Project 2

AIM

               To route the Wiring Harness on given Tailgate / Backdoor and Flatten view drawing in CATIA V5.

OBJECTIVE

             The objective of the project is to route the wiring harness on given Car Backdoor and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

INTRODUCTION

• In this project, a thorough wiring harness assembly is designed for a car’s backdoor, which includes the Number Plate lights, Brake lights, Rear wiper motor, and Locking Sensor.
• The assembly involves two 2-pin connectors for the number plate light, two 4-pin connectors for the taillights, one 6-pin connector for wiper motor, one interconnection connector, and 13 Furr tree clips for bundle routing.
• The bend ratio for the all-bundle segments should be 1.4 

ASSUMPTIONS

• Provide clips/clamps as per requirement.
• Make sure that there is no any fouling case while designing the wire harness. Additional clips/clamps may be used to avoid fouling case.
• Give additional slack if needed. 5-10% slack is sufficient.
• Avoid routing over bolt and bolted joints to avoid harness puncture.
• Avoid routing on sharp edges or else provide protection over the harness.
• Follow the clearance distance and keep away the harness from heat generation components.
• Protection should be provided as needed according to surrounding temperature.
• Avoid direct support for harness on fuel lines routed in the engine.
• Use plastic guiding channels if needed.
• Branch length should be greater than 50mm.
• Minimum distance between two branch points should be at least 50mm.
• Minimum distance between clip and branch point should be at least 25mm.
• Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
• The wiring harness should be easy to assemble and easy to access.
• While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and other placements can be defined properly for the wire harness routing.
• If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

DESIGN METHODOLOGY

STEP 1 - Download the Backdoor CAD data and required connectors CAD data from the given source. Creating context assembly.

• A Context Assembly for Backdoor Harness has created which will work as the main assembly as shown in above figure.
• A Context Assembly will contain Backdoor Assembly and Backdoor Harness Geometrical Bundle Assembly.

STEP 2 – Defining connectors and furr tree clips Electrically.

Inter Connection Connector (C-776438-4)

2 Pole Connector

4 Pole Connector (C-1563689-1)

6 Pole Connector (C-DT06-6S)

Furr tree clip

STEP 3 – Location of Connectors at appropriate area.

STEP 4 – Location of Furr tree clip at required position.

STEP 5 – Bundle routing from Interconnection connector to Left Brake Light.

• Bundle routing from Interconnection connector to Left brake light is the Main branch. It is routed from interconnection connector, passing through the furr tree clips. From this main branch, sub branches are originated to connect the different connectors at different locations.

STEP 6 – Creating Branch point for routing the Right brake light & Locking sensor.

STEP 7 – Bundle routing for Locking Sensor.

STEP 8 – Creating Branch point for routing the Right brake light.

STEP 9 – Bundle routing for Right Brake Light.

STEP 10 – Creating Branch point for routing the Rear wiper motor & Number Plate lights.

STEP 11 – Bundle routing for Rear Wiper Motor.

STEP 12 – Bundle routing for Number Plate lights.

STEP 13 – Adding Protective covering to bundles.

STEP 14 – Checking bundle continuity.

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

• By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments.
• Here, we have selected for the 'True' 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.

STEP 15 – Creating flatten view of the Backdoor 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.

STEP 16 – Creating a flatten view drawing for the Backdoor 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 Backdoor Harness Flattening Product file into the Drawing file.
• We have to define drawing properties as shown in above figure. It should be noted that in 'Dress up' settings 3D wireframe is always ON. If this setting is not selected then the bundle segments won't be visible on drawing view.

STEP 17 – Conversion to CAT.PART

CONCLUSION

In this way, we have routed wiring harness for the Backdoor of car. Also, prepared flatten view drawing with proper sheet in CATIA V5.