, a plurality of outer stranded wires are spirally wound on the central lead, an ultrathin insulating layer is sleeved on the outer stranded wires, and an outer sheath is sleeved on the ultrathin insulating layer. And the outer peripheral wall of the outer sheath is provided with a spiral convex rib which is spirally wound. According to the utility model, the ultrathin insulating layer is used, and the extra outer sheath is used for protecting the ultrathin insulating layer, so that the thickness of the insulating layer is greatly reduced, the cost is reduced for ETFE, the safety of the ultrathin insulating layer is ensured by the outer sheath, and the overall wear resistance of the wire harness is improved by the spiral convex ribs on the outer sheath.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, specifically to an insulated ultra-thin automotive wire and its production winding equipment. Background Technology

[0002] Automotive wiring harnesses refer to the various wire harnesses used in automobiles. Currently, all wiring harnesses in automobiles are equipped with insulation layers to ensure safety during wiring and routing. There are various insulation materials used in automotive wiring harnesses, including PVC, PE, XLPE, and rubber. These insulation materials serve as the outer sheath of the wiring harness, simultaneously providing insulation and outer protection, which often results in thicker insulation sheaths. When ETFE material is used as an insulation layer, its high price limits its application in automotive wiring harnesses, as it is mostly used in applications with higher performance requirements. Utility Model Content

[0003] To achieve the above objectives, this utility model specifically adopts the following technical solution:

[0004] An ultra-thin insulated automotive wire and a production winding device are disclosed, comprising a wire harness body, wherein the wire harness body includes a central conductor, a plurality of outer stranded wires are spirally wound on the central conductor, an ultra-thin insulation layer is sleeved on the outer stranded wires, an outer sheath is sleeved on the ultra-thin insulation layer, and spirally wound helical ribs are installed on the outer peripheral wall of the outer sheath.

[0005] Furthermore, the thickness of the ultra-thin insulation layer is 0.05mm-0.25mm. Compared to the 0.6mm-4.5mm thickness of insulation layers such as PVC and PE, the thinness of this insulation layer is obvious.

[0006] Furthermore, the spiral direction of the spiral rib is opposite to that of the outer strand. By utilizing their respective materials and spiral elasticity, they can mutually restrict each other's tightening or loosening, thus ensuring the stability of the outer strand.

[0007] Furthermore, the outer sheath is woven from copper wire, tin-plated copper wire, or aluminum-magnesium-gold wire, and the spiral ribs are made of aluminum-magnesium-gold wire or iron wire. The metal braided outer sheath can also be used as a shielding layer. Of course, if shielding stability is not a concern, the outer sheath can also be made of other non-metallic materials; these are all conventional alternatives.

[0008] A production winding device for ultra-thin insulated automotive wire and a production winding equipment includes a winding machine. A wire harness loosening mechanism is installed at the front of the winding machine for the wire harness body to pass through. The wire harness loosening mechanism includes a sleeve with a pre-formed spiral groove on its inner wall to mate with a spiral rib. The wire harness body passes through the sleeve, and the spiral rib is located within the spiral groove. The sleeve rotates in conjunction with the wire harness body, thereby releasing the torque caused by the twisting of the wire harness body.

[0009] Furthermore, a toothed ring is fixedly installed on the outer circumference of the first sleeve, and anti-detachment rings are fixedly installed on the outer circumference of the first sleeve on both sides of the toothed ring. A planetary carrier is fitted on the first sleeve outside the anti-detachment rings on both sides. A driving gear and two auxiliary gears are movably installed on the planetary carrier. The driving gear and the auxiliary gears mesh with the toothed ring. A second motor is fixedly installed on the planetary carrier at the position corresponding to the driving gear. The output end of the second motor 46 is fixedly connected to the driving gear 44. The first sleeve obtains the ability to rotate actively and can reliably and specifically rotate in a direction, thereby releasing torque.

[0010] Furthermore, the front side of the wire harness loosening mechanism is provided with at least two sets of pre-loosening components. Each pre-loosening component includes a sleeve, within which a guide groove is pre-set to mate with the spiral rib. The diameter of the guide groove is larger than the diameter of the spiral groove. In the two sets of wire harness loosening mechanisms, the diameter of the guide groove in the front set is larger than that in the rear set. The pre-loosening components first loosen a portion of the torque, and the remaining torque is then released by the wire harness loosening mechanism. The two mechanisms cooperate to reliably and stably release the torque.

[0011] Furthermore, two limiting rings are fixedly installed on the outer wall of the second sleeve. A fixing seat is provided on the outer side of the second sleeve, and a bearing is installed in the fixing seat corresponding to the position of the limiting ring. The inner ring of the bearing is fixed on the second sleeve, and the outer ring of the bearing is fixed to the fixing seat. A floor support frame is installed on both the fixing seat and the bottom of the base. The second sleeve is unpowered and rotates due to the torsion of the wire harness body.

