METHOD FOR MANUFACTURING AN ELECTRICAL HARNESS

Abstract

A method for manufacturing an electrical harness comprising a reference member and a secondary member and at least one electric wire, a protective sheath and at least two shrink sleeves comprising a reference shrink sleeve and a secondary shrink sleeve. According to the disclosure, the method comprises at least the following steps: assembling of the electric wire, the protective sheath, the two shrink sleeves, the reference member and the secondary member, the two shrink sleeves being arranged in a non-contracted state; in a reference portion of the electrical harness, reference contraction of the reference shrink sleeve; in a secondary portion of the electrical harness, angular positioning of the secondary member according to a relative angular orientation; holding of the secondary member in position; and secondary contraction of the secondary shrink sleeve.

Claims

1. A method for manufacturing an electrical harness, the electrical harness comprising at least one reference member, at least one secondary member and at least one electric wire extending between the at least one reference member and the at least one secondary member, the electrical harness comprising at least one protective sheath for protecting the at least one electric wire and at least two shrink sleeves, the at least two shrink sleeves comprising at least one reference shrink sleeve and at least one secondary shrink sleeve, the at least one reference shrink sleeve being arranged so as to at least partially cover the at least one reference member and the at least one protective sheath, the at least one secondary shrink sleeve being arranged so as to at least partially cover the at least one secondary member and the at least one protective sheath, wherein the method comprises at least the following steps: assembling of the at least one electric wire, the at least one protective sheath, the at least two shrink sleeves, the at least one reference member and the at least one secondary member, the at least two shrink sleeves being arranged in a non-contracted state; in a reference portion of the electrical harness, reference contraction of the at least one reference shrink sleeve, the reference contraction step allowing the at least one protective sheath to be immobilized relative to the at least one reference member, the at least one reference member allowing the electrical harness to be assigned at least one reference plane; in a secondary portion of the electrical harness different from the reference portion, angular positioning of the at least one secondary member relative to the reference plane according to a relative angular orientation, the relative angular orientation being defined in a plane perpendicular to a longitudinal direction OX along which the at least one protective sheath extends longitudinally opposite the at least one secondary member; holding of the at least one secondary member in position in the relative angular orientation; and secondary contraction of the at least one secondary shrink sleeve.

2. The method according to claim 1 wherein the method comprises a preliminary step of determining the relative angular orientation.

3. The method according to claim 2 wherein the preliminary step is carried out by manufacturing a model electrical harness directly on a model aircraft, the model electrical harness being different from the electrical harness and comprising at least one model reference member, at least one model secondary member, at least one model electric wire extending between the at least one model reference member and the at least one model secondary member, at least one model protective sheath for protecting the at least one model electric wire and at least two model shrink sleeves, the at least two model shrink sleeves comprising at least one model reference shrink sleeve and at least one model secondary shrink sleeve, the at least one model reference shrink sleeve being arranged so as to at least partially cover the at least one model reference member and the at least one model protective sheath, the at least one model secondary shrink sleeve being arranged so as to at least partially cover the at least one model secondary member and the at least one model protective sheath.

4. The method according to claim 3 wherein the preliminary step comprises the following sub-steps: marking of a reference line on the at least one model protective sheath by means of marks arranged on the at least one model protective sheath; preliminary assembling of the at least one model electric wire, the at least one model protective sheath, the at least two model shrink sleeves, the at least one model reference member and the at least one model secondary member, the at least two model shrink sleeves being arranged in a non-contracted state, the preliminary assembling sub-step being carried out on a working plane; in a model reference portion of the model electrical harness, preliminary reference contraction allowing a model reference plane to be assigned to the model electrical harness, the model reference plane being defined by means of the marks arranged on the at least one model protective sheath; positioning of the model electrical harness on the model aircraft and connection of at least one model secondary member with at least one piece of electrical equipment of the model aircraft; in a model secondary portion of the model electrical harness different from the model reference portion, preliminary secondary contraction of the at least one model secondary shrink sleeve; and measuring of the relative angular orientation between the marks arranged on the at least one model protective sheath and the at least one model secondary member.

