Manufacturing method of wire harness

Abstract

To reduce a cost price of a wire harness.SOLUTION: A method for producing a wire harness comprises: a step of assembling a harness; a step of installing a release member for placing a release member 600 to the wire harness every time when a harness assembly step is finished, when assembling a plurality of sets of wire harnesses 1; and a step of joining the components of the wire harness to each wire harness set, wherein the harness assembly step comprises a first outer layer installation step for installing an outer installation member 20A of one outer layer, among the plurality of mesh and sheet-like outer installing members 20 having insulation properties on an outer surface to a jig board 500; an inner layer installation step in which a protection target portion 11 of at least one cable distribution wire 10 is disposed on the outer installation member of one outer layer; and a second outer layer installation step in which the outer installation member 20B of the other outer layer in the plurality of outer installation members is superimposed on the protection target portion and the outer installation member on which the protection target is placed, and in the joining step, a plurality of outer installation members in the wire harness are joined for each set of the wire harness.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a wire harness. [Background technology]

[0002] In a wire harness, the electric wires are arranged along structures such as a vehicle body, a power train, etc. For this reason, in this wire harness, an adhesive tape that is wound around the electric wires and a corrugated tube that houses the electric wires are used as exterior members that protect the electric wires from interference with surrounding parts, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-241790 [Patent Document 2] JP 2020-10453 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional wire harness, the exterior member is attached to the electric wire by wrapping an adhesive tape around the electric wire or inserting the electric wire into a corrugated tube. Therefore, in the conventional wire harness, especially when the electric wire has a complicated wiring path or is branched, the exterior member needs to be manually attached to the electric wire in order to stabilize the quality after assembly. Therefore, the conventional wire harness has room for reducing the cost in the manufacturing process.

[0005] SUMMARY OF THE PRESENT EMBODIMENTS Accordingly, an object of the present invention is to provide a method for manufacturing a wire harness that can reduce costs. [Means for solving the problem]

[0006] The present invention includes a harness assembling process for assembling a wire harness, a release member providing process for placing a release member capable of preventing adhesion between adjacent wire harnesses on the wire harnesses that have been subjected to the harness assembling process each time the harness assembling process is completed when assembling a plurality of sets of the wire harnesses, and a joining process for joining components of the wire harnesses to each other for each set of the wire harnesses. The harness assembling process is performed using a mesh-like sheet-like wire harness having an insulating outer surface. The method includes a first outer layer installation step of installing one of a plurality of outer layers of the outer members on a fixture plate, an inner layer installation step of arranging a protected portion of at least one electric cable in the outer layer of the outer members, and a second outer layer installation step of overlapping the other outer layer of the plurality of outer members on the protected portion and the outer member on which the protected portion is placed, and the joining step is characterized in that the multiple outer members of the wire harness are joined for each set of the wire harness. Effect of the Invention

[0007] In the method for manufacturing a wire harness according to the present invention, the exterior member can be assembled to the part to be protected by simply sandwiching the part to be protected between a pair of exterior members. Therefore, in the method for manufacturing a wire harness, it is not necessary to wrap an adhesive tape around the part to be protected or to insert the part to be protected into a corrugated tube, as in the conventional method. Therefore, even if the wiring path of the wiring wire is complicated or the wiring wire is branched, the exterior member can be assembled to the part to be protected without relying on manual labor. In addition, in the method for manufacturing a wire harness, a release member is placed every time the harness assembly process is completed in the same manner as in the exterior member until the harness assembly process of the final wire harness is completed, and multiple wire harnesses can be assembled in succession. Therefore, the method for manufacturing a wire harness according to the present invention contributes to the automation of the manufacturing process, and therefore the cost can be reduced. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a plan view showing a wire harness according to an embodiment. [Diagram 2] FIG. 2 is an exploded perspective view showing the wire harness of the embodiment. [Diagram 3] FIG. 3 is a perspective view showing the fixture plate of the embodiment. [Figure 4] FIG. 4 is an explanatory diagram illustrating a first outer layer providing step for the first set according to the embodiment. [Diagram 5] FIG. 5 is an explanatory diagram for explaining the first inner layer installing step (electric wire installing step) of the embodiment. [Figure 6] FIG. 6 is an explanatory diagram illustrating the first set of second outer layer providing steps according to the embodiment. [Figure 7] FIG. 7 is an explanatory diagram for explaining the release member providing step of the embodiment. [Figure 8] FIG. 8 is an explanatory diagram illustrating a second set of first outer layer providing steps according to the embodiment. [Figure 9] FIG. 9 is an explanatory diagram for explaining the second inner layer installing step (electric wire installing step) of the embodiment. [Figure 10] FIG. 10 is an explanatory diagram illustrating the second outer layer providing step of the second set in the embodiment. [Figure 11] FIG. 11 is an explanatory diagram illustrating a second outer layer providing step for a second set according to the embodiment. [Figure 12] FIG. 12 is an explanatory diagram for explaining the joining step of the embodiment. [Figure 13] FIG. 13 is an exploded perspective view showing a modified example of the wire harness of the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of the method for manufacturing a wire harness according to the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to the embodiment.

[0010] [Embodiment] One embodiment of the method for manufacturing a wire harness according to the present invention will be described with reference to FIGS.

