Patent Application
20170229211
Technical Field
The present disclosure relates to a covered wire including a covered conductor, a covered wire with terminal, a wire harness and a method of manufacturing a covered wire, and particularly relates to a covered wire, a covered wire with terminal, a wire harness and a method of manufacturing a covered wire in which detection of a defect such as a hole that is unintentionally produced in a covering layer in a manufacturing process is facilitated.
Background
In the related art, a so-called wire harness is used as an electric wiring structure for transportation vehicles such as automobiles, trains, and aircrafts, or an electric wiring structure for industrial robots. A wire harness is a member including covered wires each having a conductor made of copper or copper alloy, aluminum or aluminum alloy and fitted with terminals (connectors) made of copper or copper alloy (e.g., brass), aluminum or aluminum alloy. With recent rapid advancement in performances and functions of automobiles, various electrical devices and control devices installed in vehicles tend to increase in number, and electric wiring structures used for those devices also tend to increase in number. However, even if a defect such as a flaw, a crack, or a hole is produced in a covering layer unintentionally by some reason during the manufacturing process of a wire harness, an electric wire in which a defect has been produced could be directly assembled in a wire harness. In order to prevent such a situation, there is a need for a method with which a defect that is produced in a covering layer can be detected during a manufacturing process of a covered wire or a manufacturing process of a wire harness.
For example, by inspecting a covered wire immediately after a step of forming a covering layer over a conductor and detecting, by image analysis or the like, a defect formed in the covering layer, a covered wire in which a defect is produced can be removed as a reject product. However, if a defect is produced unintentionally in a subsequent step of manufacturing an electric wiring structure, which includes covered wires routed by bundling or the like, it is not possible to detect such a defect with the method mentioned above.
A covered wire of the related art used for an electric wiring structure of vehicles is described, for example, in Japanese Laid-Open Patent Publication No. 2004-134212, as an aluminum electric wire that is used for an automotive wire harness and having a characteristic equivalent to a copper wire.
However, the aforementioned Japanese Laid-Open Patent Publication No. 2004-134212 neither discloses nor suggests a method of defecting a defect that is produced in a covering layer.
Also, when manufacturing a covered wire, there is a method of detecting a defect in a covering layer with a flaw detector before a final winding-up step. However, with this method, it is not possible to detect a defect in the covering layer at the stage of manufacturing a wire harness using such covered wires.
The present disclosure is related to providing a covered wire, a covered wire with terminal, a wire harness and a method of manufacturing a covered wire, with which a defect that is produced in a covered wire manufacturing process as well as in a wire harness manufacturing process can be easily detected and further a defect in the wire harness can be easily detected.
For a covered wire that is applicable to a wire harness, the inventors have provided a plurality of inclusions between a conductor and a covering layer or in a covering layer, and carried out studies on an appropriate size and an appropriate density of the inclusions. As a result, the inventors have found that, in a case where a defect such as a flaw or a hole is produced in a covering layer in a process of manufacturing a covered wire or a wire harness, production of the defect can be easily detected utilizing the leakage of the inclusions from defect, and thus obtained the present invention.
According to a first aspect of the present disclosure, a covered wire includes a wire comprising a metal, a covering layer provided at a periphery of the wire, and inclusions comprising at least one of a metal and a metal oxide, the inclusions being provided between the wire and the covering layer or in the covering layer, an average size of each of the inclusions being less than a thickness of the covering layer.
According to a second aspect of the present disclosure, a covered wire with terminal includes a covered wire and a terminal fitted to an end portion of the covered wire, the covered wire including a wire comprising metal, a covering layer provided on a periphery of the wire, and inclusions comprising at least one of a metal and a metal oxide, the inclusions being disposed between the wire and the covering layer or in the covering layer, an average size of each of the inclusions being less than a thickness of the covering layer.
