Project 2

*Here are a few examples of real-world examples that were taken into account when constructing the wiring harness for this project.

To complete this project, the following industry best practises and regulations regarding wiring harness packaging must be adhered to-

When designing the wiring harness, ease of manufacture, installation, removal, and maintenance must be taken into account.

1. Avoid routing through tiny structural holes or apertures to reduce handling and chaffing during installation.
2. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, a slack value between 1-5% is used.
3. When designing the wiring harness in the CAD environment, it should be ensured that there are no instances of fouling. To prevent fouling, additional clips or clamps may be employed.
4. Avoid harness routing near sharp edges or else protect the harness.
5. Enough mounting equipment such as clips and clamps should be provided.
6. The branch length should be greater than 50mm.
7. The minimum distance between the clip to the branch point should be at least 25mm.
8. The minimum distance between the two branch points should be at least 50mm.
9. The wiring harness should be easy to assemble and easy to excess.
10. Clips/ clamps used for the wiring harness should be readily available in the market to avoid extra costs for custom mounting solutions.

*Step 1- Creating Assembly

• As seen in the above diagram, a Context Assembly for Backdoor Wire Harness has been developed and will serve as the primary assembly.

Step 2- To Define the Connectors

Here, according to the requirement, we are using

1. ‘C-776438’ Which is a 12 Pole connector is used as an inline Connector
2. 'C-DT06-4S' which is a 4-pole connector for Taillight
3. 'C-DT06-2S' which is a 4-pole connector for Number Plate Light

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*‘C-776438’

*'C-DT06-4

*'C-DT06-2S'

We make use of Omega Clips as support.

We must first specify it electrically with geometrical parameters, entry, and departure points on both the left and right sides of the clips, as indicated in the picture below, before mounting the Omega clips on the Backdoor to serve as support and a guiding channel.

*Step 3: Mounting the Omega Clips and Placing the Connectors-

Mounting Points of the Omega Clips

Placement of the Connectors

1)We utilised a variety of commands, including manipulation, snap, smart move, compass, and so on, to put the Omega clips and Connectors.
2)All of the components are prepared for routing.
3)There are 16 Omega clips, 1 Interconnection connector, and all 4 connectors mounted.

*Step 4: Bundle Routing-

• The bundle segment is routed from the interconnection connector to the Omega clips and guided towards the 4 and 2 Pin connectors. while maintaining the Bend radius ratio of 1.4.
• We have used bundle thickness 5-10mm

*Step 5- Adding protective coverings and guiding channels top shell to harness bundle

The whole wiring harness layout for the Backdoor is shown in the image below. Now, all bundle segments must be covered with protective coverings.

*Step 6-Checking bundle continuity

In this step, we must first ensure that multi-branch capability is selected before proceeding to Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.

Selecting 'True' displays all connected bundle segments while selecting 'False' displays all non-connected bundle segments.

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Step 7: Creating flatten view of the Backdoor Wire harness geometrical bundle assembly

In this step, we will use Catia V5's Electrical Harness Flattening workbench to create a flattened view. We should also ensure that the flattening file is saved in the same folder as the other harness assembly files.

1) The interconnection connector's face was flattened after the bundle assembly was extracted into a Back Door Wire Harness Flattening Product file.

2)We developed a flattened view.

3) Using the flattening workbench's 'Rotate' option, bundle segments connected to the four cam-shaft connectors must be rotated.

4)It should be noticed that the flattening plane is the 'face' of the interconnection connector, therefore we can only rotate the bundle segments along that plane.

5)We used various features such as bend, rotate, and roll to streamline the harness for better representation.

The flattened view's final representation

*Step 10-Creating a flattened view drawing for the wiring harness assembly

Creating a new drawing file and specifying all necessary drawing settings are shown in the above figure. The Drawing file needs to have the front view of the Backdoor wire Harness Flattening Product file. We need to define drawing properties, as seen in the preceding figure. It should be noted that in the "Dress up settings," the 3D wireframe is always ON. The bundle segments won't be seen in the drawing view if this option is disabled. Final Drawing view: Backdoor wire harness flattens

*Overall Images of the Assembly-