[0011] Reference numeral 1 in Fig. 1 and Fig. 2 indicates a wire harness assembled by the manufacturing method of this embodiment. This wire harness 1 has, as a minimum configuration, at least one wire 10 having a portion 11 to be protected sandwiched between a pair of sheet-like exterior members 20 (Figs. 1 and 2). This wire harness 1 includes a plurality of mesh-like sheet-like exterior members 20 having insulating outer surfaces, and at least one wire 10 having a portion 11 to be protected sandwiched between the pair of overlapping exterior members 20.

[0012] The electric wire arrangement 10 refers to a single electric wire or an electric wire bundle in which multiple electric wires are bundled together. This electric wire arrangement 10 is arranged along structures such as a vehicle body or a power train. For this reason, in this electric wire arrangement 10, a place where interference with surrounding parts is expected is set as a protected portion 11, and this protected portion 11 is wrapped with an exterior member 20 to protect it from the outside.

[0013] The exterior member 20 is a sheet-like member formed into a mesh shape, and is given flexibility so as to enable deformation, such as to follow the shape of the sandwiched electric wire 10. This exterior member 20 is formed from an insulating material such as synthetic rubber so as to give insulating properties to the outer surface while giving flexibility to the entire exterior member 20.

[0014] Moreover, it is preferable that the exterior member 20 is formed from an insulating material having a large coefficient of friction on the outer surface in order to prevent the sandwiched electric wire 10 from shifting from its original position.

[0015] In addition, the exterior member 20 may contain metal wires like reinforcing threads in order to maintain the shape after deformation. For example, in the exterior member 20, the wires may be woven into a mesh, and a mesh-like insulating portion may be formed of an insulating material such as synthetic rubber along the mesh of the mesh-like shape-retaining member. Here, the mesh-like shape-retaining member may function as a shielding member like a so-called braid. Therefore, the exterior member 20 can suppress the intrusion of noise from the outside by simply sandwiching the cable 10 between a pair of exterior members 20 without wrapping the cable 10 in a separate braid.

[0016] The multiple exterior members 20 are stacked, and the portion 11 to be protected of the electric wire 10 is sandwiched between the pair of exterior members 20. The multiple exterior members 20 have joints 25 where at least a portion of each of the multiple exterior members 20 is joined together (FIG. 1). All of the multiple exterior members 20 may be the same material, or all or a portion of the multiple exterior members 20 may be different materials having different shapes or materials, for example. In this example, the same rectangular exterior members 20 are used for all of them.

[0017] In other words, the minimum configuration of the wire harness 1 is a layer configuration including an exterior member 20A of one outer layer and an exterior member 20B of the other outer layer, and including an electric wire 10 with a portion to be protected 11 sandwiched between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer (FIGS. 1 and 2). That is, the minimum configuration of the wire harness 1 is one having only one layer (hereinafter referred to as "wire layer") in which the portion to be protected 11 is arranged. The wire harness 1 can also be configured to have a plurality of electric wire layers between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer.

[0018] The wire harness 1 is assembled on a jig plate 500 (FIGS. 3 to 10). Here, a manufacturing method capable of assembling a plurality of wire harnesses 1 in succession on the jig plate 500 will be described.

[0019] This manufacturing method includes a harness assembly process (FIGS. 4 to 6 and 8 to 10) for assembling the wire harness 1, a release member installation process (FIG. 7) for placing a release member 600 capable of preventing sticking between adjacent wire harnesses 1 on the wire harnesses 1 for which the harness assembly process has been completed each time a harness assembly process is completed when assembling a plurality of sets of wire harnesses 1, and a joining process (FIG. 11) for joining components of the wire harness 1 for each set of wire harnesses 1. The joining process may be performed each time a harness assembly process is completed, or may be performed collectively for all wire harnesses 1 after the harness assembly processes for all sets of wire harnesses 1 have been completed. Here, the joining process is performed after the harness assembly processes for all sets of wire harnesses 1 have been completed.

[0020] The harness assembling process includes a first outer layer laying step, an inner layer laying step, and a second outer layer laying step.

[0021] Here, first, a harness assembling process will be described in which one electric wire layer is disposed between exterior member 20A of one outer layer and exterior member 20B of the other outer layer.

[0022] In the first outer layer installation step, an outer layer member 20A of one of the multiple outer layers 20 is installed on a fixture plate 500 (FIG. 4). Then, in the inner layer installation step, at least one protected portion 11 of the wire 10 is arranged in the outer layer member 20A (FIG. 5).

[0023] In the inner layer installation step, when the part to be protected 11 is routed, the part to be protected 11 is passed through a gap between two electric wire routing pins 510 arranged along the routing path of the part to be protected 11 on the jig plate 500 (FIG. 5). Here, the jig plate 500 has at least two electric wire routing pins 510 arranged in pairs at multiple locations along the routing path of the part to be protected 11 (FIGS. 3 to 10). For example, the electric wire routing pins 510 are arranged in pairs of at least two at locations that will be bending points of the part to be protected 11, along the routing path of the part to be protected 11.

[0024] If the electric wire routing pin 510 is not located directly below the exterior member 20A when installing the exterior member 20A of one outer layer in the first outer layer installation step, it will not interfere with the installation work of the exterior member 20A. However, depending on the routing path of the protected part 11, the electric wire routing pin 510 may be located directly below the exterior member 20A when installing the exterior member 20A of one outer layer in the first outer layer installation step. The example given here shows this situation (FIG. 4). Therefore, in the first outer layer installation step, when installing the exterior member 20A of one outer layer, the electric wire routing pin 510, which is thicker than the through hole 21 (FIG. 1) of the mesh in the exterior member 20A, is inserted into the through hole 21.