According to a third aspect of the present disclosure, a wire harness includes a covered wire with terminal combined with another wire, the covered wire with terminal includes a covered wire and a terminal fitted to an end portion of the covered wire, the covered wire including a wire comprising metal, a covering layer provided on a periphery of the wire, and inclusions comprising at least one of a metal and a metal oxide, the inclusions being disposed between the wire and the covering layer or in the covering layer, an average size of each of the inclusions being less than a thickness of the covering layer.
According to a fourth aspect of the present disclosure, a method of manufacturing a covered wire, the method includes forming a wire, the wire being one of an individual wire and a stranded wire, the stranded wire comprising a plurality of individual wires stranded together, attaching inclusions to the wire, the inclusions comprising at least one of a metal and a metal oxide, and forming a covering layer over the wire.
According to the present disclosure, by providing a plurality of inclusions between the conductor and the covering layer or in the covering layer, and in particular, by determining an average size of each of the inclusions and/or number density of the inclusions to be within the aforementioned ranges, in a case where a defect such as a flaw, a crack, or a hole is produced in the covering layer in a manufacturing process, the inclusions leak out from the covered wire to an outside through such a defect. By detecting or sensing the inclusions which have leaked out, it is possible to easily detect that a defect is produced in the covered wire by visual inspection or a sensor, not only in the covered wire manufacturing process but also in the wire harness manufacturing process. Further, it may result in an improvement in a percentage of good products of a covered wire and a wire harness, and harnesses having a good insulation performance can be supplied steadily.
Further features of the present disclosure will become apparent from the following detailed description of exemplary embodiments with reference to the accompanying drawings.
As shown in
The wire 11 is a stranded wire including a plurality of individual wires 11a stranded together, and made of, for example, aluminum, an aluminum alloy, copper or a copper alloy. In the present embodiment, the wire 11 is a stranded wire, but it is not limited thereto, and it may be a solid wire.
The covering layer 12 is, for example, an insulating layer that is a layer of polyvinyl chloride (PVC), crosslinked polyethylene, etc., or a multilayered structure including one of those layers, but it is not particularly limited thereto, as long as it is capable of insulating the wire 11 from outside. The thickness of the covering layer 12 is determined by observing a cross-section with a microscope, measuring the maximum covering thickness and the minimum covering thickness, performing similar measurements for three cross sections, and taking an average value of the obtained measurement values as a thickness of the covering layer 12.
As shown in
<Size, Density and Components of the Inclusions>
In order to detect a defect in the covered wire 1 utilizing the leakage of the inclusions 13, it is preferable that inclusions are of a size with which they are easy to fall from a defect, i.e., have a small size, so that the inclusions 13 leak out as soon as the defect is produced in the covering layer 12, and on the other hand, inclusions of a certain size are required so that the inclusions can be easily viewed and detected when they have leaked, and an average size of each of the inclusions 13 needs to be less than the thickness of the covering layer 12. For example, in a case where each of the inclusions 13 has a generally elliptical shape in a plan view, an average size of the inclusion 13 can be determined based on an average value of a major diameter and a minor diameter of a particle which is an inclusion:
(average size)={(major diameter)+(minor diameter)}/2.
An average size of the inclusion 13 may also be determined based on an average value of a size in a longitudinal direction and a size in a widthwise direction, which is orthogonal to the longitudinal direction. Measurement of size is carried out using a magnifying glass. For a shape other than a substantially elliptical shape, such as a crescent shape, diagonals of a rectangle containing said shape are drawn, and an average size is calculated by taking the diagonal having the longest length as a major diameter and the diagonal having the shortest length as a minor diameter. This is because in a case where the average size of the inclusion 13 is greater than the thickness of the covering layer, the covering may break, and an insulation property may be lost. Specifically, it is preferable that the average size of each of the inclusion 13 in a direction of thickness of the covering layer 12 is less than or equal to half of the thickness of the covering layer 12 in a state where the inclusions 13 are contained in the covering layer 12. Thereby, the possibility of losing an insulation property is suppressed, and the inclusions are capable of leaking out from a defect and detection of the inclusions is facilitated. For ease of visual inspection, a lower limit of the average size of the inclusion 13 is preferably around 1 μm, and the broadest portion of the inclusion 13, e.g., a maximum value of a projected area of the inclusion 13, is preferably greater than or equal to 100 μm2. Thereby, detection of the inclusions 13 that have leaked out from a defect by visual inspection or with a sensor is facilitated.
