Project 2

Route the Wiring harness on Given car body and Prepare flatten 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, Assumptions if any along with CATIA 3D data.

AIM

Route the wire harness on back door and prepare flatten drawing using CATIA V5

OBJECTIVE

Route the wire harness for car back door

prepare flatten view drawing in CATIA V5

Apply all packaging rules and industrial best price

Apply protection covering as required

Packaging rules and assumption made in the project

Avoid harness routing and clipping in blind zone

Provide additional slack to the according to surroundings

Provide enough clearance for the wire harness

Provide guiding channel if required

Enough clamps to be provided to ensure positive clearance with surrounding

Distance between two clamp in same branch to 200 mm

Use rubber grommet for protection and vibration

Branch length should be minimum 50 mm

Minimum distance between clip and branch point should be 23 mm

Maximum branches on a single point should be 4

TECHNICAL SPECIFICATIONS AND ASSUMPTIONS:

Wiring harness routing shall be ease in manufacturing, accessibility, maintenance and removal.

Avoid routing through small structural holes, bolts, bolted joints, screwed joints to avoid harness puncture

Provide additional slack to the harness according to the surrounding and harness bending requirements.

Provide additional slack to the harness branch which connects to the loads and covered with enclosures.

Avoid routing near sharp edges or over the sharp edges, in case of non avoidable situations additional protection should be provided.

Ensure harness is routed atleast 100mm away from ABC pedals.

Enough clips and clamps shall be provided to ensure the positive clearance with surroundings and safety of wiring harness.

Keep the harness away from engine heat generation components, heating lines and EGR components.

Avoid direct support of harness on fuel lines routed in engine, in that case a separator clamp to be provided to satisfy clearance requirements.

Harness branch length should minimum 50mm.

Minimum distance between clip and nearest branching point should be 25mm.

Limit the number of branches from single branching point to 4.

Harness Protection should be provided according to the surrounding temperature.

Clips/Clamps that are used should be selected such that they are easily available in the market.

The given car body hatch focuses on different areas of study under which comprises of routing harness bundles for two tail lamps and two number plate lights which connects the car main electrical system.

For all these four lights a Deustch 2 pole connectors are used (DT06-2s) and a an Interconnection connector which connects from car body hatch to the main car body wiring harness and is used at a preferred location from where the routing for these lights starts. For interconnection 12 pole connector is used.

As for the mounting parts clips/clamps which are used where ever necessary, hellerman mounting clip and fixing clips are used.

PROCEDURE:

DOWNLOADED BACKDOOR FILE

Step1: Creating Car body context assembly and Geometrical assembly

Car body hatch context assembly contains 3D data of car body hatch and all the non electrical data are stored in it and also the geometrical bundle assembly which consists of the electrical data needed for the project.

Defining 12 pole inter connector electrically and position it.

Defining 2 pole connector electrically.

1. Wiper motor connector
2. Number plate light connector
3. Back camera connector
4. Tail lamp connector
5. Back sensor connector
6. Locking mechanism connector
7. Tail lamp connector
8. Back Contact Connector.

Defining Clips as support

Positioning the Defined Clips as support

Bundle routing from interconnection connector to all the connectors arranged and all the mounting clips

The dimensions assigned for bundles, like diameter and bend radius are assumed and actual values are provided at a later stage. From the below figure it is seen that the routing starts from the interconnection connector and goes through all the clips and then to the all the connectors.

The bend radius for all the bundles is assumed to be 1.4mm

Creation of protection covering(COT Tubes) for the routing

Creation of Flattening for the routing

SUMMARY

Rules to be followed-

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. Wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommanded if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions

So with the Above Rules we have made the back door harness

• We have used Connectors 173090 - 2 pole connector, 1563689-1 4 Pole and 776438-4 12 poles Connectors
• 2 pole connector is used for the Locking mechanism
• 4 pole connector we have used 4 in numbers. For Light housing, Wiper motor and Back camera
• 12 Pole connector is used for interconnection
• We have used COT tubes on all required areas According to diameter
• Furr tree clips are used for clamping

CONCLUSION:

Thus we have Routed the Wiring harness on Given car body and Prepare flatten view in CATIA V5.