Wiring harness for the internal wiring of an electrical device and method for the optimized production of internal wiring.

Abstract

The invention relates to a cable harness for the internal wiring of an electrical device, wherein the cable harness can be inserted into the electrical device along an assembly direction during an assembly process and electrical devices can be connected within the electrical device by means of the cable harness, with at least one electrical conductor and contacting devices associated with the electrical conductor, wherein the contacting devices are electrically conductively connected to the electrical conductor and, in an assembly position of the cable harness, an electrical connection of the electrical devices via the electrical conductor is made possible by means of the contacting devices during the assembly process, wherein a dimensionally stable support structure mechanically connected to the electrical conductor is associated with the electrical conductor, wherein the assembly position of the cable harness is defined independently of the assembly process by means of the dimensionally stable support structure.Furthermore, the invention relates to a method for the optimized production of internal wiring of an electrical device.

Description

[0001] The invention relates to a cable harness for the internal wiring of an electrical device according to the preamble of claim 1. Furthermore, the invention relates to a method for the optimized production of internal wiring of an electrical device according to claim 10.

[0002] Common wiring systems for electrical appliances, such as power tools, washing machines, dryers, and similar devices, are constructed from interconnected, often coiled, strands of cable, known as coiled cable harnesses. These harnesses are prefabricated, fitted with connectors, and then inserted into the appliance. Due to the flexibility of such cable harnesses, this work is usually done manually. Furthermore, attaching electrical components, such as control boards or motors, using the connectors is also only possible manually, as the connection to the connector is flexible.

[0003] The purpose of the invention is to improve the state of the art.

[0004] The problem is solved by a cable harness for the internal wiring of an electrical device according to claim 1. Advantageous embodiments are listed in dependent claims 2 to 9.

[0005] A key concept of the invention is that a dimensionally stable support structure is assigned to the electrical conductor, which is mechanically connected to and supports the conductor. This defines the mounting geometry or position of the cable harness and is preset and predefined independently of the assembly process. Consequently, the thus stiffened and supported cable harness can be easily and precisely inserted and placed into, for example, the housing of an electrical device, much like a mechanical component, without requiring any geometric adjustments or complex routing work.

[0006] It is mentioned here that the corresponding electrical conductors are designed, for example, as cables or cable bundles and can include individual electrical conductor elements, such as individual strands, individual cables, or even individual wires or conductor tracks. These conductor elements can be insulated or uninsulated and / or shielded. For example, such electrical conductors are used to distribute operating voltage within the electrical device and / or to control corresponding components of the electrical device, i.e., electrical equipment, whereby the corresponding phase conductors are insulated and an earth conductor can remain uninsulated.

[0007] Provided the dimensionally stable support structure is connected to the electrical conductor by a force-fit and / or form-fit connection, a single unit is formed that can, for example, be guided and assembled together in a production process. For instance, the dimensionally stable support structure can be used as a mechanical unit to insert the entire cable harness into a device.

[0008] The dimensionally stable support structure is produced, for example, by injection molding, whereby the electrical conductor can also be directly overmolded using this process. In particular, the dimensionally stable support structure can also provide electrical insulation for the electrical conductor, so that, for example, safety-relevant areas of the conductor are encased. This allows the cable harness to be integrally designed as a dimensionally stable, insulated busbar. Likewise, electronic assemblies, interference suppression components such as ferrite cores, or electromechanical components can be directly molded during the injection molding process.

[0009] For the dimensionally stable support structure, plastics are used, for example, in particular polyethylene, polypropylene and / or polyvinyl chloride.

[0010] If a contacting device has a geometric engagement, this engagement can be introduced into a corresponding receptacle during the assembly process. For example, contacting devices can be geometrically supported in addition to the dimensionally stable support structure and positioned relative to, for example, the housing of the electrical device.

[0011] In particular, the respective geometric intervention is formed as a single piece and / or dimensionally stable with the dimensionally stable support structure. Specifically, the cable harness can be designed as an integral, dimensionally stable structure in which both the electrical conductor is geometrically defined and the corresponding contact devices are securely and immovably positioned. For example, the outer geometry of the respective connectors can directly serve as a geometric positioning aid and thus as a geometric intervention.

[0012] For example, the respective contacting device also includes an electrical connector, whereby such electrical connectors may have electrical plug contacts. Thus, for instance, a respective electrical connector with corresponding electrical plug contacts can be designed such that electrical conductor elements, such as individual cable strands, are each assigned to a precisely positioned plug contact. Consequently, the electrical connection of electrical devices to the contacting device can also be automated, since the position of the contacting device is exactly defined and known.

[0013] Provided that the respective contacting device is aligned parallel to the mounting direction, the mounting direction can also be used as the contacting direction.

[0014] In another aspect, the problem is solved by a method for the optimized production of an internal wiring of an electrical device according to claim 10.