The number density of the inclusions 13 is preferably one particle/mm3 to 3000 particles/mm3. In a case where the inclusions 13 are provided in the above-mentioned range of number density, detection of the inclusions 13 that have leaked out from the defect is facilitated. In a case where the number density of the inclusions 13 exceeds 3000 particles/mm3, distortion of the shape of the covered wire 1 or a thickness deviation of the covering layer 12 is likely to occur, and in a case where it is less than one particle/mm3, an amount of inclusions 13 leaking out from a defect becomes less, and it becomes difficult to detect a defect.
The inclusions 13 are composed primarily of a metal having a higher reflectivity in comparison to resins or the like, and, for example, those having an average reflectivity of greater than or equal to 70% for visible light are preferable. With the average reflectivity of greater than or equal to 70% for visible light, the reflectivity is higher than that of the floor surface of the workplace, and thus detection of the inclusions can be facilitated. Also, it is preferable that the metal content of a single inclusion 13 is greater than or equal to 50% by volume. The inclusion 13 contains a metal oxide or the like at a surface and/or internally, and in a case where the metal content of a pure metal component to the entire inclusion is greater than or equal to 50% by volume, metallic luster facilitates detection of the inclusion 13. Particularly, in a case where the metal is Cu or Fe and the metal content of the inclusions 13 is less than 50% by volume, an average reflectivity for visible light may greatly decrease. In a case where particular attention is required for a decrease in electric conductivity and a wire surface, it is preferable that the inclusions 13 are comprised of or consisting of a metal or an alloy material containing components that are the same or equivalent to those of the wire 11.
<Method of Manufacturing Inclusions>
The inclusions 13 per se can be prepared by machining or grinding a metal ingot. Also, when using the inclusions 13 of components equivalent to those of the individual wire 11a, a method of manufacturing inclusions 13 may include machining from an individual wire 11a during the manufacturing process of a covered wire 1, or detaching from an outer surface 11b of the individual wire 11a as a result of the individual wires 11a coming into contact with each other. Specific embodiments of the method of manufacturing the inclusions include, for example, the following methods.
(i) Sinter alumina (Al2O3), grind the obtained sintered alumina with a ball mill, and thereafter classify the ground alumina (perform particle sizing) using a sieving machine to obtain inclusions of a predetermined size.
(ii) Cut (peel) the surface of a metal of a desired composition, grind the obtained peeled product with a ball mill, and thereafter classify the ground alumina (perform particle sizing) using a sieving machine to obtain inclusions of a predetermined size.
<Method of Providing Inclusions>
By providing the inclusions 13 onto the outer surface 11b of the individual wire 11a before applying the covering layer 12 to the wire 11, the inclusions 13 can be provided between the wire 11 and the covering layer 12. For example, a method of attaching the inclusions 13 after having applied a tacky fluid to an outer surface 11b of the individual wire 11a that has been subjected to wire drawing, or a method of spraying the inclusions 13 from top, bottom, right and left of the wire 11 just before applying a resin for forming a covering layer 12 to the wire 11 may be used.
For example, just before the covering layer forming step, application may be performed by regulating the rate of flow of gas containing the inclusions in-line. A viscous liquid may be coated on an outer surface of the wire for the purpose of improving a density of the inclusions. Also, the inclusions may be applied together with air to the outer peripheral surface of the wire from four directions, i.e., top, bottom, right and left, for the purpose of uniformly providing on an outer periphery of the wire.
