Project 2

ELECTRICAL DEFINATION AND CATALOG CREATION FOR CONNECTOR:

First we have downloaded the connector from te.com and and open it in catia v5 software for defined it electrically we neeed to switch to PART WORKBENCH and defined the following:

1. Connector connection point
2. Bundle connection point
3. Connector connection axis system
4. And Cavity connection point and axis system(if needed)

Now we will switch to the ELECTRICAL PART DESIGN go to DEFINED CONNECTOR >CLICK ON PART > A popup window will be open, give the number of bundle entry point >ok see below image(1) for more detailes

Now we will difined bundle entry poit go to DEFINE BUNDLE CONNECTION POINT>click on part>A popup window will be open, give all necessary see below image(2) for more detailes

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Now go to the DEFINE CONNECTOR CONNECTION POINT>click on part>A popup window will be open, give all necessary see below image(1) for more detailes

Now our connector has succesfully Electrically defined . Now we will add the connector in the catalog, for this go to STORE DEVICE>select the folder>select family as connector as shown in below image (2)

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Now similaly we will defined all the connector as Electrical Component and add them in the catalog as same as mentioned above

ELECTRICAL DEFINATION AND CATALOG CREATION FOR CLIPS AND CLAMPS:

First we have downloaded the P Clamps from te.com and and open it in catia v5 software for defined it electrically we neeed to switch to PART WORKBENCH and defined the following:

1. Entry point and Exit point
2. Entry plane, Exit plane and Base plane (all planes should be parallel with their respective surfaces)

Now we will switch to the ELECTRICAL PART DESIGN go to DEFINED SUPPORT PART>click on part>A popup window will be open, give all necessary see below image(1) for more detailes

Now we will defined it as a support one mmore time from the other side here the first entry point is hidden so that we cannot select it as a second entry point see below image (2)

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Now again go to DEFINE SUPPORT>CLICK ON PARTA> popup window will be open, give all necessary see below image(2) for more detailes >OK

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Here our P Clamp is is fully electrically defined similarly we will difined all the clamps and Fir tree clip as discussed above

Now we will add the above clamps in the catalog for this go to DTORE DEVICE>select the folder>and choose the family as a clips and clamps as shown in below image

All Above clips and clamps are Electrically defined.

• CLEARANCE MANAGEMENT:

Clearance managementbasically focussed on the wiring harness clearance with the surrounding parts. This is primary requirement for the routing and packaging.

This study is a part of geometrical integration.

Clearance requirement varies between industry to industry. how ever following requirements can be used to understand th basics of clearance management.

Wiring harness to STATIC PARTS- 10mm, to dynamic parts-25mm, to sharp edge-10mm, To fueline, brake line, hydraulic line-50mm, exhaust manifold & component-200mm, heat source (unsheilded)-200mm, heat source sheilded-50 mm etc.

• Clipping/Clamping selection:

Clips are used to route the harness and for harness clamping in each area.

Different types of clips:

• Fir tree mount and cable tie assambly: the mount can slides along the strap of the tie for proper orientation
• High temperature fir treee mount cable: it provides exccelent resistance in operating temparature upto 270degree
• Fir tree nount tube clip: this tube clips allow the installer to provide the force on it to fit the bundle with it
• C clip with fir tree mount: this allows for easy insertion of clip into a parallel drilled hole
• Cable tie mount: desidned to provide stability to wire bundle
• Dual clamps ties: it is designes to provide parallel seperation between hoses, wire , cables and tubing.
• Dual swivel: these mount can be easy rotated by hand saddles spacers are used to prevent chaffing and wear

• Harness fixing requirements:
• Wiring harness should be routed in such a way that it is easy to assamble on vehicle.
• wiring harness topology plays an importatnt role to meet this critaria
• wiring harness shoud be routed that it would be easy access in service and faluire analysis
• Distance between two clamps on a straight branch should be minimum of 200mm.
• The minimum branch length should be 50mm.
• Minimum distance between clip and nearest branching point should be 25mm.
• The minimum distance between two straight connection points should be 200mm.
• The minimum distance between two breakout points should be 50mm.
• To limit the number of branches from a single branch point to 4.
• Avoid routing wiring harness near the exhaust manifold and its components and also from other unshielded heat sources. If re routing is not possible then maintain a minimum distance of 200mm.

WIRING HARNESS ROUTING PROCESS IN CAR BACK DOOR:

First we will create the product file and name it as Context File and Save it the file,

Open the back door cad part and copy it and past it in the context file,

Now insert new product in the conext and name it as geometrical bundle, in this product file we only have harness parts like clip and clamps and bundle and all connectors.

Now go to CATALOG BROWSER > select the connectors,clamps etc. which we want to insert >double click on it and >ok>close

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Now switch to ASSAMBLY DESIGN and place the Connectors , Fir tree clip, in the required position as shown in the below image and numbered are discussed below

1. This Connector is used for the interconnection with the coming wiring harness from the vehicle
2. Defogger-A defogger is necessary to clear the fog/mist from the windshield quickly. It improves visibility during cold weather when fog is a common phenomenon. It is a system that blows hot air into the windshield and quickly removes the water droplets accumulated on the glass surface.
3. This connector is used for the tail lamp of the vehicle
4. This connectors are used for the Wiper moter connection as well as sensor and camera

While positioning the Clips make sure that there is maximum distance betweeen the clips should not exceed the 200mm see below image 1

Now we will switch to the Electrical Harness assambly > click on the BRANCH DEFINITION >Give diameter >Route definition>select the clamp and connector >ok>hive slack if required>ok see the below image2

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Now we will add the Protective covering on the bundle where ever required go to PROTECTIVE COVERING> and select as shown in the below image

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Now we have routed the bundle in the back door as shown in below image

FLATTENING & DRAWING CREATION THE BUNDLE GEOMETRY:

First we open the Geometrical Bundle Wiring Harness assambly in different window

Now create the New Product File for Flattening switch to ELECTRICAL HARNESS FLATTENING>do setting in Flattening Parameters > ok

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Now tile the window vertically and click on top of the model tree>EXTRACT>select the geometrucal bundle assambly as shown in below image:

Now click on FLATTEN> select the bundle > select all as shown in below image1, and flattened image in 2

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Now we will Create new DRAWING and save it and click on Front view go to flatten cad part and select front view >rotate the drawing as it is in the actual > click on screen>here the drawing is no fit in the sheet so we will scale down the drawing to 1:2 save ok