Project 2

Project 2

AIM:- To Route the Wiring harness on the Given car body Backdoor 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.

BACKDOOR WIRING HARNESS:-

If you use the car every day, the door will open and close many times. In case of Back door, the trunk could be open and close many times in daily life. Backdoor wiring harness mainly introduced to connect the brake lights, number plate lights, rear wiper motor, defogger connections. The harness routing should be maintained properly with all the supporting components like clips, clamps with proper protective covers, rubber grommets.

DESIGN CRITERIA AND PACKAGING ASSUMPTIONS:-

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints. It may damage the harness or puncture the harness. Keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

ASSUMPTIONS:–

• We have to route the wiring harness for two tail light,one number plate and one for wiper and connect them to main electrical system of as car.
• For two tail light we are using light weight connector .
• A car body also have an interconnection connector which connects from a car body hatch to the, a car body wiring harness and is used a preferred location from where the routing for these lights starts.
• We use C-776438-4 interconnection connector.
• As for the mounting parts clips. which are used where ever necessary, furr tree clips are used.

DESIGN METHODOLOGY:–

STEP1:- Download the backdoor cad data from given our website.

STEP2:- Defining all the connector cad data clips and clamps as required for routing the backdoor.

Here we will use 1 interconnection connector and 4 light weight connector which is required for the routing.

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 electrically defined and then added to the Catia model.

STEP 3:- Defining clip as support.

• We will use mounting clip for the mounting purpose.
• We have to define geometrical parameters, bundle entry points and exit points from both left and right side of the clip.
• We have defined these clips electrically as a support in electrical part design workbench.

We need to mount the Furr tree clips on the Backdoor to provide support 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 4:- ROUTING THE WIRING HARNESS

Adding all the connector, clips and clamps as required position with the help of manipulation tool, and using of compass. All the clamps and fir tree clips are positioned.

STEP 5:- CHECK THE BUNDLE CONTINUITY

In this step, first we have to make sure that multi-branch able 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 False option and searched for results. No bundle segments are highlighted found showing that means all the bundle segments are electrically connected.

STEP 6:- Adding Protection Covering

By using protection covering tool we protect all the bundle. We have created a catalogue and we add the protection cover of 15mm diameter and 10 mm diameter. Here we Create a gap from the end and start extremity.

STEP 7:- CREATE FLATTEN VIEW

Now we open a new product file for the Electrical harness Flattening. Here we save the already made geometrical bundle segment and we extract the geometrical bundle to flatten harness by apply flattening parameters we flatten the geometrical bundle.once the branches are flattened, we do some modification in the branches using the Rotate, bend, straighten etc. tools in the Electrical harness flattening.

STEP 8:- CREATE A FLATTEN VIEW DRAWING

Now we're creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. It should be noted that the 3D wireframe is always ON in the 'Dress up settings. If this option is not enabled, the bundle segments will not be visible in the drawing view. the Backdoor wire Harness Flattens view's final Drawing view.

Before creating flatten view, first we have to define flattening parameters. Make sure that selecting ‘Single line’ for bundle segment and Double line for protective covering.

Pdf screen shot of Drawing:-

CONCLUSION:-

Routing of the wiring harness for the 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 provide details like clearance, clipping, selection, harness fixing requirements, harness continuity in order to design the harness.