JP2018160414A - Manufacturing method and manufacturing system of electric wire with terminal - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an electric wire with a terminal capable of accurately forming a single wire bundle formed by ultrasonic bonding regardless of the thickness of the core wire bundle of the electric wire. SOLUTION: This manufacturing method is a manufacturing method of an electric wire 1 with a terminal in which a terminal 20 is crimped to an electric wire 10 having a core wire bundle 13 in which a plurality of conductor core wires 12 are bundled, and a pressing process is performed on the core wire bundle 13. The first step of pre-molding the core wire bundle 13 so that the core wire bundle 13 has a predetermined preliminary shape, and the plurality of conductor core wires 12 are mutually formed by performing an ultrasonic joining process on the pre-formed core wire bundle 13A. It includes a second step of forming a joint core wire 13B that is joined and has a predetermined target shape, and a third step of crimping the terminal 20 to the joint core wire 13B. The target shape is a rectangular parallelepiped shape corresponding to the shape of the terminal 20, and the preliminary shape is a rectangular parallelepiped shape in which one of the height and the width is smaller than that of the target shape and the other of the height and width is larger than that of the target shape. is there. [Selection diagram] Fig. 4

Description

  The present invention relates to a method for manufacturing an electric wire with a terminal in which a terminal is crimped to an electric wire having a core wire bundle in which a plurality of conductor core wires are bundled, and a manufacturing system for manufacturing such an electric wire with a terminal.

  Conventionally, an electric wire having a core wire bundle (for example, a stranded wire) in which a plurality of conductor core wires are bundled has been proposed from the viewpoint of improving the bending strength while increasing the allowable current of the electric wire. When the terminal is crimped to such a core wire bundle (stranded wire), the conductor core wire located on the outer peripheral portion of the core wire bundle is in direct contact with and electrically connected to the terminal, but is located in the center portion of the core wire bundle. The conductor core wire is electrically connected to the terminal via a conductor located on the outer peripheral portion. Therefore, in order to improve the overall conductivity between the core wire bundle and the terminal, in addition to the conductivity between the conductor core wire and the terminal (conductivity of the outer periphery), the conductivity between the conductor core wires. It is desirable to improve (conductivity at the center).

  On the other hand, in recent years, aluminum, aluminum alloys, and the like are sometimes used as materials for conductor core wires because they are lighter and less expensive than copper. However, in this case, since the insulating property of the oxide film (aluminum oxide) naturally formed on the surface of the conductor core wire is high, various measures for improving the above-described conductivity (conductivity at the outer peripheral portion and conductivity at the central portion). Need to be creative.

  For example, in one of the conventional methods for manufacturing an electric wire with a terminal (hereinafter referred to as “conventional manufacturing method”), an ultrasonic bonding process is applied to a core wire bundle (stranded wire) made of an aluminum conductor core wire, thereby providing a conductor. The conductor core wires are joined together while destroying the oxide film on the surface of the core wire, and the core wire bundle is integrated (single wire). Thereby, the conductor core wire located in the outer peripheral part of the core wire bundle and the conductor core wire located in the center part substantially come into direct contact with the terminal. As a result, compared to the case where such a single wire is not formed, the overall conductivity between the core wire bundle and the terminal can be improved as the conductivity of the central portion is improved (for example, Patent Documents). 1-3.)

JP, 2006-115525, A JP 2011-082127 A JP 2009-231079 A

  According to experiments conducted by the inventor and the like, when the core wire bundle is actually integrated (single wire) by a conventional manufacturing method, as the thickness of the core wire bundle becomes larger (in the so-called thick wire), ultrasonic bonding processing is performed. It became clear that there was a tendency for the dimensional accuracy of the single core wire bundle after application to be reduced. In other words, it has been clarified that the thicker the core wire bundle, the larger the variation in the shape of the single core wire bundle. This variation is due to individual differences in the degree of twisting and winding of the core wire bundle (conductor core wire) before making a single wire, and springback (repulsive force against the pressing force during ultrasonic bonding) as the core wire bundle is thicker. This is thought to be due to the fact that the

  From the viewpoint of improving the connection reliability between the electric wire and the terminal, it is desirable that the variation in the shape of the core wire bundle after the single wire is as small as possible.

  The present invention has been made in view of the above-described circumstances, and an object of the present invention is to provide an electric wire with a terminal capable of accurately converting a core wire bundle into a single wire by ultrasonic bonding processing regardless of the thickness of the core wire bundle of the wire. A manufacturing method and a manufacturing system are provided.

In order to achieve the above-described object, the “method for manufacturing an electric wire with terminal” according to the present invention is characterized by the following (1) to (3).
(1)
A method for producing a terminal-attached electric wire in which a terminal is crimped to an electric wire having a core wire bundle in which a plurality of conductor core wires are bundled,
A first step of performing preforming so that the core wire bundle has a predetermined preliminary shape by performing a pressing process on the core wire bundle;
A second step of forming a bonded core wire having a predetermined target shape by bonding the plurality of conductor core wires to each other by performing an ultrasonic bonding process on the core wire bundle that has undergone the preforming;
A third step of crimping the terminal to the bonding core wire,
It is a manufacturing method of the electric wire with a terminal.
(2)
In the manufacturing method according to (1) above,
The target shape is
A rectangular parallelepiped shape corresponding to the shape of the terminal,
The preliminary shape is
A rectangular parallelepiped shape different from the target shape, wherein one of the height and width is smaller than the corresponding one of the height and width in the target shape and the other of the height and width is the height and width in the target shape A rectangular parallelepiped shape larger than the corresponding other of
It is a manufacturing method of the electric wire with a terminal.
(3)
In the production method according to (1) or (2) above,
The plurality of conductor core wires are
Formed from aluminum or aluminum alloy,
It is a manufacturing method of the electric wire with a terminal.

  According to the manufacturing method of the electric wire with a terminal having the configuration (1), the core wire bundle is preformed before the ultrasonic bonding process is performed on the core wire bundle of the electric wire. According to experiments conducted by the inventors, if the shape of the core wire bundle is processed into a shape suitable for ultrasonic bonding processing (predetermined preliminary shape) by this preforming, the final shape is compared with the case where no preforming is performed. It has become clear that variations in the shape of the core wire bundle (after being made into a single wire by the ultrasonic bonding process) can be reduced. In other words, it has been clarified that the core wire bundle can be made into a single wire with high accuracy by appropriately performing the preforming.

  Therefore, the manufacturing method of this structure can make a core wire bundle into a single wire with high precision by ultrasonic bonding processing irrespective of the thickness of the core wire bundle of an electric wire.

  According to the method for manufacturing a terminal-attached electric wire having the configuration of (2) above, as an example of the preliminary shape of the core wire bundle, one of the height and width is the height and width in the final shape of the core wire bundle (target shape). A rectangular parallelepiped shape that is smaller than the corresponding one and whose height and width are other than the other corresponding to the height and width in the target shape (for example, a preliminary shape that is smaller in width and larger in height than the target shape) ) Is adopted. According to experiments conducted by the inventors, it has been clarified that the core wire bundle can be made into a single wire with high accuracy, particularly in the width direction, by performing such preforming. Therefore, according to the manufacturing method of this configuration, the core wire bundle can be made into a single wire with higher accuracy.

