Project 1

AIM

   To  Route the Wiring harness on Given Engine and Prepare flattened 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.

ELECTRICAL DISTRIBUTION SYSYTEM

   Electrical Distribution System deals with the physical and logical Architectures,Schematic development,Power Distribution,wiring harness design,wiring harness componenet design of given electrical system.

E&E ARCHITECTURE

   E&E Architecture is high level connectivity diagram represent the number of system,subsystem and logical connectivity between them.It is also extended to show the Control Area Network (CAN) between  different Electronic Controllers.

LOGICAL SCHEMATICS

   It is a detailed design of E&E Architecture which is extended to show the logical connectivity between the different components and controls of the given system,subsystem.

ELECTRICAL SHCHEMATICS

   Electrical S chematics is a detailed design of logical schematics which describes the pin to pin connectivity,Properties,Fusing Distribution,Grounding Distribution,Inter connects, wire properties,Circuit properties,Specification of component etc.., This is the end result of Electrical core design of system and used as an primary input for harness design.

WIRING HARNESS TOPOLOGY

   Wiring Harness Topology is Strategy to divide or split the harness between different pieces to achieve the best manufacturability,Serviceability, Cost Effective design.

WIRING HARNESS ROUTING

   Wiring Harness Routing deals wioth desired path of wiring harness into given vehicle environment by applying set of  design roles and industry best practices.

WIRING HARNESS PACKAGING

   Wiring harness packaging deals with fixing of wiring harness routing to ensure the safe,Reliable,and Durability of wiring harness by applying set of design rules and industry best practices.

WIRING HARNESS INTRODUCTION

   It refers to the Assembly of 

•     Wires
• Connectors
• Terminals
• Protection Covering
• Insulation
• Clip & Clamping
• Fuse & Relay Box
• Retension Devices Guiding Channels Electronic Components

 DESIGN FLOW OF EDS SYSYTEM

CONNECTOR

   Connector is an electro mechanical device used to join the electrical circuits. Electrical connectors consists of Housing,Terminals,wedge,Locks,Seals,Cavity,Mounting Cam etc..,

PROCEDURE

• Download the File and Save the folder as cad part
• Create Catalog
• Catalog creation

File -> New -> Catalogue document -> Add Family -> Save

P clamp

• Download P clamp cat part and open part body
• Define part body
• Create Entry Point And Entry Plane
• Create Exit Point And Exit Plane
• Create Plane In Base
• Open Electrical part Design
• Define Electrical Support  and Click object
• Select the Entry point and entry plane. Then Exit Plane and Base Plane
• Again Click Electrical Support. Select the Exit point and plane. Then the Exit plane default and select the base plane

WORKING PROCEDURE

• Create Product name it as Wiring harness assembly
• Create new product name it as geometrical bundle
• Open Mechanical Assembly design workbench
• Download connectors
• Create Electrical design with Bundle connection point and connectoe connection point
• Copy And Paste the respective connectors in Geometrical bundle product
• Use Manipulation command and move to respective place
• After that click Geometrical bundle workbench .it changes electrical part
• Open Wiring harness assembly
• click multiple branch document
• create routing diameter 10mm from connector DT06-08SA TO DT06-06SA
• After that ADD BRANCH Point in required area for branches
• Again click Multible branch document
• create a sub branches in DT06-4SA AND DT06-2SA Connectors
• Click Protective covering and select the catalogue for cot tubes 15mm
• Start extrimity point and end extrimity point 30mm CDT06-08SA and DT06-06SA connectors
• Click Protective covering and select the catalogue for cot tubes 10mm
• Start extrimity point and end extrimity point 30mm for  DT06-2SA and DT06-4SA connectors
• Click Harness Flattening workbench and Click the Flattening command
• Select the bundle and click all
• Next click the scale option and give the respective dimensions
• Finally Creating a Drawing

BUNDLE CONNECTIVITY STATUS

• Open the Mechanical Assembly workbench
• Go to Edit option click Search 
• Click Advanced and select the Electrical and Bundle segment
• Click fully connected

SAVE AS CAT.PART

• Open the Mechanical Assembly workbench 
• Open Tool option and Click the Generate CAT PART From product
• Select the Assembly click ok
• Save as IGS file.

HARNESS FLATTENING

• Click flattening parameters
• go to general settings
• pick the algorithm mode coarse and angle mode regular and angle 20 degree
• Tich the exact ,keep exist and radius of bundle
• Next go to drawing option 
• click bundle segment single line and protective covering double line

PROCEDURE

•     Open the Harness Assembly Flattening workbench
• click the Extract option and Go to the assembly and click the product
• Click the Flatten option and select all branches 
• Rotate the respective place
• Click scale option and Dimension to be taken as per drawing

DRAWING CREATION

•    Click the File and create new Drawing file
• Click front view and click the datum or face
• Go to properties click view
• tick thre fillets,boundaries,display view frame and 3d spec
• Tick the 3d wire frame and always visible and click ok
• Select the Ballon options and click the connectors
• Open the Edit option Select Background sheet
• Click the title box
• Click the Bill Of Material option
• Save the Drawing

RESULT

    Thus, the Route the Wiring harness on Given Engine and Prepare flattened 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 to be Completed.