Project 2

Project 2: Back Door Wiring Harness Assembly:

Objective:

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.

Back Door Assembly Part:

Construction of the Harness Assembly Bundle:

Step 1: Creating Context 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: Positioning the Connectors & Clip/Clamps to the Back Door Assembly:

Here, according to the requirement, we are using

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.

For Support, we use Furr Tree Clips

We need to mount the Furr Tree 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.

Mounting the Furr Tree Clips and Placing the Connectors

Mounting Points of the Furr Tree Clips in Required Places.

Placement Of Connector 1 for Wiper Connection:

Placement Of Connector 2 for Number Plate Light Connection:

Placement Of Connector 3 for Back Light Connection:

Step 3: Bundle routing from Interconnection:

• Here, we are routing the bundle segment from interconnection connector to Furr Tree. The diameter for this routing path is 10mm and bend radius ratio is assumed to be 1.4.
• we can see that the bundle segment inside the guiding channel is created by using pre-made sketch as routing definition.
• In above figure, we are routed bundle segment from the newly created branch points to the 8 fuel-injector connectors. 
• Similarly, we have done routing for the left side guiding channel also as shown in the figure.

Step 4: Adding protective coverings:

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

Step 5: 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.

Check For Fully Connected Bundle:

Check For not Fully Connected Bundle:

Step 6: Flatten the Bundle Routing:

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. 

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

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

Step 7: Creating the Drawing File For this Flattened Bundle segment:

Creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

We have to define drawing properties as shown in above figure. It should be noted that in 'Dress up' settings 3D wireframe is always ON. If this setting is not selected then th bundle segments won't be visible on drawing view.

Assumptions:

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.

Conclusion:

Thus,Finally the Bundle Assembly is Routed With Protective Covering And Creating Drawing and now the Drawing is Ready For Pre Release for Production.