  According to the method for manufacturing a terminal-attached electric wire having the configuration of (3) above, the insulating film formed on the surface is made of aluminum or aluminum alloy, which has a greater insulating property than a commonly used copper conductor core wire (copper wire). In using the conductor core wire (aluminum wire), the effect (improvement of connection reliability between the electric wire and the terminal) due to the above-described single wire with high accuracy can be obtained.

In order to achieve the above-described object, the “system for manufacturing an electric wire with terminal” according to the present invention is characterized by the following (4) to (9).
(4)
A manufacturing system of a terminal-attached electric wire in which a terminal is crimped to an electric wire in which a core wire bundle in which a plurality of conductor core wires are bundled is covered with an insulating layer,
A preforming device for performing preforming so that the core wire bundle has a predetermined preliminary shape by performing a pressing process on the core wire bundle;
An ultrasonic bonding apparatus in which the plurality of conductor core wires are bonded to each other and form a bonded core wire having a predetermined target shape by performing an ultrasonic bonding process on the core wire bundle that has undergone the preforming;
A terminal crimping device for crimping the terminal to the bonding core wire,
It is a manufacturing system for electric wires with terminals.
(5)
In the manufacturing system according to (4) above,
The preforming device is
A mold group for forming the core wire bundle into a rectangular parallelepiped preliminary shape, the first mold sandwiching the core wire bundle so as to press in the height direction of the preliminary shape, and the pressing by the first mold A mold group that includes a second mold that sandwiches the core wire bundle so as to be pressed in the width direction of the preliminary shape independently.
It is a manufacturing system for electric wires with terminals.
(6)
In the manufacturing system according to (5) above,
The first mold and the second mold are:
Defining a molding chamber for pressing the core wire bundle exposed from the end of the electric wire, and defining a retracting chamber for releasing the insulating layer in the vicinity of the core wire bundle to be pressed out of the molding chamber;
It is a manufacturing system for electric wires with terminals.
(7)
In the manufacturing system according to (6) above,
The first mold and the second mold are:
The corners of the mold that come into contact with the insulating layer in the retreat chamber are chamfered,
It is a manufacturing system for electric wires with terminals.
(8)
In the manufacturing system according to (6) or (7) above,
The first mold is
Having a recess that regulates the spread of the tip by accommodating the tip of the core wire bundle disposed in the molding chamber so as to surround it;
It is a manufacturing system for electric wires with terminals.
(9)
In the manufacturing system according to any one of (5) to (8) above,
The first mold is
A surface wider than the thickness before pressing of the core wire bundle in the width direction and pressing the core wire bundle from one side in the height direction, and a thickness before pressing of the core wire bundle in the height direction The core wire bundle is pressed from the other in the height direction and the other in the width direction in a state where the core wire bundle is supported by a wide surface that presses the core wire bundle from one in the width direction. Configured to press from,
It is a manufacturing system for electric wires with terminals.

  According to the manufacturing system for a terminal-attached electric wire having the configuration (4), the core wire bundle is preformed before the ultrasonic bonding process is performed on the core wire bundle of the electric wire. According to experiments conducted by the inventors, if the shape of the core wire bundle is processed into a shape suitable for ultrasonic bonding processing (predetermined preliminary shape) by this preforming, the final shape is compared with the case where no preforming is performed. It has become clear that variations in the shape of the core wire bundle (after being made into a single wire by the ultrasonic bonding process) can be reduced. In other words, it has been clarified that the core wire bundle can be made into a single wire with high accuracy by appropriately performing the preforming.

  Therefore, the manufacturing system of this configuration can make the core wire bundle into a single wire with high accuracy by ultrasonic bonding processing regardless of the thickness of the core wire bundle of the electric wire.

  According to the manufacturing system of the terminal-attached electric wire having the configuration (5), the pressure in the height direction and the pressure in the width direction can be independently performed when the preforming is performed. According to such preforming, when the pressing in the height direction and the pressing in the width direction are performed in a lump (for example, pressing using a convex indenter to pack the core wire bundle into the concave recess ), The degree of pressing can be controlled independently, so that highly accurate preforming can be realized.

  According to the terminal-attached electric wire manufacturing system having the configuration (6) above, when the core wire bundle is pressed inside the molding chamber, the insulator near the core wire bundle (the insulator at the end of the electric wire is peeled off). After that, the end portion of the insulator remaining on the electric wire is released into the retreat chamber, and the pressing of the insulator can be avoided. In other words, only the core wire bundle can be pressed in the molding chamber. As a result, the core wire bundle can be accurately pressed from the height direction and the width direction in a state where the inclination (displacement) of the core wire bundle due to pressing the insulators together is small, and thus high-precision preforming can be realized. . For example, it is possible to prevent a single core wire bundle from being inclined (so-called warping) with respect to the axis of the electric wire.

  According to the manufacturing system of the electric wire with a terminal having the configuration of the above (7), when the corner of the mold contacting the insulating layer in the retreat chamber is chamfered, there is no chamfer (the corner is sharp). In comparison with the above, it is possible to avoid an excessive force from being applied to the core wire bundle near the boundary between the insulating layer and the core wire bundle during the preforming. Thereby, damage (unintentional cutting etc.) of the core wire bundle near the boundary between the insulating layer and the core wire bundle can be prevented.

  According to the manufacturing system of the electric wire with a terminal of the composition of the above (8), the expansion of the tip part of the core wire bundle can be suppressed by the hollow part. Thereby, it can suppress that the front-end | tip of a core wire bundle spreads in the case of preforming, and it can prevent that a core wire bundle is pinched by the mating surface of a metal mold | die (fraying of a core wire bundle).

  According to the system for manufacturing an electric wire with a terminal configured as described in (9) above, the core wire bundle is supported by a surface wider than the width in the width direction of the core wire bundle before pressing, and the height of the core wire bundle before pressing is increased. The core wire bundle can be pressed from the height direction and the width direction in a state where the core wire bundle is supported by a surface wider than the thickness. Thereby, when the core wire bundle is pressed in the height direction and the width direction, the core wire bundle can be prevented from being sandwiched between the mating surfaces of the molds (the fray of the core wire bundle).

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method and manufacturing system of the electric wire with a terminal which can make a core wire bundle into a single wire accurately by ultrasonic bonding process irrespective of the thickness of the core wire bundle of an electric wire can be provided.

  The present invention has been briefly described above. Further, details of the present invention will be further clarified by reading a form for carrying out the invention described below (hereinafter referred to as “embodiment”) with reference to the accompanying drawings.

