INTERCONNECTING MULTIPLE HARNESSES ELETRICALLY, CHECKING BUNDLE CONTINUITY & PROVIDING ANNOTATIONS

OBJECTIVE STATEMENT:

The objective of this project is to design and develop a fully routed and annotated automotive wiring harness assembly in .igs format, using the following steps:

 

1. Route the harness layout in the Electrical workbench using the provided connectors.
2. Check the bundle continuity and provide a snapshot of the result.
3. Add annotations to all connectors using industry-standard nomenclature.
4. Check for bundle warnings and provide a snapshot.
5. Generate a CAT.part of the harness assembly and convert it to .igs format.

 

This project will demonstrate my ability to:

• Apply industry standard practices to design and route automotive wiring harnesses.
• Utilize the Electrical workbench to perform bundle continuity and warning checks.
• Add annotations to connectors in accordance with industry standards.
• Generate CAT.parts and convert them to .igs format for downstream manufacturing and documentation.

 

The successful completion of this project will result in a deliverable that meets all customer requirements and is ready for production.

 

HARNESS LAYOUT:

 

CONNECTORS PROVIDED FOR HARNESS A:

1. DT04-08PC-CE01 (FEMALE CONNECTOR)

2. DTS26F15-35SNV001.1 

3. C-1-174357-2.1

4. DT06-08SA-CE01

5. DT06-08SA-EP07.1

 

CONNECTORS PROVIDED FOR HARNESS B:

1. DT06-08SA-CE13.1 (MALE CONNECTOR)

2. DTS26F15-35SNV001.1

3. DT06-3S-CP01.1

4. DT06-08SA-CE04.1

5. DT06-08SA-EP07.1

 

HARNESS A:

First, we'll define each connector in the Electrical Part Design Workbench:

1. Create the required geometrical features, which are branching points at the mating side and bundle entry side.

2. Use the Define Connector command in the Electrical Device Definition toolbar to define the geometrical features as connectors.

3. At the desired locations, define the Bundle Connection Point and Connector Connection Point.

 

Once the connectors are electrically defined, they can be used in the Assembly Design Workbench to create a wiring harness assembly. To do this, follow these steps:

1. Create a sketch with respect to one of the connectors.

2. Use the Snap feature to align and place the rest of the connectors at their intended locations.

 

The Electrical Wiring Harness Assembly Workbench in CATIA V5 is used to define the geometric bundle that links the various connection points of an electrical wiring harness. This workbench allows us to create and manage the bundle segments, which are the individual wires that make up the harness.

 

DEFINING THE PRODUCT AS GEOMETRICAL BUNDLE:

To create a Harness Assembly Product we must first define the product as Geometrical Bundle. This can be done using the Geometrical Bundle command under the Creation toolbar.

Once we have defined the product as a Geometrical Bundle, we can use the Multi Branchable Document command to switch to the Wiring Harness Installation Workbench. This workbench is used to define the routing of the bundle segments.

 

DEFINING BUNDLE SEGMENTS:

To define a bundle segment, we must first create a Branch Definition. This can be done using the Branch Definition command under the General toolbar.

 

In the Branch Definition dialogue box, we must specify the following:

Bundle Diameter: The diameter of the bundle segment.

Bend Radius Ratio/Length: The bend radius ratio is the ratio of the minimum allowable bend radius to the bundle diameter. For example, a bend radius ratio of 1.4 means that the minimum allowable bend radius is 40% more than the bundle diameter.

    

Once we have specified the Branch Definition, we can use the Route Definition command to create the bundle segment.

In the Route Definition dialogue box, we must select the connectors that we want to route together. we can also use the Tangent Management option to shape the bundle segment into the desired shape by changing the tangent direction or changing the constraint type from 'Explicit' to 'From Curve' but in our case, we won't need to do that since we'll get our desired bundle segment just by altering the tangent direction whenever required. 

   

 

CREATING SUB-BRANCHES:

To create a sub-branch of the harness, we can use the Add Branch Point command. This command will create a branch point at the selected location.

Once we have created a branch point, we can use the Branch Definition and Route Definition dialogue boxes to define the sub-branch.

For the main branch of the harness, we should use a bundle segment diameter of 10mm and a bend radius ratio of 1.4. This means that the minimum allowable bend radius for the main branch will be 14mm.

For all other sub-branches, we should use a bundle segment diameter of 5mm and a bend radius ratio of 1.4. This means that the minimum allowable bend radius for the sub-branches will be 7.5mm.

