CONNECTORS AND MOUNTING CLIPS ELECTRICALLY DEFINED & ASSEMBLED

OBJECTIVE: To utilize the Electrical Part Workbench tools in CATIA V5 to define and assign the required electrical properties for connectors and connector clips obtained from Tyco Electronics or TE Connectivity's website CAD files. 

 

INTRODUCTION:

ELECTRICAL DISTRIBUTION SYSTEM(EDS): The Electrical Distribution System(EDS) deals with Physical and Logical Architecture, Schematic Development, Power Distribution, Wiring Harness Design, and Wiring Harness Component Design.

 

1. Physical and Logical Architecture: The physical architecture of the EDS refers to the physical arrangement and layout of electrical components, connectors, and wiring harnesses within a vehicle. It involves determining the optimal placement of components to ensure efficient power distribution and minimize interference. Logical architecture, on the other hand, focuses on the functional organization and interconnections between electrical systems and subsystems, ensuring proper communication and coordination.

 

2. Schematic Development: Schematic development involves creating detailed electrical diagrams or schematics that illustrate the connections and relationships between various electrical components in the system. These schematics provide a visual representation of the electrical system, including power sources, relays, switches, sensors, and other electrical devices. Schematics enable engineers to analyze, troubleshoot, and modify the system effectively.

 

3. Power Distribution: Power distribution within the EDS involves managing the flow of electrical energy from the power source (battery or generator) to various electrical components and subsystems. This includes designing and implementing appropriate fusing, circuit protection, and power routing strategies to ensure the safe and reliable distribution of power. Power distribution systems may also incorporate voltage regulation and conditioning mechanisms to maintain optimal voltage levels.

 

4. Wiring Harness Design: Wiring harness design focuses on the development of a structured network of electrical cables, connectors, and terminals that interconnect various electrical components in the vehicle. It involves determining the appropriate wire sizes, insulation materials, and routing paths to ensure efficient transmission of electrical signals and power. Factors such as electromagnetic compatibility, mechanical durability, and serviceability are considered during the design process.

 

5. Wiring Harness Component Design: Wiring harness component design involves creating and selecting the necessary connectors, terminals, splices, and other electrical components required to assemble the wiring harness. This includes considering factors like electrical conductivity, mechanical strength, environmental compatibility, and manufacturability. Component design also involves ensuring proper mating and alignment of connectors, as well as incorporating features for ease of installation and maintenance.

 

Each aspect of the Electrical Distribution System plays a crucial role in ensuring efficient and reliable electrical functionality within a vehicle. By carefully addressing physical and logical architecture, schematic development, power distribution, wiring harness design, and wiring harness component design, engineers can create robust and optimized electrical systems that meet the requirements of modern vehicles.

 

CONNECTORS & TERMINALS: These are essential components in the electrical wiring harness of an automobile. They play a crucial role in establishing secure and reliable electrical connections between various components and subsystems within the vehicle. Connectors and terminals are selected based on factors such as current-carrying capacity, voltage rating, environmental conditions, ease of assembly, and serviceability. Proper selection and installation of connectors and terminals are critical for ensuring reliable and safe electrical connections within the wiring harness of an automobile.

 

CONNECTORS: Connectors are coupling devices used to join two or more electrical conductors (wires) together, allowing for easy disconnection and reconnection when necessary. They provide a means for establishing and breaking electrical connections without the need for soldering or permanent bonding.

KEY FEATURES AND FUNCTIONS OF CONNECTORS INCLUDE:

1. Housing: Connectors consist of housing that encloses the electrical contacts and provides mechanical support and protection to the connection. The housing is typically made of plastic or other insulating materials.

2. Electrical Contacts: Connectors have electrical contacts inside the housing that make direct contact with the wire conductors. These contacts are designed to securely grip the wire and establish a reliable electrical connection.

3. Gender: Connectors can be either male or female, with male connectors having pins or prongs that fit into female connectors with corresponding sockets or receptacles. This ensures proper mating and alignment of the connectors.

4. Locking Mechanism: Connectors often feature a locking mechanism to ensure a secure and vibration-resistant connection. This can be in the form of tabs, clips, screws, or other mechanisms that hold the connectors together.