In a case where the wire is a stranded wire, the inclusions may be provided in a twisting step. For example, the stranded wire may be provided with inclusions by applying, coating, applying with air, or manufacturing the inclusions by causing the individual wires to rub against each other.
With the methods of providing the inclusions as described above, in principle, all of the inclusions 13 are in contact with the outer surface 11b of the individual wire 11a, and comes to a state where they are provided at an interface between the individual wire 11a and the covering layer 12. However, exceptionally, there is a case in which viscosity between the inclusions 13 and the individual wire 11a inevitably weakens in the application step, and the inclusions 13 loosely exist in the resin before hardening, and thereafter the resin is hardened and the covering layer 12 is formed. In this case, although the inclusions 13 are not in contact with the outer surface 11b of the individual wire 11a and exist within the covering layer 12, a defect can be detected by such inclusions 13.
<Improvement of Reflectivity of Inclusions>
The inclusions 13 are detected by whether reflected light produced by incident light reflecting on a surface of the inclusion exists or not. Therefore, considering the ease of viewing or detection, it is more preferable that the inclusions 13 are composed of a metal material. The reflectivity of the metallic material varies due to surface irregularity. However, microscopically, diffuse reflection light is produced on a surface of the metal material together with strong specular reflection light (regular reflection light), and thus the inclusions 13 can be detected by metallic luster more easily and positively. Incident light may be sunlight, and may be infrared light emitted from an infrared irradiation apparatus or the like, as long as it is a detectable electromagnetic wave. In the present embodiment, the material of inclusion 13 is preferably one or more of an aluminum alloy (6xxx series aluminum alloy), an aluminum oxide (alumina), a magnesium alloy and a magnesium oxide.
<Method of Measuring Number Density of Inclusion>
The number density of the inclusions 13 as described above is the number of inclusions 13 per unit volume of an electric wire. When there are N inclusions for an electric wire having a wire outer diameter of R and a length of L, a number density D can be expressed by the following computational expression (1):
D=4N/πR2·L (1)
The number density of inclusions is measured at five positions, and an average thereof is used as a number density D. Five pieces of electric wire are prepared by cutting out a length of 5 cm at each of the positions situated at an interval of 1 m. Then an obtained electric wire is disassembled, and the inclusions 13 at an inside are taken out onto a flat platform and counted by visual inspection. Alternatively, when there are a large number of inclusions 13, the number may be counted by image analysis. For image analysis, a software for binarizing an image, such as “Image J” (developed by Wayne Rasband) is available. It is to be noted that, in a case where there are remaining inclusions 13 at the wire and the covering layer, these are also counted. Thereafter, the number densities at the respective positions are calculated from the aforementioned computation expression (1), and the number density D is obtained by calculating an average of the number densities.
<Detection Methods of Inclusions Leaked Out from a Defect of the Electric Wire>
After the covering layer forming process, at any step such as a covered wire winding process and the wire harness manufacturing process to be described below, if an unintended defect is produced, the inclusions are detectable. Here, as a method of efficiently detecting the inclusions that have leaked out, for example, there are methods as follows:
(i) Since an operation of assembling a covered wire into a wire harness is generally performed on a single piece of board, a black board is used, and the inclusions fallen on the black board are viewed. Further, in a case where the aforementioned assembling operation is performed on a floor surface, a black-color coated floor surface is used, and the inclusions fallen on the floor surface is viewed.
(ii) Using a black returnable box (container) for carrying the assembled wire harness, the inclusions fallen in a returnable box are viewed with the wire harness being placed in the returnable box. Since production of an unintended hole may be produced before assembling the wire harness due to an unexpected shock, the inclusions can be efficiently detected by performing detection in the wire harness assembling step. Also, since the inclusions that have fallen off are retained in the returnable box, it becomes easier to view the inclusions even if a very small amount of the inclusions 13 that have fallen down, and production of a defect can be detected at an early stage.
