Project 2

PROJECT 2:- BACKDOOR WIRING HARNESS ROUTING AND FLATTENING

OBJECTIVES:

Route the Wiring harness on Given car BACKDOOR or 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. Apply Protection coverings as required.

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 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.

STEP:-1 CREATING CONTEXT ASSEMBLY

• We have created context assembly for the tail gate of the car as main assembly.
• This context assembly contains the 3D cad data for the tail gate of the car and car tail gate harness geometrical bundle.

STEP:-2 DEFINING THE ALL CONNECTORS TO ELECTRICALLY

• We have 3-pole connector for interconnection connector defined to electrically.
• We should have to define it electrically that is to define geometrical parameters, bundle connection point and connector connection point.

• The cavity mounting part of the connector we have defined electrically shown in above figure.

• We have 4-pole connector, and 2-pole connectors for Tail lights and number plate light and parking camera, wiper motor.
• We are defined to the connectors electrically in bundle entry point,connector connection point.

DT06-2S

DTP06-4S

• Here we are using support clip like fir tree clip.
• The fir tree clip is defined to electrically as shown in below figure.

• The below figure is represent We have positioned the firtree clip on tail gate in desired location using manipulation commands.

Step 3: Adding connectors to the 2 tail lights and number plate lights and parking camera,wiper motor.

• We have added both 2-pole,3-pole connectors and 4-pole connectors inside the tail gate harness geometrical bundle assembly.
• We have used commands like manipulation, compass, snap and smart move to place all the connectors to their desired location.
• We have placed all the connectors at their desired position as shown in below figures.

STEP:-4 CREATE BUNDLE ROUTING

• Now, the car tail gate assembly is ready for the bundle routing as shown in below image.
• Also, we have activated harness assembly as geometrical bundle.

• Let, we have started bundle routing from interconnection connector and assumed diameter of main trunk is 10mm.
• The diameter of bundle leading to 2 tail lights and number plate lights,parking camera,wiper motor diameter is 5mm respectively.
• The bend ratio is assumed to be 1.4 and appropriate slack between 1-5% is given wherever needed.

STEP:-5 ADDING PROTECTIVE COVERING FOR BUNDLE HARNESS

• After bundle routing, we have to add protective covering to the harness bundle so that it will get protected from the damage.
• Here, we have used currogated tube for the current harness assembly.
• We have given start and end extremity wherever needed for the currogated tubes as shown in below image.

Step:-6 Checking bundle continuity

• First, we have to select 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 bundle segments while selecting 'False' condition will show all the non-connected bundle segments.
• Here, we have selected 'True' condition and search for the results. All the bundle segments are highlighted and showing that all the bundle segments are connected electrically as shown in below image.

Step:-7 CREATE FALTTENING FOR THE BUNDLE HARNESS ROUTING

• 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 an active plane and selected all the branches as shown in below image.

STEP:-8 CREATING FLATTERN VIEW DRAWING

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

• As shown in below image, we have to insert front view of the harness assembly into drawing file and define drawing properties.
• It should be noted that for the Dress-up feature 3D wireframe is always ON. If this setting is not selected then the bundle segments will not be visible on the drawing view.

Final part of the car tail gate wiring harness flattening drawing

BACKGROUND VIEW OF THE FLATTENING DRAWING

CONCLUSION:

NRouting 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 routing the wiring harness, implemented industry best practices in the harness design. Also, provided details like clearance, clipping selection, harness fixing requirements, harness continuity in order to design the harness.