CN-121983390-A - Method for manufacturing light-weight automobile conformal wiring harness by utilizing multi-material micro 3D printing

Abstract

The invention discloses a method for manufacturing a light-weight automobile conformal wiring harness by utilizing multi-material micro 3D printing, which relates to the technical field of automobile wiring harness structure manufacturing, and comprises the following steps of S10, carrying out three-dimensional modeling on an automobile structure needing wiring harness arrangement, and processing a curved surface model substrate matched with the surface of an automobile, and S20, attaching at least two materials for printing the automobile wiring harness structure on the curved surface model substrate matched with the surface of the automobile to the model substrate to print the automobile wiring harness structure in a curved surface mode. The automobile wire harness and the automobile structure can be completely conformal and tightly attached, breakage is not easy to occur at the positions of bending and form mutation, bending stress is small, wiring can be completed in a narrow space, the automation degree of wire harness production and assembly can be effectively improved, the manual participation process is greatly reduced, the labor cost is reduced, workpieces are not required to be frequently switched, manufacturing process parameters are not required to be adjusted, batch production can be further facilitated, production speed is higher, and automation is more facilitated.

Inventors

• XU QUAN
• LAN HONGBO
• HOU WEI
• ZHAO JIAWEI
• WANG JINGKAI
• HOU HAOMIN
• CHEN RONGQI

Assignees

• 合肥创源微纳科技有限公司

Dates

Publication Date

20260505

Application Date

20260203

Claims (10)

1. 1. A method for manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing, comprising: s10, carrying out three-dimensional modeling on an automobile structure needing harness arrangement, and processing a curved surface model substrate matched with the surface of an automobile; s20, attaching at least two materials for printing the automobile wire harness structure to a model substrate curved surface printing automobile wire harness structure on a curved surface model substrate of the surface of the matched automobile; S30, demolding treatment is carried out between the prepared wire harness structure and the curved surface model substrate matched with the surface of the automobile.
2. 2. The method for manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 1, wherein the S20 step comprises: s21, preparing a printing functional material, and importing a printing program; S22, according to the imported printing program, in each cycle printing, attaching a model substrate to the model substrate to print each intermediate layer according to the sequence of the intermediate layers, wherein part/all of the intermediate layers printed later are positioned above the intermediate layers printed earlier.
3. 3. The method of claim 2, wherein in step S22, the intermediate layer comprises at least an insulating layer and a conductive layer, wherein the insulating layer is at least at a lowest part of the intermediate layer set, and when the plurality of conductive layers are present, the plurality of conductive layers are not adjacent to each other.
4. 4. The method for manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 2, wherein in the step S22, the number of printing cycles is N, N being a positive integer not less than 1.
5. 5. The method of manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 2, wherein after step S22, the step S20 further comprises: s23, attaching a curved surface printing packaging layer above each intermediate layer on a curved surface model substrate of the surface of the matched automobile according to the imported printing program, wherein part/all of the packaging layer is positioned above all the intermediate layers; s24, printing a fixing structure and a connecting structure on the intermediate layer and/or the packaging layer according to the imported printing program.
6. 6. The method of manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 2, wherein in the step S22, the intermediate layer further comprises a shielding layer, the shielding layer is not adjacent to the conductive layer, and when there are a plurality of shielding layers, the shielding layers are not adjacent to each other.
7. 7. The method for manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 2, wherein the step S22 further comprises performing an in-situ curing process on the printed interlayer after the printing of the interlayer is completed.
8. 8. The method of manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 5, wherein after the step S24, the step S20 further comprises: s25, connecting the connecting terminals, the connectors and the connecting structures printed in the step S24 together; and S26, connecting the fixing piece with the fixing structure printed in the step S24.
9. 9. The method of manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing according to claim 8, wherein after the step S26, the step S20 further comprises: And S27, cleaning and relevant detection processing are carried out on the printed wire harness structure.
10. 10. The method of claim 8, wherein the connection in S25 is configured as one or more of a snap connection, a threaded connection, and an adhesive, and the connection in S26 is configured as one or more of a snap connection, a threaded connection, and an adhesive.