 

HARNESS B:

We're going to repeat these previous steps for our second harness layout called 'Harness B' as shown below:

 

BUNDLE CONTINUITY CHECK:

HARNESS A:

To check if our Bundle Segment is connected in the correct manner and ensure that there are no loose connections, we're going to go under the 'Search' option under 'Edit' as shown below:

 

In the 'Search' dialogue box, we'll go under the 'Advanced' section, choose our workbench as 'Electrical', We'll choose 'Type' as 'Bundle Segment' and under 'Attribute' we'll choose 'Fully Connected' which will open up another dialogue box for us named as 'Attribute Criterion' where we'll choose the condition initially as 'True' and later as 'False'. 

 

After choosing our attribute as 'True' if we click on the search button below, CATIA will inspect our Bundle Segment and see if all of our branches are connected or not.  

Our Multi Branchable Segment for Harness A under the Specification Tree:

 

Results after Bundle Continuity Check using the 'Search' tool:

 

If we choose our 'Attribute Criterion' as false and click on 'Search' then it'll show us if there's any bundle segment that is not connected to our bundle segment.

From the above image, we can notice that none of the names of our branches from the Bundle Segment for Harness A has appeared as being not connected with our bundle segment which means all of these connectors are fully connected with each other. 

 

HARNESS B:

 

When the attribute criterion is 'True'

 

When the attribute criterion is 'False'

So, we can conclude that all of our connectors are fully connected with each other and there's no discontinuity between them at any point. 

 

CONNECTING HARNESS A & B WITH EACH OTHER ELECTRICALLY:

Now, we're going to connect both of our harnesses together. Firstly, we'll create a new product file in CATIA and import both of our harnesses inside it using the import existing component command present in the Assembly Workbench.

 

Then we're going to align them with each other according to the layout that was provided to us. We're going to use the 'Snap' command from the 'Move' toolbar from that workbench to align the mating male and female connectors with each other as shown in the images below:

 

Now, to connect both of these harnesses electronically, we're going to move on to the Electrical Assembly Design Workbench and use the command 'Connect Electrical Devices' from the Electrical Connection Point Definition toolbar as shown in the image below:

 

Now, we're going to click on the respective female connector of Harness A that we're going to connect with the male connector of Harness B. After the initial click on the first connector belonging to Harness A, we'll notice that CATIA will automatically suggest us the there's a connection point available at the opposite male connector from Harness B as shown in the image below:

 

The moment we click on the connector of Harness B, both of these connectors will get connected with each other electrically using various constraints as shown below:

 

ANNOTATIONS:

The Annotations command in CATIA V5 Assembly Workbench allows you to add text, symbols, and other annotations to your assemblies. This can be useful for documenting your design, providing instructions for assembly, or identifying important features.

 

1. View Creation Command

The View Creation command allows us to create a new view of your assembly. This can be useful for creating detailed drawings of specific subassemblies or components, or for creating exploded views of your assembly. The View Creation command is a fundamental feature of the Annotations command. It enables us to create different types of views to represent the assembly. These views can be 2D or 3D representations of the assembly, aiding in documentation and facilitating communication. By generating orthographic views, isometric views exploded views, or section views, we can provide a comprehensive understanding of the assembly's structure, configuration, and spatial relationships. These views can then be annotated with dimensions, notes, and other annotations to enhance clarity and comprehension.

 

To use the View Creation command, follow these steps:

• Click the Annotations tab in the Command Manager.
• In the Annotations group, click the View Creation command.
• In the View Creation dialogue box, select the type of view that you want to create.
• Click OK to create the view.

 

2. Flag Note with Leader Command

The Flag Note with Leader command allows us to add a flag note to your assembly. Flag notes are typically used to highlight important features or to provide instructions for assembly. The Flag Note with Leader command is a versatile annotation tool within the Annotations command. It allows you to attach flag-shaped symbols, called flag notes, to specific components or features within the assembly. These flag notes serve as graphical representations of notes or comments associated with the designated elements. The flag symbol is connected to the component or feature through a leader line, clearly indicating the relationship between the note and the object it pertains to. This command is particularly useful for conveying design intent, assembly instructions, observations, or any other relevant information that needs to be communicated visually.

To use the Flag Note with Leader command, follow these steps:

• Click the Annotations tab in the Command Manager.
• In the Annotations group, click the Flag Note with the Leader command.
• Click on the face or edge of the assembly where we want to place the flag note.
• In the Flag Note dialogue box, enter the text for your flag note.
• Click OK to create the flag note.