FIG. 1 is a diagram for explaining the outline of a pre-process (preliminary molding and ultrasonic bonding) of a terminal crimping process in the method of manufacturing a terminal-attached electric wire according to the embodiment of the present invention. Each of FIG.1 (c) is a perspective view in the edge part of an electric wire. FIG. 2 is a diagram for explaining the outline of a terminal crimping process in the method of manufacturing a terminal-attached electric wire according to the embodiment of the present invention, and each of FIGS. 2 (a) and 2 (b) is an end portion of the electric wire. FIG. FIG. 3 is a diagram for explaining the transition of the shape of the core bundle of wires. FIG. 3 (a) is a front view of a preformed core bundle (molded core bundle), and FIG. FIG. 3C is a front view of a core wire bundle (bonded core wire) subjected to sonic bonding, and FIG. 3C is a view for explaining the shape of the bonded core wire. FIG. 4 is a perspective view of a preforming device for preforming a core wire bundle. 5A and 5B are diagrams showing a lower mold and a slide in the preforming apparatus. FIG. 5A is a perspective view of the lower mold and the slide, and FIG. It is the perspective view which expanded the part concerned. FIG. 6 is a perspective view of the periphery of the slide in the preforming apparatus. FIG. 7 is a perspective view of the upper mold in the preforming apparatus. FIG. 8 is a view corresponding to FIG. 4 in a state where the electric wire is placed on the preforming apparatus. FIG. 9 is a cross-sectional view taken along the line AA in FIG. 10A and 10B are diagrams showing a preforming device in a state where a core wire bundle is preformed, in which FIG. 10A is a front view of the preforming device, and FIG. 10B is a line BB in FIG. FIG. FIG. 11 is a schematic diagram of an ultrasonic bonding apparatus that ultrasonically bonds a core wire bundle. FIG. 12 is a perspective view of a terminal crimping apparatus and a wire for crimping a terminal to the wire. FIG. 13 is a diagram for explaining a method of crimping a terminal by a terminal crimping device. FIG. 13 (a) is a front view of the terminal crimping device in which a terminal and a joining core wire of an electric wire are arranged, and FIG. It is a front view of the anvil in which the joining core wire of the terminal and the electric wire is arranged. FIG. 14 is a front view of the terminal crimping apparatus in a state in which the terminal is crimped to the electric wire. FIG. 15 is a cross-sectional view of a crimped portion of an electric wire with a terminal obtained by crimping a terminal to an electric wire. 16 (a) to 16 (c) are graphs showing the effect of the presence or absence of preforming on the variation in the width and height of the core wire bundle after being made into a single wire.

  Hereinafter, a manufacturing method and a manufacturing system of an electric wire with a terminal concerning an embodiment of the present invention are explained, referring to drawings.

  First of all, when the terminal 20 is crimped to the electric wire 10, ultrasonic bonding processing by the ultrasonic bonding apparatus 30 is performed from the viewpoint of improvement of conductivity, etc., and the terminal by the terminal crimping apparatus (anvil 40 and crimper 50). 20 crimping processes are performed. However, in the embodiment of the present invention, the preforming for the electric wire 10 (specifically, the core wire bundle) is performed by the preforming device 60 before the ultrasonic bonding process. Hereinafter, the configuration and operation of these devices will be described in detail.

  As shown in FIG.1 and FIG.2, in the manufacturing method of the electric wire with a terminal concerning this embodiment, first, as shown to Fig.1 (a), the insulation coating 11 of the electric wire 10 is peeled off, and several conductors are shown. The core wire bundle 13 composed of the core wires 12 is exposed. Next, as shown in FIG. 1B, the core wire bundle 13 is subjected to a preforming process (details will be described later) to form a preformed formed core wire bundle 13A. Next, as shown in FIG. 1C, ultrasonic bonding processing (details will be described later) is performed on the formed core wire bundle 13A to form a bonded core wire 13B in which the adjacent conductor core wires 12 are bonded to each other.

  As shown in FIG. 1A, the electric wire 10 is configured to cover the outer periphery of a core wire bundle 13 having a circular cross section in which a plurality of conductor core wires 12 are bundled with an insulating coating 11. In this example, the conductor core wire 12 is a non-plated strand made of aluminum or an aluminum alloy. In other words, the electric wire 10 is a so-called aluminum electric wire or an aluminum alloy electric wire.

  Next, as shown in FIG. 2A, after the bonding core wire 13B is arranged at a predetermined position of the terminal 20, the terminal 20 is connected to the bonding core wire 13B (and the surrounding insulation coating 11 as shown in FIG. 2B). ). Thereby, the electric wire 1 with a terminal is manufactured.

  Describing in more detail each of the above steps, as shown in FIGS. 1 (b) and 3 (a), a core wire bundle 13A obtained by pre-forming the core wire bundle 13 of the electric wire 10 has a cross section perpendicular to the axis thereof. It has a substantially rectangular shape (in this example, a rectangular shape R having a height Q larger than the width P). As can be understood from FIG. 3A, the cross section of the core wire bundle 13A has a shape in which each side of the rectangle is slightly swollen outward in an arc shape. Since the core wire bundle 13A is obtained only by pressing the core wire bundle 13, in the core wire bundle 13A, the plurality of conductor core wires 12 constituting the core wire bundle 13 are independent from each other (joined together). Not)

  As shown in FIG. 1C, FIG. 3B, and FIG. 3C, the bonding core wire 13B obtained by ultrasonically bonding the formed core wire bundle 13A has a rectangular shape (in the cross section perpendicular to the axis). In the example, it has a shape of a rectangular shape S (width X greater than height Y). In the bonding core wire 13B, the plurality of conductor core wires 12 constituting the core wire bundle 13 are bonded to each other by ultrasonic vibration. As will be described later, in this example, preforming and ultrasonic bonding are performed so that P <X and Y <Q.

  As illustrated in FIG. 2A, the terminal 20 includes an electrical connection portion 21 and a crimp connection portion 22. The terminal 20 is formed, for example, by pressing a metal plate made of a conductive metal material such as copper or a copper alloy. Therefore, in this example, the thickness of the terminal 20 is substantially the same at any location.

  The electrical connection portion 21 includes a flat connection plate portion 23, and a connection hole 23 a is formed in the connection plate portion 23. For example, the connection plate portion 23 is electrically connected to the terminal block by inserting a fastening bolt into the connection hole 23a and fastening it to the terminal block of the connection device.

  The crimping connection part 22 has a conductor crimping part 24 and an outer jacket crimping part 25 in this order from the electrical connection part 21 side. The conductor crimping portion 24 includes a base portion 26 and a pair of conductor crimping pieces 27 (crimping pieces) formed on both sides of the base portion 26. On the base portion 26, the bonding core wire 13B is placed. The conductor crimping piece 27 is extended from the base portion 26 so as to sandwich the joining core wire 13B. As shown in FIG. 2B, the conductor crimping portion 24 is crimped to the joining core wire 13 </ b> B of the electric wire 10 by bending (clamping) the pair of conductor crimping pieces 27 inward. Thereby, the terminal 20 is electrically connected to the core wire bundle 13 of the electric wire 10.

  The jacket crimping part 25 has a base part 28 and a pair of jacket crimping pieces 29 formed on both sides of the base part 28. The base portion 28 of the outer cover crimping portion 25 extends from the base portion 26 of the conductor crimping portion 24. The insulating coating 11 of the electric wire 10 is placed on the base portion 28. The outer cover crimping piece 29 extends from the base portion 28 so as to sandwich the insulating coating 11 portion of the electric wire 10. As shown in FIG. 2 (b), the jacket crimping portion 25 is crimped to the portion of the insulating coating 11 of the electric wire 10 by bending (clamping) the pair of jacket crimping pieces 29 inward. It will be fixed.

