Cable harness formboard and method for assembling a cable harness formboard

Abstract

Cable harness forming board (1) for producing a cable harness with a plurality of guides (10) and / or laying forks (20) protruding from a mounting plane (M) for producing a predetermined laying structure shape (L), wherein the cable harness formboard (1) is formed from a plurality of cable harness formboard segments (2) which can be arranged in series and which are fixed to a segment frame (3) by means of at least one fastening means (4), wherein the segment frame (3) has a grid structure, the grid structure being designed according to the respective cable harness formboard segments (2).

Description

[0001] The invention relates to a cable harness forming board for the production of a cable harness or wiring harness and a method for assembling a corresponding cable harness forming board.

[0002] For the purposes of the present invention, cable harnesses and conductor strings are also understood to be, for example, cable sets and conductor strings.

[0003] Wiring harnesses consist of a group of several electrical conductors and are used, for example, in vehicles for the electrical connection of components, consumers, sources, sinks, storage devices, distributors, and assemblies. The electrical conductors are grouped together in sections, running parallel to each other with predetermined branch connections. It is known that a so-called cable formboard, also known as a wiring harness formboard, is used to manufacture a wiring harness. In the following, the term wiring harness formboard is used synonymously with cable formboard.

[0004] Devices used in the assembly of cable sets or cable harnesses are already known from US patent applications 4,979,544 A, JP H07-282,654 A, and DD 109,478 A1. Further prior art in this technical field is disclosed in documents CN 106,024,208 A, US 5,109,597 A, US 2021 / 0110,952 A1, US 9721,702 B1, CN 108,539,556 A, JP 2012-104,258 A, CN 105,882,292 A, and DE 10,2019,129,488 A1.

[0005] Typical wiring harnesses, such as those used in automobiles and industrial technical systems and machinery, consist of numerous different cables and wires whose ends are fitted with contacts or contact elements or connectors, in whose contact chambers contacts are inserted. Furthermore, mechanical clips, fasteners, or adhesive tapes are used to bundle several individual wires that are routed as a single strand. Additionally, cable protection, such as hoses, and routing elements, such as cable ducts, are used.

[0006] The aforementioned components are assembled on forming or laying boards to complete the respective cable set. These forming boards typically provide a surface area corresponding to the space required for a fully extended cable set to be produced. The cables and wires are then laid around the static supports and guides attached to the forming board, such as dowel pins. Mechanical components are then attached, and the cable strands to be bundled are wrapped with adhesive tape or a suitable band, if necessary.

[0007] On the wiring harness formboard, the specific structure of the wiring harness to be produced is predetermined by the arrangement of guides in a mounting grid. Following a predetermined routing sequence, the individual electrical wires and connectors are placed onto the formboard. The production of the finished wiring harnesses often takes place in so-called transfer or cycle lines, where the individual wires and connectors are laid or mounted sequentially on the formboard in several cycles. Once the complete wiring harness is finished, it is removed from the formboard, and a new, possibly different, wiring harness can be produced.

[0008] A disadvantage of this approach is that if the demand for wiring harnesses changes, for example during a model change in vehicle manufacturing, all wiring harness forming boards on the production line must be reconfigured. This involves rearranging the guides, nails, pins, or forks on the forming board to define the new wiring harness structure. The labor and time required to reconfigure the wiring harness forming boards is very high.

[0009] A further problem is that the high variance of the cable harnesses to be manufactured results in considerable assembly effort and a large number of static guides, component holders, slots, and / or dowel pins are required, but only a limited number of these are needed for the specific cable harness being manufactured. Another disadvantage is that this excessive number of guides on a mounting board hinders both the assembly process and the removal of the cable harness from the board.

[0010] A cable harness layout board is typically made of wood. The predetermined layout pattern is printed onto paper using a plotter and then glued to the wooden board by hand. However, this manual gluing process often leads to inaccuracies in achieving the desired layout pattern.

[0011] The invention is therefore based on the objective of overcoming the aforementioned disadvantages and reducing the work and time required for installing and converting the cable harness forming boards according to a cable harness structure, as well as mapping a desired laying structure shape as precisely as possible on the cable harness forming board.

[0012] This problem is solved by the combination of features according to claim 1.

[0013] According to the invention, a cable harness mold board for manufacturing a cable harness, in particular for manufacturing a cable harness for the wiring of a vehicle, is proposed, comprising a plurality of guides and / or routing forks projecting from a mounting plane for creating a predetermined routing structure. The cable harness mold board is formed from a plurality of interconnectable cable harness mold board segments, which are fixed to a segment frame by means of at least one fastening element. The advantage of this is that individual cable harness mold board segments can be replaced if the predetermined routing structure is changed, and the entire cable harness mold board does not need to be remade. In this way, the required labor and time for installing and reconfiguring the cable harness mold boards are reduced.

