Challenge

Project 1

SSameer Biswas25 Jan 2023

Automotive Wiring Harness using CATIA V5 - Challenges

Project 1

Statement of assignment:-

Route the Wiring harness on Given Engine and Prepare to flatten the view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

Available connector 3D data can be used, or can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, and Assumptions, along with CATIA 3D data.

Solution:-

The wiring harness procedure is followed to route the wiring harness on the given 3D engine data. A 2D drawing of the harness is also prepared after flattening the harness, following packaging rules like the distance between the branch point and connectors of a bundle segment, slack for the end connector, and clearance of the harness with the help of clips and clamps.

Wiring Harness Procedure:

Identify the Harness assembly component
Define all Harness assemblies as Electrical
Prepare Harness assembly
Define assembly as Electrical Assembly
Change/Customize tool sets as required
Start Routing the bundles following the Packaging guidelines

Connector Definition

Download 3D Connector

Mechanical Part Design Workbench -

Defining Geometrical Parameters (Points and Axis system)

1. Bundle entry side center point

Selecting required random points to get a center point for a suitable point type.

2. Mating side center point

Selecting required random points to get a center point for a suitable point type.

3. Mating side axis system

Creating an axis system concerning the center point as the origin of the axis. The Y axis is directed at the mating direction, the X axis is directed towards the locking side and the Z axis is directed upwards.

Electrical Part Design Workbench -

Define part as Connector

Defining part as an electrical connector in Electrical Part Design Workbench using 'Define Connector', and also selecting the number of terminations for the connector.

Define Bundle Connection Point

Defining bundle connection point at the bundle entry side where representation is the face of the side, point as the center point, and initial condition also as the face of the side.

Define Connector Connection Point

Defining connector connection point at the mating side of the connector where representation is the center point, contact is the face of the side, coincidence is the Y axis, and, orientation is the X axis.

Define cavity connection point (if connector needs mounting clip)

A cavity connection is defined as the connecting part for a connector clip where representation is the center point of the cavity connection, contact is the connection face, coincidence is the Y axis and, orientation is the X axis.

A catalog is also been created for all the electrical components and can be used for the Geometrical bundle assembly, through 'Catalog Browser'.

Mounting Clip Definition

Download 3D part

Mechanical Part Design Workbench -

Defining geometrical properties (points and axis system)

1. Mounting clip center point

Selecting the edge of the connecting part to get a center point, under point type curve.

2. Mounting clip axis system

Creating an axis system for the cavity, the origin is the center point, the Y axis is directed towards the insertion, the X axis is directed upwards and, the Z axis is directed to the side. The axis direction should follow the connector's cavity connection axis direction for proper mounting.

Electrical Part Design Workbench -

Define part as a Mounting Equipment

The clip is defined as electrical mounting equipment.

Defining Cavity

A connector clip is defined as the cavity where representation is the center point, contact is the face of the connecting part, coincidence is the Y axis and, orientation is the X axis.

Electrical Assembly Design Workbench -

Connect Electrical Devices

The connector and connector clip are connected in the electrical assembly design workbench using 'Connect Electrical Devices'.

The components used as sensors or dummy connectors are electrically defined by following the same steps for defining the connectors.

Clip/Clamp Definition

Get the Clip/Clamp 3D part

Mechanical Part Design Workbench -

Define the Geometry Parameters

1. Points and Planes

Defining the points for both sides through point definition.

2. Creating entry, exit, and base planes through plane definition.

Electrical Part Design Workbench -

Define part as support

The support definition for the clip/clamp is defined twice to make bilateral connectivity. The point selected for the side will be the entry side of the bundle, which is done for both sides. The entry point & plane, base & exit plane is defined in the support definition.

Guiding Channel Definition

Download 3D part

Mechanical Part Design Workbench -

Defining geometrical properties (points and curves)

1. Bundle entry side center point

Selecting required random points to get a center point for a suitable point type.

2. Line Definition

Defining the line for the required curve using line type Point-Direction and managing the length of the curve in Start and End in line definition.

Electrical Part Design Workbench -

Define part as Equipment

Defining part as an electrical component in Electrical Part Design Workbench using 'Define Equipment'.

Define Bundle Connection Point

Defining bundle connection point at the bundle entry side where representation is the face of the side, point as the center point, and initial condition also as the face of the side.

Mechanical Assembly Design Workbench -

Symmetry

Assembly Symmetry Wizard

1. Select the symmetry plane

2. Select the product to be transformed

Preparation of the Harness Assembly

1. Harness Context Assembly

All the supportive context and Geometrical Bundle Assembly are the components of the harness context assembly.

2. Geometrical Bundle

Mechanical Assembly Design

Catalog Browser

All the electrical connectors are loaded in the geometrical bundle using Catalog Browser from their catalog. Manipulation, Snap, and Compass are the tools used from the mechanical assembly design workbench to place the connectors at the desired positions of the sketch.

Electrical Harness Assembly

Geometric Bundle

The geometric Bundle command is used to electrify the geometrical bundle.

Multi-Branchable Document

The multi-Branchable Document command is used to initiate branches for the electrical components using Branch Definition.

Electrical Harness Installation

Branch Definition

The Branch Definition command is used to define the branches between the components. Branch diameter, Bend Radius (ratio 1.4), and Build Mode (slack) are set in the branch definition before proceeding with the Route Definition.

In Route Definition, objects/components are selected for which the branches are to be made.

Add Branch Point

Branch points are created from the main branch using Add Branch Point command. The branch is selected for which the branch point is to be created and distance is defined as per the packaging guidelines for the branch point. New branches can be created through the same branch point.

Protective Covering

Protective covering (COT Tubes) on all branches are connected with the end extremity of 30/20mm (from the end of the connector). Bundle segments are selected then the protective coverings are implemented using the COT Tubes catalog.

Bundle Continuity

Edit

Bundle Continuity is checked for bundle segment for fully connected.

CATPart of Harness Assembly

Mechanical Assembly Design Workbench -

Tools

Generate CATPart from the Product

Generate CATPart from Product is used from Tools to convert the CATProduct to ALLCATPart and then the same file is saved using save as in .igs format.