5. Environmental Protection: Connectors may have features to protect against environmental factors such as moisture, dust, vibration, and temperature variations. These features can include seals, gaskets, and protective coatings.

 

 

TERMINALS: Terminals, also known as contacts or pins, are the metal connectors within a connector housing that make direct electrical contact with the wires. They serve as the interface between the connector and the wire conductors.

KEY FEATURES AND FUNCTIONS OF TERMINALS INCLUDE:

1. Contact Area: Terminals have a contact area that makes electrical contact with the wire. This contact area can be a crimped section, a soldered joint, or a piercing mechanism, depending on the type of terminal.

2. Wire Attachment: Terminals provide a means for attaching the wire conductor to the connector. This can be achieved through crimping, soldering, or insulation displacement techniques.

3. Conductivity: Terminals are made of conductive materials, typically metals like copper or brass, to ensure low resistance and efficient electrical conductivity.

4. Secure Connection: Terminals are designed to securely hold the wire conductor and prevent it from coming loose or losing electrical contact, even under vibration or other mechanical stresses.

5. Compatibility: Terminals are designed to fit specific connector housings, ensuring proper alignment and mating with the corresponding connector.

 

PHYSICAL AND LOGICAL ARCHITECTURE OF THE WIRING HARNESS OF AN AUTOMOBILE:

The physical and logical architecture of the wiring harness are closely intertwined, with the physical layout being influenced by the logical organization. Proper design and integration of both aspects are critical to ensure reliable and efficient electrical system performance in automobiles.

 

PHYSICAL ARCHITECTURE:

The physical architecture refers to the physical layout and arrangement of the wiring harness components within the vehicle. It involves the physical routing and positioning of the wires, connectors, terminals, and other electrical components.

KEY ASPECTS OF PHYSICAL ARCHITECTURE INCLUDE:

1. Wire Routing: Determining the optimal paths for routing the wires throughout the vehicle to ensure proper connectivity between various electrical components. Factors such as accessibility, protection from heat, vibration, and interference, and minimizing wire lengths are considered.
2. Connectors and Terminals: Selecting appropriate connectors and terminals to establish secure and reliable electrical connections. Factors such as current carrying capacity, environmental protection, and ease of assembly and disassembly are taken into account.
3. Wire Bundling: Grouping and bundling wires based on their functions and routing requirements. This helps in organizing the wiring harness, simplifying maintenance and troubleshooting, and reducing electromagnetic interference.
4. Mounting and Securing: Ensuring proper mounting and securing of the wiring harness components to prevent movement, chafing, or damage during vehicle operation. This involves using clips, brackets, and other fastening methods.

 

LOGICAL ARCHITECTURE

The logical architecture of the wiring harness focuses on the functional organization and interconnections between various electrical components. It determines how signals and power are distributed within the vehicle's electrical system.

KEY ASPECTS OF LOGICAL ARCHITECTURE INCLUDE:

1. Signal Routing: Defining the routes and paths for transmitting electrical signals between different components, such as sensors, switches, actuators, and control units. This ensures proper communication and coordination between the various subsystems in the vehicle.
2. Power Distribution: Determining the distribution of power supply to different electrical components and systems. This involves considering factors such as voltage levels, current ratings, load balancing, and protection mechanisms (fuses, circuit breakers).
3. Multiplexing and Networking: Implementing techniques like multiplexing and networking to optimize the use of wires and reduce wiring complexity. This allows multiple signals to be carried over a single wire, reducing the overall number of wires required.
4. Data Communication: Facilitating communication between electronic control units (ECUs) and other devices through protocols such as CAN (Controller Area Network) or LIN (Local Interconnect Network). This enables data exchange for diagnostics, vehicle monitoring, and software updates.

