Project 2

Project 2

Aim:-

Statement of assignment:

Route the Wiring harness on Given car body and Prepare flatten 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.

Sol:-

Backdoor/Tailgate

The trunk or boot of a car is the vehicle's main storage or cargo compartment it also have a hatch at the rear of the vehicle. It is also called a tailgate.These doors can be operated manually or electric powered. here we design the trunk or back door wire harness using the Catia.The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement.Inner panel is attached to the outer panel using mastic sealant.

Types of doors based on working position

1. Top Mounted Door
2. Side mounted Door
3. Bottom Door

Rules to be followed-

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. Wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommanded if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

What is Wiring Harness ?

A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for “drop-in” installation.

Diff b/w Wire Harness & Cable Assemblies:-

Wire harnesses are often confused with cable assemblies however, the two are quite different. The main difference is that a cable assembly normally has only two ends, whereas a wire harness contains multiple breakouts (ends) that run in many different directions with multiple terminations on each breakout.

Wire assemblies are most commonly used in the transportation industry, including automobiles, buses, trucks, and planes. Construction machinery, industrial equipment, electronics and white goods (household appliances) will also be constructed using wire harnesses.

Benefits of Wiring Harness:-

Decreased installation time: Many vehicles require miles of wiring in order to operate. A wire harness assembly process greatly simplifies the manufacturing of these vehicles by integrating all the wires and cables needed into a single apparatus. The installation then becomes a simple matter of “dropping in” the harness, rather than running all of the wires individually.

Security and safety: When wires and cables are bound within a single harness, the individual components are more secure against the adverse effects of vibrations, abrasions and moisture. Space is optimized and the risk of an electrical short is reduced because the wires have been constructed into a non-flexing bundle. The risk of electrical fire is also reduced when the wires are bound within a flame-retardant sleeve.

What is Connectors?

Connectors are the electro-mechanical devices used to form a continuous electronic signal to connect wire harnesses to a power source or circuit. On a basic level, connectors consist of male-ended plugs and female-ended jacks that can be joined together to relay an electronic signal.

We ues connectors in this assemblies.

• DT06-2S

TE Internal #: DT06-2S
Connector & Housing Type : Housing for Female Terminals
Mating Pin Diameter : 1.59 mm [ .063 in ]
Connector System : Wire-to-Wire
Number of Positions : 2
Centerline (Pitch) : 5.46 mm [ .215 in ]

• DT06-4S

Internal #: DT06-4ST
Connector & Housing Type : Housing for Female Terminals
Mating Pin Diameter : 1.59 mm [ .063 in ]
Connector System : Wire-to-Wire
Number of Positions : 4
Centerline (Pitch) : 4.45 mm [ .175 in ]

• 776438-4

TE Internal #: 776438-4
TE Internal Description: AS 16, 12P CAP ASSY, KEY, 4
Connector & Housing Type: Housing for Male Terminals
Mating Pin Diameter: 1.5 mm [ .059 in]
Connector System: Wire-to-Wire
Number of Positions: 12
Centreline (Pitch): 4.5 mm [ .177 in]

What is Protective Covering?

Popular cable and wire harness coverings include: Heat shrink tubing—wraps snugly around wires and smooths out rough surfaces, providing thermal and electrical insulation. Adhesive-backed tubing provides a strong seal against moisture and chemicals that can corrode harness components.

Name

ID (mm)

OD (mm)

Thickness (mm)

10mm COT

7

10

1.5

15mm COT

12

15

1.5

Firtree Clip:-

Push-in Fir Tree Fasteners & Fir Tree Clips for secure attaching. For applications such as fixing material over wood (such as upholstery), Fir Tree Fasteners, also known as Fir Tree Clips are a tried-and-trusted solution.

Catia Workbanch:-

Harness Connectivity:-

Flattening Workbanch:-

Conclusion -

Routing of the wiring harness for the car Backdoor assembly has been succesfully done and prepared flatten-view drawing in Catia V5 as per the design requirements.