  Next, a preforming device 60 for preforming the core wire bundle 13 of the electric wire 10 will be described with reference to FIGS. Hereinafter, for convenience of explanation, as shown in FIG. 4, the x-axis direction (front-rear direction), the y-axis direction (left-right direction), the z-axis direction (up-down direction), and the front, rear, left, right, upper and lower Define The front-rear direction, the left-right direction, and the up-down direction are orthogonal to each other.

  As shown in FIG. 4, the preforming device 60 is placed as a mold so as to be movable relative to the lower mold 70 in the left-right direction at a part of the upper surface of the lower mold 70 and the lower mold 70. A slider 80 and an upper mold 90 arranged to be movable relative to the lower mold 70 in the vertical direction in the space above the lower mold 70 are provided. Here, the lower mold 70 and the upper mold 90 correspond to the “first mold” of the present invention, and the lower mold 70 and the slider 80 correspond to the “second mold” of the present invention.

  First, the lower mold 70 will be described. As shown in FIGS. 4 and 5, a stepped surface 71 facing rearward (extending parallel to the yz plane) is provided in the vicinity of the substantially central portion in the front-rear direction on the upper side surface of the lower mold 70 over the entire left-right direction. Is formed. On the front side of the step surface 71 on the upper side surface of the lower mold 70, there is a facing surface 72 (extending parallel to the xy plane), a position below the mating surface 72 and facing upward (x A floor surface 73 (extending parallel to the -y plane) is formed. As will be described later, the mating surface 72 is overlapped with the mating surface 91 (see FIG. 7 described later) of the upper mold 90, and the floor surface 73 is formed in a molding chamber T (described later) for pressing the core wire bundle 13. (See FIG. 10 (b)). The floor surface 73 and the lower surface 81 of the slider 80 are in close contact with each other, and the slider 80 slides in the left-right direction in this state.

  As a step surface connecting the mating surface 72 and the floor surface 73, a side surface 74 facing right (extending parallel to the xz plane) and a front surface 75 facing rearward (extending parallel to the yz plane) A mating surface 76 that is located to the right of the side surface 74 and faces rightward (extends in parallel to the xz plane) is formed continuously in a crank shape. As will be described later, the side surface 74 defines a part of the molding chamber T (see FIG. 10B). The front surface 75 and the side surface 85 of the slider 80 are in close contact with each other, and the slider 80 slides in this state. The mating surface 76 is overlapped with the mating surface 86 of the slider 80.

  In the lower left region of the front surface 75, a recessed portion 77 that is recessed forward is formed. As will be described later, the recess 77 accommodates the tip of the core wire bundle 13 of the electric wire 10 placed on the lower mold 70.

  As shown in FIG. 5, chamfering is performed on a corner portion 78 a where the step surface 71 and the side surface 74 intersect and a corner portion 78 b where the step surface 71 and the floor surface 73 intersect. As the chamfering, round chamfering (so-called R chamfering) is preferably performed. As will be described later, the corner portions 78a and 78b are portions where the core wire bundle 13 in the vicinity of the boundary between the end surface of the insulating coating 11 and the core wire bundle 13 in the electric wire 10 abuts during the preforming process. In addition, chamfering is performed at corners where the floor surface 73 and the side surface 74 intersect, corners where the floor surface 73 and the front surface 75 intersect, and corners where the floor surface 73 and the mating surface 76 intersect. Not (so-called pin angle).

  As shown in FIG. 4, on the rear side of the step surface 71 on the upper surface of the lower mold 70, an arcuate surface 79 having an arcuate cross section that opens upward and is depressed downward is formed from the step surface 71 to the rear end surface of the lower mold 70. It extends so as to extend in the front-rear direction (see also FIG. 10A described later). As will be described later, the arc-shaped surface 79 becomes a portion on which the end portion of the insulating coating 11 of the electric wire 10 is placed at the time of preforming. In addition, a portion connecting the arcuate surface 79 and the side surface 74 and a portion connecting the arcuate surface 79 and the floor surface 73 in the stepped surface 71 are portions where the end surface of the insulating coating 11 of the electric wire 10 abuts. Furthermore, the arcuate surface 79 defines a part of a retracting chamber U (see FIG. 10A described later) for allowing the insulating coating 11 to escape from the molding chamber T.

  Next, the slider 80 will be described. As shown in FIGS. 4 to 6, the slider 80 is placed on the floor surface 73 of the lower mold 70, and the lower surface 81 moves so as to slide on the floor surface 73 while moving relative to the lower mold 70. Relative movement is possible in the left-right direction.

  The slider 80 has a rear surface as a side surface that connects a lower surface 81 (extending parallel to the xy plane) and an upper surface 82 (extending parallel to the xy plane) facing upward in the slider 80. A side surface 83 (extending parallel to the yz plane), a side surface 84 facing left (extending parallel to the xz plane), and a side surface facing front (extending parallel to the yz plane) 85 are continuously formed in a U-shape. The side surface 83 is positioned so as to be flush with the step surface 71 of the lower mold 70. The side surface 84 faces the side surface 74 of the lower mold 70. The side surface 85 moves so as to slide on the front surface 75 of the lower mold 70. As will be described later, the side surface 84 defines a part of the molding chamber T (see FIG. 10B).

  Further, as a side surface connecting the lower surface 81 and the upper surface 82 of the slider 80, a mating surface 86 is formed which is located to the right of the side surface 84 and faces left (extends in parallel to the xz plane). The mating surface 86 is overlapped with the mating surface 76 of the lower mold 70.

  As shown in FIG. 6, chamfering is applied to a corner portion 87 where the side surface 83 and the side surface 84 intersect. As the chamfering, round chamfering (so-called R chamfering) is preferably performed. Like the corner portions 78a and 78b (see FIG. 5B), the corner portion 87 is a core wire bundle 13 in the vicinity of the boundary between the end surface of the insulating coating 11 and the core wire bundle 13 in the electric wire 10 during the preforming process. It becomes a part which contacts. In addition, chamfering is not performed on a corner portion where the side surface 84 and the upper surface 82 intersect, a corner portion where the side surface 84 and the lower surface 81 intersect, and a corner portion where the side surface 84 and the side surface 85 intersect (so-called chamfering). It is a pin angle).

  Next, the upper mold 90 will be described. As shown in FIG. 4, the upper mold 90 is disposed in an upper space of the lower mold 70 and can be moved relative to the lower mold 70 in the vertical direction. More specifically, as shown in FIG. 7, the upper mold 90 has a mating surface 91 facing downward (extending parallel to the xy plane), a lower side of the mating surface 91 and facing downward. A lower surface 92 (extending parallel to the xy plane) is formed. The mating surface 91 is overlapped with the mating surface 72 (see FIG. 4) of the lower mold 70, and the lower surface 92 faces the floor surface 73 of the lower mold 70, and the molding chamber T (FIG. 10B). (See))).