[0025] In this wire harness 1, since the exterior member 20 is formed in a mesh shape, by utilizing the through holes 21, the exterior member 20 can be installed on the jig plate 500 without performing any work such as providing another through hole in the exterior member 20. Furthermore, in this wire harness 1, by making the through holes 21 of the mesh of the exterior member 20 smaller than the electric wire routing pins 510, the through holes 21 of the mesh of the exterior member 20 and the electric wire routing pins 510 can be utilized to suppress misalignment of the exterior member 20 on the jig plate 500.

[0026] In the illustrated jig plate 500, two electric wire routing pins 510 making up one set are arranged in three locations, and three electric wire routing pins 510 making up one set are arranged in one location (FIGS. 3 to 10). In the illustrated inner layer installation step, the protected portions 11 of the two wiring wires 10 are arranged in the exterior member 20A of one outer layer.

[0027] The pair of electric wire routing pins 510 are all arranged at three locations where the protected portion 11 of the wire 10 sandwiched between the pair of exterior members 20 is pulled out from between the pair of exterior members 20 (locations that serve as so-called wire outlets) (FIGS. 3 to 10). One of the three pairs of electric wire routing pins 510 (a pair of electric wire routing pins 510A) is arranged at a location where an electric wire outlet is provided for pulling one end side of the two wires 10 out from between the pair of exterior members 20 (FIG. 5). One of the remaining two pairs of electric wire routing pins 510 (a pair of electric wire routing pins 510B) is arranged at a location where an electric wire outlet is provided for pulling the other end side of one wire 10 out, and the other of the remaining pairs of electric wire routing pins 510 (a pair of electric wire routing pins 510C) is arranged at a location where an electric wire outlet is provided for pulling the other end side of the other wire 10 out (FIG. 5).

[0028] Moreover, the three electric wire routing pins 510 (510D) in a set are arranged at the vertices of a triangle, and three gaps are formed between the two electric wire routing pins 510D (FIGS. 3 to 8). In the three electric wire routing pins 510D, the protected portion 11 of the two wiring electric wires 10 that have passed through the gap between the pair of electric wire routing pins 510A is passed through one of the three gaps (FIG. 5). In the three electric wire routing pins 510D, the protected portion 11 of one wiring electric wire 10 is passed through one of the remaining two gaps, and the protected portion 11 of the other wiring electric wire 10 is passed through the other of the remaining two gaps (FIG. 5). These three electric wire routing pins 510D route the protected portion 11 of one of the electric wires 10 that passes through one gap toward a pair of electric wire routing pins 510B, and route the protected portion 11 of the other electric wire 10 that passes through the other gap toward a pair of electric wire routing pins 510C (Figure 5).

[0029] In this example, only one layer of the protected parts 11 of the two electric wires 10 constitutes an electric wire layer. Therefore, the inner layer installation process in this example can be said to be an electric wire installation process in which only the protected parts 11 of the electric wires 10 are routed.

[0030] In the second outer layer installation step, the outer layer 20B of the other outer layer of the multiple outer layers 20 is superimposed on the protection target portion 11 and the outer layer 20 on which the protection target portion 11 is placed (FIG. 6). In this exemplary second outer layer installation step, when the outer layer 20B of the other outer layer is installed, the electric wire wiring pin 510 is inserted into the through hole of the mesh in the outer layer 20B, as in the first outer layer installation step. In this exemplary second outer layer installation step, the outer layer 20B of the other outer layer is superimposed on the protection target portion 11 of the two wires 10 and the outer layer 20A of one outer layer on which the two protection target portions 11 are placed.

[0031] In this manufacturing method, the harness assembling process of the first wire harness 1A is completed by completing the second outer layer providing process. In this manufacturing method, a release member providing process is performed before starting the harness assembling process of the second wire harness 1B (FIG. 7).

[0032] In the release member installation process, a release member 600 is placed on the wire harness 1A after the harness assembly process (i.e., on the exterior member 20B of the other outer layer of this wire harness 1A) (FIG. 7). The release member 600 is formed into a sheet shape and is arranged between the two wire harnesses 1 (1A, 1B) so that the exterior members 20 do not stick to each other. The release member 600 is formed, for example, to a size equal to or larger than that of the exterior member 20, and is placed on the wire harness 1A after the harness assembly process so as to cover and conceal the exterior member 20B of the other outer layer. For example, so-called release paper, release film, etc. are used as the release member 600 here.

[0033] In this exemplary mold release member installation step, the electric wire routing pin 510 is present directly below the mold release member 600. For this reason, the mold release member 600 is formed in a mesh shape like the exterior member 20 so that the electric wire routing pin 510 can be inserted for each of the electric wire routing pins 510, and the electric wire routing pins 510 are inserted into the through holes of the mesh. If the mold release member 600 is not formed in a mesh shape, a through hole through which the electric wire routing pin 510 can be inserted may be provided for each of the electric wire routing pins 510 in accordance with the arrangement of the electric wire routing pins 510 on the jig plate 500.

