Backdoor wiring harness design

WIRING HARNESS DESIGN OF BACKDOOR

AIM;

To Route the Wiring harness on the Given car body Backdoor and prepare the flatten view drawing in CATIA V5.

OBJECTIVE;

The objective of this project is to route the wiring harness and prepare flatten view drawing for the Backdoor of the car. All types of packaging rules have to be considered while routing the harness and industry-based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

BACKDOOR WIRING HARNESS;

In the case of car doors, as the door of the automobiles opens and closes, the wires bend. If you use the car every day, the door will open and close many times. In case of Back door, the trunk could be open and close many times in daily life. Backdoor wiring harness mainly introduced to connect the brake lights, number plate lights, rear wiper motor, defogger connections. The harness routing should be maintained properly with all the supporting components like clips, clamps with proper protective covers, rubber grommets.

Rules Followed while Routing;

• Provide clips/clamps as per requirement.
• Make sure that there is no any fouling case while designing the wire harness. Additional clips/clamps may be used to avoid fouling case.
• Give additional slack if needed. 5-10% slack is sufficient. Provide additional slack if needed according to the surrounding and harness bending requirement.
• If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
• Enough Clips Clamps shall be provided to ensure positive clearance with surroundings and safety of wiring harness.
• Fir tree clips and other clips can be added to the geometrical bundle as they are electrically defined and are part of the wire harness routing and should be provided with the wire bundle package.
• Avoid routing on sharp edges or else provide protection over the harness.
• Follow the clearance distance and keep away the harness from heat generation components.
• Protection should be provided as needed according to surrounding temperature.
• Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
• Branch length should be greater than 50mm.the no of branch from a single branch point to 4.
• Minimum distance between two branch points should be at least 50mm.
• Minimum distance between clip and branch point should be at least 25mm.
• The wiring harness should be easy to assemble and easy to access.

Step1-Creating context assembly;

STEP 2 - Defining connectors electrically;

Choosing right components for the wire harness routing.here we are using the components for backdoor upper and lower lights,wiper motor,sensors,and defogging equipment.the connectors used are first elecrically defined and then added to the catia model.

The type of connectors used are given below-

STEP 3 - Adding connectors and needed equipments

Opening the equipments in catia and using the snap and smart move and positioning the connectores and supports.

Step4- Bundle routing;

STEP 5 - Bundle continuity check;

Now we check the bundle continuity check for the further process.

STEP 6 - Adding protective covering to the harness bundle;

By using protection covering tool we protect all the bundle.we have created a catlouge and we add the protection cover of 15mm diameter and 10 mm diameter.here we Create a gap from the end and start extremity.

Step7- Create flatten view;

Now we open a new product file for the Electrical harness Flattening.here we save the already made geometrical bundle segment and we extract the geometrical bundle to flatten harness by apply flattening parameters we flattten the geometrical bundle.

STEP 8 - Creating a flatten view drawing;

After the modification we synchronize the changes wich are done to the real file and then we open new file for drawing using A0 size having scale of 3:4.and we extract the flattened model to the new drawing sheet made.

Conclusion - Routing of the wiring harness for the car Backdoor assembly has been succesfully done and prepared flatten-view drawing in Catia V5 as per the design requirements.