  As a step surface connecting the mating surface 91 and the lower surface 92, a side surface 93 facing left (extending parallel to the xz plane) and a side surface 94 facing front (extending parallel to the yz plane), A side surface 95 that is located on the right side of the side surface 93 and faces the left side (extending parallel to the xz plane) is continuously formed in a crank shape. The side surface 93 and the side surface 74 of the lower mold 70 are in close contact with each other, and the side surface 93 slides on the side surface 74 in this state. Further, the side surface 94 slides in close contact with the front surface 75 of the lower mold 70, and the side surface 95 slides in close contact with the mating surface 76 of the lower mold 70.

  Further, the upper mold 90 is formed with a step surface 96 that is continuous with the lower surface 92 and the side surface 93 and faces rearward (extends parallel to the yz plane). The step surface 96 is positioned so as to be flush with the step surface 71 of the lower mold 70.

  A corner 97 where the step surface 96 and the lower surface 92 intersect is chamfered. As the chamfering, round chamfering (so-called R chamfering) is preferably performed. Like the corner portions 78a and 78b (see FIG. 5B) and the corner portion 87 (see FIG. 6), the corner portion 97 is formed with the end face of the insulating coating 11 in the electric wire 10 during the preforming process. The core wire bundle 13 in the vicinity of the boundary with the core wire bundle 13 comes into contact with the core wire bundle 13. In addition, chamfering is not given to the corner | angular part which the lower surface 92 and the side surface 93 cross | intersect (it is what is called a pin angle).

  Further, the upper mold 90 has an arcuate surface 98 having an arc-shaped cross section facing the lower left side on the rear side of the step surface 96 so as to extend in the front-rear direction from the step surface 96 to the rear end surface of the upper mold 90. (See also FIG. 10A described later). At the time of preforming, the arcuate surface 98 defines a part of the retreat chamber U (see FIG. 10A).

  As shown in FIGS. 8 and 9, in the electric wire 10, the end portion of the insulating coating 11 is placed on the arcuate surface 79 of the lower mold 70, and the end surface (front end surface) of the insulating coating 11 is the stepped surface of the lower mold 70. The lower mold 70 is placed so that the exposed core wire bundle 13 is placed on the floor surface 73 of the lower mold 70 and the tip end portion of the core wire bundle 13 is received in the recess 77 of the lower mold 70. 70. At this time, as shown in FIG. 9, it is preferable to provide a gap between the front end surface of the core wire bundle 13 and the bottom surface of the recessed portion 77.

  In order to perform the pre-forming process, the upper die 90 is moved downward (see arrow A) as shown in FIG. 10 with the electric wire 10 placed on the lower die 70 as described above, and the slider is also moved. Move 80 to the left (see arrow B). 10B, a rectangular parallelepiped for preforming the core wire bundle 13 by the floor surface 73 and the side surface 74 of the lower mold, the side surface 84 of the slider 80, and the lower surface 92 of the upper mold 90, as shown in FIG. 10A, the insulating coating 11 is formed outside the molding chamber T by the arc-shaped surface 79 of the lower mold 70 and the arc-shaped surface 98 of the upper mold 90, as shown in FIG. A evacuation chamber U is defined for escape. Note that a gap is provided between a surface 100 that is continuous with the arcuate surface 79 of the lower mold 70 and faces upward, and a surface 99 that is continuous with the arcuate surface 98 of the upper mold 90 and faces downward. This gap prevents the insulation coating 11 from being caught.

  From this state, the slider 80 is moved to the left until the mating surface 86 of the slider 80 contacts the mating surface 76 of the lower mold 70 (see FIG. 5A), and the core wire bundle in the molding chamber T 13 is pressed between the side surface 74 and the side surface 84 in the width direction (left-right direction), and the core wire bundle 13 in the molding chamber T is pressed between the floor surface 73 and the lower surface 92 in the height direction (up-down direction). It is supposed to be sandwiched like In addition, in the state where the core wire bundle 13 is sandwiched in this way (even if it is in a state where the mating surface 91 of the upper mold 90 is in contact with the mating surface 72 of the lower mold 70 as shown in FIG. 10B). ) Since a gap is secured between the upper surface 82 of the slider 80 and the lower surface 92 of the upper mold 90, the slider 80 can be relatively moved in the left-right direction.

  As a result, the core wire bundle 13 is preformed in the forming chamber T, and the formed core wire bundle 13A has a cross-sectional shape that is a substantially rectangular shape having a height Q larger than the width P as shown in FIG. Is formed. The pressing force of the slider 80 and the upper mold 90 acts only on the core wire bundle 13 in the molding chamber T and does not act on the insulating coating 11 in the retreat chamber U.

  Next, an ultrasonic bonding apparatus 30 for ultrasonic bonding the formed core wire bundle 13A of the electric wire 10 will be described with reference to FIG. As shown in FIG. 11, the ultrasonic bonding apparatus 30 includes a horn 31, an anvil plate 32, a gliding jaw 33, and an anvil 34. The horn 31 is ultrasonically vibrated in the front-rear direction in the drawing by an ultrasonic oscillator. A knurl (not shown) composed of a plurality of ridges extending in a direction orthogonal to the vibration direction is formed on the upper surface of the horn 31 (the surface in contact with the molded core wire bundle 13A). Slip between 13A is suppressed. In the ultrasonic bonding apparatus 30, a rectangular space in a sectional view defined by the horn 31, the anvil plate 32, the gliding jaw 33, and the anvil 34 is a bonding processing chamber V, and the space is disposed in the bonding processing chamber V. The conductor core wires 12 of the formed core wire bundle 13A are ultrasonically joined together.

  The anvil plate 32 is disposed on the side of the horn 31. The gliding jaw 33 is disposed at a position facing the anvil plate 32 on the upper surface of the horn 31 and is movable in a direction approaching or separating from the anvil plate 32. In FIG. 11, the gliding jaw 33 moves in the direction indicated by the arrow C in the drawing, and presses the formed core wire bundle 13A in this direction.

  The anvil 34 is disposed above the horn 31 and the anvil plate 32, and can move in a direction approaching or separating from the horn 31 by moving up and down. In FIG. 11, the anvil 34 moves in the direction indicated by the arrow D in the figure, and presses the formed core wire bundle 13 </ b> A in this direction.

  The ultrasonic bonding apparatus 30 moves the gliding jaw 33 and the anvil 34 as described above, so that the width and height of the bonding processing chamber V (and consequently the width and height of the bonding core wire 13B to which the formed core wire bundle 13A has been bonded). Can be changed freely. In this way, by adjusting the width and height of the bonding processing chamber V, the bonding core wire 13B having a desired target shape can be formed.

  Next, a terminal crimping device (anvil 40, crimper 50) for crimping the terminal 20 to the bonding core wire 13B will be described with reference to FIGS. As shown in FIGS. 12 and 13, the terminal 20 is crimped to the electric wire 10 by a terminal crimping device (anvil 40, crimper 50). The anvil 40 is disposed below the terminal 20 and the bonding core wire 13B, and the crimper 50 is disposed above the terminal 20 and the bonding core wire 13B. The crimper 50 is movable in the vertical direction relative to the anvil 40.

  The anvil 40 has a support surface 41 curved at the top so as to be recessed downward. When the terminal 20 is crimped, the support surface 41 supports the base portion 26 of the terminal 20. Specifically, the outer surface of the base portion 26 of the terminal 20 comes into contact with the support surface 41.

