Project 2

Aim: Route the Wiring Harness on given Car body and prepare flatten view drawing in Catia V5

Objective: The objective of this project is to route the wiring harness and prepare flatten view drawing for the tailgate of the car. All types of packaging rules have to be considered while routing the harness and industry based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

The wiring harness packaging rules and the industry best practices that have to be followed to complete this project are as follows:-

1. Easy manufacturing, installation, removal, and maintenance have to be considered while designing the wiring harness.

2. Routing through small structural holes or opening shall be avoided to minimize chaffing and handling during installation.

3. Avoid harness routing and clipping in the blind zone or hard to reach areas during harness assembly or in service.

4. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, the slack value between 1-5% is used.

5. It should be made sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.

6. Avoid harness routing near sharp edges or else provide protection over the harness.

7. Enough mounting equipment such as clips and clamps should be provided.

8. The branch length should be greater than 50mm.

9. The minimum distance between the clip to the branch point should be at least 25mm.

10. The minimum distance between the two branch points should be at least 50mm.

11. The wiring harness should be easy to assemble and easy to excess.

12. Clips/ clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

STEP1- Creating context assembly

A context assembly has to be created which will serve as the main assembly for the car back door. The context assembly will contain the 3D-CAD data for the car body hatch and the car body harness geometrical bundle.

STEP2- Defining 4-pole connector electrically

The 4-pole connector used for this harness assembly is Deutsch "C-DT06-4S". The CAD data for this connector was downloaded from TE.com. To define the connector electrically we should define the geometrical parameters, bundle-connection point, and the connector-connection point for the downloaded connector.

STEP3- Adding connectors the to the 2 tail lights and the license plate light.

All the 4-pole connectors are added inside the Body harness geometrical bundle assembly. Manipulation tools along with a compass, snap, and smart move features should be used to locate all the 3 connectors in their desired locations.

STEP4 - Placing the Main connector in the top side of the car hatch

The 8-pole connector used for this harness assembly is Deutsch "C-DT06-08-SA". The CAD data for this connector was downloaded from TE.com. To define the connector electrically we should define the geometrical parameters, bundle-connection point, and the connector-connection point for the downloaded connector.

Then placing the connector in the top side of the backdoor.

STEP5-Defining clip mounts as supports

In this wiring routing we have the door surface haven't the flattened surface. So we are using the mounting clips on the surface and routing the wire. Here I'm using the furr tree clip for the mounting on the inner surface on the car back door assemby.

I'm placing the furr tree clips for the better routing inside the door.

STEP6- Bundle routing

After connecting all the connectors and clips, now the assembly is ready for the bundle routing. So we'll start the routing by going to the Wiring Harness Installation window. And we want to activate the Geometric Bundle in the assembly. Then we'll work on it.

I'm giving the main bundle wire has 15mm and for Tail lights using 10mm also for Number plate light bundle has 5mm.

STEP7-Adding protective covering to the harness bundle

After all the routing was completed, we'll start to give the protective layer to the budle segment in the door. We have to add protective covering to the harness bundle so that it will get protected from the damage. Here, we have used Slit COT tubes for the current harness assembly.

The above figure shows that all the protective coverings are placed on there places.

STEP8-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.

By giving "FALSE" option to know the not fully connected bundles in the segment.

Step 9: 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.
• While extracting our geometric bundle to the flattening product, it will create a product with an extension of EHF.

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

• We have designed the fatten view by using feature like roll for better representation of the harness as shown in below image.

Step 10: Creating a flatten view drawing for the wiring harness assembly

• Now, we have to make new drawing file and define all the necessary drawing parameters as shown in below image.

• 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.

Final draft of the model :