Project 2

WIRING HARNESS OF TAIL GATE

OBJECTIVE :

1) Route the Wiring harness on Tail Gate 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.

2) Available connector 3D data can be used, downloaded from www.te.com

3) Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity.

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 connectors as follows

Clip and clamp is used to set the location of wire-

• Furr Tree Clip

• 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

CHECKING BUNDLE CONTINUITY

• In this step, first we have to make sure that multi-branchable is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected
• By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments.
• Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.
• Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are not electrically connected as shown in below figure.

CREATING FLATTEN VIEW OF THE ENGINE HARNESS GEOMETRICAL BUNDLE ASSEMBLY-

In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved.

1) Before creating flatten view, first we have to define flattening parameters.

2) We have extracted the bundle assembly into Backdoor Harness Flattening Product file and then flattened the file along face of interconnection connector as shown in above figure.

3) At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

4) We have created a flatten view as shown in above figure.Here, we have used different features like bend, rotate, roll to streamline the harness for better representation.

CREATING A FLATTEN VIEW DRAWING FOR THE WIRING HARNESS ASSEMBLY-

CONCLUSION :

This Project Concludes the Wiring Harness Assembly and Installation of Tail Gate and wire Flatened for Drawing Creation.