Project 2

WIRING HARNESS FOR TAILGATE

AIM:

• To route the wiring harness for the given Tailgate.
• Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design.
• Apply Protection coverings as required.

INTRODUCTION:

WIRING HARNESS OR CABLE HARNESS:

A cable harness, also known as a wire harness, wiring harness, cable assembly, wiring assembly, or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power. The cables are bound together by a durable material such as rubber, vinyl, electrical tape, conduit, a weave of extruded string, or a combination thereof.

1. Wiring Harness

Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pinboard (assembly board), according to design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.

Given car door file:

PACKAGING RULES:

• 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, minimizing chafing and handling 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.

Step 1: Creating Context Assembly

Defining connectors

Define 32 pole connector

• make connector connection point and bundle point

• Create cavity point on bottom side of the connect

clip

• Make the 2 Part in ELectrical asembly design and connect with Connect electrical device tool

• Connect clip and connector

P CLAMP

• Open the p clamp and make as support definition
• Define entry and exit plane
• As well as support plane

C-1563689-12

• Defining connector connection point using connector connection point command and define the parameters as shown in the image below

PLACING ELECTRICALLY DEFINE PART ON CAR DOOR

• 32 pole connector is placed on top of the door

• P clamp also connected on the door where the bundle goes

• 2 Connector are placed near the tail light and 1 connector are placed on near c15 connector

Routing the wiring haraness

• Go to multi branch document and give necessary bundle radius and connection point

• Continue the process all the connector and p clamp are connected

• connect to the connect neat tail light and licence plate and also provide different color for recognisie easily

Adding protective coverings and guiding channels top shell to harness bundle

To protect the bundle protection covering are provided in diameter of 10mm,15mm,20mm

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.
• Also check 'false' And move to next stage

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 importing the harness straighten the bundle using plane or face
• Provide roll and rotate make the bundle presentable
• Make sure all the connection are correct

DRAFTING

• Open drawing and import the file
• As shown in below image, we have to insert front view of the harness assembly into drawing file and define drawing properties.
• 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 VIEWS:

Conclusion:

Routing of the wiring harness for the car tail gate assembly has done and prepared flatten-view drawing in Catia. Applied all the packaging rules while routing the wiring harness. Also, provided details clearance, clipping selection, harness fixing requirements, harness continuity in order to design the harness.