[0014] In an advantageous embodiment, the predetermined laying pattern is formed on the cable harness mold segments by means of direct printing or UV direct printing. A portion corresponding to the predetermined laying pattern is printed on each cable harness mold segment. Provided the cable harness mold segments are arranged in a predetermined configuration, the predetermined laying pattern is represented on the cable harness mold. This eliminates the need for manually affixing a paper print to the cable harness mold or the respective cable harness mold segment, thereby increasing the accuracy of the predetermined laying pattern.

[0015] Preferably, the cable harness forming board is designed such that the respective cable harness forming board segment has a predetermined position on the segment frame and a proportion of the laying structure shape corresponding to the predetermined position is formed by means of direct printing on the cable harness forming board segment.

[0016] In one embodiment of the invention, the respective cable harness molding board segment is partially or completely made of rigid PVC foam. This material is particularly advantageous because it is easy to machine and print on. Furthermore, a cable harness molding board segment made of rigid PVC foam is lightweight and highly durable.

[0017] Furthermore, a design is advantageous in which the numerous cable harness formboard segments are congruent in shape, preferably square or rectangular. This simplifies the assembly or conversion of the respective cable harness formboard segment.

[0018] It is further advantageous if the respective cable harness forming board segment has a length-to-width ratio of 5:4 and, in particular, a length of 500 mm and a width of 400 mm. These dimensions of a cable harness forming board are especially favorable for creating a lay-up structure.

[0019] In an alternative embodiment of the present cable harness formboard, the multitude of cable harness formboard segments is provided to have at least two different geometries or outer contours, in particular a square and a rectangular one. In this way, a large number of variations regarding the geometry of the cable harness formboard can be implemented, which can be optimally adapted to the respective laying structure.

[0020] In a further advantageous embodiment, the invention provides that each cable harness formboard segment can be individually mounted from one side of the segment frame. This allows the individual segments to be reassembled into a larger cable harness formboard via the segment frame. Because the cable harness formboard can be mounted from one side, technical changes to the layup structure can be implemented quickly by modifying the cable harness formboard.

[0021] In an advantageous embodiment, the respective fastening element is a collar screw, preferably with a washer. This optimizes the fixing of the corresponding cable harness formboard segments to the segment frame.

[0022] Preferably, the cable harness mold board is designed such that each cable harness mold board segment has a recess for receiving the corresponding fastening element. The recess is preferably a bore hole through which the fastening element protrudes and can thus be fixed to the segment frame.

[0023] Furthermore, a design is advantageous in which the respective cable harness molding segment has a milled recess for the corresponding fastener, such that the fastener and the mounting surface have a flush transition when installed. In this way, the collar of the collar screw and, if applicable, the washer do not protrude from the cable harness molding segment, thus optimizing the installation of a cable harness, as, for example, individual wires cannot become caught on protruding components.

[0024] In a further advantageous embodiment, the invention provides that the recess is formed at an edge or corner of the respective cable harness molding segment such that a receptacle for a fastening element is formed by means of two or four cable harness molding segments. The fastening element secures the corresponding two or four cable harness molding segments simultaneously in the assembled state. This optimizes the fixing of the cable harness molding segments and reduces the number of components or fastening elements.

[0025] The cable harness molding board according to the invention is designed such that the segment frame has a grid structure or is designed in a grid-like form. Furthermore, according to the invention, the grid structure is designed according to the respective cable harness molding board segments. An embodiment is also advantageous in which the respective fastening element is fixed to the grid structure. The grid-like structure is particularly suitable for mounting the cable harness molding board segments.

[0026] In one embodiment, it is provided that the mounting plane is at least partially formed by the segment frame.

[0027] In a preferred embodiment of the invention, the segment frame has a plurality of projections. The mounting plane for at least one cable harness molding board segment is formed by means of the free ends of the plurality of projections. In this way, a three-dimensional cable harness molding board can be implemented, which in turn allows for further variations in the manufacture of a cable harness, such as a central tunnel crossing.

[0028] Preferably, the cable harness mold board is designed such that the corresponding fastening element is fixed to a projection. This achieves the fixation of the corresponding cable harness mold board segment.

[0029] The cable harness mold board according to the invention is designed in one embodiment such that the segment frame has at least two sub-segment frames that can be fixed to one another for pre-assembling the cable harness mold board segments, and a proportion of the multiple cable harness mold board segments is fixed to each sub-segment frame. The advantage of this is that individual sections of the cable harness mold board can be replaced together with several cable harness mold board segments, thus enabling a quick-change system.