[0012] Furthermore, the winding machine includes a shaft seat, a winding drum mounted on one side of the shaft seat, and a motor fixedly mounted on the other side of the shaft seat opposite to the winding drum. The shaft of the motor is connected to the winding drum via a transmission. The winding drum can wind the wire harness body into a disc shape to meet transportation requirements.

[0013] Furthermore, a winding guide is installed between the winding machine and the wire harness unwinding mechanism. The winding guide includes a lead screw, with floor-mounted support frames fixedly installed at both ends of the lead screw. A linear motor is driven onto the lead screw, and a support plate is fixedly installed on the top of the linear motor, on which the wire harness rests. The winding guide provides adjustment for the winding position of the wire harness on the winding drum, ensuring neat and aesthetically pleasing winding.

[0014] The beneficial effects of this utility model are as follows:

[0015] 1. This utility model uses an ultra-thin insulation layer and provides protection for the insulation layer through an additional outer sheath, which greatly reduces the thickness of the insulation layer. For ETFE, the cost is reduced. At the same time, the outer sheath ensures the safety of the insulation layer, and the spiral ribs on the outer sheath increase the overall wear resistance of the wire harness.

[0016] 2. In this utility model, the spiral rib and the outer strand have opposite spiral directions, which can constrain each other. When the outer strand is twisted and relaxed, the spiral rib is tightened. Conversely, when the spiral rib is twisted and relaxed, the outer strand is tightened, and the mutually constrained strands are twisted and loosened.

[0017] 3. This utility model loosens the wire harness before winding it up. When the wire harness is twisted during winding, the internal torque is generated. The torque can be released by the loosening mechanism, thereby ensuring that the wire harness can be wound up neatly and orderly.

[0018] 4. In this utility model, by adding an additional non-powered pre-relaxation component, the torque of the wire harness after large twisting can be partially released in advance, and the multi-layer progressive release can ensure complete torque release. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the wire harness structure in this utility model;

[0020] Figure 2 This is a perspective view of the winding equipment used in this utility model;

[0021] Figure 3 This is a schematic diagram of the installation of the wire harness release mechanism in this utility model;

[0022] Figure 4 This is a cross-sectional view of the wire harness release mechanism in this utility model;

[0023] Figure 5 This is a cross-sectional view of the pre-relaxation component in this utility model;

[0024] Figure 6 This is a perspective view of the sleeve one in this utility model.

[0025] Reference numerals: 1. Wire harness body; 11. Center conductor; 12. Outer stranded wire; 13. Ultra-thin insulation layer; 14. Outer sheath; 15. Spiral rib; 2. Winding machine; 21. Shaft seat; 22. Winding drum; 23. Motor 1; 3. Winding guide; 31. Lead screw; 32. Linear motor; 33. Support plate; 34. Support frame; 4. Wire harness loosening mechanism; 41. Sleeve 1; 42. Gear ring; 43. Planetary carrier; 44. Drive gear; 45. Auxiliary gear; 46. Motor 2; 47. Anti-derailment ring; 48. Spiral groove; 49. Base; 5. Pre-loosening assembly; 51. Sleeve 2; 52. Guide groove; 53. Limiting ring; 54. Bearing; 55. Fixing seat; 6. Floor frame. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0027] This application provides an ultra-thin insulated automotive wire and its production winding equipment, mainly solving the problem that ETFE insulation is expensive and difficult to apply to automotive wiring harnesses. The following technical solution is provided, which will be discussed in conjunction with... Figures 1-6 Please provide a detailed explanation:

[0028] An ultra-thin insulated automotive wiring harness and its production winding equipment are disclosed. The wiring harness body 1 includes a center conductor 11, outer stranded wires 12, an ultra-thin insulation layer 13, and an outer sheath 14. Multiple outer stranded wires 12 are spirally wound around the center conductor 11. The ultra-thin insulation layer 13 is located outside the outer stranded wires 12, and the outer stranded wires 12 and the center conductor 11 are encased within the ultra-thin insulation layer 13. The outer sheath 14 is encased outside the ultra-thin insulation layer 13. The ultra-thin insulation layer 13 is made of ETFE material with a thickness of 0.05mm-0.25mm. ETFE material has excellent performance, thus allowing for a thin insulation layer. The outer sheath 14 protects the ultra-thin insulation layer 13 and the internal wiring harness, separating the insulation and protection functions of the original integrated PVC outer sheath.

[0029] In some embodiments, a spirally wound rib 15 is integrally formed on the outer peripheral wall of the outer sheath 14. The spiral direction of the spiral rib 15 is opposite to the spiral direction of the outer stranded wire 12. The outer sheath 14 is woven from copper wire, tin-plated copper wire, or aluminum-magnesium-gold wire, and the spiral rib 15 is made of aluminum-magnesium-gold wire or iron wire. The outer sheath 14 is woven from metal materials, which can be used as a shielding layer. At the same time, metal has higher wear resistance, making it especially suitable for use in locations that are prone to friction with components.