5. The method according to claim 4 wherein the sub-step of measuring the relative angular orientation is implemented with the model electrical harness being left fully mounted on the model aircraft.

6. The method according to claim 4 wherein the preliminary step comprises a sub-step of removing the model electrical harness from the model aircraft, the sub-step of measuring the relative angular orientation being implemented after the removal sub-step.

7. The method according to claim 1 wherein the at least one reference member comprises a reference connector, the at least one reference plane corresponding to a plane defined as a function of a position of the reference connector.

8. The method according to claim 1 wherein the at least one reference member comprises at least one branch joint with three branches, the at least one reference plane corresponding to a plane containing the three branches of the at least one branch joint with three branches.

9. The method according to claim 8 wherein the at least one reference member comprises two branch joints with three branches comprising a first branch joint and a second branch joint, the at least one reference plane comprising a first reference plane and a second reference plane, the at least one reference shrink sleeve comprising a first reference shrink sleeve and a second reference shrink sleeve, the first reference shrink sleeve being arranged so as to at least partially cover at least one of the three branches of the first branch joint and the at least one protective sheath, the second reference shrink sleeve being arranged so as to at least partially cover at least one of the three branches of the second branch joint and the at least one protective sheath.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0100] The disclosure and its advantages appear in greater detail from the following description of examples given by way of illustration with reference to the accompanying figures, in which:

[0101] FIG. 1 is a perspective view of a first embodiment of an electrical harness manufactured according to a manufacturing method according to the disclosure;

[0102] FIG. 2 is a top view of a second embodiment of an electrical harness manufactured according to the manufacturing method according to the disclosure;

[0103] FIG. 3 is a perspective view of a third embodiment of an electrical harness manufactured according to the manufacturing method according to the disclosure;

[0104] FIG. 4 is another perspective view of a variant of the first embodiment of an electrical harness manufactured according to the manufacturing method according to the disclosure;

[0105] FIG. 5 is a logic diagram showing a first variant of the manufacturing method according to the disclosure;

[0106] FIG. 6 is a logic diagram showing a second variant of the manufacturing method according to the disclosure;

[0107] FIG. 7 is a perspective view of a model electrical harness manufactured in a preliminary step of the manufacturing method according to the disclosure;

[0108] FIG. 8, is a diagram showing another example of a preliminary step of the manufacturing method according to the disclosure; and

[0109] FIG. 9 is a perspective view of a tool for manufacturing an electrical harness, according to the disclosure.

DETAILED DESCRIPTION

[0110] As mentioned above, the disclosure relates to a method for manufacturing an electrical harness intended, for example, to equip an aircraft. The disclosure can also relate to a method for manufacturing an electrical harness in fields other than the aeronautics field.

[0111] Elements present in more than one of the figures may, if appropriate, be given the same references in each of them.

[0112] As shown in FIG. 1, such an electrical harness 30 comprises at least one electric wire 22 extending between a reference member 31 formed in this example by a straight connector and a secondary member 32 formed by an 90° angled connector in this variant of the first embodiment of an electrical harness 30.

[0113] Such an electric wire 22 is moreover protected by a protective sheath 34. A first end of this protective sheath 34 cooperates with the reference member 31 in a reference portion 131. A second end of the protective sheath 34 cooperates with the secondary member 32 in a secondary portion 132.

[0114] In order to tightly seal such an electrical harness 30, shrink sleeves 36, 37 are also used and shown in FIG. 1 in a non-contracted state. Thus, in a reference portion 131, a reference shrink sleeve 36 is positioned so as to partially cover the reference member 31 and the protective sheath 34. Similarly, in a secondary portion 132, a secondary sleeve 37 is positioned so as to partially cover the secondary member 32 and the protective sheath 34.

