Project 1

AIM

To route the Wiring Harness on given Car Door and Flatten view drawing in CATIA V5.

OBJECTIVE

The objective of the project is to route the wiring harness on given Car Door and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

INTRODUCTION

• The door wiring harness connects to the window motor, lock actuator, and switch. Plus, it has some powerful connections to the battery and other components. Some of these include ground and window switches and relays.
• In this project, we have 6 main connection points, where we have to route bundle to all the points. They are Interconnection connector, Door control switches connector, Speaker System connector, Window winding Motor connector, Door lock sensor connector, Puddle lamp connector.
• The plastic guiding channel used in this harness should be made of a material that can withstand at least 150 degrees Celsius.
• The bend ratio for the all-bundle segments should be 1.4

ASSUMPTIONS

• 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.
• Avoid routing over bolt and bolted joints to avoid harness puncture.
• 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.
• Avoid direct support for harness on fuel lines routed in the engine.
• Use plastic guiding channels if needed.
• Branch length should be greater than 50mm.
• Minimum distance between two branch points should be at least 50mm.
• Minimum distance between clip and branch point should be at least 25mm.
• Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
• The wiring harness should be easy to assemble and easy to access.
• While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and other placements can be defined properly for the wire harness routing.
• If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

DESIGN METHODOLOGY

STEP 1 - Download the side door CAD data and required connectors CAD data from the given source. Creating context assembly.

• A Context Assembly for side door Harness has created which will work as the main assembly as shown in above figure.
• A Context Assembly will contain side door Assembly and door Harness Geometrical Bundle Assembly.

STEP 2 – Defining connectors and furr tree clips Electrically.

2 Pole Connector

Inter Connection Connector (C-776438-4)

4 Pole Connector

6 Pole Connector

Furr tree clip

STEP 3 – Defining Plastic channel Electrically.

STEP 4 – Location of Connectors at appropriate area.

STEP 5 – Location of plastic channel at appropriate area.

• Plastic guiding channel is best option for proper and easy routing of the wiring harness. It will reduce the complex wiring harness routing as well as protects the harness from any damage.

STEP 6 – Location of Furr tree clip at required position.

STEP 7 – Bundle routing from Interconnection connector to Guiding channel.

• Bundle routing from Interconnection connector to Guiding channel is the Main branch. It is routed from interconnection connector, passing through the two furr tree clips and guiding channel. From this main branch, sub branches are originated to connect the different connectors at different locations.

STEP 8 – Bundle routing from Guiding channel to Door lock sensor connector.

STEP 9 – Creating 2 Branch points near furr tree clip.

• These two branch points are created to connect the Speaker System connector and Door control switches connector from the main branch.

STEP 10 – Bundle routing for Speaker System connector.

STEP 11 – Bundle routing for Door control switches connector.

STEP 12 – Creating 2 Branch points for Window winding Motor connector and Puddle lamp connector.

STEP 13 – Bundle routing for Window winding Motor connector.

STEP 14 – Bundle routing for Puddle lamp connector.

STEP 15 – Adding Protective covering to bundles

STEP 16 – Checking bundle continuity.

In this step, first we have to make sure that multi-branchable is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected

• By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments.
• Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

STEP 17 – Creating flatten view of the side door harness geometrical bundle assembly.

• In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved.

STEP 18 – Creating a flatten view drawing for the door wiring harness assembly.

• In above figure, we are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.
• We have to define drawing properties as shown in above figure. It should be noted that in 'Dress up' settings 3D wireframe is always ON. If this setting is not selected then the bundle segments won't be visible on drawing view.

STEP 19 – Conversion to CAT.PART

CONCLUSION

In this way, we have routed wiring harness for the side door of car. Also, prepared flatten view drawing with proper sheet in CATIA V5.