 

COMPONENTS USED IN WIRING HARNESS

1. WIRES
2. CONNECTORS
3. TERMINALS
4. PROTECTION COVERINGS
5. INSULATIONS
6. CLIPS & CLAMPS
7. FUSE & RELAY BOXES
8. RETENTION DEVICES
9. GUIDING CHANNELS
10. ELECTRONIC COMPONENTS

 

 

WIRING HARNESS DESIGN PROCESS:

 

INTRODUCTION TO WIRING HARNESS ASSEMBLY

1. Wire Preparation: The assembly process begins with wire preparation. This involves cutting wires to the required lengths, stripping off the insulation from the ends, and crimping terminals or connectors onto the exposed wire ends. Proper wire gauges and insulation materials are chosen based on the electrical requirements and environmental factors.
2. Terminal Preparation: Next, the terminals that will be attached to the wires are prepared. This includes selecting the appropriate terminals, applying any necessary coatings or treatments for corrosion resistance, and crimping or soldering them onto the wires. The terminals are chosen based on factors such as current capacity, wire gauge compatibility, and connector compatibility.
3. Connector Assembly: Once the terminals are attached to the wires, the connectors are prepared for assembly. This involves inserting the terminals into the connector housing, ensuring proper alignment and engagement. The connectors may also include secondary locking mechanisms to secure the terminals in place and prevent accidental disconnection.
4. Routing and Securing: After the connectors are assembled, the wiring harness is routed through the vehicle's framework, following predetermined routing paths. The harness is secured using various methods, such as clips, brackets, or adhesive tapes, to prevent movement, chafing, or interference with other components. Care is taken to avoid sharp edges, hot surfaces, or areas prone to vibration that could damage the wiring.
5. Connection and Integration: Once the harness is properly routed and secured, the individual connectors are connected to their respective components or subsystems within the vehicle. This includes connecting to sensors, switches, actuators, control modules, and other electrical devices. The connections are made by matching the appropriate terminals or connectors and ensuring proper engagement, alignment, and locking mechanisms.
6. Testing and Quality Assurance: After the wiring harness assembly is complete, thorough testing and quality assurance procedures are carried out. This includes conducting continuity tests to ensure proper electrical connections, performing insulation resistance tests to check for any shorts or faults, and verifying the functionality of the connected components. Any issues or discrepancies are identified and rectified during this stage.
7. Final Inspection and Packaging: Once the assembly and testing are completed, a final inspection of the wiring harness is conducted. This includes visual checks for proper routing, secure connections, and adherence to design specifications. The harness is then carefully packaged, often with protective covers or sleeves, to ensure its integrity during transportation and installation.

By following these detailed steps, the wiring harness assembly process ensures the creation of a reliable and efficient electrical system within the vehicle. This comprehensive approach addresses wire preparation, terminal and connector assembly, routing and securing, connection and integration, testing and quality assurance, as well as final inspection and packaging.

 

INTRODUCTION TO CATIA V5 VIRTUAL ENVIRONMENT FOR WIRING HARNESS DESIGN:

1. Start Menu:

Open CATIA V5 and access the 'Start Menu', which is typically located at the top left corner of the interface. Click on it to reveal a list of options.

2. Equipment and Systems:

Under the 'Start Menu', locate and click on the 'Equipments and Systems' option. This option provides a range of tools and functionalities related to designing and managing electrical systems and components.

3. Electrical Harness Discipline:

Within the 'Equipments and Systems' option, locate and click on the 'Electrical Harness Discipline'. This selection will open a sub-menu with eight more options, each offering specific tools and capabilities for electrical harness design and related tasks.

 

STRUCTURE TREE IN CATIA V5 FOR ELECTRICAL WIRING HARNESS DESIGN:

In CATIA V5, a wiring harness is represented as an assembly called a "Geometrical Bundle" in the Structure Tree. This Geometrical Bundle contains various components that make up the wiring harness design. The first component is the "Multi-Branchable" which stores the routing information for the wiring harness. This is automatically created when routing the electrical components in the Electrical Harness Installation module.

Following the Multi-Branchable, the Structure Tree will list the Connectors and Terminals used in the wiring harness design. These connectors and terminals play a crucial role in connecting the electrical components. Additionally, clips, clamps, guiding channels, and brackets used in the wiring harness design will be listed as assembly components in the Structure Tree.

The order of listing in the Structure Tree is as follows: Multi-Branchable, Connectors, Terminals, Clips, Clamps, Guiding Channels, and Brackets. Each of these components contributes to the overall assembly of the wiring harness design.