[0034] In this manufacturing method, a release member 600 is placed on the wire harness 1A (on the exterior member 20B of the other outer layer), and then the harness assembly process of the next set of wire harnesses 1B is started (FIGS. 8 to 10). For this second set of wire harnesses 1B, in the first outer layer installation process, one of the exterior members 20A of the multiple exterior members 20 is placed on the release member 600 (FIG. 8). Then, in the inner layer installation process, at least one of the wiring wires 10 is arranged in the exterior member 20A of the one outer layer (FIG. 9). In the second outer layer installation process, the exterior member 20B of the other outer layer of the multiple exterior members 20 is superimposed on the exterior member 20 (the exterior member 20A of the one outer layer) on which the protection member 11 is placed (FIGS. 10 and 11).

[0035] In this manufacturing method, the harness assembling step and the release member providing step are alternately repeated until the harness assembling step is completed for the final set of wire harnesses 1. Here, the second set of wire harnesses 1B is regarded as the final set.

[0036] In this manufacturing method, the joining step may be performed every time the harness assembly step is completed, or the joining step may be performed after the harness assembly steps are completed for all the sets of wire harnesses 1. In this example, the joining step is performed after the harness assembly steps are completed for all the sets of wire harnesses 1.

[0037] In the joining process, the multiple exterior members 20 in the wire harness 1 are joined for each set of the wire harness 1. In the wire harness 1, a joint 25 is formed for each set through this joining process. In the joint 25, the multiple exterior members 20 are bonded or welded to each other at least partially for each pair of overlapping exterior members 20.

[0038] For example, in the joining step, at least a portion of the overlapping exterior member 20A of one outer layer and the exterior member 20B of the other outer layer may be bonded together with an adhesive for each set of wire harnesses 1. Also, in the joining step, the exterior member 20 may be made sticky or adhesive so that the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer that are overlapped with each other may be made to self-adhere to each other for each set of wire harnesses 1.

[0039] In the joining step, at least a portion of the overlapping exterior member 20A of one outer layer and the exterior member 20B of the other outer layer may be welded to each other for each set of wire harnesses 1 using a known welding technique such as ultrasonic welding. For example, in this joining step, the overlapping exterior member 20A of one outer layer and the exterior member 20B of the other outer layer are sandwiched between anvil 701 and horn 702 and pressurized, and ultrasonic vibration is transmitted from horn 702 to the exterior member 20A and the exterior member 20B to weld at least a portion of the exterior member 20A and the exterior member 20B to each other (FIG. 12). Here, since the exterior member 20 is formed in a mesh shape, anvil 701 and horn 702 that are thicker than the through holes of the mesh are used.

[0040] The joining process shown here is a process in which, using anvil 701 and horn 702 prepared for each set of wire harnesses 1, the wire harnesses 1 are sandwiched and pressurized from the exterior member 20A side of one outer layer and the exterior member 20B side of the other outer layer between the anvil 701 and horn 702, and the multiple exterior members 20 of the wire harnesses 1 are welded together by ultrasonic vibration applied from the horn 702. Therefore, in this joining process, a combination of anvil 701 and horn 702 arranged in a shifted manner for each set of wire harnesses 1 is used.

[0041] In this joining process, when the release member 600 and another wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20A of one outer layer of the wire harness 1 to be joined, the tip of the anvil 701 inserted into the through hole (hereinafter referred to as the "connector insertion hole") 602 of the release member 600 and the through hole (hereinafter referred to as the "connector insertion hole") 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20A of one outer layer of the wire harness 1 to be joined, and when the release member 600 and another wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20B of the other outer layer of the wire harness 1 to be joined, the tip of the horn 702 inserted into the connector insertion hole 602 of the release member 600 and the connector insertion hole 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20B of the other outer layer of the wire harness 1 to be joined (FIG. 12).

[0042] In this exemplary joining process, the exterior member 20A of one outer layer of the first wire harness 1A and the exterior member 20B of the other outer layer are sandwiched between the anvil 701A and the horn 702A (FIG. 12). Therefore, when carrying out this joining process, the connector insertion holes 602, 22 for allowing the tip of the horn 702A to reach the exterior member 20B of the other outer layer of the first wire harness 1A are formed in advance in all of the release members 600 on the side of the exterior member 20B of the other outer layer of the first wire harness 1A and in the multiple exterior members 20 of the second or subsequent wire harnesses 1 (wire harness 1B, etc.). Here, a connector insertion hole 602A for inserting the horn 702A is formed in the release member 600 placed on the first wire harness 1A, and a connector insertion hole 22A for inserting the horn 702A is formed in the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the second wire harness 1B (FIG. 12). In this joining process, an anvil 701A is erected from the jig plate 500. However, in this joining process, the jig plate 500 may be used as the anvil 701A.

[0043] In this joining process, the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the second wire harness 1B are sandwiched between the anvil 701B and the horn 702B. Therefore, when performing this joining process, the release member 600 between the first and second wire harnesses 1A, 1B, and the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the first wire harness 1A have connector insertion holes 602B, 22B formed therein for allowing the tip of the anvil 701B to reach the exterior member 20A of one outer layer of the second wire harness 1B (FIG. 12). In the harness assembling process for the first wire harness 1A, when installing the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer in the first outer layer installing process and the second outer layer installing process, for example, anvil 701B erected from the jig plate 500 is inserted into the connector insertion hole 22B. Then, in the release member installing process, when placing the release member 600 on the first wire harness 1A, the anvil 701B is inserted into the connector insertion hole 602B.

