Project 2

ANSWER

AIM

Route the wiring harness on the specified car body and be ready in CATIA V5 to flatten the view drawing. All packaging regulations and industry best practises covered in this course must be applied, as shown in the design. As needed, apply protective covers.

You can use the 3D connector data that is readily available, or you can download the connectors at www.te.com.

Compile and provide CATIA 3D data together with any essential reports, such as clearance, clipping/clamping selection, harness fixing requirements, harness continuity, and any assumptions.

STEPS

• The car's back door is seen in the image above, and a wiring harness needs to be made for it.
• There will be a wire harness made for the no-plate lights and the taillights.
• There are two 2-pin connectors for the no-plate lights, two 4-pin connectors for the taillights, and a 12-pin Inline connector.
• It will be connected to the Main Harness through the inline connector.
• All bundle segment bend ratios must be 1.4.

BACKGROUND TECHNICAL SPEIFICATIONS AND ASSUMPTIONS

Below are a few examples of real-world examples that were taken into account when constructing the wiring harness for this project.

To perform this job, the following industry best practises and regulations regarding wiring harness packaging must be adhered to:-

1.When designing the wiring harness, ease of manufacture, installation, removal, and maintenance must be taken into account.
2.To reduce chaffing and handling during installation, routing through minor structural holes or gaps must be avoided.
3. While assembling or servicing a harness, avoid routing and clipping in the blind zone or in places that are difficult to access.
4.According to the surrounding conditions and the harness bending requirements, add more slack if necessary. Slack values between 1 and 5 percent are used for this project.
5.When designing the wiring harness in a CAD environment, it is important to ensure that there are no instances of fouling. To prevent fouling, additional clips or clamps may be employed.
6. Avoid routing the harness close to jagged edges, or otherwise shield the harness.

7.A sufficient supply of mounting tools, such as clips and clamps, should be offered.
8. A branch should have a length larger than 50mm.
9. There should be at least 25mm between the clip and the branch point.
10.There should be at least 50mm between the two branch sites.
11. The wire harness should be simple to put together and remove.
12.In order to prevent additional expenditures for unique mounting solutions, the clips or clamps utilised for the wiring harness should be easily accessible on the market.

STEPS

STEP1 CREATING ASSEMBLY

• The main assembly, as depicted in the above diagram, will be a Context Assembly for Backdoor Wire Harness.
• Backdoor Wire Harness Geometrical Bundle Assembly and Backdoor Assembly data will both be present in a Context Assembly.

STEP 2 TO DEFINE CONNECTORS

Here, we are employing in accordance with the demand

1.‘C-776438’ What is utilised as an inline connector is a 12 Pole connector.
2. "C-DT06-4S," a 4-pole taillight connector.
3. "C-DT06-2S," a 4-pole number plate light connector
This CAD information came from te.com. At the Electrical Part Design workbench for the downloaded connector, we must first define the geometrical parameters such as the bundle connection point and connector connection point before we can electrically define a connector.

STEP 3 MOUNTING THE CLIPS AND PLACING THE CONNECTORS

• We utilised a variety of commands, including manipulation, snap, smart move, compass, and so on, to put the Omega clips and Connectors.
• All of the components are prepared for routing.
• There are 16 Omega clips, 1 Interconnection connector, and all 4 connectors mounted.

STEP 4 BUNDLE ROUTING

• The bundle segment is steered towards the 4 and 2 Pin connectors by being routed from the interconnection connector to the Omega clips. while preserving the 1.4 bend radius ratio.
• We used bundles with a thickness of 5–10mm.

STEP 5 ADDING PROTECTIVE COVERINGS

The whole wiring harness layout for the Backdoor is shown in the image below. Now, all bundle segments must be covered with protective coverings.

STEP 6 CHECKING BUNDLE CONNECTIVITY

Before moving on to Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected in this step, we must first make sure that multi-branch capability is selected.

All connected bundle segments are displayed when "True" is chosen, whereas all disconnected bundle segments are displayed when "False" is chosen.

In this instance, we selected the 'Yes' option and ran a search. The bundle segments are all highlighted in the figure below, demonstrating that they are all electrically coupled.

STEP 7 CREATING FLATEN VIEW OF BACKDOOR

To produce a flattened view in this stage, we'll use the Electrical Harness Flattening workbench in Catia V5. The flattening file should be saved in the same folder as the other harness assembly files, as well.

• The interconnection connector's face was flattened after the bundle assembly was extracted into a Back Door Wire Harness Flattening Product file.
• Our perspective became flattened.
• The 'Rotate' function of the flattening workbench must be used to rotate bundle segments connected to the four cam-shaft connectors.
• It should be remembered that the flattening plane is the connecting connector's "face."
• We streamlined the harness for better depiction by utilising multiple functionalities like bend, rotate, and roll.

STEP 8 CREATING A FLATTENED VIEW DRAWING OF THE ASSEMBLY

We're making a fresh drawing file and setting up all the necessary drawing specifications. The Drawing file needs to have the front view of the Backdoor wire Harness Flattening Product file. We need to define drawing properties, as seen in the preceding figure. It should be noted that in the "Dress up settings," the 3D wireframe is always ON. The bundle segments won't be seen in the drawing view if this option is disabled. Final Design view: Backdoor wire harness flattens