Publications within the Structure Tree contain properties related to the converted mechanical assembly into an electrical assembly. They provide relevant information and specifications for the wiring harness and its components.

It is important to note that some products in the Structure Tree may consist of multiple part files, such as the guiding channel product file, which may have multiple parts for each guiding channel used in the design.

 

When the Multi-Branchble feature is expanded within CATIA, you will come across various elements. These include electrical routing and geometrical sets, which encompass all the geometric features related to electrical routing and its associated geometry. Within these sets, you will find the geometrical properties such as planes, axes, and points that are crucial for the creation of the electrical components.

It is important to note that these geometric features are not specifically created within the electrical module but are still stored within the part file. This is because future electrical components will be designed concerning these geometric features.

In the context of publication, when we begin adding electrical properties to our mechanical files, these properties become locked through publications. The publication folder acts as a container for all the electrical properties that are assigned to the parts within the assembly. 

The publication folder can include various elements such as extremity points, which represent the starting and ending points of bundle segments. It can also ensure that 'Branchable 1' is added to the multi-branch product file. In this case, 'Branchable 1' refers to a specific harness branch that contains the bundle segment 1. It is advisable to maintain separate branches for different bundle segments to ensure clarity and organization.

Overall, the Multi-Branchble feature in CATIA allows for managing electrical routing and its associated geometry within the part file. By utilizing publications, the electrical properties can be added and locked, ensuring accurate representation and integration within the assembly.

 

WIRING HARNESS DESIGN PROCESS IN CATIA V5 VIRTUAL ENVIRONMENT: 

 

1. FIRST CONNECTOR: DT06-08SA FROM TE CONNECTIVITY

DOWNLOAD LINK FOR THE CONNECTOR CAD FILE: 

Deutsch DT06 – 08SA ( https://www.te.com/usa-en/product-DT06-08SA.html)

   

 

The Deutsch DT06-08SA connector, manufactured by TE Connectivity, is a versatile and robust connector designed for use in various applications, particularly in the automotive industry. Let's delve into the details of this connector:

    

The Deutsch DT06-08SA connector is a rectangular, environmentally-sealed connector known for its reliability and durability. It features a thermoplastic housing that offers excellent resistance to moisture, chemicals, and vibrations. The connector is equipped with eight size 16 socket terminals, ensuring reliable electrical connections. Its environmental sealing meets IP68 and IP69K ratings, providing dust, water, and high-pressure washdown resistance. The bayonet-style locking system ensures secure mating and prevents accidental disconnections. The connector offers flexible mounting options and operates within a wide temperature range of -55°C to 125°C. It is commonly used in automotive, industrial, and commercial applications that require rugged and waterproof connectors. Overall, the Deutsch DT06-08SA connector is a reliable and robust solution for demanding electrical connectivity needs.

 

Now, to begin with, the process of defining our connector definition, firstly, we have to create a point that will act as a branching point for our connector as shown below:

 

1. Branching Point on the Mating Side:

 

2. Branching Point on the Bundle Entry Side:

 

Now, we're going to define the Axis System on the Mating Side at the respective Branching point as shown below:

 

The Y-axis in our Axis System should be facing towards the Mating Direction or Mouting Direction as shown in the above image.

The X-axis can point in either direction of the horizontal axis since the Locking Mechanism is present on both sides.

The Z-axis should point towards the upwards direction of the connector in this case as shown in the image. 

 

Now, we'll move on to the Electrical Part Design Workbench to define our connector electrically. 

To define our connector, we'll initiate the process by clicking on the 'Define Connector' icon in the 'Electrical Device Definition' Toolbar. 

Once clicked, we'll click on the connector and this action will select the entire connector as a single entity and subsequently open a dialogue box, as illustrated below:

Inside the Connector Definition Dialogue Box, we'll select the 'Type' as 'Single Insert Connector' since we only have the housing of one mating connector. Hence, we'll need to define the respective properties such as bundle entry point only once in our case. After that, we'll write the Part Number as shown in the image concerning the connector part number given on the website from where we have downloaded this connector CAD file. Finally, we'll provide the value for the 'Number of Terminations' as 8 since we can see from the above image that there are 8 terminals provided in our connector that can receive wires for connection. 

