Project 2

AIM: To Route the Wiring harness on Given Backdoor 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.

Analysing the given data.

The 3D model of the Backdoor is downloaded from the link provided. The model is analysed for designing the Wiring Harness.

Connections

• The backdoor need connections for 2 rear indicator lights on each side. They need 4 pole connectors.
• It also need 4 pole connectors to connect the bundle to the wiper.
• It require a 3 pole connector to connect to the door lock mechanism.
• A 3 pole connector is required to connect the bundle to the rear view camera.
• A 2 pole connector is required to connect the defoger.
• A 12 pole interconnection connector will be required to take out the complete connections from the backdoor harness assembly.

Wiring harness can be routed using fur tree clip in which cable ties can be tied. Fur tree clips can be mounted on the sheet metal, by making holes, which should be discussed with the concerned design team.

Also on the top of the backdoor, a hole is required to take out the main bundle. This also has to be descussed with concerned team. From the hole the bundle can be taken out with a grommet to protect from the movement of the door.

Currently the routing has to done by hiding the surfaces in those area.

Electrical Component Selection

Connectors:

C-1718562-1: It is a 4 pole connector. It can be used for connecting to the rear lights and to the wiper.

C-5-2297794-1: It is a 2 pole connector and can be used to connect the defoger.

C-5-2297807-1: It is a 3 pole connector that can be used to connect the rear view camera and door lock mechanism.

C-776438-4 : It is a 12 pole wire to wire connector that can be used as the interconnection connector in the in the harness assembly.

The connector are selected considering the size, no. of poles, operating conditions, connection type and mounting strategy.

Clips and Clamps:

Fir Tree Clip:

Catalogue Creation

A new CatalogueDocument is created. Two families of COT Tubes(Conduit type),Clips & Clamps and connectors(electrical type) are defined.

The COT tubes of required dimensions are created in the electrical part design workbench and are added to the COT family of the catalogue.

Electrically defining the components

Referance points and axis system are created which are necessary for defining the connector connection point and bundle connection point of the connector. In the Electrical part design workbench, the parts are defined as electrical connectors. The connector connection point and bundle connection point of the connector are defined with the help of previously defined points and axis systems. The connectors are added to the catalogue in the connector family.

For the Fir tree clip the necesasry planes and points are defined. It is defined as support part using the planes and points in the Electrical part design workbench.

Clip is also added to catalogue

Creating the Product file

A new product file named 'Backdoor_Harness_Context' is created. A product file named 'Backdoor_Harness_Geometrical_Bundle' is added to the product file. All the connectors which are electrically defined are inserted to 'Backdoor_Harness_Geometrical_Bundle' product. This product is electrically defined as Geometrical bundle in the Electrical Harness Assembly workbench.

Positioning the Components

The connector added into the geometrical bundle is positioned assuming the possible location

Wiring Harness Routing

A multibranchable document is created in the geometrical bundle. The routing is done with the the different connectors and also with the help Fir Tree clips. The routing is completed following the industry best practices and rules. Slacks are given in the segments which are necessary. The main branch is given 15mm diameter, and 5mm to sub branches going to the connectors.

Bundle Connectivity:

The bundle connectivity is checked using the search tool in the edit menu.

TRUE:

FALSE:

Adding Protective Covering

In the Electrical Harness Assembly Worlbench, using the 'Protective Covering' tool, the cot tube is added to different bundle segments according to the bundle diameter.

And appropriate gap is provided for the covering from the connectors.

Electrical Harness Flattening & Drawing

A new product file for Electrical Harness flattening is created and opened in the Electrical Harness Flattening workbench. Harness Flattening parameters are defined. Then the Harness Assembly is extracted to the flattening product. Then it is flattened. Using different tools, the bundles are rotated and rolled.

Then a drawing file created with the flattened assembly product file. The Title frame and Bill of materials are added to the drawing.The components are marked with balloons with reference to teh BOM. The drawing is also converted into .pdf format for the ease of sharing.

Rendered Images of Final Product:

With the referance Backdoor Environment

Geometric Bundle Alone