Project 2

AIM:

To route the Wiring harness on given car body back door 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 Backdoor 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.

DESIGN METHODOLOGY:

STEP1- Download the backdoor cad data from given our website.

STEP2- Defining all the connector cad data clips and clamps as required for routing the backdoor.

Here we will use 2 pole connector and 12 pole connector which is required for the routing.

Choosing right components for the wire harness routing. Here we are using the components for backdoor upper and lower lights, wiper motor, sensors, and defogging equipment. The connectors used are first electrically defined and then added to the Catia model.

STEP 3- Defining clip as support.

We will use mounting clip for the mounting purpose.

We have to define geometrical parameters, bundle entry points and exit points from both left and right side of the clip.

We have defined these clips electrically as a support in electrical part design workbench.

We need to mount the Fir tree clips on the Backdoor to provide support so we must first define it electrically with geometrical parameters, entry, and exit points on both the left and right sides of the clips.

Provide L clip for mount interconnection connector.

STEP 4- creating context assembly with a new product file for the tail gate of the car as main assembly.

The context assembly contains the all 3D data for the backdoor car backdoor geometrical bundle.

STEP 5- Adding all the connector clips, clamps in required position.

STEP 6- ROUTING THE WIRING HARNESS

Adding all the connector, clips and clamps as required position with the help of manipulation tool, and using of compass. All the clamps and fir tree clips are positioned.

STEP 7- CHECK THE BUNDLE CONTINUITY

In this step, first we have to make sure that multi-branch able is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical Type-Bundle Segment>Attribute-Fully Connected

By selecting True’ option will show all the connected bundle segments while selecting.

False’ option will show all the non-connected bundle segments.

Here, we have selected for the False option and searched for results. No bundle segments are highlighted found showing that means all the bundle segments are electrically connected.

STEP 8- CREATE FLATTEN VIEW

Now we open a new product file for the Electrical harness Flattening. Here we save the already made geometrical bundle segment and we extract the geometrical bundle to flatten harness by apply flattening parameters we flatten the geometrical bundle.once the branches are flattened, we do some modification in the branches using the Rotate, bend, straighten etc. tools in the Electrical harness flattening.

STEP 9- CREATE A FLATTEN VIEW DRAWING

Now we're creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. It should be noted that the 3D wireframe is always ON in the 'Dress up settings. If this option is not enabled, the bundle segments will not be visible in the drawing view. the Backdoor wire Harness Flattens view's final Drawing view.Before creating flatten view, first we have to define flattening parameters. Make sure that selecting ‘Single line’ for bundle segment and Double line for protective covering.

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