Project 2

OBJECTIVE

 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.

INTRODUCTION

In this Wiring Harness routing process we have used 12 pole interconnection connector ( C-776438-4 ) and 2 pole connectors ( Dt06- 2s) for all the electrical features

Wiring Harness

Automotive wiring harness is defined as an assembly of wires, terminals, and connectors that run throughout the vehicle to transmit information and electric power. Automotive wire harness is designed according to electrical & dimensional requirement of automobiles and is integrated to connect different parts of vehicle such as body, engine, dashboard, chassis, and others. Automotive wiring harness enables transmission of control signals and electrical power to electronic & electrical devices in an automotive to ensure basic functionality & enhanced safety.

Harnesses are designed as per the electrical and geometrical requirements of automobiles, and are embedded in the body, engine, and chassis of vehicles. Body wiring harnesses are embedded into dashboards, door locks, power windows, and interior electrical components. Engine wiring harnesses embed into speed sensors, lock breaking systems, cruise control systems, and fuel injection systems. Chassis wiring comprise of the front, rear and main harnesses.

CONNECTOR

An electric connector is an electro mechanical device used to create electrical termination and create electric circuit. Electric connector consist of Housing, Terminal, wedge locks, seals, cavity, mounting cams, etc. These are responsible to make connection between harness and component.

Following Parameters are required to define for any connector:-

1- Geometric Parameter -  Points and Co- ordinate system (Axis)

2- Connector Connection Points - This points is used for the connection of one connector with another connector

3- Harness Bundle Entry Point - This Point define where bundle segment point will end when routed to the electrical connector

4- Cavity Connection Point (Optional) - This point is used to define the connection of a connector with mounting clips. This only applies when the connector have the mounting feature for mounting clips.

 

ROUTING PROCESS:-

STEP 1-  Download the Engine Cad data & the required Connectors

STEP 2- Define connectors & Connector clip  as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors & Clip.

•  Create required Geometrical parameters. Create 2 points on the middle of both ends of the part and Create a axis system on the mating face. Put Y axis to the other Mating part and X axis towards the Locking system
• Define Part as a Connector
• Define " Bundle Connection Point "
• Define connector connection point.
• Define cavity connection point. ( If necessesary )

STEP-3- Create a new product file for the assembly of the backdoor and the routing. ( I have hidden the outer panel of the backdoor for better visibility of routing)

STEP-4- Place all the connector at a convinient position for easy routing

1- Wiper Motor Connector

2&3- Lugage access Gate Connector

4 & 5- Tail lamp connectors

6- Back Camera Sensor connector

7- Number Plate Light Connector

STEP-5 - Place the Furr clips according to the desired routing path

STEP-6 - Start Routing the bundle from the interconnection connector and go along with the clips and connect all the CONNECTORS .  Main Bundle diamter is 10 mm and sub-branch diameter is 5mm.

STEP-7 - Provide protective covering to the bundle

STEP-8- Check for the Bundle Continuity, Check For the bundle continuity. Here we have chosen FALSE option so if there is any discontinity it will be shown in the below description. Here nothing is shown in the description so there is no discontinuity.

STEP-9- For the Flattening operation, 

• Create a new Product file 
• Go to Electrical Harness Fattening Workbench
• Extract the Geometrical Bundle into the new product file
• Use Flatten Command to flatten the bundle

STEP-10- Create a drawing File and Project the view of the Flattening Bundle

CONCLUSION

Here I have completed Wiring Harness of the Backdoor with all the routing parameter, Packaging rule and Industries Practices.