[0030] A production winding device for an insulated ultra-thin automotive wire and a production winding equipment includes a winding machine 2, a winding guide 3, and a wire harness unwinding mechanism 4;

[0031] The winding machine 2 is used for winding and packaging after the automobile production line is completed. The winding machine 2 includes a shaft seat 21, a winding drum 22 is installed on one side of the shaft seat 21, and a motor 23 is fixedly installed on the other side of the shaft seat 21 opposite to the winding drum 22. The shaft of the motor 23 is connected to the winding drum 22 for transmission.

[0032] The winding guide 3 is used to drive the automotive wire to wind steadily and orderly on the winding drum 22 during winding. The winding guide 3 includes a lead screw 31, and a support frame 34 for ground support is fixedly installed at both ends of the lead screw 31. A linear motor 32 is driven on the lead screw 31, and a support plate 33 is fixedly installed on the top of the linear motor 32. The wire harness body 1 rests on the support plate 33.

[0033] The wire harness loosening mechanism 4 is used to loosen the stress carried by the automotive wires after they rotate in the forward or reverse direction. The wire harness loosening mechanism 4 includes a sleeve 41, a toothed ring 42 is fixedly installed on the outer periphery of the sleeve 41, and anti-detachment rings 47 are fixedly installed on the outer periphery of the sleeve 41 on both the front and rear sides of the toothed ring 42. The inner wall of the sleeve 41 has a spiral groove 48 that matches the spiral rib 15. The wire harness body 1 passes through the sleeve 41, and the spiral rib 15 is located in the spiral groove 48.

[0034] A planetary carrier 43 is fitted onto the sleeve 41 outside the anti-detachment rings 47 on both sides. A driving gear 44 and two auxiliary gears 45 are movably mounted on the planetary carrier 43. The driving gear 44 and the two auxiliary gears 45 are arranged at equal intervals around the sleeve 41. The driving gear 44 and the auxiliary gears 45 are meshed with the gear ring 42. A motor 46 is fixedly installed on the planetary carrier 43 at the position corresponding to the driving gear 44. The output end of the motor 46 is fixedly connected to the driving gear 44. A base 49 is fixedly installed at the bottom of the planetary carrier 43.

[0035] During winding, first manually pass the wire harness body 1 through the sleeve 41 and the support plate 33, then fix the wire harness head on the winding drum 22. The motor 23 drives the winding drum 22 to rotate. The rotation of the winding drum 22 pulls the wire harness body 1 to wind and wind on the winding drum 22. During winding, control the linear motor 32 to work, so that it moves horizontally along the lead screw 31, driving the wire harness body 1 to move, so as to adjust the position so that the wire harness body 1 can be wound on the winding drum 22 in a progressive manner.

[0036] While winding, the wire harness body 1 passes through the sleeve 41. The motor 46 drives the drive gear 44 to rotate, and the meshing relationship between the drive gear 44 and the gear ring 42 drives the entire sleeve 41 to rotate. The auxiliary gear 45 supports the sleeve 41 and rotates with the sleeve 41. The engagement of the spiral groove 48 and the spiral rib 15 limits the wire harness body 1. Taking the spiral direction of the outer stranded wire 12 as a reference, if the wire harness body 1 twists in the forward or reverse direction, the spacing of the spiral rib 15 within the twist range will expand or shrink, causing a mismatch between its spacing and the spiral groove 48. When the wire harness body 1 is forced through the sleeve 41, the spiral groove 48 can limit the spiral rib 15, causing the wire harness body 1 to undergo a restorative twist, thus loosening the wire harness.

[0037] In some embodiments, with the direction of the take-up drum 22 as the rear side, at least two sets of pre-relaxation components 5 are also provided on the front side of the wire harness relaxation mechanism 4. The pre-relaxation component 5 includes a second sleeve 51. Two limiting rings 53 are fixedly installed on the outer wall of the second sleeve 51. A fixed seat 55 is provided on the outer side of the second sleeve 51. A bearing 54 is installed in the fixed seat 55 corresponding to the position of the limiting ring 53. The inner ring of the bearing 54 is fixed on the second sleeve 51. The outer ring of the bearing 54 is fixed to the fixed seat 55. A guide groove 52 that cooperates with the spiral rib 15 is preset in the second sleeve 51. The diameter of the guide groove 52 is larger than the diameter of the spiral groove 48. The diameter of the guide groove 52 of the first set of the two sets of wire harness relaxation mechanisms 4 is larger than the diameter of the guide groove 52 of the second set. A floor support 6 is installed at the bottom of the fixed seat 55 and the base 49.