  The crimper 50 includes an arch groove 52 having a chevron 51 projecting toward the anvil 40 at the center in the width direction. The arch groove 52 is composed of two arcuate surfaces 52 a formed on both sides of the chevron 51. The arcuate surface 52 a is an arcuate convex surface that protrudes away from the support surface 41. The crimper 50 has two guide inclined surfaces 53. The guide inclined surface 53 is inclined so as to be gradually separated toward the anvil 40 side. These guide inclined surfaces 53 are formed so as to be continuous at both ends of the arch groove 52.

  Then, the manufacturing method of the electric wire 1 with a terminal which concerns on this embodiment is demonstrated.

(Terminal treatment process)
As shown in FIG. 1A, the insulation coating 11 at the end of the electric wire 10 is peeled off, and the core wire bundle 13 in which the conductor core wires 12 are bundled is exposed for a predetermined length. The predetermined length of the core wire bundle 13 to be exposed may be a length sufficient to crimp the terminal 20.

(Preliminary molding process)
As shown in FIG.1 (b), the preforming process is performed with respect to the core wire bundle 13 exposed by the edge part of the electric wire 10, and the forming core wire bundle 13A is formed. Specifically, as shown in FIGS. 8 and 9, the electric wire 10 with the core wire bundle 13 exposed at the end is placed on the lower mold 70 of the preforming device 60, and as shown in FIG. 90 is moved downward (in the direction of arrow A in the figure) and slider 80 is moved in the left direction (in the direction of arrow B in the figure). Thereby, the core wire bundle 13 in the molding chamber T is pressed from the width direction (left-right direction) and the height direction (up-down direction). Then, in the molding chamber T, the core wire bundle 13 is preformed, and as shown in FIG. 3A, a molded core wire bundle 13A having a cross-sectional shape that is a substantially rectangular shape having a height Q larger than the width P is obtained. It is formed. In the formed core wire bundle 13A, the plurality of conductor core wires 12 constituting the core wire bundle 13 are independent from each other (not joined to each other).

  In this preforming step, the pressing operation in the height direction and the pressing operation in the width direction are performed independently, so when performing these pressings in a lump (for example, after stuffing the core wire bundle into the concave recess, Compared with the case of pressing with a convex indenter so as to close the depression, the moldability (dimensional accuracy) is excellent.

  Further, during the press molding of the core wire bundle 13 in the molding chamber T, the end portion of the insulating coating 11 in the vicinity of the core wire bundle 13 is released to the retracting chamber U, so that the insulating coating 11 is not pressed. In other words, only the core wire bundle 13 is pressed. As a result, the core wire bundle 13 can be pressed accurately from the height direction and the width direction (in a state where the inclination (deviation) in the pressing direction is small). Therefore, it is possible to prevent the axis of the formed core wire bundle 13 </ b> A (and hence the joint core wire 13 </ b> B formed thereafter) from being inclined with respect to the axis of the electric wire 10 (the joint core wire 13 </ b> B is warped, etc.).

  Furthermore, corners 78a and 78b (see FIG. 5 (b)) of the lower mold 70, where the core wire bundle 13 near the boundary between the end face of the insulating coating 11 and the core wire bundle 13 in the electric wire 10 comes into contact, and the slider 80. The corner 87 (see FIG. 6) and the corner 97 (see FIG. 7) of the upper mold 90 are chamfered. Therefore, compared with the case where there is no such chamfering (the corners are sharp), an excessive force is exerted on the core wire bundle 13 near the boundary between the end surface of the insulating coating 11 and the core wire bundle 13 in the preforming step. Can be avoided. Therefore, damage to the core wire bundle 13 in the vicinity of the boundary between the end face of the insulating coating 11 and the core wire bundle 13 can be prevented.

  Furthermore, when the electric wire 10 is placed on the lower mold 70, the tip end portion of the core wire bundle 13 of the electric wire 10 is accommodated in the hollow portion 77 of the lower die 70 (see FIG. 9). The spread of the tip of the can be suppressed. As a result, fraying of the core wire bundle 13 can be suppressed during preforming, and the core wire bundle 13 (conductor core wire 12) can be prevented from being sandwiched between the mating surfaces of the molds.

  Further, when performing the pressing operation in the height direction and the pressing operation in the width direction, as shown in FIG. 10B, the lower mold 70 wider than the thickness in the width direction (left-right direction) before the core wire bundle 13 is pressed. The core wire bundle 13 is supported from the lower side in the height direction by the floor surface 73 and the core wire bundle 13 is supported from the left side in the width direction by the lower side surface 74 wider than the thickness in the height direction of the core wire bundle 13. Thus, the core wire bundle 13 can be pressed from the height direction and the width direction. Thereby, when pressing the core wire bundle 13 from the height direction and the width direction, the core wire bundle 13 (conductor core wire 12) can be prevented from entering the mating surface of the mold. Therefore, even if the core wire bundle 13 is frayed during preforming, the core wire bundle 13 (conductor core wire 12) can be prevented from being sandwiched between the mating surfaces of the molds.

(Ultrasonic bonding process)
As shown in FIG.1 (c), the joining core wire 13B by which the some conductor core wire 12 was mutually joined is formed by ultrasonically bonding the shaping | molding core wire bundle 13A of the electric wire 10 formed at the preforming process. Specifically, as shown in FIG. 11, the formed core wire bundle 13A is disposed in the bonding processing chamber V of the ultrasonic bonding apparatus 30, and the direction in which the gliding jaw 33 is close to the anvil plate 32 (the direction of arrow C in FIG. 11). ) And the anvil 34 is moved in the direction approaching the horn 31 (the direction of arrow D in FIG. 11), and the formed core wire bundle 13A in the bonding processing chamber V is pressed from the width direction and the vertical direction. In this state, the horn 31 is vibrated ultrasonically. Thereby, in the bonding processing chamber V, the conductor core wires 12 are joined to each other while the oxide film formed on the surface of the conductor core wire 12 is destroyed. As a result, as shown in FIGS. 3B and 3C, a rectangular S-joining core wire 13 </ b> B having a cross-sectional shape with a width X and a height Y is formed. In the joining core wire 13B formed in this way, the conductor core wires 12 are joined and integrated (single wire), and the conductor core wires 12 are in a good conductive state.

(Terminal crimping process)
As shown in FIG.2 (b), the terminal 20 is crimped | bonded to the joining core wire 13B using a terminal crimping apparatus (anvil 40 and crimper 50). Specifically, first, as illustrated in FIG. 13B, the terminal 20 is placed on and supported by the support surface 41 of the anvil 40, and the core wire bundle 13 </ b> B ultrasonically bonded to the terminal 20 is disposed.

  After the end of the electric wire 10 is arranged on the terminal 20, the crimper 50 is lowered and brought close to the anvil 40 in order to crimp the terminal 20 to the electric wire 10 (core wire bundle 13 </ b> B). At this time, the end portion of the conductor crimping piece 27 of the terminal 20 spreading to both sides contacts the guide inclined surface 53 of the crimper 50. As a result, the conductor crimping piece 27 is deformed in the direction in which the conductor crimping pieces 27 are close to each other along the guide inclined surface 53 of the crimper 50.