Description

Method for manufacturing light-weight automobile conformal wiring harness by utilizing multi-material micro 3D printing Technical Field The invention relates to the technical field of manufacturing of automobile wire harness structures, in particular to a method for manufacturing a light-weight automobile conformal wire harness by utilizing multi-material micro 3D printing. Background The importance of the automotive harness system as a "blood vessel" and "nervous system" connecting the various functional components of the automobile is self-evident. The system is not only responsible for the transmission of energy in the automobile, but also plays a role in transmitting various signals, and is a key for ensuring the running safety and stability of the automobile. There are a number of problems with current conventional harness structures and manufacturing techniques, which are difficult to meet the stringent requirements of electric and conventional automobiles, and these problems mainly include: 1. The conformal adaptation of the automobile wire harness and the automobile body structure is poor, the occupied space is relatively large, and particularly in some narrow areas, the bending radius required by the wire harness is large (the wire part of the wire harness needs to comprise an insulating layer, a protective sleeve (such as a corrugated pipe, an adhesive tape and a woven net) and a connector shell, and a plurality of wires are bound to form a trunk and branches of the wire harness, so that the bending radius of the wire harness is large due to the structural characteristics), and the wiring difficulty is increased; 2. At present, most automobile wire harnesses are large in bending radius, part of the wire harnesses are large in diameter and high in hardness, wiring operation is difficult to complete in a narrow space, and the shock resistance of the automobile wire harnesses is weak; 3. at present, the automobile wire harness mostly adopts modes of binding fixation, cementing fixation, clamping fixation and the like, but is limited by smaller binding area with a supporting structure, and particularly when the weight of the automobile main wire harness is large or is in a non-horizontal installation state, under the working conditions of vibration, high-speed running and the like, the anti-seismic performance and conformal adaptation capability of the automobile main wire harness are obviously insufficient, and serious potential safety hazards are extremely easy to cause; 4. The assembly difficulty of the automobile wire harness is high, the assembly error is high, and the consistency and reliability of the product quality are both in a low level. The wire harness installation process is long in time consumption and poor in assembly easiness, and because the wire harness installation needs to be subjected to operations such as drilling, screw fastening and the like on site, the assembly convenience is directly reduced, and a pneumatic tool is used in the installation process, so that noise pollution of workshops is further aggravated. In addition, the condition that connectors are suspended exists in the wire harness installation process, and in the long-term operation process of a vehicle, the suspended connectors are easy to loose hidden dangers due to vibration, so that the overall reliability of the wire harness is further reduced. 5. When the wire harness structure in the traditional automobile industry is manufactured, about 70% of the working procedures still need to be completed manually, the manufacturing industry belongs to the typical labor-intensive industry, the quality consistency and stability of the wire harness are poor (a skilled worker can only assemble dozens of wire harnesses every day; the manual assembly quality fluctuates greatly, and the problems of wiring errors, virtual connection misplacement and the like easily occur in manual wiring, crimping terminals and the like); Disclosure of Invention The invention aims to solve the problems of large occupied space, high wiring difficulty, low earthquake resistance and the like caused by the fact that the existing automobile wire harness structure is difficult to match with the curved surface of the automobile body structure. In order to solve the above problems, the present invention provides a method for manufacturing a lightweight automotive conformal wiring harness using multi-material micro 3D printing, comprising: s10, carrying out three-dimensional modeling on an automobile structure needing harness arrangement, and processing a curved surface model substrate matched with the surface of an automobile; s20, attaching at least two materials for printing the automobile wire harness structure to a model substrate curved surface printing automobile wire harness structure on a curved surface model substrate of the surface of the matched automobile; S30, demolding treatment is carried out between the prepared wire harness structure