[0038] The wire harness body 1 passes through the sleeve 2 51 at the same time. When the wire harness body 1 is wound up, it first passes through the sleeve 2 51. At this time, the sleeve 2 51 and its internal guide groove 52 can loosen the wire harness body 1. Due to its large diameter, it can play a certain role in pre-loosening the wire harness body 1 with a large twist amplitude. After pre-loosening, the sleeve 1 41 will then officially loosen it. The multi-stage design helps to ensure the complete release of wire harness torque.

[0039] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An insulated ultra-thin automotive wire comprising a wire bundle body (1), characterized in that, The wire harness body (1) includes a central conductor (11), on which multiple outer stranded wires (12) are spirally wound. The outer stranded wires (12) are covered with an ultra-thin insulation layer (13), and the ultra-thin insulation layer (13) is covered with an outer sheath (14). Spiral ribs (15) are installed on the outer peripheral wall of the outer sheath (14).

2. An insulated ultra-thin automotive wire according to claim 1, wherein The thickness of the ultrathin insulating layer (13) is 0.05mm-0.25mm.

3. The ultra-thin insulated automotive wire according to claim 1, characterized in that, The spiral direction of the spiral rib (15) is opposite to the spiral direction of the outer strand (12).

4. An insulated ultra-thin automotive wire according to claim 3, wherein The outer sheath (14) is woven from copper wire, tin-plated copper wire or aluminum-magnesium gold wire, and the spiral rib (15) is made of aluminum-magnesium gold wire or iron wire.

5. A winding device for producing ultra-thin insulated automotive wire, using an ultra-thin insulated automotive wire as described in any one of claims 1-4, comprising a winding machine (2), characterized in that, The front side of the winding machine (2) is equipped with a wire harness loosening mechanism (4) through which the wire harness body (1) passes. The wire harness loosening mechanism (4) includes a sleeve (41). The inner wall of the sleeve (41) is reserved with a spiral groove (48) that matches the spiral rib (15). The wire harness body (1) passes through the sleeve (41), and the spiral rib (15) is located in the spiral groove (48).

6. The production and winding apparatus of an insulated ultra-thin automotive wire according to claim 5, characterized in that, A toothed ring (42) is fixedly installed on the outer periphery of the first sleeve (41). Anti-detachment rings (47) are fixedly installed on the outer periphery of the first sleeve (41) on both sides of the toothed ring (42). A planetary carrier (43) is fitted on the first sleeve (41) outside the anti-detachment rings (47) on both sides. A driving gear (44) and two auxiliary gears (45) are movably installed on the planetary carrier (43). The driving gear (44) and the auxiliary gears (45) are meshed with the toothed ring (42). A second motor (46) is fixedly installed on the planetary carrier (43) at the position corresponding to the driving gear (44). The output end of the second motor (46) is fixedly connected to the driving gear (44).

7. The production winding equipment for ultra-thin insulated automotive wire according to claim 6, characterized in that, The front side of the wire harness loosening mechanism (4) is also provided with at least two sets of pre-loosening components (5). The pre-loosening component (5) includes a sleeve (51). The sleeve (51) has a guide groove (52) that cooperates with the spiral rib (15). The diameter of the guide groove (52) is larger than the diameter of the spiral groove (48). The diameter of the guide groove (52) of the front set of the two sets of wire harness loosening mechanisms (4) is larger than the diameter of the guide groove (52) of the rear set.

8. The production and winding apparatus of an insulated ultra-thin automotive wire according to claim 7, characterized in that, Two limiting rings (53) are fixedly installed on the outer wall of the second sleeve (51). A fixed seat (55) is provided on the outer side of the second sleeve (51). A bearing (54) is installed in the fixed seat (55) corresponding to the position of the limiting ring (53). The inner ring of the bearing (54) is fixed on the second sleeve (51). The outer ring of the bearing (54) is fixed to the fixed seat (55). The fixed seat (55) and the bottom of the base (49) are both equipped with a floor support frame (6).

9. The production winding equipment for ultra-thin insulated automotive wire according to claim 5, characterized in that, The winding machine (2) includes a shaft seat (21), a winding drum (22) is installed on one side of the shaft seat (21), and a motor (23) is fixedly installed on the other side of the shaft seat (21) opposite to the winding drum (22). The shaft of the motor (23) is connected to the winding drum (22) for transmission.

10. The production and winding apparatus of an insulated ultra-thin automotive wire according to claim 9, characterized in that, A winding guide (3) is installed between the winding machine (2) and the wire harness unwinding mechanism (4). The winding guide (3) includes a lead screw (31). Both ends of the lead screw (31) are fixedly mounted with a support frame (34) for ground support. A linear motor (32) is driven on the lead screw (31). A tray (33) is fixedly mounted on the top of the linear motor (32). The wire harness body (1) falls on the tray (33).

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