  When the crimper 50 is further lowered and brought close to the anvil 40, the conductor crimping piece 27 reaches the arch groove 52 (see FIG. 13A), and the conductor crimping piece 27 is moved by the arch groove 52 from this state. It is deformed so that it is pressed in a direction close to each other and curved (involved) inward.

  Thereafter, as shown in FIG. 14, the anvil 40 and the crimper 50 are brought close to each other until the crimping completed state where the shape of the space sandwiched between the support surface 41 and the circular arc surface 52 a becomes a predetermined crimping shape. At this time, the conductor crimping portion 24 of the terminal 20 is sandwiched between the anvil 40 and the crimper 50, and the joining core wire 13B is pressed. As a result, as shown in FIG. 15, the terminal 20 is firmly crimped to the core wire bundle 13 (joined core wire 13 </ b> B) without a gap, and the terminal 20 is reliably connected to the core wire bundle 13 of the electric wire 10.

  In the terminal crimping step, the jacket crimping piece 29 of the terminal 20 is crimped by the jacket anvil and crimper (not shown) provided in the terminal crimping apparatus (anvil 40 and crimper 50). As a result, the outer cover crimping portion 25 of the terminal 20 is crimped and fixed to the insulating coating 11 portion of the electric wire 10.

<Evaluation>
The inventor examines the difference between the core wire bundle that has been subjected to ultrasonic bonding processing after performing preforming as described above and the core wire bundle that has been subjected to ultrasonic bonding processing without performing preforming. A test was conducted.

  Specifically, the width is smaller than and higher than the target width Wtgt with respect to the target width Wtgt (corresponding to X in FIG. 3) and the target height Htgt (corresponding to Y in FIG. 3) of the core wire bundle after ultrasonic bonding. A plurality of samples that were preformed so that the height was larger than the target height Htgt was prepared. These samples correspond to the A group in FIG. On the other hand, a plurality of samples having a width larger than the target width Wtgt and a height larger than the target height Htgt were prepared as a plurality of samples not subjected to preforming. These samples correspond to the group B in FIG.

  Similar ultrasonic waves are formed so that a core wire bundle having a target width Wtgt and a target height Htgt is formed for the sample (Group A) that has been preformed and the sample (Group B) that has not been preformed. Bonding treatment was performed. Each sample after the ultrasonic bonding treatment corresponds to group C in FIG.

  As a result, as shown in FIG. 16 (b), the width after the ultrasonic bonding treatment of the pre-formed sample (group A in FIG. 16 (a)) is the same as the sample (FIG. 16 ( It was confirmed that the variation was smaller than that in group B) in a). Further, as shown in FIG. 16 (c), the height after the ultrasonic bonding treatment of the sample that has been preformed (Group A in FIG. 16 (a)) is the same as the sample that has not been preformed (FIG. 16 (c)). It was confirmed that the variation was smaller than that in group B) in a). Note that the effect of reducing the variation was confirmed more significantly in the width than in the height of the core wire bundle.

  In this test, an electric wire having a core wire bundle diameter of 11 mm (60 sq) is used, the target width Wtgt is set to 9.8 mm, and the target height Htgt is set to 7.3 mm. Furthermore, the width of the core wire bundle in the case of performing the preforming was set to a width that is about 2 to 4% smaller than the target width Wtgt. However, in the tests conducted by the inventors under other conditions (conditions in which the core wire bundle diameter, the target width, the target height, and the degree of preforming are different), a tendency similar to that of the main test was confirmed. Yes.

<Action and effect>
As mentioned above, according to the manufacturing method and manufacturing system of the electric wire 1 with a terminal which concerns on embodiment of this invention, before performing the ultrasonic joining process with respect to the core wire bundle 13 of the electric wire 10, preforming with respect to the core wire bundle 13 is carried out. Applied. Therefore, if the shape of the core wire bundle 13 is processed into a shape suitable for the ultrasonic bonding process by this preforming, the final core wire bundle (single-wired by the ultrasonic bonding process) is compared with the case where the preforming is not performed. 13 (that is, the joining core wire 13B) can be formed with high accuracy by reducing the variation in the shape of the joining core wire 13B.

  Therefore, the manufacturing method and manufacturing system of the terminal-attached electric wire 1 according to the embodiment of the present invention provide the core wire bundle 13 (that is, the bonding core wire) that is made into a single wire by the ultrasonic bonding process regardless of the thickness of the core wire bundle 13 of the electric wire 10. 13B) can be accurately molded.

<Other aspects>
In addition, this invention is not limited to said each embodiment, A various modification is employable within the scope of the present invention. For example, the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like can be made as appropriate. In addition, the material, shape, dimensions, number, arrangement location, and the like of each component in the above-described embodiment are arbitrary and are not limited as long as the present invention can be achieved.

  For example, in the above embodiment, an aluminum wire or an aluminum alloy wire is used as the wire 10. However, instead of this, an electric wire (copper wire) in which the conductor core wire 12 is made of copper or a copper alloy may be used. Furthermore, as the terminal 20, a terminal formed from aluminum or an aluminum alloy may be used instead of a terminal formed from copper or a copper alloy.

  Furthermore, in the above-described embodiment, the preformed molded core wire bundle 13A has a rectangular cross section whose height Q is larger than the width P (see FIG. 3A), and is subjected to ultrasonic bonding processing. 13B has a rectangular cross section whose width X is larger than height Y (see FIG. 3C). However, in the present invention, the preformed core wire bundle 13A has a rectangular cross section whose height Q is smaller than the width P, and the joining core wire 13B subjected to ultrasonic joining has a width X having a height Y. It may have a smaller rectangular cross section. In this case, it is preferable that P> X and Y> Q are satisfied.

