IMPROVED METHOD OF ASSEMBLING WIRE HARNESS AND TRIM PANEL

Abstract: An improved method and apparatus for assembling a wire harness, and then securing that wire harness to a vehicle trim panel includes the use of adhesive strips. The strips are placed in a welding station prior to the wire harness being assembled through the welding stations. Once the wire harness is fully assembled, the trim panel is placed above the jig. The welding stations are provided with structure to actuate the strips and secure the strips to the trim panel. The strips then capture and hold the wires on the trim panel. In this way, the wire harness may be directly attached to the trim panel after its assembly.

Description: IMPROVED METHOD OF ASSEMBLING WERE HARNESS AND TRIM PANEL BACKGROUND OF THE INVENTION This invention relates to an improvement in securing a wire harness to a vehicle trim panel. In the prior art, wire harnesses are utilized to bundle the control wires associated with vehicle systems. Wire harnesses are assembled at a wiring jig to route the wires to desired destinations, and to connect the wires to connectors as required. As an example, in an interior trim panel for a vehicle door, wires must go to and from a vehicle control, a power supply, and be connected to several components on the vehicle door. Included in the components typically mounted in a vehicle door are window controls, power door locks, and motor driven mirrors. In addition, electrical connections must be made between the vehicle stereo, and any speakers mounted within the door panel. In sum, there are many wires that must be connected into a wire harness for a vehicle trim panel such as a door panel. The method of assembling a wire harness in the past has required an undesirably large number of steps. It is a goal of vehicle manufacturers to reduce the number of separate steps that must be performed to reach a final vehicle assembly. In addition, it is a goal to form as many modular components, from vehicle components as is possible. The prior art method of assembling wire harnesses to trim panels has not been as modular as would be desirable. As an example, Figure 1 shows a highly schematic and very simplified wire harness jig 20. Connectors 22, 24, and 26 are interconnected by wires 28. Routing fork 31 guides wires 28 toward the connectors 24 and 26. Routing fork 32 guides several of the wires to the connector 24, while fork 34 guides a wire to connector 26. As the wire harness is assembled, a worker individually places wires through the routing forks and to their appropriate destinations. The wiring harnesses are then taped to hold desired positions until they can be attached to a trim panel. Figure IB shows the second step in the process of attaching the wire harness 36 to the trim panel 38. The wire harness and trim panel are typically shipped separately to an assembly line, where they are interconnected. Thus, the two processes generally occur at separate locations. Extra manufacturing steps are required to separately transport the wire harness to the trim panel location, and then assemble the two. It would be desirable to reduce the number of separate manufacturing steps. SUMMARY OF THE INVENTION In a disclosed embodiment of this invention, welding stations are provided on the jig that are operable to actuate and secure holding strips, and thus captured wires, to the trim panel. In a first embodiment, the holding strips are formed of a material which may be actuated to secure the strip to the trim panel. In one example, the welding stations include ultrasonic members. In other examples the welding station could include vibration or heat applying members. Initially, a strip is placed in the station. After the wire harness is assembled, similar to as shown in Figure 1A, a trim panel is placed over the wire harness jig 20. The welding station is then actuated to secure the strips, and thus the wires, to the trim panel. In one embodiment, a pneumatic cylinder structure drives actuation members and the welding stations to contact the strip and hold the strip against the trim panel. The actuation members are preferably ultrasonic members mentioned above. The actuation members melt the material of the strip to secure the strip to the trim panel. Preferably, the wire harness is assembled on an assembly line, and the wire assembly and routing occurs at a first station. The assembled wire harness thenamoves to a second station at which the trim panel is moved over the jig. At the same time, a pneumatic actuation structure drives the actuation members, which are preferably ultrasonic horns, through openings in a strap holding station, to achieve the welding. These and other features of the present invention can be best understood from the following specification and drawings, of which the following is a brief description. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1A shows a simplified wire harness jig assembly. Figure IB shows a subsequent step in the attachment of a wire harness to a trim panel. Figure 2 is a schematic view of an inventive trim panel. Figure 3 shows an inventive welding station. Figure 4 A is a schematic view of the invention applied to securing a wire harness to a trim panel. Figure 4B shows a schematic view of an assembly line for the wire harness. Figure 4C shows a detail. Figure 4D shows a further detail. Figure 5 shows an actuation step of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Figure 2 shows an improved trim panel 40 in which the wire harness is attached directly to the trim panel through a plurality of securement strips 42. Securement strips 42 have a holding channel 44 holding the wires 48 on the trim panel 40 at desired orientations. The strips 42 include melted portions 46 which secure the strips 42 to the trim panel 40. Portions 46 are preferably formed at outer tabs 48 spaced on opposed sides of the channel 44. The strips 42 are secured to the panel 40 and hold the wires 28 at desired locations. As will be explained below, with this invention, the assembly of the wire harness to the trim panel is greatly simplified. Figure 3 shows welding station 50 to secure the strips 42 to the panel 40. Outer holding surface 52 include holding notches 54. An inner surface 56 includes a seat 58 which receives a strip 60 to be secured to the trim panel. It should be understood that strip 60 is shown in Figure 3 in its unsecured position, but that strip 60 becomes strip 42 when secured to the trim panel 40. Energy deflection structure 61 is formed on the outer portions of the strip 60. The strip 60 includes a central portion 62 that will become channel 44. A plurality of wires 28 are shown within portion 62. Actuation horns 63 are placed beneath, and on opposed side of, central holding portion 56. As shown, horns 60 are connected by a base portion 65. An electronic control 66 controls actuation horns 63, and in different embodiments, may cause them to apply ultrasonic force, when the strip 60 is being secured to the trim panel. A source of pneumatic fluid 68 is shown connected to a cylinder 70 beneath the base 65. The fluid system 60 and 70 is shown somewhat schematically. Other means for driving the horns 63 may replace this system. The electronics 66 are as known in the art, and a worker of ordinary skill in the art would know how to apply ultrasonic force to the horns 63. Figure 4A shows a schematic view of a control 74 for attaching a wire harness to trim panel 40. As shown, a plurality of welding stations 50 are spaced about the trim panel surface 40. As shown in Figure 4B, the wire harness is assembled at station X, and then moves to station Y. As shown in Figure 4C, the trim panels are mounted in a rotating carrier member 69 that receives a trim panel which is then rotated to move downwardly on top of the jig. Positioning structure is preferably included to insure that the trim panel 40 is properly located relative to the several routing forks 50. The horns 63 are associated with a cylinder 70 beneath the base of the jig, and beneath the base of a conveyor which brings the jig into the station Y. Now, when it is desired to achieve the welding at the station Y, the horns 63 are driven upwardly. As shown in Figure 4D, the welding stations 50 are preferably associated with routing forks 80 on each side of the welding stations. Alternatively, it should be understood that the welding stations themselves may be able to provide the routing function. Control 74 actuates the horn to cause the horns 64 to move forwardly, and to then actuate the adhesive on the strip 60 to secure the strip 60 to the trim panel. Figure 5 shows the actuation step. As shown, the horns 63 have been driven forwardly such that their tips 64 contact the strip and have forced outer tabs 48 against the trim panel 40. This squeezes the channel on the wires such that the wires are held securely. The portion 61 as shown in Figure 4 has now been melted and formed the melt portions 46 as shown in Figure 2. The tips 64 may apply ultrasonic force to melt the plastic. Alternatively, the horns may apply heat or vibration. The controls and structure for achieving any one of these actuations systems are as known in the art. It is the use of such a system with the inventive application which is the patentable feature of this invention. The present invention has simplified the assembly of a wire harness to a trim panel. Once the wire harness is assembled in