[0015] A key concept of the invention is to automate the assembly of electrical devices, as with mechanical components, including electrical cable harnesses, and, for example, to facilitate gripping the cable harness using an assembly gripper. Such an assembly gripper can be the hand of an operator or assembler, a robot, an assembly portal, or an automated assembly line equipped with a suitable gripper. A particularly essential aspect of the invention is that the cable harness is dimensionally stable and geometrically defined, especially with all necessary electrical connection options, so that the cable harness can be assembled in a geometrically defined manner.

[0016] The invention will now be explained in more detail using exemplary embodiments. These will show... Fig. 1a a dimensionally stable cable harness with precisely arranged strands and connectors, Fig. 1b a sectional view of one strand of the cable harness of the Fig. 1, Fig. 2 the wiring harness of Fig. 1 in a mounting arrangement opposite a motor housing, Fig. 3 an assembly process for inserting the wiring harness into the engine housing, as well as Fig. 4 A schematic detailed isometric view of a connection of a wiring harness to an engine.

[0017] A wiring harness 101 is used to wire the drive for an electric chainsaw. The wiring harness 101 has a strand 103, a strand 105, and a strand 107, which are joined at a crossing point 108 and arranged in a star configuration. The strands 103, 105, and 107 are pre-formed analogously to their later position in a motor housing 201. An example of strand 103 is shown here (see also...). Fig. 1b) explains that a plastic 104, here polyethylene, encompasses and thus mechanically supports conductor tracks 161, 163, and 165. The same applies analogously to strands 105 and 107. Strands 103, 105, and 107 of the cable harness 101 are each made of injection-molded polyethylene. Connectors 121, 123, and 125 are provided at the respective ends of strands 103, 105, and 107 and are electrically contacted with the conductor tracks in the cable harness 101. Connectors 121, 123, 124, and 125 each have, by way of example, contacts 131, 133, 134, and 135, respectively, which are designed as clamping contacts.

[0018] A connector 124 is arranged within strand 105. Strand 105 also has a ferrite core 141, which surrounds the strand 105 and serves for electrical damping.

[0019] On strand 107, an electronics unit 129 and an additional connector 126 are arranged. Connector 126 serves to connect to a housing ground, whereas the electronics unit 129 is molded inside strand 107 and serves to control electrical components in the wiring harness 101. Connector 125 with contacts 135 serves to connect to a mains voltage supply. Connector 121 provides the connection for a control unit.

[0020] It should be mentioned here that (for example in Fig. 1) where the cable harness 101 is shown as largely closed, the corresponding electrical conductors 161, 163 and 165 as well as further electrical conductors for connecting the respective contacts to each other and for electrically contacting the electronics 129 are integrally injected within the strands 103, 105 and 107 and are thus simultaneously insulated from the outside.

[0021] Due to its precisely defined shape, the wiring harness 101 can be inserted into the motor housing 201 without requiring any molding of the wiring harness 101 to the motor housing 201. This allows the wiring harness 101 to be installed robotically or using other automated methods. The position of connectors 123 and 124 is, for example, correctly aligned with a motor mount 203, into which an electric motor is inserted after the wiring harness 101 has been installed (see figure). Fig. 2 (electric motor not yet installed here). An external geometry of the respective connectors 121, 123, 124, 125 serves to position them relative to the motor housing 201.

[0022] A corresponding assembly process 351 is carried out by a robot 301, whereby the cable harness 101 is gripped by the robot 301 and automatically inserted into the housing 201 along an assembly direction 381. Subsequently, further components, for example a motor 321, can be inserted into the housing 201. Due to the slot-shaped arrangement of contacts 131 and 135, or, as provided for the motor 321, contacts 133 and 134 in the connectors 123 and 124, the motor 321 can then also be inserted along the assembly direction 381 and is automatically inserted into the connectors 123 and 124 with corresponding blade contacts 341 and electrically connected to the contacts 133 and 134. Consequently, the manufacturing process can be carried out automatically. The connectors 123 and 124 rest on the motor housing 201 and are supported.In this context, it should be noted that the wiring harness represents a significant simplification not only for robotic assembly but also for manual assembly, as detailed adaptation of the geometry of the wiring harness 101 to, for example, the motor housing 201 is no longer necessary. It should also be mentioned that the illustration in . Fig. Figure 4 shows a partially cutaway view of strand 105, in which a connection of the motor with contact 133 and a conductor track 461 are shown cut away. Reference symbol list 101 Wiring harness 103 strand 104 plastic 105 strand 107 strand 108 Intersection point 121 plugs 123 plugs 124 plugs 125 plugs 126 plugs 129 Electronics 131 Contact 133 Contact 134 Contact 135 Contact 141 Ferrite core 161 conductor track 163 conductor track 165 conductor track 201 Engine housing 203 Engine mounts 301 robots 321 Engine 323 pinion 341 Sword contact 381 Mounting direction 461 conductor track