[0115] A reference contraction is then carried out on the reference shrink sleeve 36, for example by heating the reference shrink sleeve 36, in order to thermally shrink it and thus immobilize the protective sheath 34 relative to the reference member 31. Therefore, this operation allows a reference plane P1 to be defined. Such a reference plane P1 is oriented in this instance perpendicular to a radial direction connected to the orientation of the reference member 31.

[0116] The secondary member 32 is then capable of pivoting about a longitudinal direction OX by a relative angular orientation θ1 relative to the protective sheath 34, and therefore relative to the reference plane P1 that was previously assigned to it in the reference portion 131.

[0117] Once oriented, the secondary member 32 and the protective sheath 34 are then held in position and a secondary contraction may be carried out on the secondary shrink sleeve 37, for example by heating the secondary shrink sleeve 37 in order to shrink the secondary shrink sleeve 37, so as to immobilize the secondary member 32 relative to the protective sheath 34 and to the reference plane

[0118] P1.

[0119] As shown in FIG. 2, an electrical harness 40 according to a second embodiment comprises at least one electric wire 22, 22′ extending between a reference member 41 formed, in this example, by a branch joint with three coplanar branches and three secondary members 42, 42′, 42″ formed by straight or angled connectors.

[0120] Such an electric wire 22, 22′ is moreover protected by three sections of the protective sheath 44, 44′, 44″. A first end of each protective sheath 44, 44′, 44″ cooperates with the reference member 41 in a reference portion 141. A second end of the protective sheath 44, 44′, 44″ cooperates with each secondary member 42, 42′, 42″ in a secondary portion 142, 142′, 142″.

[0121] As above, shrink sleeves 46, 47, 48, 49 are also positioned on this electrical harness 40 in a non-contracted state. Thus, in a reference portion 141, a reference shrink sleeve 46 is arranged so as to partially cover the reference member 41 and the protective sheath 44, 44′, 44″. Similarly, in the three secondary portions 142, 142′, 142″, secondary sleeves 47, 48, 49 are arranged so as to partially cover the three secondary members 42, 42′, 42″ and the three sections of the protective sheath 44, 44′, 44″.

[0122] A reference contraction is then carried out by heating the reference shrink sleeve 46 in order to immobilize each section of the protective sheath 44, 44′, 44″ relative to the reference member 41. A reference plane P2 is thus defined depending on the position of the three branches of the branch joint forming the reference member 41.

[0123] Each secondary member 42, 42′, 42″ is then capable of pivoting about a longitudinal direction OX by a relative angular orientation θ1 in relation to the associated section of the protective sheath 44, 44′, 44″ and therefore in relation to the reference plane P2 that was previously assigned to it in the reference portion 141.

[0124] Once oriented, these secondary members 42, 42′, 42″ and respectively the sections of the protective sheath 44, 44′, 44″ are then held in position and secondary contractions may be carried out on the secondary shrink sleeves 47, 48, 49.

[0125] Similarly, and as shown in FIG. 3, a third embodiment of an electrical harness 50 may also comprise several reference members 51, 51′ formed in this example by two branch joints with three coplanar branches and five secondary members 52, 52′, 52″, 53, 53′. Moreover, the reference member 51′ and the secondary member 52′ are in this instance combined. The secondary members 52, 52″, 53 and 53″ are formed by straight or 90° angled connectors, for example.

[0126] Five sections of the protective sheath 54, 54′, 54″, 55 and 55′ protect the electric wires of the electrical harness 50. A first reference member 51 is arranged in a first reference portion 151. A second reference member 51′ is arranged in a second reference portion 151′.

[0127] As above, the shrink sleeves 56, 57, 58, 59, 60, 61 are positioned on this electrical harness 50 in a non-contracted state. Thus, in the reference portion 151, a first reference shrink sleeve 56 is arranged so as to partially cover the reference member 51 and the protective sheath 54, 54′, 54″. Similarly, in the three secondary portions 152, 152′, 152″, first secondary sleeves 57, 58, 59 are arranged so as to partially cover the three first secondary members 52, 52′, 52″ and the three sections of the protective sheath 54, 54′, 54″.

