Project 2

Aim: To route the wiring harness on the given tailgate assembly and prepare the flatten view drawing in CATIA V5.

Given:

Backdoor cad data

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.

Back Door Harness Assembly requires the following connection connectors

C-173090-2

C-282080-1

c-776438-4-d-3d

c-1563689-1-b-3d

Back Door Harness Assembly requires the following clips

Furr tree clip 20 mm

fir tree clip

Back Door Harness Assembly

Checking bundle continuity

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

• By selecting 'FALSE' option will show all the connected bundle segments while selecting 'TRUE' option will show all the non-connected bundle segments.
• Here, we have selected for the 'FALSE' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

Creating flatten view of the engine harness geometrical bundle assembly

In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5.

We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved

• 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.
• We have extracted the bundle assembly into Engine Harness Flattening Product file and then flattened the file along face of interconnection connector
• At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

Creating a flatten view drawing for the wiring harness assembly

• in above figure, we are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.