The moment we click on 'OK' in the connector definition dialogue box, all the Electrical Properties will be assigned concerning the given parameters as shown below.

Also, All the logical properties for the connecter and terminals will be defined under the publication column as shown below:

 

Next, we're going to define the 'Bundle Connection Point' by clicking on the respective icon for it present inside the 'Electrical Connection Point Definition' Toolbar as shown below:

Now, After clicking on the icon for 'Bundle Connection Point' we'll click on our connector and the connector will get highlighted only if it is previously electrically defined as shown in the previous steps.

Now, After clicking on the connector, the 'Bundle Connection Point Definition' dialogue box will open where we'll asked to provide a suitable name for the bundle if needed. Mostly, the name is kept as it is. 

After that, we'll be asked to choose a geometrical entity such as a face or point that will act as the entry face for the connector or the face that will be normal to the bundle of wire entering via that bundle entry face. We'll choose the first face of that Bundle Entry Face as shown below:

After that, it'll ask for a point that can act as a Bundle Entry Point for the connector as we'll select the point that we have created previously as the branching point for the Bundle Entry Face as shown in the above image. 

Finally, it'll ask for an initial condition where we can select any face or line that is normal to the Bundle Entry Direction and here we'll choose the same face that we have selected as our representation as it is already acting as a normal face to the Bundle Entry Direction. 

When we finally click on 'OK' inside the 'Bundle Connection Point Definition' dialogue box, it'll show in the publication column that the Bundle Definition Properties are added and it'll show the points and faces that are being used to define our bundle connection point definition as shown below:

 

Now, we'll create a 'Connector Connection Point' using the option available under the 'Electrical Connection Point Definition' Toolbar as shown below:

After clicking on the 'Connector Connection Point' icon we'll click on our connector and it'll open up the connector connection definition dialogue box as shown below:

Here, we'll keep the default name that is provided by CATIA for our connector but it can be changed if needed. 

Next, for the 'Representation' option, we'll select our previously created Branching Point for the mating face of our connector.

Now, for the 'Contact', it should be the front face or the last face of the connector as shown below:

To ensure proper mating alignment, the 'Coincidence' parameter should be set along the Y-axis. This means that the mating component will align itself with this axis during the mating process. Similarly, the 'Orientation' parameter should be aligned along the X-axis to ensure proper alignment with the potential matching counterpart. By setting the orientation along the X-axis, we ensure that the connector is correctly oriented for seamless mating with its counterpart.

 The moment we click on 'OK' in the Connector Connection Definition dialogue box, the Electrical Properties will be added to the respective electrical column in the Structure Tree as shown below:

It'll also publish the references that are being used to create these electrical properties under the publication column as shown below:

 

Since this particular connector doesn't have any connector locking feature available, we'll not be able to provide any 'Cavity Connection Point' for it that can be used to mount a Connector Cavity or Mounting Clip. 

 

2. SECOND CONNECTOR: C-2-174357-2 FROM TE CONNECTIVITY

DOWNLOAD LINK FOR THE CONNECTOR CAD FILE: 

Tyco 174357-2 (https://www.te.com/usa-en/product-2-174357-2.html?source=header-match)

This wire-to-wire rectangular connector is a sealable, 3-position connector with a centerline of 4.8mm. It features an integrated locking mechanism and is designed for a single-row arrangement. Operating at 12V, it allows for a 180° cable exit angle and uses receptacle contacts sized at 1.8mm. Mating alignment is achieved through a polarization slot, and the connector can be freely mounted on a cable. Terminal position assurance is supported, and the housing is made of PBT material. With dimensions of 27.6mm (L) x 25.4mm (W) x 22.8mm (H), it can operate within a temperature range of -30 to 105°C (-22 to 221°F). This connector is suitable for signal circuit applications and meets the UL 94V-2 flammability rating. It is packaged in quantities of 100 units per bag and is serviceable for maintenance or replacement purposes.