[0128] A first reference contraction is then carried out by heating the first reference shrink sleeve 56, immobilizing each section of the protective sheath 54, 54′, 54″ with respect to the first reference member 51 and thus defining a first reference plane P3 depending on a position of the three branches of the branch joint forming the first reference member 51.

[0129] Each first secondary member 52, 52′, 52″ is then capable of pivoting about a longitudinal direction OX by a relative angular orientation θ1 relative to each section of the protective sheath 54, 54′, 54″ and therefore relative to the first reference plane P3 that was previously assigned to it in the first reference portion 151.

[0130] Once oriented, these first secondary members 52, 52′, 52″ and respectively the sections of the protective sheath 54, 54′, 54″ are then held in position and first secondary contractions may be carried out on the first secondary shrink sleeves 57, 58, 59.

[0131] The first secondary shrink sleeve 59 then also forms a second reference shrink sleeve 59. A second reference contraction is then carried out, immobilizing each section of the protective sheath 55, 55′ with respect to the second reference member 51′ combined with the first secondary member 52′. A second reference plane P4 is thus defined depending on the position of the three branches of the branch joint forming the second reference member 51′.

[0132] Each second secondary member 53, 53′ is then capable of pivoting about a longitudinal direction OX by a relative angular orientation θ1 relative to the associated section of the protective sheath 55, 55′ and therefore relative to the second reference plane P4 that was previously assigned to it in the second reference portion 151′.

[0133] Once oriented, these secondary members 52, 52′, 52″ and respectively the sections of the protective sheath 54, 54′, 54″ are then held in position and second secondary contractions may be carried out on the second secondary shrink sleeves 60, 61.

[0134] The different shrink sleeves 56-61 are shown here in their contracted state to ensure the electrical harness 50 is tightly sealed.

[0135] As shown in FIG. 4, the relative angular orientation θ1 may, for example, be read conventionally in the clockwise direction relative to a transverse direction OY perpendicular to the longitudinal direction OX. The relative angular orientation θ1 is then read in a transverse plane YOZ defined by two transverse directions OY and OZ perpendicular to each other and relative to the longitudinal direction OX.

[0136] Such a transverse plane YOZ is also arranged perpendicular to the reference plane P1 defined at the reference member 31.

[0137] As shown in FIGS. 5 and 6, such an electrical harness is manufactured by implementing a specific manufacturing method 1, 10.

[0138] According to a first variant of the manufacturing method shown in FIG. 5, the method 1 comprises a step 2 of assembling the electric wire or wires 22, 22′, the at least one protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′, the at least two shrink sleeves 36-37, 46-49, 56-61, the at least one reference member 31, 41, 51, 51′ and the at least one secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′.

[0139] During this assembly step 2, the at least two shrink sleeves 36-37, 46-49, 56-61 remain arranged in a non-contracted state.

[0140] Next, in a reference portion 131, 141, 151, 151′ of the electrical harness 30, 40, 50, a reference contraction step 3 is carried out on a reference shrink sleeve 36, 46, 56, 59. Such a reference contraction step 3 thus allows the electrical harness 30, 40, 50 to be assigned at least one reference plane P1, P2, P3, P4. Moreover, the reference portion 151′ may be defined at a later stage, namely after a first reference contraction step 3. The reference shrink sleeve will therefore be contracted during a second reference contraction step 3.

[0141] Thus, the reference plane P4 can be determined once the reference plane P3 has been assigned.

[0142] Therefore, in the secondary portion or portions 132, 142, 142′, 142″, 152, 152′ 152″, 153, 153′ of the electrical harness 30, 40, 50 relative to the reference portion 131, 141, 151, 151′, one or more steps 4 are implemented in order to angularly position the secondary member or members 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ relative to the at least one protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ and therefore relative to a reference plane P1, P2, P3, P4.