 

3. Notes with Leader Command

The Notes with Leader command allows us to add a text note to your assembly. Text notes are typically used to provide additional information about the assembly or its components. The Notes with Leader command is another valuable annotation tool in the Annotations command. Similar to the Flag Note with Leader command, it allows you to attach textual notes directly to components or features within the assembly. These notes are represented by a leader line that connects the text to the associated element. With this command, you can provide detailed explanations, part numbers, part names, or any other textual information that is crucial for understanding the assembly. The Notes with Leader command offers flexibility in terms of positioning, formatting, and editing the attached notes, ensuring clear and concise communication.

To use the Notes with Leader command, follow these steps:

• Click the Annotations tab in the Command Manager.
• In the Annotations group, click the Notes with Leader command.
• Click on the face or edge of the assembly where you want to place the text note.
• In the Notes with a Leader dialogue box, enter the text for your note.
• Click OK to create the text note.

 

Both the Flag Note with Leader and Notes with Leader commands can be customized to suit your specific annotation requirements. You can easily adjust the position, orientation, size, and formatting of the annotations to ensure clarity and aesthetic appeal. Additionally, these annotations can be modified or deleted as needed, allowing for easy updates and revisions to the assembly documentation.

 

ANNOTATIONS FOR HARNESS A:

 

ANNOTATIONS FOR HARNESS B:

 

 

CONVERSION OF OUR PRODUCT INTO CAT.Part AND THAN CONVERT IT IN IGS FORMAT 

First, we have to move to the Assembly Workbench and click on 'Tools'. Then under 'Tools' we'll find an option named 'Generate CATPart from Product'. We'll click on that as shown below:

It'll open up a dialogue box named 'Generate CATPart from Product' and then we can provide a new part number or we can just click on our product and it'll choose that name as the new part number by itself. We utilized the latter option. 

 

After clicking on 'OK' it'll convert the whole product file into CAT.Part file as shown below:

We can notice from the above image that all of our part files are now created into individual bodies and geometrical sets in order to form the entire product file into one single CATpart file. 

We're going to save this CATpart and then again we're going to save this CATpart in IGS format as well.

 

IGS/IGES (Initial Graphics Exchange Specification)

There are several reasons why you might want to convert your CATPart to IGS format:

IGS is a neutral file format: This means that it can be opened and read by a wide variety of CAD software, including SOLIDWORKS, NX CAD, and many others. This makes IGS a good choice for sharing files with other engineers who may be using different CAD software than you.

IGS is a well-established file format: It has been around for many years and is widely supported by CAD software vendors. This means that you can be confident that your IGS file will be able to be opened and read by other engineers, even if they are using older versions of CAD software.

IGS files are typically smaller than CATPart files: This is because IGS files only contain the geometric information for the part, not any of the CAD software-specific data. This makes IGS files a good choice for sending files over the internet or storing them on a shared network drive.

Here are some specific benefits of sharing IGS files with other engineers who are going to work on your part using other software:

Increased collaboration: By sharing IGS files, you can make it easier for other engineers to view and comment on your design. This can help to improve the quality of the design and avoid potential problems.

Reduced errors: When you share an IGS file with other engineers, they can use their own CAD software to create drawings, simulations, and other documentation. This can help to reduce the risk of errors that can occur when manually translating between different CAD formats.

Improved efficiency: Sharing IGS files can help to improve the efficiency of your design process. By eliminating the need to convert files between different CAD formats, you can save time and effort.

Overall, converting your CATPart to IGS format is a good way to improve the collaboration and efficiency of your design process. It is also a good way to ensure that your design can be opened and read by other engineers, even if they are using different CAD software than you.

 

CONCLUSION:

The electrical wiring harness layout has been successfully routed in the Electrical workbench using the provided connectors. The following assumptions were made for the harness bundle diameters:

Main branch: 10mm

Sub-branches: 5mm

All bundle segments are fully connected, as verified by the bundle continuity check. The following annotations have been added to all connectors:

No bundle warnings were detected.

A CATPart of the harness assembly has been generated and converted to IGS format.

The project has been completed successfully, fulfilling all of the requirements that were specified.

1. The harness layout is well-designed and easy to follow.
2. The bundle segments are routed in a neat and organized manner.
3. The use of annotations makes the harness assembly easy to understand and maintain.
4. The CATPart and IGS files can be easily shared with other engineers for collaboration and manufacturing purposes.

Overall, the project is a success. The harness layout has been routed correctly, the bundle segments are fully connected, and the required documentation has been generated. The CATPart and IGS files are ready to be used for downstream engineering and manufacturing tasks.