<Other Configuration of the Wire>
The wire may be a stranded wire composed of a plurality of individual wires as shown in
In any of the cases in which the wire is a stranded wire, a compressed stranded wire, or a solid wire, the defect that is produced unintentionally can be detected by the inclusions. Particularly, the wire configured as a stranded wire provides improvement in elongation, flexing property and impact resistance, and the wire configured as a compressed stranded wire provides improvement in working efficiency in the stranded wire manufacturing process, such as a decrease in stranding defect and a decrease in untwisting after stripping.
<Configuration of Covered Wire with Terminal>
Using the covered wire 1 shown in
The terminal 32 is, for example, a female terminal, and has a connecting portion 32a having a box shape and allowing insertion of, for example, an insertion tab of a male terminal, and a barrel portion 32b having a one end closed tubular shape. By crimping the barrel portion 32 with an end portion of the covered wire 31 from which the covering layer is removed being inserted into the barrel portion 32b, the wire and the covering layer crimp with the barrel portion 32b, whereby the terminal is mounted to the end portion of the covered wire 31. The barrel portion 32b is formed into a tubular shape with one end closed, for example, by welding. Specifically, by three-dimensionally pressing a planar spread-out metal substrate, a tubular body having a generally C-shaped cross section is formed, and an open portion (butted portion) of the tubular body is laser welded. Since laser welding is performed in a longitudinal direction of the tubular body, a welded portion 33a (weld-bead) is formed in generally the same direction as the longitudinal direction of the tubular body by butt welding. Also, subsequently, a welded portion 34b is formed in a direction perpendicular to the longitudinal direction of the tubular body to thereby seal a leading edge side of the barrel portion 32b and to make the barrel portion 32b into a one-end closed tubular shape. By this sealing, moisture is prevented from entering into the barrel portion 32b from the connecting portion 32a side. It is to be noted that as for the covered wire with terminal 30 shown in
<Configuration of Wire Harness>
As shown in
The present disclosure will be described in detail based on the following examples. It is to be noted that the present disclosure is not limited to examples shown below.
Using a Properzi-type continuous casting rolling mill, molten metal containing Mg, Si, Fe, Mn, Cr, Zr and Ni by a predetermined amount was continuously cast with a water-cooled mold and rolled into an aluminum alloy bar of φ9.5 mm. Then, a first wire drawing was performed out until φ2.6 mm, and a predetermined heat treatment was performed for the main purpose of softening. Further, after having performed a second wire drawing until a wire size of φ0.3 mm, the obtained seven individual wires were twisted into a stranded wire. Thereafter, a solution heat treatment and an aging heat treatment were sequentially applied, thus producing an aluminum alloy stranded wire (conductor). After having applied an oil to the obtained stranded wire, inclusions of the same composition as the wire and having an ellipsoidal shape of an average size of 0.01 mm were blown, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining an aluminum alloy covered wire containing inclusions. During this, the blowing speed was adjusted to blow the inclusions such that an average number density is 490 particles/mm3.
A tough pitch copper bar of φ9.5 mm was manufactured by SCR process with tough pitch copper. After wire drawing the tough pitch copper bar until a wire size of φ0.3 mm, the obtained seven individual wires were twisted into a stranded wire. Thereafter, a softening heat treatment was applied to produce a tough pitch copper stranded wire. After having applied an oil to the obtained stranded wire, inclusions composed primarily of magnesium and having an ellipsoidal or whisker shape of an average size of 0.07 mm were blown such that the number density was 25 particles/mm3, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining a copper alloy covered wire containing inclusions.
