Project 2

AIM: -

• Route the Wiring harness on Given Tail Gate and Prepare flatten view drawing in CATIA V5.

Objective:

• Route the Wiring harness on Given car body and Prepare flatten view drawing in CATIA V5
• Prepare flatten view drawing in CATIA V5 Apply all packaging rules, and industrial best practice.
• Apply Protection coverings as required
• Provide all necessary details like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if required

Packaging rules and assumptions made in this project

• Avoid harness routing and clipping in blind zone
• Provide additional slack to the harness according to the surrounding. 5-10% of slack is enough.
• Provide enough clearance to the wiring harness with respect to the surrounding. • Provide guide channel if required
• Use available holes for clamp and clip mounting
• Enough clamps to be provided to ensure positive clearance with surrounding and safety of wiring harness.
• Distance between two clamps on straight branch should be maximum of 200mm.
• Use rubber grommet which provide proper sealing, protect harness from sharp
• edges, provide protection against vibration, and even act as a clamp. • Branch length should be minimum of 50 mm
• Minimum distance between clip and nearest branching point should be 25mm
• Minimum distance between two breakouts should be 50mm
• Limit the number of branches from single branching point to 4.
• Provide bracket for interconnection connector parking

1.Download the car body model on which wiring harness to be routed:-

Tail gate modle is downloded as .igs file , which is then saved as a CAT.PRODUCT,for easy handling og large assembly this CAT.product is converted to a single CAT.PART . And managed in a separate product file as Back_Door.part.

2.Creating Context Assembly:-

Context assembly is created as (Assy_Car_BackDoor_Harness_Context).

3. Define Electrical devices in electrical part design module:-

In this model, 5 connectors are used, from which one is an interconnection connector, and 4 other are connectors for lights, from which two of them are used for back lights and left are used for number plate lights.

Connectors used are:

• C-776438-- is housing for male terminal, with 12 poles, and support mating pin dia. of 1.5mm. This is used as an interconnector.
• C-DTM-04-2P- is housing for male terminal, with 2 poles and support mating pin dia. Of 1.5mm. This is used for lights, Number plate light .
• C-DT06-08SA is used for brake light.
• We are using furr_clips .

We have added both 2-pole connectors and 8-pole connectors inside the tail gate harness geometrical bundle assembly.

• We have used commands like manipulation, compass, snap and smart move to place all the 4 connectors to their desired location.

• We have placed all the connectors at their desired position as shown in below figures

4.Bundle routing :-

Before , bundle routing we have to make a curve by creatinf points in hollow parts of the given gailgate.

• Now, the car tail gate assembly is ready for the bundle routing as shown in below image.
• Also , we have activated harness assembly as geometrical bundle.
• Let, we have started bundle routing from interconnection connector and assumed diameter of main trunk is 10 mm.
• The diameter of bundle leading of 2 tail light is 10 mm and number plate light is 5mm respectively.
• The bend ratio is assumed to be 1.4 and appropriate slack between 1-10% is ginen wherever needed.
• We have created branch points , from main branch to both tail gate lights and number plate light.

5.Adding protective covering to the harness bundle:-

• After bundle routing, we have to add protective covering to the harness bundle so that it will get protected from the damage.
• Here, we have used PVC tape for the current harness assembly.
• We have given start and end extremity wherever needed for the PVC tape as shown in below image.

6.Checking bundle continuity.:-

• First, we have to select multi-branchable and go through the sequence as Edit>Search>Advanced>Workbench Electrical Type-Bundle Segment>Attribute-Fully Connected.
• After selecting 'True' condition will show all the connected bundle segments while selecting 'False' condition will show all the non-connected bundle segments.
• Here, we have selected 'True' condition and search for the results. All the bundle segments are highlighted and showing that all the bundle segments are connected electrically as shown in below image

7.Create flatten view of the wiring harness bundle:-

• To create a flatten view of the harness assembly, we have to work in Electrical Harness Flattening workbench in Catia V5.
• Also, we have to make sure that the flattening file is saved into the same folder where we have all the parts of the harness assembly.
• As shown in below image, while defining the wiring harness flattening parameters make sure to select Single line for bundle segment and Double line for protective covering.

• After that, we have to extract and bring the bundle assembly into the car tail gate flattening product file.

To flatten the harness assembly, we have selected Face as an active plane and selected all the branches as shown in below image.

• Now, we have a flatten view of the wiring harness geometrical bundle assembly as shown in below image.

After creating flatten view ,we have to rotate the connectorsand clips in right direction along the selected plane using manipulation commands.

we have to designed the flatten view by using feature like roll, rorate,....options are theren to use those commands we perfrom those operations.

8.Creating a drwaing view for given flatten product:-

• As shown in below image , we have to insert front view of the harness assembly into drawing file and define drawing properties
• It should be noted that for the Dress-up feature 3D wireframe is always ON . If this setting is not selected then the bundle segments will not be visible on the drawing view.

Conclusion:

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