 

   

 

1. Branching Point on the Bundle Entry Side:

 

2. Branching Point on the Mating Side:

 

Now, we're going to define the Axis System on the Mating Side at the respective Branching point as shown below:

 

The Y-axis in our Axis System should be facing towards the Mating Direction or Mouting Direction as shown in the above image.

The X-axis should point towards the direction of the Locking Mechanism. 

The Z-axis should point towards the horizontal direction of the connector in this case as shown in the image. 

 

Since this particular connector has a 'Connector Locking Feature' available, we'll provide a 'Cavity Connection Point' for it that can be used to mount a Connector Cavity or Mounting Clip as shown below:

 

For this to work, we need another geometrical feature that can be used to mount this Cavity Connector or Mounting Clip. It will be a point concerning which the Mounting Clip will be mounted eventually. 

 

We also need to have the Axis System for the cavity connection point where the alignment of the axes of the Axis System will be the same as our Axis System created for the Mating Side of our Connector as shown below:

 

 

Now, we'll move on to the Electrical Part Design Workbench to define our connector electrically. 

To define our connector, we'll initiate the process by clicking on the 'Define Connector' icon in the 'Electrical Device Definition' Toolbar. 

Once clicked, we'll click on the connector and this action will select the entire connector as a single entity and subsequently open a dialogue box, as illustrated below:

 

Inside the Connector Definition Dialogue Box, we'll select the 'Type' as 'Single Insert Connector' since we only have the housing of one mating connector. Hence, we'll need to define the respective properties such as bundle entry point only once in our case. After that, we'll write the Part Number as shown in the image concerning the connector part number given on the website from where we have downloaded this connector CAD file. Finally, we'll provide the value for the 'Number of Terminations' as 3 since we can see from the above image that there are 3 terminals provided in our connector that can receive wires for connection. 

The moment we click on 'OK' in the connector definition dialogue box, all the Electrical Properties will be assigned concerning the given parameters as shown below.

 

Next, we're going to define the 'Bundle Connection Point' by clicking on the respective icon for it present inside the 'Electrical Connection Point Definition' Toolbar as shown below:

 

Now, After clicking on the icon for 'Bundle Connection Point' we'll click on our connector and the connector will get highlighted only if it is previously electrically defined as shown in the previous steps. Now, After clicking on the connector, the 'Bundle Connection Point Definition' dialogue box will open where we'll asked to provide a suitable name for the bundle if needed. Mostly, the name is kept as it is. After that, we'll be asked to choose a geometrical entity such as a face or point that will act as the entry face for the connector or the face that will be normal to the bundle of wire entering via that bundle entry face. We'll choose the first face of that Bundle Entry Face as shown below:

 

After that, it'll ask for a point that can act as a Bundle Entry Point for the connector as we'll select the point that we have created previously as the branching point for the Bundle Entry Face as shown in the above image. Finally, it'll ask for an initial condition where we can select any face or line that is normal to the Bundle Entry Direction and here we'll choose the same face that we have selected as our representation as it is already acting as a normal face to the Bundle Entry Direction.

When we finally click on 'OK' inside the 'Bundle Connection Point Definition' dialogue box, it'll show in the publication column that the Bundle Definition Properties are added and it'll show the points and faces that are being used to define our bundle connection point definition as shown below:

 

Now, we'll create a 'Connector Connection Point' using the option available under the 'Electrical Connection Point Definition' Toolbar as shown below:

After clicking on the 'Connector Connection Point' icon we'll click on our connector and it'll open up the connector connection definition dialogue box as shown below:

 

Here, we'll keep the default name that is provided by CATIA for our connector but it can be changed if needed. Next, for the 'Representation' option, we'll select our previously created Branching Point for the mating face of our connector.

Now, for the 'Contact', it should be the front face or the last face of the connector as shown below:

To ensure proper mating alignment, the 'Coincidence' parameter should be set along the Y-axis. This means that the mating component will align itself with this axis during the mating process. Similarly, the 'Orientation' parameter should be aligned along the X-axis to ensure proper alignment with the potential matching counterpart. By setting the orientation along the X-axis, we ensure that the connector is correctly oriented for seamless mating with its counterpart.

