Project 2

Automotive Wiring Harness using CATIA V5 - Challenges

Project 2

Aim:-

Statement of assignment:

Route the Wiring harness on the Given car body and Prepare to flatten the 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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, and Assumptions, along with CATIA 3D data.

Solution:-

The wiring harness procedure is followed to route the wiring harness on the given 3D backdoor of car body data. A 2D drawing of the harness is also been prepared after flattening the harness, followed by all the packaging rules like clearance of the bundle segments, slack for the end connector, and providing support to the bundle harness with the help of clips. Protective coverings like COT Tubes are also applied to the bundles.

Wiring Harness Procedure:

• Identify the Harness assembly component
• Define all Harness assemblies as Electrical
• Prepare Harness assembly
• Define assembly as Electrical Assembly
• Change/Customize tool sets as required
• Start Routing the bundles following the Packaging guidelines

Connector Definition

• Download 3D Connector 

Mechanical Part Design Workbench -

• Defining Geometrical Parameters (Points and Axis system)

1. Bundle entry side center point 

Selecting required random points to get a center point for a suitable point type.

2. Mating side center point 

Selecting required random points to get a center point for a suitable point type.

3. Mating side axis system 

Creating an axis system concerning the center point as the origin of the axis. The Y axis is directed at the mating direction, the X axis is directed towards the locking side and the Z axis is directed upwards.

Electrical Part Design Workbench -

• Define part as Connector

Defining part as an electrical connector in Electrical Part Design Workbench using 'Define Connector', and also selecting the number of terminations for the connector.

• Define Bundle Connection Point

• Define Connector Connection Point

• Define cavity connection point (if connector needs mounting clip)

A cavity connection is defined as the connecting part for a connector clip where representation is the center point of the cavity connection, contact is the connection face, coincidence is the Y axis and, orientation is the X axis.

A catalog is also been created for all the electrical components and can be used for the bundle assembly, through 'Catalog Browser'. 

Clip/Clamp Definition 

• Get the Clip/Clamp 3D part

Mechanical Part Design Workbench -

• Define the Geometry Parameters

1. Points and Planes

Defining the points for both sides through point definition.

2. Creating entry, exit, and base planes through plane definition.

Electrical Part Design Workbench -

• Define part as support

The support definition for the clip/clamp is defined twice to make bilateral connectivity. The point selected for the side will be the entry side of the bundle, which is done for both sides. The entry point & plane, base & exit plane is defined in the support definition.

Preparation of the Harness Assembly

1. Harness Context Assembly

All the supportive contexts like Backdoor 3D data and Geometrical Bundle Assembly are the components of the harness context assembly.

2. Geometrical Bundle

Mechanical Assembly Design

• Catalog Browser

All the electrical connectors are loaded in the geometrical bundle using Catalog Browser from their catalog. Manipulation, Snap, and Compass are the tools used from the mechanical assembly design workbench to place the connectors and clips at the desired positions of the car body.

Electrical Harness Assembly 

• Geometric Bundle

The geometric Bundle command is used to electrify the geometrical bundle.

• Multi-Branchable Document

The multi-Branchable Document command is used to initiate branches for the electrical components using Branch Definition. 

Electrical Harness Installation

• Branch Definition

The Branch Definition command is used to define the branches between the components. Branch diameter, Bend Radius (ratio 1.4), and Build Mode (slack) are set in the branch definition before proceeding with the Route Definition.

In Route Definition, objects/components are selected for which the branches are to be made.

• Add Branch Point

Branch points are created from the main branch using Add Branch Point command. The branch is selected for which the branch point is to be created and distance is defined as per the packaging guidelines for the branch point. New branches can be created through the same branch point.

• Protective Covering

Protective covering (COT Tubes) on all branches are connected with the end extremity of 30/20mm (from the end of the connector). Bundle segments are selected then the protective coverings are implemented using the COT Tubes catalog.

Bundle Continuity

• Edit

Bundle Continuity is checked for bundle segment for fully connected.

CATPart of Harness Assembly

Mechanical Assembly Design Workbench -

Tools

• Generate CATPart from the Product

Generate CATPart from Product is used from Tools to convert the CATProduct to ALLCATPart and then the same file is saved using save as in .igs format.

Electrical Harness Flattening

Creating a new product in electrical harness flattening workbench for the flattening process.

• Harness Flattening parameters

Defining all the necessary parameters for harness flattening.

• Extract

Selecting an electrically defined geometrical bundle assembly for flattening.

• Flatten

Selecting the active plane for the harness flattening and selecting all the branches of the harness assembly.

• Rotate

It is one of the manipulator tools that is used to give the flattened harness assembly an understandable shape. Also using manipulator tools from the mechanical assembly design workbench to properly place the electrical components.

Drafting

Creating a new drawing in the drafting workbench, applying the below standard and sheet style.

• Front View

Selecting the correct plane of the connector from the electrical harness flattening to get the desired form of a 2D drawing of the wiring harness assembly.

Modifying some of the changes from the drawing parameters to get the proper connecting lines for the bundles of 2D drawing.