Project 2

AUTOMOTIVE WIRING HARNESS BACKDOOR

Statement of assignment:

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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

The trunk or boot of a car is the vehicle's main storage or cargo compartment it also have a hatch at the rear of the vehicle. It is also called a tailgate.These doors can be operated manually or electric powered. here we design the trunk or back door wire harness using the CatiaV5 .The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement.Inner panel is attached to the outer panel using mastic sealant.

Types of doors based on working position

1. Top Mounted Door
2. Side mounted Door
3. Bottom Door

Aim- To route the wiring harness on the given backdoor assembly and prepare the flatten view drawing in CATIA V5.

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

Rules to be followed-

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.

Steps required-

STEP 1 - Creating context assembly

• 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:

Choosing right components for the wire harness routing.here we are using the components for backdoor upper and lower lights,wiper motor,sensors,and defogging equipment.the connectors used are first elecrically defined and then added to the catia model.

1. ‘C-776438’ Which is a 12 Pole connector is used as an inline Connector
2. 'C-DT06-4S' which is a 4-pole connector for Taillight
3. 'C-DT06-2S' which is a 2 pole connector used for light,sensors,motors.

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.

1.

2.

3.

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

STEP 3 - Adding connectors and needed equipments

Opening the equipments in catia and using the snap and smart move and positioning the connectores and supports.

STEP 4 - Bundle routing

The routing starts with interconnection connector placed

Step 8: Adding protective covering to the harness bundle

• 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 COT TUBES for the current harness assembly.
• We have given start and end extremity wherever needed for the COT TUBES .

Step 5: 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 FALSE condition and search for the results.As no bundle segments appear, it means bundles are fully connected.

Step 6: 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 an active plane and selected all the branches as shown in below image.

Step 7:

creating a flatten view drawing for the wiring harness assemblyNow, we have to make new drawing file and define all the necessary drawing parameters

we have to insert front view of the harness assembly into drawing file and define drawing properties

views

Conclusion:

Routing of the wiring harness for the backdoor 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.