Project 2

Statement of assignment:

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.

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

1. Easy manufacturing, installation, removal, and maintenance must be considered while designing the wiring harness.
2. Routing through small structural holes or openings shall be avoided to minimize chaffing and handling during installation.
3. Avoid harness routing and clipping in the blind zone or hard-to-reach areas during harness assembly or service.
4. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, a slack value between 1-5% is used.
5. It should be made sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.
6. Avoid harness routing near sharp edges or else protect the harness.
7. Enough mounting equipment such as clips and clamps should be provided.
8. The branch length should be greater than 50mm.
9. The minimum distance between the clip to the branch point should be at least 25mm.
10. The minimum distance between the two branch points should be at least 50mm.
11. The wiring harness should be easy to assemble and easy to excess.
12. Clips/ clamps used for the wiring harness should be readily available in the market to avoid extra costs for custom mounting solutions.

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 Assembly data and Backdoor Wire Harness Geometrical Bundle Assembly.

Here, according to the requirement, we are using

1. ‘C-776438’ Which is a 12 Pole connector is used as an inline Connector
2. 'C-DT06-4S' which is a 4-pole connector for Taillight
3. 'C-DT06-2S' which is a 4-pole connector for Number Plate Light

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

• For the placement of the Omega clips and the Connectors we used various commands such as manipulation, 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

• The bundle segment is routed from the interconnection connector to the Omega clips and guided towards the 4 and 2 Pin connectors. while maintaining the Bend radius ratio of 1.5
• We have used bundle thickness 5 & 10mm

we have to add protective coverings to all bundle segments after completion of routing.

we must first ensure that multi-branch capability is selected before proceeding to Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.

Selecting 'True' displays all connected bundle segments while selecting 'False' displays all non-connected bundle segments.

In this case, we chose the 'True' option and searched for results. As shown in the figure below, all of the bundle segments are highlighted, indicating that they are all electrically connected.

After this we should creating flatten view of the Backdoor Wire harness geometrical bundle assembly.

Aassembly view