[0143] As indicated above, the secondary portion or portions 153, 153′ of the electrical harness 50 can only be assigned at a later stage after having determined the reference plane P4 at the reference portion 151′. Thus, the steps 4 of angularly positioning the secondary members 53, 53′ relative to the portions of the protective sheath 55 and 55′ are also carried out once the reference plane P4 has been allocated to the electrical harness 50.

[0144] Such an angular positioning 4 is carried out according to the relative angular orientation θ1 as described in FIG. 4 in the transverse plane YOZ perpendicular to a longitudinal direction OX along which the protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ extends longitudinally.

[0145] For example, in this variant, a key or a locating pin 38 of the secondary member 32 is initially assembled during the assembly step 2 in a vertical position matching the transverse direction OY. The angular positioning step 4 then consists in rotating a secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ on itself about the longitudinal direction OX in order to position the locating pin 38, the bend of an angled connector when the secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ is formed by an angled connector 32, 42, 42″, 53′ or indeed the plane defined by the branches of a branch joint when the secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ is formed by a branch joint 52′.

[0146] Such a bend is therefore formed by a portion of the connector extending radially relative to the longitudinal direction OX. This bend may, for example, be oriented at an angle of 90° relative to the longitudinal direction OX, but other values may also be envisaged for this angle. In this case, the relative angular orientation θ1 is then assigned to a projection of the bend in a plane perpendicular to the longitudinal direction OX.

[0147] The manufacturing method 1 then comprises a step 5 of holding the secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ in position in the relative angular orientation θ1.

[0148] Finally, a secondary contraction step 6 is carried out on the secondary shrink sleeves 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′.

[0149] According to a second variant of the manufacturing method shown in FIGS. 6 and 8, the method 10 may comprise a preliminary step 11, 11′ of determining the relative angular orientation θ1. This preliminary step 11, 11′ is thus implemented prior to the assembly step 12, the reference contraction step 13, the angular positioning step 14, the step 15 of holding in position and the secondary contraction step 16. The preliminary step 11, 11′ therefore consists in manufacturing a model electrical harness 230 on a model aircraft. This model electrical harness 230 is identical to the electrical harness 30, 40, 50 that needs to be manufactured according to the manufacturing method 1, 10.

[0150] This preliminary step 11, 11′ comprises a sub-step 110, 110′ of marking a reference line on a model protective sheath 234 as shown in FIG. 7. This marking step 110, 100′ is carried out by means of marks 235 arranged on this model protective sheath 234.

[0151] The preliminary step 11, 11′ next comprises a preliminary sub-step 111, 111′ of assembling a model electric wire 222, the model protective sheath 234, two model shrink sleeves 236, 237, a model reference member 231 and a model secondary member 232. During this preliminary sub-step 111, 111′, the two model shrink sleeves 236, 237 are arranged in their non-contracted state. Such a preliminary assembling sub-step 111, 111′ is moreover carried out on a working plane.

[0152] The preliminary step 11, 11′ then comprises a preliminary reference contraction sub-step 112, 112′ for assigning a model reference plane P5 to the model electrical harness 230. This preliminary reference contraction sub-step 112, 112′ is also carried out on the working plane in a model reference portion 331 of the model electrical harness 230. Moreover, such a model reference plane P5 is defined by means of the marks 235 arranged on the model protective sheath 234.

[0153] Therefore, only the model shrink sleeve 236 is arranged in its contracted state, whereas the model shrink sleeve 237 remains arranged in its non-contracted state.

[0154] The preliminary step 11, 11′ next comprises a sub-step 113, 113′ of positioning the model electrical harness 230 on the model aircraft and connecting the model secondary member 232 formed by a connector with at least one piece of electrical equipment of the model aircraft.