The moment we click on 'OK' in the Connector Connection Definition dialogue box, the Electrical Properties will be added to the respective electrical column in the Structure Tree as shown below:

 

Next, we're going to define the 'Connector Cavity Point' for the given connector at the specified location:

After clicking on the icon for the Cavity Connection Point it'll open the Cavity Connection Point dialogue box as shown below:

For the 'Representation' we can select the point that we have created to use for the Cavity Connection Point.

For 'Contact' we can select the face that is going to mate with the face of the mating counterpart. 

The moment we click on 'OK' in the Cavity Connection Point dialogue box, we'll see that the electrical properties are being added to the electrical column and the respective references to the parameters are being published under the publication column as shown below:

 

 

3. CONNECTOR CAVITY OR MOUNTING CLIP: 85229-1 FROM TE CONNECTIVITY

DOWNLOAD LINK FOR THE CONNECTOR CAD FILE: 

Tyco 85229-1 – (https://www.te.com/usa-en/product-85229-1.html?q=85229&source=header)

The connector cavity or mounting clip is the Econoseal, TE Internal #: 85229-1. It is a clip housing designed for the 070 (EJ MK-II) connector. 

 

Here are some details about this Mounting-Clip:

- Automotive Connector Accessory Type: Mounting Clip

- Primary Product Material: PA (Polyamide)

- Primary Product Color: Black

- Operating Temperature Range: -40 – 120 °C [-40 – 248 °F]

 

This mounting clip is specifically designed for automotive applications and is made of PA, which is a durable and heat-resistant material. The black colour gives it a sleek and professional appearance. It has a wide operating temperature range of -40 to 120 °C, making it suitable for various environmental conditions.

In terms of industry standards, this mounting clip meets the UL Flammability Rating of UL 94V-2, ensuring its compliance with safety regulations. It is packaged in bags and each bag contains 1000 clips.

With this mounting clip, we can securely mount the connector C-2-174357-2, ensuring proper connection and stability.

 

We have created a point that will be used as the Origin of the Cavity Connection Point as shown below:

 

Now, we're going to place a Axis-System on that point where the alignment of its axes will be the same as of the Cavity Connection Point created on our Connector to ensure that the connection will be proper and it'll get securely locked with the mating counterpart. 

We have to ensure that the direction of the Y-axis points towards the direction of insertion and that the other two axes follow the same alignment as the Axis-System of the Connector's Cavity Connection Point as shown in the above image. 

 

Next, we're going to define our Connector Cavity as a 'Mounting Equipment' using the option 'Define Mounting Equipment' present under the 'Electrical Device Definition' Toolbar as shown below:

After defining these Mounting Clips using the Dialogue Box when we finally click on the 'OK' button we will see that the electrical properties are added to the model under the Publication column in the Structure Tree as shown below:

 

Now, we're going to define our Connection Cavity or Mounting Clip as 'Cavity' so using the option 'Define Cavity' present under the 'Electrical Connection Point Definition' Toolbar  

After clicking on the icon for 'Define Cavity' when we click on our Connector Cavity it'll open up a 'Cavity Definition' dialogue box as shown below:

For the 'Representation' parameter we're going to select the point that we had created previously at the midpoint of the upper edge of the mounting face upon which the Axis-System is created. 

For 'Contact' we're going to select the face with which the cavity and the connector are going to come in contact as shown below:

For the 'Coincidence' we're going to select the Y-axis and for the 'Orientation' we're going to select the X-axis. 

 

These Electrical Properties will get added to the model which can be seen being updated on the Structure Tree under Electrical and the references will be added under the Publication Column as shown below:

 

Next, we're going to click on the 'File' option to create a 'Product' file and then enter it into the Electrical Assembly Design Workbench from the Start Menu as shown below:

 

Now, we're going to import both of the existing components into the product file that we have created to assemble them in their accurately intended alignment inside this workbench in the following steps. 

We're going to use the options that can be used to constrain the mating connectors electrically between the connector and their respective cavity component electrically. These constraints are going to be applied using the commands 'Connect Electrical Devices' & 'Disconnect Electrical Devices' from the 'Electrical Connection Point Definition' Toolbar as shown below:

Now, we're going to click on the 'Connect Electrical Devices' command and click on our cavity. After that CATIA will wait till we select our connector to connect the selected cavity component with and the moment we hover over cursor over our connector CATIA will highlight the possible connection point to make that connection in green color as shown below:

Here it is showing that on our connector that particular cavity connection point is available for connection. 