[0044] In addition, when the third and subsequent wire harnesses 1 are also assembled, when this joining step is performed, the connector insertion holes 602A, 22B for allowing the tip of the horn 702A to reach the other outer sheath member 20B of the first wire harness 1A are formed in advance in all of the release members 600 arranged on the side of the other outer sheath member 20B of the second wire harness 1B and in the multiple sheath members 20 of the third and subsequent wire harnesses 1. The release members 600 and the multiple sheath members 20 of the third and subsequent wire harnesses 1 are formed in advance with the connector insertion holes 602B, 22B for allowing the tip of the horn 702B to reach the other outer sheath member 20B of the second wire harness 1B.

[0045] The connector insertion holes 22 , 602 of the exterior member 20 and the release member 600 are appropriately provided for each combination of the anvil 701 and the horn 702 .

[0046] In the wire harness 1 that is the last set in the assembly order, the exterior member 20B of the other outer layer becomes the final layer, and since the release member 600 is not placed on this exterior member 20B, the tip of the horn 702 can be brought into contact with this exterior member 20B. In this exemplary manufacturing method, two sets of wire harnesses 1 are assembled. Therefore, here, the exterior member 20B of the other outer layer of the second wire harness 1B becomes the final layer.

[0047] So far, the harness assembling process has been described for a case where only one electric wire layer is interposed between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer. Next, a harness assembling process will be described for a case where multiple electric wire layers are disposed between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer.

[0048] In this case, the inner layer installation step is a step of alternately repeating the arrangement of the part to be protected 11 to the exterior member 20 and the installation of the exterior member 20C of the inner layer among the multiple exterior members 20 according to the number of layers of the part to be protected 11 to be interposed between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer (FIG. 13). In this inner layer installation step, according to the number of layers of the part to be protected 11, the arrangement of the part to be protected 11 to the exterior member 20 and the overlapping of the exterior member 20C of the inner layer to the exterior member 20 on which the part to be protected 11 is placed are alternately repeated until the exterior member 20C of the inner layer becomes the final layer, and then the part to be protected 11 of the final layer is arranged in the exterior member 20C of the inner layer of the final layer.

[0049] For example, in the inner layer installation step, at least one (two in a specific example) protected portion 11 of the wire 10 is arranged in one outer layer exterior member 20A, and one inner layer exterior member 20C is superimposed on the protected portion 11 and the one outer layer exterior member 20A on which the protected portion 11 is placed. In this inner layer installation step, if an electric wire routing pin 510 is present directly below the inner layer exterior member 20C, the electric wire routing pin 510 is inserted into the through hole 21 of the mesh in the exterior member 20C when the exterior member 20C is installed. Also, in this inner layer installation step, the anvil 701 is appropriately inserted into the connector insertion hole 22 of the inner layer exterior member 20C. In the joining process, the horn 702 is appropriately inserted into the connector insertion hole 22 of the inner layer exterior member 20C, and the anvil 701 and horn 702 are used to ultrasonically weld the exterior member 20A of one outer layer, the exterior member 20C of the inner layer, and the exterior member 20B of the other outer layer together.

[0050] In this specific example, since the exterior member 20C becomes the exterior member 20C of the inner layer of the final layer, at least one (here, two) portion to be protected 11 of the wiring wire 10 is arranged in the exterior member 20C of the inner layer of the final layer as the portion to be protected 11 of the final layer. Therefore, in the second outer layer installation step, the exterior member 20B of the other outer layer is superimposed on the portion to be protected 11 of the final layer and the exterior member 20C of the inner layer of the final layer on which the portion to be protected 11 of the final layer is placed.

[0051] As described above, in the manufacturing method of the wire harness 1 of the present embodiment, the protected portion 11 of the wire 10 is simply sandwiched between a pair of exterior members 20, and the exterior member 20 can be assembled to the protected portion 11. Therefore, in the manufacturing method of the wire harness 1, unlike the conventional method, it is not necessary to wrap an adhesive tape around the protected portion 11 or insert the protected portion 11 into a corrugated tube. Therefore, even if the wiring path of the wire 10 is complicated or the wire 10 is branched, the exterior member 20 can be assembled to the protected portion 11 without relying on manual labor. In addition, in the manufacturing method of the wire harness 1, the release member 600 is placed every time the harness assembly process of the final wire harness 1 is completed in the same installation method as the exterior member 20, and multiple wire harnesses 1 can be assembled in succession. Therefore, the manufacturing method of the wire harness 1 of the present embodiment contributes to the automation of the manufacturing process, and therefore the cost can be reduced.

[0052] Incidentally, in the above-described exemplary joining step, ultrasonic welding is applied to join the exterior members 20 together, but in the joining step, instead of this, the exterior members 20 may be joined together by thermal welding. Here, the anvil 701 and the horn 702 described in the explanation of ultrasonic welding are replaced with a first electrode 701 and a second electrode 702, respectively.

[0053] This joining process is a process in which, using a first electrode 701 and a second electrode 702 prepared for each set of wire harnesses 1, the wire harnesses 1 are sandwiched and pressurized from the side of one outer layer of exterior material 20A of the wire harness 1 and the side of the other outer layer of exterior material 20B of the wire harness 1, and the multiple exterior materials 20 of the wire harness 1 are heated and thermally welded together as current flows between the first electrode 701 and the second electrode 702.

[0054] In this joining process, when the release member 600 and a wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20A of one outer layer of the wire harness 1 to be joined, the tip of the first electrode 701 inserted into the connector insertion hole 602 of the release member 600 and the connector insertion hole 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20A of one outer layer of the wire harness 1 to be joined, and when the release member 600 and a wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20B of the other outer layer of the wire harness 1 to be joined, the tip of the second electrode 702 inserted into the connector insertion hole 602 of the release member 600 and the connector insertion hole 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20B of the other outer layer of the wire harness 1 to be joined (FIG. 12).

[0055] In this exemplary joining step, the exterior member 20A of one outer layer of the first wire harness 1A and the exterior member 20B of the other outer layer are sandwiched between the first electrode 701A and the second electrode 702A (FIG. 12). Therefore, when carrying out this joining step, the connector insertion holes 602, 22 for allowing the tip of the second electrode 702A to reach the exterior member 20B of the other outer layer of the first wire harness 1A are formed in advance in all the release members 600 on the side of the exterior member 20B of the other outer layer of the first wire harness 1A and in the multiple exterior members 20 of the second or subsequent wire harnesses 1 (wire harness 1B, etc.). Here, a connector insertion hole 602A for inserting the second electrode 702A is formed in the release member 600 placed on the first wire harness 1A, and a connector insertion hole 22A for inserting the second electrode 702A is formed in the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer in the second wire harness 1B (FIG. 12). In this joining process, the first electrode 701A is erected from the jig plate 500. However, in this joining process, the jig plate 500 may be used as the first electrode 701A.

[0056] In this joining step, the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the second wire harness 1B are sandwiched between the first electrode 701B and the second electrode 702B. Therefore, when performing this joining step, the release member 600 between the first and second wire harnesses 1A and 1B, and the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the first wire harness 1A have connector insertion holes 602B and 22B formed therein for allowing the tip of the first electrode 701B to reach the exterior member 20A of one outer layer of the second wire harness 1B (FIG. 12). In the harness assembling process of the first wire harness 1A, when installing the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer in the first outer layer installing process and the second outer layer installing process, for example, the first electrode 701B erected from the jig plate 500 is inserted into the connector insertion hole 22B. Then, in the release member installing process, when the release member 600 is placed on the first wire harness 1A, the first electrode 701B is inserted into the connector insertion hole 602B.

[0057] In addition, when the third and subsequent wire harnesses 1 are also assembled, when this joining step is performed, the connector insertion holes 602A and 22B for allowing the tip of the second electrode 702A to reach the other outer sheath member 20B of the first wire harness 1A are formed in advance in all the release members 600 arranged on the side of the other outer sheath member 20B of the second wire harness 1B and the multiple sheath members 20 of the third and subsequent wire harnesses 1. The release members 600 and the multiple sheath members 20 of the third and subsequent wire harnesses 1 are formed in advance with the connector insertion holes 602B and 22B for allowing the tip of the second electrode 702B to reach the other outer sheath member 20B of the second wire harness 1B.

[0058] The connector insertion holes 22 , 602 of the exterior member 20 and the release member 600 are appropriately provided for each combination of the first electrode 701 and the second electrode 702 .

[0059] In this case, the other outer layer exterior member 20B of the second wire harness 1B is the final layer, and since the release member 600 is not placed on this exterior member 20B, the tip of the second electrode 702 can be brought into contact with this exterior member 20B.

[0060] In this illustrated inner layer installation step, when multiple electric wire layers are disposed between an exterior member 20A of one outer layer and an exterior member 20B of the other outer layer, a first electrode 701 is appropriately inserted into the connector insertion hole 22 of the exterior member 20C of the inner layer. In a joining step, a second electrode 702 is appropriately inserted into the connector insertion hole 22 of the exterior member 20C of the inner layer, and the first electrode 701 and the second electrode 702 are used to thermally weld the exterior member 20A of one outer layer, the exterior member 20C of the inner layer, and the exterior member 20B of the other outer layer.

[0061] Furthermore, in the joining step, the exterior members 20 may be joined together by high-frequency welding.

[0062] This joining step is a step of irradiating microwaves from an electron gun (not shown) to the exterior member 20B of the other outer layer of the wire harness 1 for each set of the wire harness 1, and high-frequency welding the multiple exterior members 20 of the wire harness.

[0063] In this joining process, when a release member 600 and a wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20A of one outer layer of the wire harness 1 to be joined, microwaves emitted from an electron gun are irradiated from a through hole (hereinafter referred to as a "microwave irradiation hole") 602 of the release member 600 and through holes (hereinafter referred to as a "microwave irradiation hole") 22 of the multiple exterior members 20 of the other wire harness 1 to be joined to the exterior member 20B of the other outer layer of the wire harness 1 to be joined. Here, the connector insertion holes 602 and 22 shown in the explanation of ultrasonic welding are replaced with microwave irradiation holes 602 and 22, respectively.

[0064] Specifically, this joining step is a step in which, for each set of wire harnesses 1, a first pressure member 701 and a second pressure member 702 are used to sandwich and press the wire harnesses 1 from the exterior member 20A side of one outer layer and the exterior member 20B side of the other outer layer between the first pressure member 701 and the second pressure member 702, and microwaves are irradiated from an electron gun to the exterior member 20B of the other outer layer of the wire harness 1, thereby high-frequency welding the multiple exterior members 20 of the wire harness. Here, the anvil 701 and the horn 702 described in the ultrasonic welding explanation are replaced with the first pressure member 701 and the second pressure member 702, respectively.

[0065] In this joining process, when a release member 600 and a wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20A of one outer layer of the wire harness 1 to be joined, a tip of a first pressure member 701 inserted into the microwave irradiation hole 602 of the release member 600 and the microwave irradiation hole 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20A of one outer layer of the wire harness 1 to be joined, and when a release member 600 and a wire harness 1 other than the wire harness 1 to be joined are present on the side of the exterior member 20B of the other outer layer of the wire harness 1 to be joined, a tip of a second pressure member 702 inserted into the microwave irradiation hole 602 of the release member 600 and the microwave irradiation hole 22 of the multiple exterior members 20 of the other wire harness 1 is brought into contact with the exterior member 20B of the other outer layer of the wire harness 1 to be joined. In this joining step, microwaves emitted from an electron gun are irradiated through the inside of the cylindrical second pressing member 702 to the exterior member 20B that is the other outer layer of the wire harness 1 to be joined.

[0066] In this exemplary joining process, the exterior member 20A of one outer layer of the first wire harness 1A and the exterior member 20B of the other outer layer are sandwiched between a first pressure member 701A and a second pressure member 702A. Therefore, when performing this joining process, microwave irradiation holes 602, 22 for allowing the tip of the second pressure member 702A to reach the exterior member 20B of the other outer layer of the first wire harness 1A are formed in advance in all of the release members 600 on the side of the exterior member 20B of the other outer layer of the first wire harness 1A and in the multiple exterior members 20 of the second or subsequent wire harnesses 1 (wire harness 1B, etc.). Here, a microwave irradiation hole 602A for inserting the second pressing member 702A is formed in the release member 600 placed on the first wire harness 1A, and a microwave irradiation hole 22A for inserting the second pressing member 702A is formed in the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer in the second wire harness 1B. In this joining process, the first pressing member 701A is erected from the jig plate 500. However, in this joining process, the jig plate 500 may be used as the first pressing member 701A.

[0067] In this joining step, the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the second wire harness 1B are sandwiched between the first pressure member 701B and the second pressure member 702B. Therefore, when performing this joining step, the release member 600 between the first and second wire harnesses 1A and 1B, and the microwave irradiation holes 602B and 22B for allowing the tip of the first pressure member 701B to reach the exterior member 20A of one outer layer of the second wire harness 1B are formed in the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer of the first wire harness 1A. In the harness assembling process of the first wire harness 1A, when installing the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer in the first outer layer installing process and the second outer layer installing process, for example, a first pressure member 701B erected from the jig plate 500 is inserted into the microwave irradiation hole 22B. Then, in the release member installing process, when the release member 600 is placed on the first wire harness 1A, the first pressure member 701B is inserted into the microwave irradiation hole 602B.

[0068] In addition, when the third and subsequent wire harnesses 1 are also assembled, when this joining step is performed, microwave irradiation holes 602A, 22B for allowing the tip of the second pressure member 702A to reach the other outer layer exterior member 20B of the first wire harness 1A are formed in advance in all of the release members 600 arranged on the side of the other outer layer exterior member 20B of the second wire harness 1B and in the multiple exterior members 20 of the third and subsequent wire harnesses 1. In addition, microwave irradiation holes 602B, 22B for allowing the tip of the second pressure member 702B to reach the other outer layer exterior member 20B of the second wire harness 1B are formed in advance in the release members 600 and the multiple exterior members 20 of the third and subsequent wire harnesses 1.

[0069] The microwave irradiation holes 22 , 602 of the exterior member 20 and the release member 600 are appropriately provided for each combination of the first pressure member 701 and the second pressure member 702 .

[0070] In this case, the exterior member 20B of the other outer layer of the second wire harness 1B becomes the final layer, and the release member 600 is not placed on this exterior member 20B, so that the tip of the second pressing member 702 can be brought into contact with this exterior member 20B. However, in this manufacturing method, when the exterior member 20A of one outer layer of the second wire harness 1B and the exterior member 20B of the other outer layer are in contact without pressure, the first pressing member 701 and the second pressing member 702 for the second wire harness 1B may not be provided, and the exterior member 20B of the other outer layer may be irradiated with microwaves from an electron gun in the joining step.

[0071] In this exemplary inner layer installation step, when multiple electric wire layers are arranged between the exterior member 20A of one outer layer and the exterior member 20B of the other outer layer, the first pressurizing member 701 is inserted into the microwave irradiation hole 22 of the exterior member 20C of the inner layer. In the joining step, the second pressurizing member 702 is appropriately inserted into the microwave irradiation hole 22 of the exterior member 20C of the inner layer, and the exterior member 20A of one outer layer, the exterior member 20C of the inner layer, and the exterior member 20B of the other outer layer are sandwiched and pressed using the first pressurizing member 701 and the second pressurizing member 702. In this joining step, the microwave emitted from the electron gun is irradiated to the exterior member 20B of the other outer layer through the inside of the cylindrical second pressurizing member 702, and the exterior member 20A of one outer layer, the exterior member 20C of the inner layer, and the exterior member 20B of the other outer layer are high-frequency welded. [Explanation of symbols]