Here, the characteristics of the embodiment of the method for manufacturing a terminal-attached electric wire and the manufacturing system according to the present invention described above are summarized and listed in the following (1) to (9), respectively.
(1)
A method for producing a terminal-attached electric wire (1) in which a terminal (20) is crimped to an electric wire (10) having a core wire bundle (13) in which a plurality of conductor core wires (12) are bundled,
A first step of performing preforming so that the core wire bundle (13) has a predetermined preliminary shape (FIG. 3a) by performing a pressing process on the core wire bundle (13);
The core wire bundle (13A) having undergone the preforming is subjected to an ultrasonic bonding process so that the plurality of conductor core wires (12) are bonded to each other and have a predetermined target shape (FIG. 3c). A second step of forming
A third step of crimping the terminal (20) to the bonding core wire (13B),
Manufacturing method of electric wire with terminal.
(2)
In the manufacturing method according to (1) above,
The target shape is
A rectangular parallelepiped shape (FIG. 3c) corresponding to the shape of the terminal (20),
The preliminary shape is
A rectangular parallelepiped shape different from the target shape, wherein one of the height and width is smaller than the corresponding one of the height and width in the target shape and the other of the height and width is the height and width in the target shape A rectangular parallelepiped shape (FIG. 3a) larger than the corresponding other of
Manufacturing method of electric wire with terminal.
(3)
In the production method according to (1) or (2) above,
The plurality of conductor core wires (12)
Formed from aluminum or aluminum alloy,
Manufacturing method of electric wire with terminal.
(4)
A system for producing a terminal-attached electric wire (1) in which a terminal (20) is crimped to an electric wire (10) in which a core wire bundle (13) in which a plurality of conductor core wires (12) are bundled is covered with an insulating layer (11). ,
A preforming device (60) for performing preforming so that the core wire bundle (13) has a predetermined preliminary shape (FIG. 3a) by performing a pressing process on the core wire bundle (13);
The core wire bundle (13A) having undergone the preforming is subjected to an ultrasonic bonding process so that the plurality of conductor core wires (12) are bonded to each other and have a predetermined target shape (FIG. 3c). An ultrasonic bonding apparatus (30) for forming
A terminal crimping device (40, 50) for crimping the terminal (20) to the joining core wire (13B),
Manufacturing system for electric wires with terminals.
(5)
In the manufacturing system according to (4) above,
The preforming device (60)
A mold group for forming the core wire bundle (13) into a rectangular parallelepiped preliminary shape, and a first mold (70, 90) that sandwiches the core wire bundle (13) so as to press in the height direction of the preliminary shape. And a second mold group (70, 80) that sandwiches the core wire bundle (13) so as to be pressed in the width direction of the preliminary shape independently of the pressing by the first mold, Having
Manufacturing system for electric wires with terminals.
(6)
In the manufacturing system according to (5) above,
The first mold (70, 90) and the second mold (70, 80) are:
The insulating layer (11) in the vicinity of the core wire bundle (13) to be pressed is defined while forming a molding chamber (T) for pressing the core wire bundle (13) exposed from the end of the electric wire (10). A retreat chamber (U) for escaping to the outside of the molding chamber (T),
Manufacturing system for electric wires with terminals.
(7)
In the manufacturing system according to (6) above,
The first mold (70, 90) and the second mold (70, 80) are:
Mold corners (78a, 78b, 87, 97) with which the insulating layer (11) in the retracting chamber (U) contacts are chamfered,
Manufacturing system for electric wires with terminals.
(8)
In the manufacturing system according to (6) or (7) above,
The first mold (70, 90) is
Having a recess (77) that regulates the spread of the tip by accommodating the tip of the core wire bundle (13) disposed in the molding chamber (T) so as to surround it.
Manufacturing system for electric wires with terminals.
(9)
In the manufacturing system according to any one of (5) to (8) above,
The first mold (70, 90) is
A surface (73) wider than the thickness of the core wire bundle (13) before pressing in the width direction and pressing the core wire bundle (13) from one side in the height direction; and the height A surface (74) wider than the thickness before pressing of the core wire bundle (13) in the direction and pressing the core wire bundle (13) from one side in the width direction, the core wire bundle (13) ), And the core wire bundle (13) is pressed from the other in the height direction and pressed from the other in the width direction.
Manufacturing system for electric wires with terminals.

1 Electric wire with terminal 10 Electric wire 11 Insulation coating (insulation layer)
12 Conductor Core Wire 13 Core Wire Bundle 13A Molded Core Wire Bundle 13B Bonded Core Wire 20 Terminal 30 Ultrasonic Bonding Device 40 Anvil (Terminal Crimping Device)
50 crimper (terminal crimping device)
60 Pre-forming device 70 Lower mold (first mold, second mold)
73 Floor (surface wider than the thickness before pressing the core wire bundle in the width direction)
74 Side surface (surface wider than thickness before pressing core wire bundle in height direction)
77 hollow part 78a corner (mold corner)
78b Corner (mold corner)
80 Slider (second mold)
87 Corner (Die corner)
90 Upper mold (first mold)
97 Corner (Die corner)

Claims (9)

A method for producing a terminal-attached electric wire in which a terminal is crimped to an electric wire having a core wire bundle in which a plurality of conductor core wires are bundled,
A first step of performing preforming so that the core wire bundle has a predetermined preliminary shape by performing a pressing process on the core wire bundle;
A second step of forming a bonded core wire having a predetermined target shape by bonding the plurality of conductor core wires to each other by performing an ultrasonic bonding process on the core wire bundle that has undergone the preforming;
A third step of crimping the terminal to the bonding core wire,
Manufacturing method of electric wire with terminal. The manufacturing method according to claim 1,
The target shape is
A rectangular parallelepiped shape corresponding to the shape of the terminal,
The preliminary shape is
A rectangular parallelepiped shape different from the target shape, wherein one of the height and width is smaller than the corresponding one of the height and width in the target shape and the other of the height and width is the height and width in the target shape A rectangular parallelepiped shape larger than the corresponding other of
Manufacturing method of electric wire with terminal. In the manufacturing method of Claim 1 or Claim 2,
The plurality of conductor core wires are
Formed from aluminum or aluminum alloy,
Manufacturing method of electric wire with terminal. A manufacturing system of a terminal-attached electric wire in which a terminal is crimped to an electric wire in which a core wire bundle in which a plurality of conductor core wires are bundled is covered with an insulating layer,
A preforming device for performing preforming so that the core wire bundle has a predetermined preliminary shape by performing a pressing process on the core wire bundle;
An ultrasonic bonding apparatus in which the plurality of conductor core wires are bonded to each other and form a bonded core wire having a predetermined target shape by performing an ultrasonic bonding process on the core wire bundle that has undergone the preforming;
A terminal crimping device for crimping the terminal to the bonding core wire,
Manufacturing system for electric wires with terminals. The manufacturing system according to claim 4,
The preforming device is
A mold group for forming the core wire bundle into a rectangular parallelepiped preliminary shape, the first mold sandwiching the core wire bundle so as to press in the height direction of the preliminary shape, and the pressing by the first mold A mold group that includes a second mold that sandwiches the core wire bundle so as to be pressed in the width direction of the preliminary shape independently.
Manufacturing system for electric wires with terminals. The manufacturing system according to claim 5,
The first mold and the second mold are:
Defining a molding chamber for pressing the core wire bundle exposed from the end of the electric wire, and defining a retracting chamber for releasing the insulating layer in the vicinity of the core wire bundle to be pressed out of the molding chamber;
Manufacturing system for electric wires with terminals. The manufacturing system according to claim 6,
The first mold and the second mold are:
The corners of the mold that come into contact with the insulating layer in the retreat chamber are chamfered,
Manufacturing system for electric wires with terminals. In the manufacturing system according to claim 6 or 7,
The first mold is
Having a recess that regulates the spread of the tip by accommodating the tip of the core wire bundle disposed in the molding chamber so as to surround it;
Manufacturing system for electric wires with terminals. In the manufacturing system according to any one of claims 5 to 8,
The first mold is
A surface wider than the thickness before pressing of the core wire bundle in the width direction and pressing the core wire bundle from one side in the height direction, and a thickness before pressing of the core wire bundle in the height direction The core wire bundle is pressed from the other in the height direction and the other in the width direction in a state where the core wire bundle is supported by a wide surface that presses the core wire bundle from one in the width direction. Configured to press from,
Manufacturing system for electric wires with terminals.

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