Claims

[1] Cable harness (101) for the internal wiring of an electrical device, wherein the cable harness (101) can be inserted into the electrical device during an assembly process (351) along an assembly direction (381) and electrical devices (321) can be connected within the electrical device by means of the cable harness (101), with at least one electrical conductor (161, 163, 165, 461) and contacting devices (121, 123, 124, 125, 126, 129) assigned to the electrical conductor (161, 163, 165, 461), wherein the contacting devices (121, 123, 124, 125, 126, 129) are electrically conductively connected to the electrical conductor (161, 163, 165, 461) and in an assembly position of the cable harness by means of the contacting devices (121, 123, 124, 125, 126, 129) enable an electrical connection of the electrical devices via the electrical conductor (161, 163, 165, 461) during the assembly process, characterized bythat the electrical conductor (161, 163, 165, 461) is assigned a dimensionally stable support structure (103, 105, 107) mechanically connected to the electrical conductor (161, 163, 165, 461), wherein the mounting position of the cable harness (101) is defined independently of the mounting process by means of the dimensionally stable support structure (103, 105, 107). [2] Wiring harness according to claim 1, characterized by that the dimensionally stable support structure (103, 105, 107) is connected to the electrical conductor (161, 163, 165, 461) in a force-fitting and / or form-fitting manner, wherein the electrical conductor is in particular permanently connected to the dimensionally stable support structure (103, 105, 107), in particular by means of the dimensionally stable support structure (103, 105, 107) being encompassed by the electrical conductor (161, 163, 165, 461). [3] Wiring harness according to claim 1 or 2, characterized bythat the dimensionally stable support structure (103, 105, 107) is produced by injection molding, wherein in particular the electrical conductor (161, 163, 165, 461) is encapsulated during the injection molding. [4] Wiring harness according to one of the preceding claims, characterized by that the dimensionally stable support structure (103, 105, 107) forms an electrical insulation (104) for the electrical conductor (161, 163, 165, 461). [5] Wiring harness according to one of the preceding claims, characterized by that the dimensionally stable support structure (103, 105, 107) comprises a plastic (104), in particular a polyethylene, a polypropylene and / or a polyvinyl chloride. [6] Wiring harness according to one of the preceding claims, characterized byin that a respective contacting device (121, 123, 124, 125, 126, 129) or respective contacting devices (121, 123, 124, 125, 126, 129) is assigned a geometric intervention (121, 123, 124, 125, 126, 129), wherein by means of the respective geometric intervention (121, 123, 124, 125, 126, 129) in the assembly process, a positioning of the respective contacting device (121, 123, 124, 125, 126, 129) relative to the electrical device in a respective receptacle corresponding to the respective geometric intervention (121, 123, 124, 125, 126, 129) is possible. [7] Wiring harness according to claim 6, characterized by that the respective geometric intervention (121, 123, 124, 125, 126, 129) is formed in one piece and / or dimensionally stable with the dimensionally stable support structure (103, 105, 107). [8] Wiring harness according to one of the preceding claims, characterized bythat the respective contacting device (121, 123, 124, 125, 126, 129) has an electrical plug connector (121, 123, 124, 125, 126, 129), wherein the respective electrical plug connector (121, 123, 124, 125, 126, 129) has in particular a plurality of electrical plug contacts (131, 133, 134, 135) for electrically connecting a plurality of electrical conductor elements (161, 163, 165, 161) of the electrical conductor to a respective plug receptacle (341) of the respective electrical device (321) corresponding to the plug connector. [9] Wiring harness according to one of the preceding claims, characterized bythat a contacting device (121, 123, 124, 125, 126, 129) or a respective contacting device (121, 123, 124, 125, 126, 129) is aligned substantially along the mounting direction (381), wherein by means of the alignment substantially along the mounting direction (381) a respective electrical device (321) or the respective electrical device (321) along a contacting direction (121, 123, 124, 125, 126, 129) aligned substantially parallel to the mounting direction (381) with the contacting device (121, 123, 124, 125, 126, 129) and / or with the respective contacting device (121, 123, 124, 125, 126, 129) can be contacted. [10] Method for the optimized production of internal wiring of an electrical device, wherein electrical devices (321) are connected within the electrical device by means of a cable harness (101) according to one of the preceding claims, comprising the following steps: - Picking up the cable harness (101) on the dimensionally stable support structure (103, 105, 107) by means of an assembly gripper (301), so that the cable harness (101) is picked up on the dimensionally stable support structure (103, 105, 107) by means of the assembly gripper (301), - inserting the cable harness (101) into the electrical device by means of the assembly gripper (301) along the assembly direction (381), so that the cable harness (101) is inserted into the electrical device by means of the assembly gripper (301) along the assembly direction (381), - contacting the electrical devices (321) to the respective contacting devices (121, 123, 124, 125, 126, 129), so that the internal cabling is optimized.

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