[0030] The invention further proposes a method for assembling a cable harness form board according to the preceding disclosure, in which a stored laying structure shape is first selected from a controller to implement a laying structure. Subsequently, a plurality of cable harness form board segments are provided. The plurality of cable harness form board segments are then printed according to the laying structure shape using a UV direct printer. Finally, the respective cable harness form board segment is fixed to the segment frame in a predetermined manner.

[0031] The advantage of this is that the work and time required for installing and converting the cable harness form boards according to a cable harness structure is reduced, and a desired laying structure shape can be represented as precisely as possible on the cable harness form board.

[0032] Following the fixing of the respective cable harness formboard segment to the segment frame, it is also possible to replace one or more cable harness formboard segments.

[0033] In a preferred embodiment of the method, before or after the provision of the plurality of cable harness molding board segments, the print on a previously printed cable harness molding board segment of the plurality of cable harness molding board segments is removed, preferably by means of a sandblaster. In a further advantageous embodiment, the invention provides that before or after the provision of the plurality of cable harness molding board segments, holes or recesses arranged in the cable harness molding board segments of the plurality of cable harness molding board segments are closed, in particular by means of filling or injecting a filler material. In this way, cable harness molding board segments can be reused, thereby saving material and costs.

[0034] Other advantageous embodiments of the invention are characterized in the dependent claims or are described in more detail below together with the description of the preferred embodiment of the invention with reference to the figures. The figures show: Fig. 1 a schematic view of a segment frame of a cable harness formboard; Fig. 2. A top view of a cable harness form board; Fig. 3 a side view of the wiring harness form board.

[0035] The figures are schematic examples. Identical reference symbols in the figures indicate identical functional and / or structural features.

[0036] In Fig. Figure 1 shows a schematic view of a segment frame 3 of a cable harness formboard 1. The segment frame 3 is designed to fix cable harness formboard segments 2 with a length-to-width ratio of 5:4 by means of at least one fastening element 4.

[0037] The segment frame 3 also has a grid structure, which is designed according to the respective cable harness formboard segments 2. In the Fig. In the embodiment shown in Figure 1, the segment frame 3 of the cable harness formboard 1 is designed to accommodate six cable harness formboard segments 2. The segment frame 3 also comprises three sub-segment frames 32 that can be fixed to one another for pre-assembling the cable harness formboard segments 2, and a proportion of the multiple cable harness formboard segments 2 can each be fixed to a sub-segment frame 32.

[0038] Fig. Figure 2 shows a top view of the wiring harness board 1 with the in Fig. The cable harness forming board 1, as shown in Figure 1, comprises a plurality of guides 10 and laying forks 20 projecting from a mounting plane M to produce a predetermined laying structure L. Furthermore, the cable harness forming board 1 is formed from a plurality of connectable cable harness forming board segments 2, which are fixed to the segment frame 3 by means of fastening means 4. The mounting plane M is formed by the segment frame 3.

[0039] The respective fastening element 4 is a collar screw with a washer. Furthermore, the respective cable harness formboard segment 2 has a recess 21 for receiving the corresponding fastening element 4. In addition, the respective cable harness formboard segment 2 includes a milled groove 22 for the corresponding fastening element 4 in the area of ​​the recess 21, such that the corresponding fastening element 4 and the mounting surface M have a flush transition in the assembled state shown.

[0040] The respective recess 21 is formed at an edge 23 or a corner 24 of the respective cable harness formboard segment 2 such that a receptacle for a fastening element 4 is formed by means of two or four cable harness formboard segments 2. The corresponding fastening element 4 simultaneously secures the corresponding two or four cable harness formboard segments 2 in the assembled state. The respective fastening element 4 is fixed to the grid structure. Furthermore, the respective cable harness formboard segment 2 can be individually mounted from one side of the segment frame 3.

[0041] The predetermined laying structure shape L is formed by means of UV direct printing. The respective cable harness form board segment 2 is arranged at a predetermined position on the segment frame 3, and a portion of the laying structure shape L corresponding to this predetermined position is formed on the respective cable harness form board segment 2 by means of direct printing. Furthermore, the respective cable harness form board segment 2 consists entirely of rigid PVC foam.

[0042] Furthermore, the numerous cable harness formboard segments 2 are congruent in shape and rectangular. Each cable harness formboard segment 2 has a length-to-width ratio of 5:4 and a length of 500 mm and a width of 400 mm.