Finally when we click on our connector our cavity component will instantly snap onto the intended 

We can notice that required constraints are created at intended locations and both of the components have perfectly aligned themselves with each other as shown below:

Hence, we have successfully managed to assemble these two mating components with each other providing the necessary constraints. 

 

CATALOGUING THESE COMPONENTS FOR FUTURE USE BY OTHER ENGINEERS:

Next, we can add these components to the catalogue individually as well as the assembly of both of them together.

Adding devices such as connectors and mounting clips to the catalogue in CATIA V5 can be highly beneficial for engineers for several reasons:

 

1. Easy accessibility: By cataloguing these components, they become readily available in the CATIA V5 library, making them easily accessible for future use. This eliminates the need to recreate or search for these components every time they are required, saving valuable time and effort.

 

2. Standardization and consistency: Cataloguing connectors and mounting clips ensure that standardized and approved components are used consistently throughout designs. This helps maintain design integrity, ensures compatibility, and reduces errors or inconsistencies in the assembly.

 

3. Design efficiency: With a well-organized catalogue, engineers can quickly select and insert the desired connectors and mounting clips into their designs. This streamlines the design process and improves overall efficiency, allowing engineers to focus more on the actual design rather than searching for or creating individual components.

 

4. Collaboration and knowledge sharing: Cataloguing components in the CATIA V5 library promotes collaboration and knowledge sharing among engineers and designers. When components are readily available in the library, multiple team members can easily access and use the same components, facilitating smoother collaboration and reducing the chances of design discrepancies.

 

5. Design reuse: Cataloguing components enables design reuse, which is particularly useful when working on similar projects or variations of existing designs. Engineers can easily access previously used connectors and mounting clips from the catalogue, reducing design time and promoting design consistency across projects.

 

Overall, cataloguing connectors and mounting clips in the CATIA V5 library enhances productivity, promotes standardization, facilitates collaboration, and enables efficient design reuse. It simplifies the design process and ensures that engineers have easy access to approved and compatible components, ultimately improving the overall quality and efficiency of the design workflow.

We have already created our own electrical catalogue and the steps that we have taken to create them is explained below:

First, we have to open a new file and create a new 'Catalogue Document' as shown below:

Then, we have to click on the icon that says 'Add Family' that will allow us to create our own catalogue's family. 

 

It will open up and 'Family Definition' dialogue box as shown below where we can choose the name of your catalogue's family and choose the type of catalogue that we have to create. 

 

When we click on the 'Type' button inside this dialogue box, we will come across this option to choose the kind of catalogue family domain that we want to choose for our purpose. Here, we will choose 'Electrical' as the family type we want to create and name the catalogue 'Connectors'. 

 

Next, we will save this catalogue at the desired location of our preference. 

Now, we still have to add this catalogue to our catalogue's favourites menu and the steps for that are shown in the following steps.  

 

First, we have to go to the Tools and then click on the 'Options' menu as shown below: 

 

Then, we will come across an interface that is similar to the Start Menu. Here, we have to click on the button to expand the 'Equipments & Systems' menu and then click on the 'Electrical Mapping'.  

 

 

Then click on 'OK' to save your catalogue's family in the Electrical Workbench's catalogue family. 

Now, if we want to add any component such as our connector or mounting clip to this connector, we can simply find an option called as 'Store Device' by clicking on an icon that looks like a book with blue highlights as shown below and that will open up a dialogue box named as 'Device Storage' as shown below:

We will click on the 'Family' option to choose the family that we want to include inside and as we already have a family named 'CONNECTORS' we will choose that one and finally click on 'OK'. Our Connector is now added to the newly created electrical catalogue. We'll add the Mounting Clip and the Assembled Product as well into the catalogue following the same steps mentioned above. 

 

ELECTRICAL ASSEMBLY:

 

KEYSHOT RENDERINGS OF THE FINAL ELECTRICAL ASSEMBLY: