Project 2

Statement of assignment:

Route the Wiring harness on the Given car body 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 you 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 if any along with CATIA 3D data.

• The figure above is the Backdoor of a car for which a Wiring Harness has to be designed
• A wiring harness will be done for the taillights and the no plate lights
• There are 2 4pin Taillight connectors and 2 2pin for the no plate lights and a 12-pin Inline connector
• The inline connector that will connect it to the Main Harness
• The bend ratio should be 1.4 for all bundle segments.

BACKGROUND, TECHNICAL SPECIFICATIONS, AND ASSUMPTIONS

Below are the few references from the real world which were considered while designing the wiring harness for this project

The wiring harness packaging rules and the industry best practices that have to be followed to complete this project are as follows:-

1. Easy manufacturing, installation, removal, and maintenance must be considered while designing the wiring harness.
2. Routing through small structural holes or openings shall be avoided to minimize chaffing and handling during installation.
3. Avoid harness routing and clipping in the blind zone or hard-to-reach areas during harness assembly or service.
4. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, a slack value between 1-5% is used.
5. It should be made sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.
6. Avoid harness routing near sharp edges or else protect the harness.
7. Enough mounting equipment such as clips and clamps should be provided.
8. The branch length should be greater than 50mm.
9. The minimum distance between the clip to the branch point should be at least 25mm.
10. The minimum distance between the two branch points should be at least 50mm.
11. The wiring harness should be easy to assemble and easy to excess.
12. Clips/ clamps used for the wiring harness should be readily available in the market to avoid extra costs for custom mounting solutions.

Step 1: Creating Assembly

• A Context Assembly for Backdoor Wire Harness has been created, which will work as the main assembly as shown in the figure above.
• A Context Assembly will contain Backdoor Assembly data and Backdoor Wire Harness Geometrical Bundle Assembly.

Step 2: To Define the Connectors

Here, according to the requirement, we are using

1. ‘C-776438’ Which is a 12 Pole connector is used as an inline Connector
2. 'C-DT06-4S' which is a 4-pole connector for Taillight
3. 'C-DT06-2S' which is a 4-pole connector for Number Plate Light

This CAD data was obtained from te.com. To electrically define a connector, we must first define the geometrical parameters such as the bundle connection point and connector connection point in the Electrical Part Design workbench for the downloaded connector.

‘C-776438’

'C-DT06-4

'C-DT06-2S'

For Support, we use Omega Clips

We need to mount the Omega clips on the Backdoor to provide support as well as act as a guiding channel, so we must first define it electrically with geometrical parameters, entry, and exit points on both the left and right sides of the clips, as shown in the figure below.

Step 3: Mounting the Omega Clips and Placing the Connectors

Mounting Points of the Omega Clips

Placement of the Connectors

• For the placement of the Omega clips and the Connectors we used various commands such as manipulation, snap, smart move, compass, and so on.
• The entire assembly is ready for routing
• Mounted are all 4 connectors,16 Omega clips, and 1 Interconnection connector

Step 4: Bundle Routing:

• The bundle segment is routed from the interconnection connector to the Omega clips and guided towards the 4 and 2 Pin connectors. while maintaining the Bend radius ratio of 1.4.
• We have used bundle thickness 5-10mm

Step 5: Adding protective coverings and guiding channels top shell to harness bundle

Here is the below figure, we have done with the whole wiring harness routing for the Backdoor. Now, we have to add protective coverings to all bundle segments

Step 6: Checking bundle continuity

In this step, we must first ensure that multi-branch capability is selected before proceeding to Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.

Selecting 'True' displays all connected bundle segments while selecting 'False' displays all non-connected bundle segments.

In this case, we chose the 'True' option and searched for results. As shown in the figure below, all of the bundle segments are highlighted, indicating that they are all electrically connected.

Step 7: Creating flatten view of the Backdoor Wire harness geometrical bundle assembly

In this step, we will use Catia V5's Electrical Harness Flattening workbench to create a flattened view. We should also ensure that the flattening file is saved in the same folder as the other harness assembly files.

• The bundle assembly was extracted into a Back door wire Harness Flattening Product file, which was then flattened along the face of the interconnection connector.
• We developed a flattened view.
• we must rotate bundle segments connecting to the four cam-shaft connectors using the 'Rotate' feature of the flattening workbench.
• It should be noted that the 'face' of the interconnection connector serves as the flattening plane, so we must rotate the bundle segments only along that plane.
• We used various features such as bend, rotate, and roll to streamline the harness for better representation.

The flattened view's final representation

Step 10: Creating a flattened view drawing for the wiring harness assembly

In the figure above, we're creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. As shown in the preceding figure, we must define drawing properties. It should be noted that the 3D wireframe is always ON in the 'Dress up settings. If this option is not enabled, the bundle segments will not be visible in the drawing view. the Backdoor wire Harness Flattens view's final Drawing view

Overall Images of the Assembly

given backdoor:

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.
3. Give additional slack if needed. 5-15% slack is sufficient.
4. Avoid routing on sharp edges or else provide protection over the harness.
5. Follow the clearance distance and keep away the harness from heat generation components.
6. Protection should be provided as needed according to surrounding temperature.
7. Branch length should be greater than 50mm.
8. Minimum distance between two branch points should be at least 50mm.
9. Minimum distance between clip and branch point should be at least 25mm.
10. Avoid too many sheet metal brackets on the engine.
11. The wiring harness should be easy to assemble and easy to access.
12. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and another placements can be defined properly for the wire harness routing.
13. 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.

Routing the Wiring Harness:

1. First, we have to consider the components we need for the routing. Here we are only considering the taillights and the number plate lights.
2. Here we are considering 2 different types of connectors as follows

1.intercinnection connector

2. 2 pole connector used for light

3. Clip and clamp is used to set the location of wire

Fir tree clamp is used for 5mm dai and p clamp used for 10mm diameter

Steps for routing:

1. First Defining all the connectors as electrical components and the clips as the supporting equipment.
2. Locate all the connector , clip, and cavity at the desired location.
3. Now by using multi-branch bundle route all the connector with the clip and clamp
4. By create a catlouge and add the protection cover od 15mm diameter and 8 mm diameter.
5. Now by using protection covering tool , protect all the bundle.
6. Create a gap from the end and start extremity by 10mm or 20mm

now by using electrical harenss flattening we can straight or flat all the wire connected with the connectors.