Using a Properzi-type continuous casting rolling mill, molten metal containing Mg, Si and Fe by a predetermined amount was continuously cast with a water-cooled mold and rolled into an aluminum alloy bar of φ9.5 mm. Then, a first wire drawing was performed out until φ2.6 mm, and a predetermined heat treatment was performed for the main purpose of softening. Further, after having performed a second wire drawing until a wire size of φ0.3 mm, the obtained seven individual wires were twisted into a stranded wire. Thereafter, a solution heat treatment and an aging heat treatment were sequentially applied, thus producing an aluminum alloy stranded wire. After having applied an oil to the obtained stranded wire, inclusions of the same composition as the wire and having a spherical shape of an average size of φ0.01 mm were blown, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining an aluminum alloy covered wire containing inclusions. During this, the blowing speed was adjusted such that inclusions were blown such that the average number density is 2860 particles/mm3.
Using a Properzi-type continuous casting rolling mill, molten metal containing Mg, Si, Fe, Mn, Cr, Zr and Ni by a predetermined amount was continuously cast with a water-cooled mold and rolled into an aluminum alloy bar of φ9.5 mm. Then, a first wire drawing was performed out until φ2.6 mm, and a predetermined heat treatment was performed for the main purpose of softening. Further, after having performed a second wire drawing until a wire size of φ0.3 mm, the obtained seven individual wires were twisted into a stranded wire. Thereafter, a solution heat treatment and an aging heat treatment were sequentially applied, thus producing an aluminum alloy stranded wire, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining an aluminum alloy covered wire that does not contain inclusions.
A tough pitch copper bar of φ9.5 mm was manufactured by SCR with tough pitch copper. After performing wire drawing until a wire size of φ0.3 mm, the obtained seven individual wires were twisted into a stranded wire. Thereafter, a softening heat treatment was applied to produce a tough pitch copper stranded wire, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining a copper alloy covered wire that does not contain inclusions.
Onto a conductor of the same components as Example 1, inclusions of the same composition as the conductor and having an ellipsoidal shape of an average size of 1.1 mm were blown such that an average number density is 440 particles/mm3, and thereafter covering of PVC resin was performed with an extruder to provide a covering layer of a thickness of 0.2 mm, thus obtaining an aluminum alloy covered wire containing inclusions.
Then, each of the obtained covered wires was evaluated by a method shown below.
A hole of 3 mm in length and 0.5 mm in width and penetrating through the covering was formed in the covering layer of the covered wire to simulate a hole which may be produced due to an unintended impact during working. Thereafter, on a black sheet, a movement simulating installation of a wire harness was applied to the covered wire, and detection of the inclusions was performed. A case where inclusions leaked out from a hole of the covered wire were detected is indicated as “GOOD”, and a case where the inclusions were not detected is indicated as “BAD”.
Uniformity of a covering layer thickness is measured by a laser outer diameter measuring apparatus, and evaluated from the measured value.
Results of evaluation by the aforementioned method is shown in Table 1.
As shown in Table 1, in Examples 1 to 3, it was possible to detect a large number of inclusions, which have leaked out of the hole in the covered wire, on a black sheet.
Whereas in Comparative Examples 1 and 2, inclusions, which have leaked out of the hole in the covered wire, were not detected. In Comparative Example 3, an average size of each of the inclusions is beyond the scope of the present disclosure, and thus, the covered layer thickness after the resin covering became non-uniform, and a covering layer defect was produced.
According to the invention, it becomes easier to detect a defect such as a flaw, a crack, or a hole that is produced in the covering layer in a manufacturing process, and it is possible to suppress a decrease in an electric wire characteristic in an electric wire usage environment and occurrence of electric leakage, and to provide a covered wire that is safer than those of the related art. Accordingly, it is useful for a harness mounted on a vehicle and a wiring body of an industrial robot, and particularly useful for an automotive wire harness.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-228105 | Nov 2014 | JP | national |
This is a continuation application of International Patent Application No. PCT/JP2015/081342 filed Nov. 6, 2015, which claims the benefit of Japanese Patent Application No. 2014-228105, filed Nov. 10, 2014, the full contents of all of which are hereby incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2015/081342 | Nov 2015 | US |
| Child | 15493869 | US |
