Project 2

Project 2: Back Door Wiring Harness Assembly:

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

A wire harness, also commonly referred to as a wiring harness, is an exterior sheath used to cover some types of electronic wires. Generally, wiring harnesses are made of thermoplastic or thermoset materials that can help protect the cables from the environment.

Automobiles today come with some great features. Their design, though, calls for deft wiring considerations. An automotive wiring harness is an assembly of wires, connectors, and other electrical parts. You use it in a vehicle for the transmission of signals.

Design of Wire Harness

The design of the harness comprising of the interconnected mesh of wires is crucial. Select the important components like connectors, fuses, and sensors. Ensure their reliability.

Study the schematic circuit diagram. Divide the entire vehicle into detachable parts like chassis, body, and engine. Then design the wiring harness that suits the requirements. Ensure that it fits the customer requirements, shape, and size of the vehicle. Chalk out electrical routing in a way that reduces complexity and uses minimal space.

There are three types of engine wire harnesses based on the vehicle part you are looking at. The engine wire harness is a set of wires, connectors, and terminals to relay the signal to and from the engine. It also communicates messages from all sensors within the engine.

The body wiring harness routes electrical and electronic bits of information. It’s what keeps the major components of the automobile working. The body wiring takes care of power windows, lighting, and other accessories. And then, you need a chassis wiring harness for connecting the components.

Construction of the Harness Assembly Bundle:

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 inline Connector
2. 'C-DT06-4S' which is a 4-pole connector for Taillight
3. 'C-DT06-2S' which is a 4-pole connector for Number Plate Light

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.

Step3-->Placing of connecters in required positions

Step 4: 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 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.

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:

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