Project 2
AIM : Route the wiring harness on given car body and prepare flatten view drawing in catia v5
OBJECTIVE: The objective of this project is to route the wiring harness and prepare flatten view drawing for the tailgate of the car. All types of packaging rules have to be considered while routing the harness and industry based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.
ASSUMPTIONS;
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.
.Now, we have to route wiring harness for two tail lights and two number plate lights, and connect them to main electrical system of car.
.For two tail lights and two number plate lights, we are using 8-pole connector and 2-pole connector respectively.
.A car body also have an interconnection connector which will connect the wiring harness of tail gate of the car body to the main harness of the vehicle.
.We will use 12-pole electrical connector with a mounting clip as an interconnection connector.
.The bend ratio for all the bundle segment is considered to be 1.4
STEP 1: CREATING CONTEXT ASSEMBLY.
.We have created context assembly for the tail gate of the car as main assembly as shown in above figure.
.This context assembly contains the 3D cad data for the tail gate of the car and car tail gate harness geometrical bundle.
STEP 2: DIFINING 2- POLE AND 8-POLE CONNECTORS ELECTRICALLY.
.Here, we will use 2-Pole and 8-Pole connectors for this assembly and for that we have downloaded these connectors from TE.Com
.We should have to define it electrically that is to define geometrical parameters, bundle connection point and connector connection point.
.Here, we have defined 2-Pole connector electrically for two number plate lights of the car as shown in above figure.
.In above figure, we have defined 8-Pole connector electrically for two tail lights of the car.
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
