Routing of Wire Harness layout in CATIA V5 Electrical workbench

AIM- Routing of Harness layout in CATIA V5 Electrical workbench.

OBJECTIVE- The objective of this project is to route the harness layout in electrical workbench.

FIGURE A: SHOWS THE 2-D SCHEMATIC LAYOUT OF THE REQUIRED HARNESS

The above figure shows the length of each wire branch and the connectors associated with them.

The following Deutsch connectors are used in this harness:-

1. DT06-2S (QTY-2)
2. DT06-4S (QTY-2)
3. DT06-6S (QTY-1)
4. DT06-8S (QTY-1)

It is required to add protective covering on all branches leading to connector DT06-2S and DT06-4S with end extremity at 30mm (from connector end).

Harness bundle diameter for each branch has to be assumed.

FIGURE B: SHOWS THE ASSUMED HARNESS BUNDLE DIAMETER FOR EACH BRANCH. THE ASSUMED HARNESS BUNDLE DIAMETER ARE 10mm (ORANGE BUNDLE), 7mm (BLACK BUNDLE) AND 4mm (YELLOW BUNDLE)

The following steps have to follow to create this harness bundle layout.

1. Download all the required Deutsch connectors from TE.com
2. Completely define the geometrical and electrical parameters for all the connectors in the electric part design workbench in CATIA V5.
3. Make a new product file and rename it as “Geometric Bundle Assembly” in electric harness assembly workbench.
4. Insert all the connectors into the assembly and orient or place them approximately in the desired location.
5. Create bundle segments between DT06-8S and DT06-6S.
6. Create the branching points as needed to route the bundle to the different connectors.
7. Add appropriate size protective covering or corrugated tubes on the required segments of the harness bundle.

CONTENT-

STEP1: COMPLETELY DEFINE ALL THE FOUR DEUTSCH CONNECTORS GEOMETRICALLY AND ELECTRICALLY

STEP2:

Make a new product file in electric assembly design workbench and name it as “geometric bundle assembly”. Once the product is created convert it into a Geometrical Bundle.

STEP3- SWITCH TO ASSEMBLY DESIGN WORKBENCH AND INSERT ALL THE DEUTSCH CONNECTORS

STEP4: ORIENT AND LOCATE ALL THE CONNECTORS APPROXIMATELY IN THE REQUIRED LOCATION

While moving the connector it is important to note that as the length of each bundle segment is given we have to define each bundle with respect to the bundle length not slack percentage. So, at this stage, we have to make sure that when we position the connectors the distance between the connectors is roughly less than the actual bundle segment length given.

STEP5: CREATING BUNDLE SEGMENTS AND BRANCHING POINTS BETWEEN THE CONNECTORS

First, we have to create the bundle segment between the connectors DT06-8S and DT06-6S.

Second, create the branch points and add the segments to join the two DT06-4S connectors.

Third, make sure to give the assumed value of the bundle segment diameter and the given value of the bundle segment length to the respective bundle segments.

STEP6: COMPLETE THE BUNDLE ROUTING TO THE REMAINING DT06-2S CONNECTORS

STEP7: ADD PROTECTIVE COVERINGS ON THE REQUIRED SEGMENTS FOR HARNESS BUNDLE

Corrugated tube protective covering is added to all the bundle segments leading to the connectors DT06-2S and DT06-4S.

For the 7mm bundle segment diameter, the corrugated tube with a 10mm inner diameter is used (10mm COT). Similarly, for the 4mm bundle segment diameter, the corrugated tube with 5mm inner diameter is used (5mm COT).

End extremity of 30mm is used from the connector end and the start extremity for the corrugated tubes is assumed appropriately.

MISCELLANEOUS STEP: CHECK THE COMPLETED GEOMETRIC BUNDLE ASSEMBLY FOR ANY ERRORS OR GHOST LINKS BY USING CATDUA V5

CONCLUSION- Routing of Harness layout in CATIA V5 Electrical workbench is done after considering all the given data. Assumptions were as needed to complete the Harness routing.

FIGURE C: FINAL RENDERED IMAGE OF THE REQUIRED WIRE HARNESS BUNDLE LAYOUT