[0072] 1,1A,1B Wire harness 10 Cable distribution 11 Protected Areas 20 Exterior materials 20A One outer layer of exterior material 20B Other outer layer exterior material 20C Inner layer exterior material 21 Through hole 22 Connector insertion hole, microwave irradiation hole 500 Jig plate 510 Wire routing pin 600 Release material 602 Connector insertion hole, microwave irradiation hole 701 Anvil, first electrode, first pressure member 702 Horn, second electrode, second pressure member

Claims

1. a harness assembly process for assembling a wire harness; a release member installation step of placing a release member capable of preventing sticking between adjacent wire harnesses on the wire harnesses that have been subjected to the harness assembly step each time the harness assembly step is completed when assembling a plurality of sets of the wire harnesses; a joining step of joining components of the wire harness together for each set of the wire harness; having The harness assembly process includes: a first outer layer installation step of installing one of a plurality of mesh-like and sheet-like exterior members having insulating outer surfaces on a jig plate; an inner layer installation process of arranging a protected portion of at least one electric cable in the exterior member of the one outer layer; a second outer layer installation step of overlapping the other outer layer of the multiple outer layers on the protection target and the outer layer on which the protection target is placed; having In the joining step, a plurality of the exterior members of the wire harness are joined for each set of the wire harness.

2. The joining step is a step of using an anvil and a horn prepared for each set of the wire harness, clamping and pressurizing the wire harness from the exterior member side of the one outer layer and the exterior member side of the other outer layer between the anvil and the horn for each set of the wire harness, and welding the multiple exterior members of the wire harness by ultrasonic vibration applied from the horn, 2. The method for manufacturing a wire harness according to claim 1, wherein in the joining step, when the release member and the wire harness other than the wire harness to be joined are present on the exterior member side of the one outer layer of the wire harness to be joined, a tip of the anvil inserted into a connector insertion hole of the release member and connector insertion holes of the multiple exterior members of the other wire harness is brought into contact with the exterior member of the one outer layer of the wire harness to be joined, and when the release member and the wire harness other than the wire harness to be joined are present on the exterior member side of the other outer layer of the wire harness to be joined, a tip of the horn inserted into the connector insertion hole of the release member and connector insertion holes of the multiple exterior members of the other wire harness is brought into contact with the exterior member of the other outer layer of the wire harness to be joined.

3. The joining step is a step of using a first electrode and a second electrode prepared for each set of the wire harness, sandwiching and pressurizing the wire harness from the exterior member side of the one outer layer and the exterior member side of the other outer layer between the first electrode and the second electrode, and heating and thermally welding the multiple exterior members of the wire harness as current flows between the first electrode and the second electrode, 2. The method for manufacturing a wire harness according to claim 1, wherein in the joining step, when the release member and the wire harness other than the wire harness to be joined are present on the exterior member side of the one outer layer of the wire harness to be joined, a tip of the first electrode inserted into a connector insertion hole of the release member and a connector insertion hole of the multiple exterior members of the other wire harness is brought into contact with the exterior member of the one outer layer of the wire harness to be joined, and when the release member and the wire harness other than the wire harness to be joined are present on the exterior member side of the other outer layer of the wire harness to be joined, a tip of the second electrode inserted into a connector insertion hole of the release member and a connector insertion hole of the multiple exterior members of the other wire harness is brought into contact with the exterior member of the other outer layer of the wire harness to be joined.

4. the joining step is a step of irradiating the exterior member of the other outer layer of the wire harness with microwaves from an electron gun for each set of the wire harness, thereby high-frequency welding the multiple exterior members of the wire harness; 2. The method for manufacturing a wire harness according to claim 1, wherein, in the joining step, when the release member and the wire harness other than the wire harness to be joined are present on the exterior member side of the one outer layer of the wire harness to be joined, the microwaves emitted from the electron gun are irradiated to the exterior member of the other outer layer of the wire harness to be joined from a microwave irradiation hole of the release member and microwave irradiation holes of the multiple exterior members of the other wire harness.

5. the inner layer installation step is a step of alternately repeating the routing of the part to be protected and the installation of the outer layer of the inner layer among the plurality of outer layers according to the number of layers of the part to be protected interposed between the outer layer of the one outer layer and the outer layer of the other outer layer, In the inner layer installation step, depending on the number of layers of the part to be protected, the arrangement of the part to be protected relative to the exterior member and the overlapping of the exterior member of the inner layer with the part to be protected and the exterior member on which the part to be protected is placed are alternately repeated until the exterior member of the inner layer is the final layer, and then the part to be protected of the final layer is arranged in the exterior member of the inner layer of the final layer, 5. The method for manufacturing a wire harness according to claim 1, wherein in the second outer layer installation process, the exterior member of the other outer layer is superimposed on the protected portion of the final layer and the exterior member of the inner layer of the final layer on which the protected portion of the final layer is placed.

6. In the inner layer installation step, when the part to be protected is routed, the part to be protected is passed through a gap between two electric wire routing pins arranged along a routing path of the part to be protected on the jig plate, 5. The method for manufacturing a wire harness according to claim 1, wherein in the first outer layer installing step and the second outer layer installing step, when installing the exterior member in each step, the wire routing pin having a thickness larger than that of the through hole is inserted into a through hole of a mesh in the exterior member.

Images