[0155] In a model secondary portion 332 of the model electrical harness 230 different from the model reference portion 331, a preliminary secondary contraction sub-step 114, 114′ is next carried out on the model secondary shrink sleeve 237, followed by a sub-step 115, 115′ of measuring the relative angular orientation θ1 between the marks 235 and the model secondary member 232.

[0156] Such a measuring sub-step 115, 115′ may be implemented in different ways.

[0157] For example, as shown in FIG. 6, this sub-step 115 of measuring the relative angular orientation θ1 may be implemented with the model electrical harness 230 being left fully mounted on the model aircraft. Optionally, only the model secondary member 232 may be temporarily disconnected from the electrical equipment with which it cooperates.

[0158] Alternatively, and as shown in FIG. 8, the preliminary step 11′ may comprise a sub-step 116′ of removing the model electrical harness 230 from the model aircraft. The sub-step 115′ of measuring the relative angular orientation θ1 is then implemented after the removal sub-step 116′.

[0159] As shown in FIG. 9, the disclosure also relates to a tool 70 allowing at least one secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ to be angularly positioned and held in position relative to at least one protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ according to a relative angular orientation θ1. Such a tool 70 can then be used to help manufacture an electrical harness 30, 40, 50 according to the method 1, 10 as previously described.

[0160] This tool 70 therefore comprises a planar fixed plate 71 and at least one immobilization device 72 for immobilizing a protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ of the electrical harness 30, 40, 50 and secure the protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ to the fixed plate 71.

[0161] The tool 70 also comprises a movable part 73 capable of pivoting about an axis of rotation AXROT arranged parallel to the fixed plate 71. Such an axis of rotation AXROT is thus intended to coincide with a longitudinal direction OX of the protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′.

[0162] Furthermore, at least one immobilization support 74 is configured to immobilize a secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ of the electrical harness 30, 40, 50 and constrain this secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ in rotation with the movable part 73.

[0163] The tool 70 also comprises a graduated angular scale 75 for positioning the protective sheath 34, 44, 44′, 44″, 54, 54′, 54″, 55, 55′ and the secondary member 32, 42, 42′, 42″, 52, 52′, 52″, 53, 53′ according to the relative angular orientation θ1.

[0164] Moreover, such a tool 70 may advantageously comprise an angular locking means 76 for locking the movable part 73 in position relative to the fixed plate 71. Such an angular locking means 76 may in particular be in the form of an indexing pin cooperating with at least one hole or at least one notch of complementary shape.

[0165] According to another example, the tool 70 may comprise at least one guide bearing 77 for guiding the movable part 73 in rotation relative to the fixed plate 71.

[0166] The tool 70 may also comprise a fixed disk 78 secured to the fixed plate 71. As shown, such a fixed disk 78 may comprise the graduated angular scale 75 for indicating the relative angular orientation θ1.

[0167] The movable part 73 may comprise a movable disk 80 comprising, in order to indicate the relative angular orientation θ1, a radial index 79 intended to be arranged opposite the graduated angular scale 75. According to another example not shown here, the movable part 73 may comprise a movable disk 80 comprising, in order to indicate the relative angular orientation θ1, the graduated angular scale 75. In this case, the radial index 79 may be arranged on the fixed plate 71 or indeed on a part secured to the fixed plate 71.

[0168] This movable part 73 may comprise a movable plate 81 on which the immobilization support or supports 74 are mounted.

[0169] Furthermore, such a tool 70 may also be used to take a measurement of the relative angular orientation θ1 on a model electrical harness 230. Once the electrical harness 30, 40, 50 has been manufactured, the tool 70 may be used to check one or more relative angular orientations θ1 before this electrical harness 30, 40, 50 is assembled on an aircraft or indeed during or after assembly if, for example, a problem is identified.

[0170] Naturally, the present disclosure is subject to numerous variations as regards its implementation. Although several implementations are described above, it should readily be understood that an exhaustive identification of all possible embodiments is not conceivable. It is naturally possible to replace any of the means described with equivalent means without going beyond the ambit of the present disclosure.