Project 2

Aim: Route the Wiring Harness on given Car body and prepare 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 tailgate 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.

Back Door Assembly Part:

                                       

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

1. ‘C-776438’ Which is a 12 Pole connector is used as an Interconnection Connector
2. 'C-DT06-08SA' which is a -8 pole connector for Taillight
3. 'C-1563689' which is a 4-pole connector for Wiper Motor 
4. 'C-DT06-2S' which is a 2-pole connector for Number Plate

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.

C-776438- 12 Pole Connector

                                  

C-DT06-08SA - 8 Pole Connector

                                         

C-1563689 -4 Pole Connector

                                     

C-DT06-2S- 2 Pole Connector

                                  

For Support, we use Mouting Like P Clamp and Furr Tree Clips

We need to mount the P Clamp and 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.

P Clamp for Package the Wiring into respective Routing P Clamp Size 10mm Tolerance 0.25 (Unilateral)

                                

Furr Tree Clips

                                 

 Placement Of Various types of Connectors and also used to Support required Positions

                              

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: 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: TRUE Condition

                              

Check For Fully Connected Bundle: False Condition

                           

Step 5: 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.

                      

v                    

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.

                   

                   

                   

                 

Conclusion:

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