Project 2

BACK DOOR:

Aim :

• Route the Wiring Harness on a given Car body and prepare flatten view drawing in Catia V5

Objective :

• The objective of this projects is to route the wiring harness and the prepare flatten view drawing for tailgate of the car. All types of packaging rules have to considered while routing the harness and industry based practice's shall be demonstrated in harness design. All necessary details like: clearance, clipping / clamping selection, harness fixing requirements, harness continuity should have be provided in order to design the wiring harness.

Assumptions :

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 the close conditions to avoid excess slack.
6. Routing through the small structural holes and openings shall be avoided. To minimize the chaffing and handling of the wiring harness during installation.
7. It should be make sure that there's no case of the fouling while designing the wiring harness in CAD environment. Additional mounting equipments like clips/clamps may be used to avoid the fouling.
8. Use of rubber grommet is recommanded if harness is passing through the sheet metal panels. Example- firewall, passing to a door, tail gate etc.
9. The branch length should be greater than the 50mm.
10. The minimum distance between that clip and branch point should be at least 25mm.
11. The minimum distance between that two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available on the market to avoid extra cost for the custom mounting solutions.

• Now, we have to route wiring harness for the two tail lights and two number plate lights, and connect them to main electrical system of car.
• For two tail lights and two number plate lights, we are using 8-pole connector and 2-pole connector respectively.
• A car body also have an interconnection connectosr which will connect the wiring harness of tail gate of the car body to the main harness of the vehicles.
• We will use 12-pole electrical connector with a mounting clip as an interconnection connector.
• The bend ratio for the bundle segment is considered to be 1.4

Creating Context Assembly:

• We have created the context assembly for the tail gate of the car as an main assembly as shown in above figure.
• This context assembly that contains the 3D cad data for the tail gate of the car and the car tail gate harness geometrical bundles.

Difining 2-pole and the 12-pole connectors electrically:

• Here, we will use 2-Pole and the 12-Pole connectors for this assembly and for that we shoul have to downloaded these connectors from TE.com
• We should have to define it electrically that is to define geometrical parameters, the bundle connection point and the connector connection point.

• In above figure, we have defined a 12-Pole connector electrically for the two tail lights of the car

• Here, we have defined 2 - Pole connector electrically for the two number plate lights of the car has shown in above figure.

• Here, we have defined 2-Pole connectors electrically for the two number plate lights of the car has shown in above figure..

Adding connectors to the 2 tail lights and the 2 number plate lights:

• We have added the both 2-pole connectors and 12 -pole connectors inside the tail gate of harness geometrical bundle assembly.
• We have the used commands like manipulation, compass, snap and smart move to the place all the 4 connectors to their desired locations.
• We have placed all the connectors at their desired position as shown in the below figures.

Defining and locating the interconnection connector

• A 12-pole "C-776438-4" is used to an interconnection connector

Bundle routing:

Before, bundle routing we have to make a curve by creating points in the hollow part of the given tailgate. So we have made a curve from through 11 points from the interconnection connector has shown in below image.

Adding protective covering to harness bundle:

• After bundle routing, we have to add protective the covering to for harness bundle so that it will get protected from the damages.
• Here, we have used PVC tapes for the current harness assembly.
• We have given a start and end extremity wherever needed for PVC tape has shown in below image.

Checking bundle continuity:

• First, we have to select the multi-branchable and go through the sequence as Edit>Search>Advanced>Workbench- Electrical>Type-Bundle Segment>Attribute-Fully Connected.
• After selecting 'True' condition will show all the connected bundles segment while selecting the 'False' condition will show all the non-connected bundle segments.
• Here, we have selected 'True' condition and the search for the results. All the bundle segments are highlighted and showing that all the bundle segments and are connected electrically as shown in below image.

Create flatten view of the wiring harness bundle

• To create a flatten view of the harness assembly, we have to work in Electrical Harness Flattening workbench in Catia V5.
• Also, we have to make sure that the flattening file is saved into the same folder where we have all the parts of the harness assembly.
• As shown in below image, while defining the wiring harness flattening parameters make sure to select Single line for bundle segment and Double line for protective covering.

• After that, we have to extract and bring the bundle assembly into the car tail gate flattening product file.
• To flatten the harness assembly, we have selected Face as active plane and the selected all the branches as shown in below image.

• Now, we have a flatten view of the wiring harnessand.. geometrical bundle assembly as shown in below image.

• We have designed the flatten view by the using feature like rotate for better representation of the harness as shown in below image.

a flatten view drawing for the wiring harness assembly:

• Now, we have to make new drawing file and the define all the necessary drawing parameters as shown in below images.

Final drawing of the flatten view for the cars tail gate wiring harness assembly with all the components

Conclusion :

• Routing of the wiring harness for the car tail gate assembly has done and prepared flatten-view drawing in Catia V5. Applied all the packaging rules while routin the wiring harness, and implemented industry best practices in the harness designs. Also , provided the details like clearance , clipping selection , harness fixing requirements, harness continuity in order to design the harness.