Project 2

Project 2.

AIM:

Route the Wiring harness on Given car body 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.

DESIGN CRITERIA AND PACKAGING ASSUMPTIONS:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints. It may damage the harness or puncture the harness. Keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

Routing the Wiring Harness:

1. First, we have to consider the components we need for the routing.
2. Here we are considering 4 different types of connectors and 2 types of fur tree clips as follows.

• Interconnections.
• Taillights.
• Backdoor Speakers.
• Back door Wiper Motor.

Interconnection Connector:

Tail Light Connectors.

Right hand side.

Left hand side.

Backdoor Speaker Connectors.

Right hand side.

Left hand side.

Backdoor Wiper motor Connector.

Fur tree 20mm.

Curve Fur tree radius 5mm.

Routing of the wiring harness.

Bundle Continuity Check.

Right hand side.

Left hand side.

Protection Coverings.

Corroguated Tubes.

PVC tapes.

Flattening view of the wiring harness assembly RH.

Flattening view of the wiring harness assembly LH.

Drawing of the Wiring Harness RH :

Drawing of the Wiring Harness LH :

CONCLUSION:

The wiring harness has been designed for the given tailgate assembly and the flattened view is drafted.