Project 1

AIM:

To design and develop the wire harness routing for the given side door by following the design and packaging rules.

OBJECTIVE:

• To define all the connectors electrically and save it in the catalogue.
• To place the all connectors and cavities to the required positions
• To place the Omega fir tree clips at the required position by following the packaging rule.
• To create the wiring harness routing as per required and create branch points where required and also followed the packaging rules.
• Prepare the flattened product using flattening workbench.
• prepare the drawing file of the harness assembly.

Design Methodology

1) Create the product file as "side door assy." in which all the part and product files will be assembled which are required for routing.

2) Create an additional product file in the "Side door assy." as "geometrical bundle" for wire routing.

3) Electrically defining the connectors and supporting components.

CONNECTORS

1) 1-174357-2

2) DT06-08SA

3) DT06-2S

4) DT06-4S

5) 174359-2

Supporting components

1) Omega fir tree clip

2) Connector Mounting clip

4) Add all the connectors to the geometric bundle product file and place them over the side door assy. in proper positions using smart move, snap, manipulation etc... commands.

Side door assy.

Position of interconnection connector

Position of omega fir tree clips

Connector for Power window control switch

Speaker System connectors

Door lock sensor connector

Connector - Door control switches

Important packaging rules

• Minimum branch bundle length should be 50 mm.
• Provide the enough slack length to avoid the damages due to engine rocking.
• The minimum distance between the clip and branch point should be 25 mm.
• The minimum distance between the two breakout should be 50 mm.

5) Wire Routing

6) Continuity Checking

After completing the routing check the continuity of the bundle segments.

Edit-- search--advanced.

False segment

True segment

7) Applying protective covering over the wire bundle

8) Wire harness flattening

9) Representation of flattened harness into the drawing sheet