[0043] In Fig. 3 is a side view of the in Fig.The cable harness formboard 1 shown in Figure 2 is depicted. The segment frame 3 comprises a plurality of projections 31. The mounting plane M for a cable harness formboard segment 2 is formed by means of the free ends of the plurality of projections 31. Furthermore, the corresponding fastening element 4 (not shown) is fixed to each projection 31.

Claims

[1] Cable harness forming board (1) for producing a cable harness with a plurality of guides (10) and / or laying forks (20) protruding from a mounting plane (M) to produce a predetermined laying structure shape (L), wherein the cable harness formboard (1) is formed from a plurality of cable harness formboard segments (2) which can be arranged in series and which are fixed to a segment frame (3) by means of at least one fastening means (4), wherein the segment frame (3) has a grid structure, the grid structure being designed according to the respective cable harness formboard segments (2). [2] Cable harness forming board (1) according to claim 1, wherein the predetermined laying structure shape (L) is formed by means of direct printing or UV direct printing. [3] Cable harness forming board (1) according to claim 2, wherein the respective cable harness forming board segment (2) has a predetermined position on the segment frame (3) and a portion of the laying structure form (L) corresponding to the predetermined position is formed by means of direct printing on the cable harness forming board segment (2). [4] Cable harness formboard (1) according to any one of the preceding claims 1 to 3, wherein the respective cable harness formboard segment (2) is partially or completely made of a rigid PVC foam. [5] Cable harness formboard (1) according to one of the preceding claims, wherein the plurality of cable harness formboard segments (2) are congruent in their shape. [6] Cable harness formboard (1) according to the preceding claim, wherein the respective cable harness formboard segment (2) has a length-to-width ratio of 5:

4. [7] Cable harness forming board (1) according to any one of the preceding claims 1 to 5, wherein the plurality of cable harness forming board segments (2) has at least two different geometries or outer contours. [8] Cable harness formboard (1) according to one of the preceding claims, wherein the respective cable harness formboard segment (2) can be mounted individually from one side of the segment frame (3). [9] Cable harness form board (1) according to one of the preceding claims, wherein the respective fastening means (4) is a collar screw. [10] Cable harness formboard (1) according to one of the preceding claims, wherein the respective cable harness formboard segment (2) has a recess (21) for receiving the corresponding fastening means (4). [11] Cable harness formboard (1) according to the preceding claim, wherein the respective cable harness formboard segment (2) has a milling (22) for the corresponding fastening means (4) in the area of ​​the recess (21), such that the corresponding fastening means (4) and the mounting plane (M) have a flush transition in a mounted state. [12] Cable harness formboard (1) according to one of the preceding claims 10 and 11, wherein the recess (21) is formed at an edge (23) or a corner (24) of the respective cable harness formboard segment (2) such that a receptacle for a fastening means (4) is formed by means of two or four cable harness formboard segments (2), wherein the fastening means (4) simultaneously fixes the corresponding two or four cable harness formboard segments (2) in the assembled state. [13] Cable harness form board (1) according to one of the preceding claims, wherein the respective fastening means (4) is fixed to the grid structure. [14] Cable harness form board (1) according to one of the preceding claims, wherein the mounting plane (M) is formed by the segment frame (3). [15] Cable harness formboard (1) according to one of the preceding claims, wherein the segment frame (3) has a plurality of projections (31), wherein the mounting plane (M) for at least one cable harness formboard segment (2) is formed by means of the free ends of the plurality of projections (31). [16] Cable harness form board (1) according to the preceding claim, wherein the corresponding fastening means (4) is fixed to a projection (31) in each case. [17] Cable harness formboard (1) according to one of the preceding claims, wherein the segment frame (3) has at least two partial segment frames (32) that can be fixed to one another for pre-assembling the cable harness formboard segments (2) and a proportion of the plurality of cable harness formboard segments (2) is fixed to a partial segment frame (32). [18] Method for assembling a cable harness form board (1) according to one of the preceding claims, comprising the following steps: a. Selecting a saved laying structure shape (L) to implement a laying structure from a controller; b. Providing a large number of cable harness formboard segments (2); c. Printing the multitude of cable harness form board segments (2) according to the laying structure shape (L) using a UV direct printer; d. Fixing the respective cable harness form board segment (2) to the segment frame (3) in a predetermined manner. [19] Method according to claim 18, wherein before or after providing the plurality of cable harness formboard segments (2) a removal of a print of an already printed cable harness formboard segment (2) of the plurality of cable harness formboard segments (2) takes place. [20] Method according to one of the preceding claims 18 or 19, wherein before or after the provision of the plurality of cable harness formboard segments (2) a closing of holes or recesses arranged in cable harness formboard segments (2) of the plurality of cable harness formboard segments (2) takes place.

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