Wiring harness and prepare flatten-view drawing for the given car body hatch

Objective:

The objective of this project is to route the wiring harness and prepare flatten-view drawing for the given car body hatch. All types of packaging rules and constraints have to be considered while routing the harness. Industry best practices should be implemented in the harness design. All necessary details like clearance/ clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

The wiring harness packaging rules and the industry best practices that have to be followed to complete this project are as follows: -

1. Easy manufacturing, installation, removal, and maintenance have to be considered while designing the wiring harness.
2. Routing through small structural holes or opening 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 in service.
4. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, the 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 provide protection over 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 easily available in the market to avoid extra cost for custom mounting solutions.

For This project I considered tailgate contains 2 Lights, one wiper, Reversing sensor, Lock sensor.

I used one intermediate connector of 12Pole to connect with main power. For light, lock, reversing sensor C-DTO6-2S connector which is having 2poles is used.

For the wiper motor connection used C-DTO6-4S connector which is having 4poles. And I have used furr tree clips used to route the wiring routing as support.

First after opening the Product file Rename, it as following:

After that save the file.

Add one more product file and rename, as follows:

After renaming tailgate assembly import the given tailgate (Back Door) file to the target assembly to the working assembly workbench.

Than use “save management” save than propagate directory to save of all components of assembly.

Again, create one more product file to import Electrical Components as “Geometric_Bun_electrical_harness” than need to follow the save management option to save all components. Before importing the components, each component needs to define as Electrical Components.

After defining electrical properties, the components as follows:

1. C-DT06-2S (2pole connector)

Electrical Properties are defined using the above rounded toolbars

2. C-DT06-4S (4pole connector)

3. 12 Pole connector

4. Furtree clip

After placing the all coponents in aproprieate place. Importing and placing apropriate positioning the components all to be done at Assembly design workbench.

After placement of coponents shift to wiring harness assembly workbench to do wiring harness.

After shfiting to harness assembly workbench need to Provide that the “Geometric_Bun_electrical_harness” as Geometric Bundle. After defining geometrical bundle properties need to go to the multi – branchable document option in CREATION tool bar at same workbench to route harness branch definition.

In this routing I have used 10mm & 5mm bundles and slack provided as per the requirement from 0 to 5%.

In routing I have considered 10mm as main branch of the assembly and connector bundle connections 5mm. after completion of routing the routing is covered with corrugated tube. After routing with protection, the assembly as follows:

FLATTENING:

After completion of harness routing need to create new product file to create the flattening.

After creating the product file need to shift to the Electrical Harness Flattenning workbench.

Now need to provide flattening parameters, for the product

After creation of parameters need to extract the geometric bundle harness to the flattening work bench. After extract the EHF file will created and save using Save Management.

To make flatten the above assembly use command flatten and select the following face as active plane.

than select all bundle and click ok. The flattening file as follows:

Drawing of Flatten harness assembly:

In this first create the drawing file and save the document and import the flatten assembly to the sheet. Go to Insert à Generationà Automatic Bill of Material and select on the sheet Billa of material table will appear.