a jig such as shown in Figure 1A, the trim panel is then placed over the assembly. The welding stations 50 are then actuated to secure the strips 42 to the trim panel 40. In this way, the intermediate step of transporting the wire harness to the trim panel assembler, and then securing the two is eliminated. Less assembly time is required, and fewer components need be stored. In one embodiment, the strips 42 are preferably formed to be compatible with the material of the trim panel 40. If the trim panel 40 is formed of a material then the strip 42 is preferably formed of the same material. The energy deflection portion ensures an evenly melted strip. In preferred embodiments of this invention, the strip could be a polyproplyene, or of A.B.S. plastic. Again, it is the material of the trim panel which will dictate the selection of the material for the strip. Preferred embodiments of this invention have been disclosed, however, a worker of ordinary skill in the art would recognize that certain modifications will come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims: CLAJTMS What is claimed is: 1. A trim panel comprising: a trim body to be mounted into a vehicle, said trim body having a first trim side to be displayed outwardly of a vehicle, and an opposed second side to be concealed within the vehicle; a wire harness secured to said second side; and said wire harness being secured to said second side by a plurality of strips, said strips having a central portion holding wires against said second side, and said strips being secured to said second side by melted portions. 2. A trim panel as recited in Claim 1 , wherein said melted plastic material is formed from energy deflection portions. 3. A trim panel as recited in Claim 1 , wherein said strip includes two outer tabs on both sides of said central portion, said central portion defining a channel, said tabs including portions secured to said trim panel, said central channel capturing and bundling said wires. 4. A method of securing a wire harness to a vehicle trim panel comprising the steps of: 1) providing a wire harness assembly jig including attachment stations, said attachment stations being provided with actuation structure to actuate holding strips and secure said holding strips to a trim panel; 2) placing holding strips in said attachment stations; 3) assembling wires to said wire harness assembly jig, and through said attachment stations; 4) placing a trim panel adjacent said wire harness assembly jig; and 5) utilizing said attachment stations to actuate and secure said strips to said trim assembly, and capture said wires on said trim assembly. 5. A method as recited in Claim 4, wherein actuating horns move relative to said attachment stations to move said strip and hold said strip against said trim panel. 6. A method as recited in Claim 5, wherein said actuating horns cause said strips to melt such that said strip is secured to said trim panel. 7. A method as recited in Claim 6, wherein said actuating horns apply an ultrasonic force to said strips to cause said material to melt. 8. A method as recited in Claim 6, wherein said actuating horns are maintained at a securement station on a wire harness assembly line. 9. A method as recited in Claim 8, wherein said attachment stations are provided with a central seat, said strip being placed in said seat, and said wires then being placed within a central portion of said strip. 10. A method as recited in Claim 9, wherein said strips include a first base plastic material and energy deflector portions, said portions melting to secure said strip to said trim panel. 11. A welding station for use in a wire harness assembly jig comprising: a pair of spaced arms extending in a first direction; a central seat defined between said arms, said central seat being adapted to receive a strip, and to provide a guide for wires being assembled into a wire harness; and actuation structure for actuating said strip to secure said strip to a trim panel. 12. A station as recited in Claim 11 , wherein said actuation structure includes an actuation horn member movable relative to said central seat to move the strip against a trim panel. 13. A routing fork as recited in Claim 12, wherein said actuation horns are provided with an ultrasonic control. 14. A routing fork as recited in Claim 11 , wherein a fluid motor is provided to drive said actuation structure toward the trim panel and hold the strip against the trim panel.

Inventors: KRANE MICHAEL A, NAGY STEVE, ZUTECK MIKE, KRANE, MICHAEL, A., NAGY, STEVE, ZUTECK, MIKE
Applicants: UNITED TECHNOLOGIES AUTOMOTIVE, UNITED TECHNOLOGIES AUTOMOTIVE, INC.
Application year: 1997
Main classification: B60R16
IPC codes: B60R13, B60R16