Project 2

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 parctices studies in this coures shall be demonstrated i design. Apply protection coverins 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 requirement, Harness continuity and Assumptions if any along with CATIA 3D data.

• The figure above is the Backdoor of a car for which a wiring Harness has to be designed.
• A Wiring harness will be done for the taillights and the no plate lights.
• There are 2,4pin taillight connectors and 2,2 pin for the no plate lights and a 12pin Inline connector
• The Inline Connector that will connect it to the main Harness.
• The bend Ratio should be 1.4 for all bundle segments.

BACKGROUND, TECHNICAL SPECIFICATIONSAND ASSUMPTIONS:

The Wiring harness packaging rules and the industry best practices that have to be followed to complete this project are as follows:-

• Esay manufacturing, installation, removal and maintenance must be considered while designing the wiring harness.
• Routing through small structurasl holes or openings shall be avoided to minimize chaffing and handling during installation.
• Avoid Harness routing and clipping in the blind zone or hard-to-reach arech during harness assembly
• Avoid harness routing near sharp edges or eles protect the harness.
• Enough mounting equipment such as clipd and clamps should be provided.
• The branch length should be greater than 50mm.
• The minimum distance between the clip to the branch point should be at least 25mm.
• The minimum distance between the two branch points should be at least 50mm.
• The wiring harness should be easy to assemblyand easy to excess.

Creating Assembly

• A Context Assembly for Backdoor Wire harness has been created,which will work as the main assembly as shown in the figure above.
• A Context Assembly will contain Backdoor Assemby data and Backdoor wire harness Geometrical Bundle Assembly

To Define the Connectors

Here, according to the requirement, we are using

• 'C-776438' Which is a 12 pole connector is used as an in line connector.
• 'C-DT06-4S' which is a 4-pole connectorfor taillight.
• 'C-DT06-2S' which is a 4-pole connector for number plate light

This CAd data was obtained from te.com. To electrically define a connector, we must first define the geometrical parameters such as the bundle connection point and connector connection point in the Electrical Part Design workbench for the downloaded connector.

'C-776438'

'C-DT06-4

'C-DT06-2S'

For Support, we use Omega Clips

For Support, We use Omega Clips

We need to mount the Omega clips on the Backdoor to provide support as well as act as a guiding channel, so we must first define it electrically with geometrical parameters, entry and exit points on both the left and right sides of the clips, as shown in the figure below.

Mounting the Omega Clips and Placing the Connectors

Mounting Points of the Omega Clips

Placementof the Connectors

• For the plcement of the Omega clips and the Connectors we used various commands such as mainpulation, snap, smart move, compass and so on.
• The entire assembly is ready for routing
• Mounted are all 4 connectors, 16 omega clips, and 1 Interconnection connector

Bundle Routing:

• The bundle segment is routed from the interconnection connector to the Omega clips and guided towards the 4 and 2pin connectors while maintaining the bend radius ratio of 1.4
• We have used bundle thickness 5-10mm.

Adding Protective Coverings and guiding channels top shell to harness boundle

Here is the below figure, we have done with the whole wiring harness routing for the Backdoor. Now, we have to add protective coverings to all bundle segments.

Checking bundle continuity

In this Step, We must first wnsure that multi-Branch capability is selected before proceeding to Edit>search>Advanced>workbench-Electrical>type -Bundle segment>Attribute-Fully Connected.

Creating Flatten view of the Backdoor Wire harness geometrical bundle assembly

In this stepp, we will use CATIA V5 Electrical harness Flatting Workbench to Create a flattened view. We should also ensure that the Flattening file is saved in the same folder as the other harness assembly files.

• The bundle assembly was extracted into a book door wire harness Flattening product file, which was then flattened along the face of the inter connection connector.
• We developed a flattened view.
• We used various features such as bend, rotate and roll to streamilne the harness for better representation.

The Flattened view's Final representation

Creating a flattened view Drawing for the wiring harness assembly

In the Figure above, we are creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening product file must be inserted into the Drawing file. As shown in the preceding figure, we must define drawing properties. It should be noted that the 3D wireframe is always on in the Dressup settings.

Overall Images of the Assembly